Champion 120-135-150

WORKSHOP MANUAL
Head offices:
V.le Ing. F. Cassani, 15
24047 Treviglio (BG)
Tel. 0363/4211
www.lamborghini-tractors.com
CHAMPION 120
CHAMPION 135
CHAMPION 150
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.

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
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
always disconnect the battery terminals and unplug bolts, 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 information and diagrams regarding the machine's electrical

and electronic systems.
This section also contains a guide to the use of the ALL ROUND TESTER,
which is required for machine configuration and fault diagnosis.
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 This section contains the procedures regarding the removal and overhaul
of the engine and the transmission (H-M-L, front and rear gearbox).
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.
.......... ᐉ: .............................................................. 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
• .......... ᐉ: ............................................................ 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
1400
Capacity: kg
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 5.9030.648.0 Installer for outer oil seal
T2 5.9030.864.0 Tool for positioning steering sensor plate
T3 5.9030.861.0 Special wrench for 4WD pinion retaining nut
T4 5.9030.862.0 Installer for 4WD pinion seal
T5 5.9030.863.0 Service shim thickness 2±0.1 mm for pinion adjustment
T6 5.9030.618.4/10 Slide hammer puller
T7 5.9030.858.0 Installer for input side oil seal
T8 5.9030.859.0 Special wrench for removal/refit of brake damper
T9 5.9030.860.0 Tool for lift and sensor position check
T10 5.9030.730.0 All Round Tester
T10A 011.5445.4 Control unit wiring
T10B 011.6178.4 Armrest wiring
T11 5.9030.433.0 Gauge for measuring valve stand-in, etc.
T12 5.9030.012.0 Valve spring remover
T13 5.9030.877.0 Bore gauge for valve guides
T14 5.9030.850.0 Valve guide removal tool
T15 5.9030.851.0 3V valve guide installer
T16 5.9030.853.0 Bore gauge for cross-head rocker arms
T17 5.9030.651.4 Square for connecting rods
T18 5.9030.008.4/10 Crankshaft gear puller
T19 5.9030.349.0 Cylinder hone
T20 5.9030.732.4 Installer for oil jets on 3V
T21 5.9030.735.0 Dial gauge stand for 3V engine
T22 5.9030.635.0 Push-rod guide pliers
T23 5.9030.617.4/10 Dial gauge for testing injection advance
T24 5.9030.634.0 Timing cover alignment tool
T25 5.9030.654.0/10 Piston ring clamp
T26 5.9030.640.0 Angle-tightening wrench
T27 5.9030.675.0 Turbo pressure test fitting
T28 5.9030.667.4 Digital thermometer
T29 5.9030.631.4/10 Cylinder liner clamping blocks
00-13
SPECIAL TOOLS
SYMBOL CODE DESCRIPTION NOTES

T30 5.9030.480.0 Installer for high-pressure Orbitrol ring
T31 5.9030.501.4 Installer for steering cylinder oil seal
T32 5.9030.876.0 Reference dowel for injection pump installation
T33 5.9030.875.0 Centering tool for injection pump control rod
T34 5.9030.870.0 Wrench for holding HML input shaft
T35 5.9030.692.0 Wrench for main clutch locknut
T36 5.9030.691.0 Main clutch spring compressor
T37 5.9030.704.4 Service screws for assembly of M - L clutches (Qty. 6)

Air jet tool for expulsion of H clutch piston and for checking
T38 5.9030.871.0
maximum piston stroke
T39 5.9030.872.0 Tool for overhaul of M - L clutches
T40 5.9030.708.0 Box wrench for ring nut 2.1219.039.0/20 - 2.1219.039.0/10
T41 5.9030.854.0 Spacer Ø 60 - Ø 45 l=60 (adjustment of primary shaft)

Spacer Ø 60 - Ø 45 thickness 4 mm (adjustment of primary
T42 5.9030.855.0
shaft taper roller bearings)
T43 5.9030.856.0 Internal and external struts for transmission removal
Tool for installing primary bearing “A”, secondary bearing “B”
T44 5.9030.736.0
and studs “C”
T45 5.9030.857.0 Tool for holding secondary shaft when tightening ring nut
General
T46 5.9030.390.0 Copper mallet
purpose tool
T47 5.9030.873.0 Tool for installation/removal of primary shaft
T48 5.9030.865.0 Installer for rear PTO oil seal Installer for rear PTO oil seal
T49 5.9030.719.0 Special wrench for intermediate timing gear
T50 5.9030.720.0 Box wrench for pinion shaft
T51 5.9030.529.0 30 kg Spring dynamometer
T52 5.9030.866.0 Installer for 4WD gear spring
T53 5.9030.867.0 Brake discs support (forcella)
T54 5.9030.869.0 Box wrench for splined 4WD shaft (ring nut tightening)
T55 5.9030.868.0 PTO clutch spring installer

Tool for tightening rear PTO output shaft ring nut Tool for
T56 5.9030.494.0
tightening rear PTO output shaft ring nut
00-14
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
ᐉ/min = US.gpm x 3.785 US.gpm = ᐉ/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/ᐉ x 10.00
kg/ᐉ=
lb./US.gall x 0.120 lb./US.gal. = kg/ᐉ 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 1.379 psi = bar x 14.503
00-15
CONTENTS
SECTION 10
CONTENTS
HYDRAULIC SYSTEM.................................................. 1 AUXILIARY SERVICES CONTROL VALVE

• INTRODUCTION................................................................. 1 (LOAD SENSING)........................................................ 38
• DEFINITIONS OF VALVE ELEMENTS ............................... 39
OPEN CENTER (OC) HYDRAULIC SYSTEM .............. 2
• CONTROL VALVE TYPES ................................................. 40
• OPEN CENTRE HYDRAULIC DIAGRAM (1/3)..................... 4
• DESCRIPTION OF COMPONENTS................................... 42
• OPEN CENTRE HYDRAULIC DIAGRAM (2/3)..................... 5
• OPEN CENTRE HYDRAULIC DIAGRAM (3/3)..................... 6 POWER SHIFT CONTROL VALVE............................. 43
• A. LUBRICATION CIRCUIT ................................................. 7 MAIN CLUTCH CONTROL VALVE ............................ 52
• B. OIL LEVEL MAINTENANCE CIRCUIT ............................ 7
SERVICES CONTROL VALVE.................................... 53
• C. STEERING AND POWER SHIFT CONTROL CIRCUIT .. 8
RANGE GEARBOX CONTROL VALVE ...................... 54
• D. AUXILIARY SERVICES CIRCUIT ................................... 9
PRIORITY VALVE (OC version only) ......................... 55
LOAD SENSING (LS) HYDRAULIC SYSTEM............ 10
• LOAD SENSING HYDRAULIC DIAGRAM (1/3) ................. 12 POWER STEERING .................................................... 56
• LOAD SENSING HYDRAULIC DIAGRAM (2/3) ................. 13 TRAILER BRAKING VALVE........................................ 57
• LOAD SENSING HYDRAULIC DIAGRAM (3/3) ................. 14 • ITALY VERSION ............................................................... 57
• A. OIL LEVEL MAINTENANCE CIRCUIT .......................... 15 • EXPORT VERSION ........................................................... 60
• B. STEERING AND POWER SHIFT POWER SHIFT TRANSMISSION ............................... 63
CONTROL CIRCUIT ..................................................... 15
FRONT AXLE .............................................................. 81
• C. AUXILIARY SERVICES AND
LUBRICATION CIRCUIT.............................................. 16 REAR AXLE................................................................. 83
AUXILIARY SERVICES CIRCUIT PUMP REAR PTO.................................................................. 85
(OPEN CENTRE)......................................................... 17 REAR POWER LIFT .................................................... 90
OIL LEVEL MAINTENANCE CIRCUIT PUMP ........... 18 BRAKING SYSTEM..................................................... 95
VARIABLE DISPLACEMENT PUMP (LS Version) ... 19 HYDRAULIC FRONT AXLE SUSPENSION ............. 101
AUXILIARY SERVICES CONTROL VALVE FRONT SUSPENSION CONTROL VALVE............... 102
(OPEN CENTRE)......................................................... 32
• DEFINITIONS OF VALVE ELEMENTS ............................... 33
• CONTROL VALVE TYPES ................................................ 34
• DESCRIPTION OF COMPONENTS.................................. 36
10-i
HYDRAULIC SYSTEM INTRODUCTION
HYDRAULIC SYSTEM
INTRODUCTION
1. DEFINITION
The term "hydraulic system" denotes the combination of all tractor components which use fluid to convert the energy
generated by the internal combustion engine into mechanical energy.
2. DESCRIPTION
The tractors in this series may be equipped with either of the following two versions of hydraulic system:
• “Open Center” (OC) version
• “Load Sensing” (LS) version
Each of these versions may be divided into four main components:
• Transmission lubrication circuit
• Oil level maintenance circuit
• Steering and Power Shift control circuit
• Auxiliary services and rear lift circuit
Each of these circuits is equipped with one or more hydraulic pumps that convert the power supplied by the engine into hy-
draulic energy.
The oil flow generated by the pumps is sent to devices that control the flow to the actuators (hydraulic cylinders or clutch
control pistons).
The actuators convert the hydraulic energy into mechanical energy.
10-1
HYDRAULIC SYSTEM OPEN CENTER
OPEN CENTER (OC) HYDRAULIC SYSTEM
1. COMPONENTS
A Secondary shaft lubrication circuit
B Oil level maintenance circuit
C Auxiliary services circuit
D Steering and Power Shift control circuit
D 16
20
E 17
11 15 18
12
13 14 19
C 7 8
4
6 9 10
5
2 3 A
1 B
REAR GEARBOX FRONT GEARBOX D0001210
10-2
18 3 11 4
A B
8 15 12 5 1 2
16 13 19 17
9
10
9
8 7 6
D0001480
1. Transfer pump 9. Auxiliary service control valve (6/8 ways)

2. Secondary shaft lubrication pump 10. Lift control valve
3. Filter (160 µm) 11. Steering and Power Shift pump
4. Tandem pump for auxiliary control valves and rear lift 12. Filter (25 µm)
4A Pump stage for hydraulic trailer braking 13. Resonators
4B Pump stage for front suspension 14. Power steering
5. Filters (25 µm) 15. Filter (15 µm)
6. Trailer braking valve (Optional) 16. Power Shift control valve
7. Priority valve (Optional) 17. Services control valve (differential lock, 4WD engage-
8. Front suspension control valve ment, rear PTO engagement)
(Optional) 18. Main clutch control valve
19. Range gearbox control valve
20. Cooler
10-3
HYDRAULIC SYSTEM OPEN CENTRE HYDRAULIC DIAGRAM (1/3)
OPEN CENTRE HYDRAULIC DIAGRAM (1/3)
V0= 0.7 ᐉ
SOLLEVATORE ANTERIORE (OPTIONAL)
P0= 130 bar FRONT LIFT (OPTIONAL)
1 16 ᐉ/min
4
OPTIONAL
2 16 ᐉ/min 10 11
4 R P N
B
70 bar
OPTIONAL 0
4 F 1 2 A
5 5
V0= 0.7 ᐉ FRENO RIMORCHIO (OPTIONAL) R P
1.2
P P P0= 130 bar

3 P
TRAILER BRAKE (OPTIONAL) N 145 bar OPTIONAL
Dal freno sinistro

B
12
Y1 From L.H. brakes 0
3 F 1 2 A
N Y2
R P
1.2
13 OPTIONAL
N 145 bar
N2 A
9 DOWN
14
LS E
6 A
B
8 13 OPTIONAL
11 bar T
LS B
UP A
V0= 1.4 ᐉ P T T
220 bar
T 3 bar
P0= 65 bar
DOWN
N1
S R
T
R P
210 bar 210 bar
T
UP
B
V0= 0.75 ᐉ H Mech.actuated
P0= 140 bar 0
P
2 F 1 2
A
P CF EF
190 bar
1.2
R P N
LS 145 bar
N
OPTIONAL
T
22 10 bar
21 R P
15
P
SOSPENSIONI ANTERIORI (OPTIONAL) B
7 7 FRONT SUSPENDED AXLE (OPTIONAL) OPTIONAL 0
1 1 2 A
2÷40 ᐉ/min
R P
N OPTIONAL
11 cm3/giro R P N
16 cm3/giro
11÷43,2 ᐉ/min 7,6÷29,7 ᐉ/min
20 190 bar
R P
OPTIONAL
19 16
0,5 bar
assoluti
25 ␮m
18 17
SCATOLA CAMBIO ANTERIORE SCATOLA CAMBIO POSTERIORE

FRONT GEAR BOX REAR GEAR BOX D0002090
1- Accumulatore 7- Cilindri sospensione assale anteriore 13 - Cilindri ausiliari sollevatore 19 - Sensore di intasamento filtro
2- Regolatore di flusso 8- Valvola di frenatura rimorchio 14 - Cilindro sollevatore 20 - Pompa doppia
3- Dispositivo ammortizzatore 9- Pressostato NC 15 - Cilindro 3° punto idraulico 21 - Valvola prioritaria
4- Rubinetti esclusione sollevatore anteriore 10 - Distributore servizi ausiliari 16 - Innesto rapido freno rimorchio 22 - Valvola di massima
5- Cilindri sollevatore anteriore 11 - Cilindro tirante idraulico 17 - Innesto rapido scarico libero
6- Gruppo distributore sospensione anteriore 12 - Innesti rapidi anteriori 18 - Gruppo filtri
10-4
PTO POSTERIORE
IMPIANTO DI STERZATURA REAR PTO
STEERING SYSTEM
CAMBIO GAMMA ELETTROIDRAULICO BLOCCAGGIO
13
ELECTRO-HYDRAULIC RANGE CONTROL DIFFERENZIALI
L.H. R.H. INNESTO DT 14 cm3
DIFFERENTIALS LOCK 4WD CLUTCH 3-7 bar
7 7 7 cm3
8,3-15 bar
7 cm3
8,3-15 bar
FRONT REAR
27cm
0,8-0,9 bar
3
RH RM
L R
0,8-1,5 L/min 0,8-1,5 L/min 12 bar
6,3 cm3x 2
ø1,2 ø1,2 M12x1,5
M12x1,5
M12x1,5 ø1,2
M12x1,5 M12x1,5
B B B B B A B
A C A C A C A C A C P T
ø 1,2
150 bar 10 11
6
15 bar
P T
12
SCATOLA CAMBIO ANTERIORE
8 FRONT GEAR BOX
15 micron
P
M12x1,5
ø5
270 cm3 3.4 bar

40 bar max
M12x1,5
2.4 bar
9
ø7
270 cm3
5
19 cm3/giro
(13-51 L/min) 6 bar
18
4 Sx E 600-2350 RPM
i = 31/27
0,5 bar
assoluti
(7,6-29,7 L/min)
(13-51 L/min)
3
19 cm3/giro
11 cm3/giro
2 25 ␮m
15 17 Dx
160 ␮m
FILTER
1 LUBRIFICAZIONE ALBERO SECONDARIO

MESH
14 16 SECONDARY SHAFT LUBRIFICATION
SCATOLA CAMBIO POSTERIORE SCATOLA CAMBIO ANTERIORE

REAR GEAR BOX FRONT GEAR BOX
D0002550
1- Temperature sensor 7- Steering cylinder 13 - Rear PTO unit 13 -Rear PTO unit
2- Filter 8- Pressurised filter 14 - Wire mesh filter
3- Clogged filter sensor 9- Clogged filter sensor 15 - Transfer pump
4- Power Shift pumps 10 - Range control unit 16 - Filter
5- Resonators 11 - Services control valve 17 - Secondary shaft lubrication pump
6- Power steering 12 - Low pressure alarm sensor 18 - Pressure relief valve
10-5
FRIZIONE CENTRALE
MAIN CLUTCH
COMANDO INVERSORE 52,0 cm3

REVERSE GEAR UNIT 4 bar
MEDIUM HIGH LOW 3° 2° 1° 2 0,8-1,5 L/min
C1
5
ø 0,7
9,3 cm3 15,4 cm3 11,3 cm3 33,4 cm3 33,4 cm3 68,2 cm3
10,9 bar 2,6 bar 2,2 bar 4,5 bar 4,5 bar 4,5 bar
15 bar 3
0,3-0,8 L/min. 0,3-0,8 L/min. 0,3-0,8 L/min. 0,3-0,8 L/min.
6
N H L 3 2 1 A B
4 bar
ø2,5 ø2,5 ø2,5 ø2,5 ø2,5
U2
BANDA DI REGOLAZIONE:
14 bar 14 bar 14 bar 14 bar 14 bar REGOLATION BAND:
4 bar 2,5-14 bar
15 bar
ø2,5 ø2,5
T T T T T
T
12 bar 12 bar
A P A P A P A P A P A P
M3
L1
0,3 bar
0,3 bar
0,3 bar
0,3 bar
0,3 bar
ø1,7
19 bar
7
p0=10 bar
v0=0,7 L
0,3 bar
Hp. 21 bar
4
Md. 0-19 bar
U1
0/19-19/0 bar
21 bar
1 ø1,7
T P1
M2 M1
ø1
LUBRIFICAZIONE LUBRIFICAZIONE LUBRIFICAZIONE

GRUPPO PTO POST. CUSCINETTI PTO POST. ALBERO PRIMARIO
REAR PTO LUBRIFICATION PTO BEARING LUBRIFICATION MAIN SHAFT LUBRIFICATION

D0002560
1- Power Shift control valve 5 - Main clutch

2- Reverse shuttle unit 6 - Main clutch control valve
3- Selected gear sensor 7 - Cooler
4- Accumulator
10-6
HYDRAULIC SYSTEM OPEN CENTRE
A. LUBRICATION CIRCUIT
FUNCTION
The lubrication circuit delivers oil under pressure to the rotating parts of the secondary transmission shaft.
1 2
FRONT GEARBOX D0001220
OPERATION
The gear pump (2) draws in oil from the rear gearbox and sends it under pressure to the secondary transmission shaft.
The circuit includes:
• a pressure relief valve (3) set to 6 bar (87 psi) that prevents an excessive increase in oil pressure on cold starting and
in very cold weather conditions.
• an intake filter (1) of 160 µm.
B. OIL LEVEL MAINTENANCE CIRCUIT

FUNCTION
The oil level maintenance circuit ensures that the correct oil level is maintained in the rear gearbox.
OPERATION
The gear pump (1) draws in oil from the front gearbox and sends to the rear gearbox. This circuit includes a mesh filter (2)
which removes larger particles from the oil.
10-7
OPEN CENTRE
C. STEERING AND POWER SHIFT CONTROL CIRCUIT
FUNCTION
The steering and Power Shift control circuit sends oil under pressure to the services used to control the Power Shift trans-
mission and the steering.
This circuit also sends oil under pressure for lubrication of the primary shaft and the rear PTO.
6 11
7 13
2 1 4 3 5 8
12
10
OPERATION
The gear pump (1) draws in oil (through filter (2)) from the rear gearbox and sends it under pressure to the power steering (3)
via the resonators (4). The oil is then sent under pressure through the pressurised filter (5) to the Power Shift control valves (6),
the services control valve (7), the main clutch control valve (8) and the range gearbox control valve (9).
Excess oil is then sent to the rotating parts of the rear PTO (10) and the primary shaft (12).
The circuit also includes an oil-cooler bypass valve (13) (set to 15 bar (217.5 psi)) that prevents an excessive increase in the
lubrication circuit pressure on cold starting of the tractor and during operation in very cold climatic conditions.
10-8
OPEN CENTRE
D. AUXILIARY SERVICES CIRCUIT
FUNCTION
The auxiliary services circuit sends oil under pressure to the control valves for external implements and the rear lift.
This circuit also provides pressurised oil for the optional trailer braking circuit and control valve block.
5 6
1A
7 3 4
2
1B
REAR GEARBOX D0001250
OPERATION
The gear pumps (1A) and (1B) draw oil (through filters (2)) from the rear gearbox and send it to the auxiliary service control
valve block (3) and to the rear lift control valve (4).
On tractors equipped with front axle suspension, the necessary oil is supplied by the gear pump (1A). The priority valve (5)
ensures that the front suspension control valve (6) receives only the necessary amount of oil.
On tractors equipped with the trailer braking valve, the oil required for operation of this valve is supplied by the gear pump (1B).
Priority is given to the trailer braking valve (7), from which oil then passes to the auxiliary service control valves (3) and to
the rear lift control valve (4).
10-9
HYDRAULIC SYSTEM LOAD SENSING
LOAD SENSING (LS) HYDRAULIC SYSTEM
1. COMPOSITION
A Oil level maintenance circuit
B Steering and Power Shift circuit
C Auxiliary services and lubrication circuit
B 15
19
E 16
12 13 17
11 14
18
C
4
3
7
5
6 9 10
21
2 8
8
20
A
1
10-10
17 21 5 3
7 14 20 4 1 11 2
15 12 18 16
9
10
9
7 17 8 3 6
D0001490
1. Oil level maintenance pump 12. Resonators

2. Filter (160 µm) 13. Power steering
3. Boost pump 14. Filter (15 µm)
4. Filter (15 µm) 15. Power Shift control valve
5. Variable displacement pump 16. Services control valve (differential lock, 4WD engage-
6. Trailer braking valve (Optional) ment, rear PTO engagement)
7. Front suspension control valve (Optional) 17. Main clutch control valve
8. Bistable valve 18. Range gearbox control valve
9. Auxiliary service control valve (6/8 ways) 19. Cooler
10. Lift control valve 20. Ejector
11. Steering and Power Shift pump 21. Flow control valve (5 ᐉ/min. - 1.321 US.gpm)
10-11
HYDRAULIC SYSTEM LOAD SENSING HYDRAULIC DIAGRAM (1/3)
LOAD SENSING HYDRAULIC DIAGRAM (1/3)
V0= 0.7 ᐉ
SOLLEVATORE ANTERIORE (OPTIONAL)
P0= 130 bar FRONT LIFT (OPTIONAL)
1 16 ᐉ/min
4
2 16 ᐉ/min 11 R Y P
4 8 R Y P 5 - 80 ᐉ/min
70 bar 2 1.2
160 bar
A
5 5 1 0 2 F
V0= 0.7 ᐉ
FRENO RIMORCHIO (OPTIONAL)
P P P0= 130 bar
3 P
TRAILER BRAKE (OPTIONAL) R Y P
B
5 - 80 ᐉ/min
Dal freno sinistro
Y2 From L.H. brakes
LS 8
6 A
Y1
OPTIONAL
A
LS
V0= 1.4 ᐉ P T T 1 0 2
T LS
P0= 65 bar
DOWN N B
R Y P
S 12
E
210 bar 210 bar
10 9 B A
R1
11 bar
B T
UP
DOWN
13 OPTIONAL
UP 220 bar
V0= 0.75 ᐉ H A
P0= 140 bar P 14
X 7/16-20 UNF-2B
220 bar 13 OPTIONAL
16/22 bar
⌬p (FR):
P
R Y P 5 - 80 ᐉ/min
p max (DR):
1.2
SOSPENSIONE ANTERIORE (OPTIONAL)
7 7 160 bar
200 bar
FRONT SUSPENDED AXLE (OPTIONAL) OPTIONAL
A
1 0 2 F
B
QMAX. 103 ᐉ/min B
5 ᐉ/min
45.0 cm3/giro max
(29-113 ᐉ/min)
15
R Y
i = 31/29
P X Rx
OPTIONAL
Sx
27 OPTIONAL
23
28 S L1 L
M12x1.5 d c 1 0 2 F A
29 22 B
R Y P X Rx
1.5 bar
FP
16
B15 = 200 24 DMV
22 bar
Ø 1.5 26 OPTIONAL OPTIONAL

3.4 bar 20 21
SECONDARY SHAFT 25 2.4 bar

160 ␮m 17
19
18
SCATOLA CAMBIO ANTERIORE SCATOLA CAMBIO POSTERIORE

FRONT GEAR BOX REAR GEAR BOX D0001270
1- Accumulator 7- Front axle suspension cylinders 13 - Auxiliary lift cylinders 19 - Wire mesh filter 25 - Clogged filter sensor
2- Flow control valve 8- Bistable valve 14 - Lift cylinder 20 - Charge pump 26 - Hydraulic ejector
3- Damper 9- Trailer braking valve 15 - Quick-action front couplers 21 - Power Shift pump 27 - Flow control valve
4- Front lift shut-off cock 10 - NC pressure switch 16 - Top link hydraulic cylinder 22 - Pressure relief valve 28 - Temperature sensor
5- Front lift cylinders 11 - Auxiliary services control valve 17 - Quick-action trailer brake coupler 23 - Variable displacement pump 29 - Secondary shaft lubrication
6- Front suspension control valve block 12 - Hydraulic lift rod cylinder 18 - Quick-action drain coupler 24 - Pressurised filter
10-12
PTO POSTERIORE
IMPIANTO DI STERZATURA REAR PTO
STEERING SYSTEM
CAMBIO GAMMA ELETTROIDRAULICO 13
ELECTRO-HYDRAULIC RANGE CONTROL
L.H. R.H.
BLOCCAGGIO DIFFERENZIALI INNESTO DT 14 cm3
3-7 bar
DIFFERENTIALS LOCK 4WD CLUTCH
7 cm 3 7 cm3
FRONT REAR 27cm3
7 7 8,3-15 bar 8,3-15 bar 0,8-0,9 bar
RH RM
L R
0,8-1,5 L/min 0,8-1,5 L/min 12 bar
6,3 cm3x 2
ø1,2 ø1,2 M12x1,5
M12x1,5
M12x1,5 ø1,2
M12x1,5 M12x1,5
B B B B B A B
A C A C A C A C A C P T
ø 1,2
150 bar
10 11
6
15 bar
P T
12
SCATOLA CAMBIO ANTERIORE
8 FRONT GEAR BOX
15 micron
P
M12x1,5
ø5
270 cm 3
3.4 bar
40 bar max
M12x1,5
ø7
270 cm3
5 2.4 bar
9
CILINDRATA VARIABILE
DISPLACEMENT PUMP
TO VARIABLE
ALLA POMPA
19 cm3/giro
(13-51 L/min)
2 3 4
1,5 bar
600-2350 RPM
Dx Dx E i = 31/27
(13-51 L/min)
63,4 cm3/giro
19 cm3/giro
(40-159 L/min)
i=31/29
15
1 160 ␮m
FILTER
MESH
14

D0002570
1- Filter 6- Power steering 11 - Services control valve

2- Charge pump 7- Steering cylinders 12 - Low pressure alarm sensor
3- Pressure relief valve 8- Pressurised filter 13 - Rear PTO unit
4- Power Shift pump 9- Clogged filter sensor 14 - Wire mesh filter
5- Resonators 10 - Range control unit 15 - Transfer pump
10-13
FRIZIONE CENTRALE
MAIN CLUTCH
52,0 cm3
4 bar
0,8-1,5 L/min
COMANDO INVERSORE
REVERSE GEAR UNIT
MEDIUM HIGH LOW 3° 2° 1° C1
5
2
9,3 cm3 15,4 cm3 11,3 cm3 33,4 cm3 33,4 cm3 68,2 cm3
10,9 bar 2,6 bar 2,2 bar 4,5 bar 4,5 bar 4,5 bar
ø 0,7
3
RM AV 15 bar
0,3-0,8 L/min. 0,3-0,8 L/min. 0,3-0,8 L/min. 0,3-0,8 L/min.
6
N H L 3 2 1 A B
4 bar
ø2,5 ø2,5 ø2,5 ø2,5 ø2,5

REGOLATION BAND
U2 2,5-14 bar
14 bar 14 bar 14 bar 14 bar 14 bar

4 bar
15 bar
ø2,5 ø2,5
T T T T T
T
12 bar 12 bar
A P A P A P A P A P A P 7
M3
L1
0,3 bar
0,3 bar
0,3 bar
0,3 bar
0,3 bar
ø1,7
19 bar
p0=10 bar
v0=0,7 L
0,3 bar
Hp. 21 bar
4
Md. 0-19 bar
U1 ø1,7
0/19-19/0 bar ø1
21 bar
1
T P1
M2 M1
LUBRIFICAZIONE LUBRIFICAZIONE LUBRIFICAZIONE

P GRUPPO PTO POST.
REAR PTO LUBRIFICATION
CUSCINETTI PTO POST.
PTO BEARING LUBRIFICATION
ALBERO PRIMARIO
MAIN SHAFT LUBRIFICATION

D0002580
1- Power Shift control valve 5 - Main clutch

2- Reverse shuttle unit 6 - Main clutch control valve
3- Selected gear sensor 7 - Cooler
4- Accumulator
10-14
A. OIL LEVEL MAINTENANCE CIRCUIT
FUNCTION
The oil level maintenance circuit ensures that the correct oil level is maintained in the rear gearbox.
OPERATION
The gear pump (1) draws in oil from the front gearbox and sends it to the rear gearbox.
This circuit includes a mesh filter (2) to remove larger particles.
B. STEERING AND POWER SHIFT CONTROL CIRCUIT

FUNCTION
The steering and Power Shift control circuit sends oil under pressure to the controls for the Power Shift transmission and
the steering. This circuit also sends oil under pressure for lubrication of the primary shaft and the rear PTO.
6 11
7 13
2 1 4 3 5 8
9
12
10
OPERATION
The gear pump (1) draws in oil (through filter (2)) from the rear gearbox and sends it under pressure to the power steering (3)
via the resonators (4). The oil is then sent under pressure through the pressurised filter (5) to the Power Shift control valves (6),
the services control valve (7), the main clutch control valve (8) and the range gearbox control valve (9). Excess oil is then sent
to the rotating parts of the rear PTO (10) and the primary shaft (12).The circuit also includes an oil-cooler bypass valve (13)
(set to 15 bar (217.5 psi)) that prevents an excessive increase in the lubrication circuit pressure on cold starting of the tractor
and during operation in very cold climatic conditions.
10-15
C. AUXILIARY SERVICES AND LUBRICATION CIRCUIT
FUNCTION
The auxiliary services circuit sends oil under pressure to the control valves used to control implements and the rear lift. This
circuit also provides oil for lubrication of the secondary shaft and the optional trailer braking and front axle suspension cir-
cuits.
1 3
12
8 7 4
11
10
5
OPERATION
The gear pump (1) draws in oil (through filter (2)) from the rear gearbox and sends it under pressure to the filter (3) and to the
variable displacement pump (4).
The oil is also used for lubrication of the secondary shaft (5); valve (6), (setting 1.5 bar (21.7 psi)) prevents excessive pres-
sure in the lubrication circuit on cold starting and in very cold climatic conditions.
The pump (4) sends oil under pressure to the auxiliary service control valves (7), to the lift control valve (8) and to the ex-
hauster (9). The oil sent to the exhauster (9) passes through a flow control valve (10), which limits the flow rate to a maximum
of 5 ᐉ/min (1.321 US.gpm).
On tractors equipped with the trailer braking valve (11), this valve receives oil from the pump (4) with priority over the other
control valves, whereas on tractors equipped with front axle suspension (12), the front axle suspension control valve re-
ceives oil in parallel with the auxiliary services control valves (7).
10-16
AUXILIARY SERVICES CIRCUIT PUMP OPEN CENTRE
AUXILIARY SERVICES CIRCUIT PUMP (OPEN CENTRE)
A B
A B
D0001300
CHARACTERISTICS PUMP A PUMP B NOTES
Displacement 16 cc/rev 11 cc/rev
Maximum operating pressure 200 bar (2900 psi) 200 bar (2900 psi)
Maximum capacity 43.2 ᐉ/min (11.413 US.gpm) 29.7 ᐉ/min (7.847 US.gpm) at 2350 rpm engine speed
10-17
OIL LEVEL MAINTENANCE CIRCUIT PUMP OPEN CENTRE - LOAD SENSING
OIL LEVEL MAINTENANCE CIRCUIT PUMP
A A
1
3
8
7
6 A-A
5
D0001310
CHARACTERISTICS 1. Bearing
Displacement: 19 cc/rev 2. Pump support
Maximum capacity:51.3 ᐉ/min (15.553 US.gpm) 3. Drive gear
at 2350 engine rpm 4. Flange
5. Inner gear
6. Pump housing
7. Outer gear
8. Drive shaft
10-18
VARIABLE DISPLACEMENT PUMP LOAD SENSING
VARIABLE DISPLACEMENT PUMP (LS Version)
1 b
A
a 2
B
X
B B
c d
S L1 L
View X
D0000650
PORT CONNECTIONS COMPONENTS

a. Port L - To gearbox 1. Load Sensing valve
b. Port X - From auxiliary control valve or services 2. Pressure control valve
c. Port B - To auxiliary control valve (Port P) or services
d. Port S - From boost pump
FUNCTION
Port L: drain
Port X: LS signal
Port S: suction
Port B: delivery
10-19
6
5
4
3 7
8
9
2
1
16
15
14
13 12 11 10
A-A
D0000520
COMPONENTS
1. Drive shaft 9. Cover
2. Shaft seal 10. Bearing
3. Swash plate spring 11. Valve plate
4. Swash plate 12. Pistons (9)
5. Control arm 13. Piston retaining ring
6. Control piston 14. Piston shoe
7. Cylinder block 15. Taper roller bearing
8. Spacer 16. Pump housing
10-20
1 2 3 4 5 6
12 11 10 9 8 7
B-B D0000540
COMPONENTS
1. Load Sensing valve spool 7. Adjuster nuts
2. Choke 8. Spring cover
3. Collar 9. Pressure control valve springs
4. Load Sensing valve springs 10. Collar
5. Spring cover 11. Choke (Ø 0.6 mm) (0.024 in.)
6. Adjuster nuts 12. Pressure control valve spool
10-21
VARIABLE DISPLACEMENT PUMP
1. HYDRAULIC PUMP
FUNCTION
• The rotation and torque of the pump shaft are con-
verted into hydraulic energy and the flow of pressu-
rised oil is regulated in accordance with the demand
from the various actuators.
• It is possible to vary the pump delivery by changing
the angle of the swash plate.
5
3 A 4
2
6 B 7
D0000550
CONSTRUCTION
• The cylinder block (4) is keyed onto the shaft (1) by • The pistons (5) stroke axially inside the cylinder
the broaching B. The shaft (1) is supported by the bores in the cylinder block (4).
front and rear bearings.
• The rotation of the cylinder block (4) pressurises the
• The ends of the pistons are spherical; the piston shoes (6) oil in the cylinder bores; the valve plate (7) deter-
are staked over to form a single assembly. The piston (5) mines the inlet and outlet ports .
and shoe (6) together form a ball joint. The oil in each of the cylinder bores is drawn in and
discharged through the openings in the valve plate (7).
• The swash plate (3) has a flat surface A against which
the piston shoes (6) slide as the cylinder block ro-
tates.
10-22
VARIABLE DISPLACEMENT PUMP
OPERATION
1. Operation of the pump
1 - The cylinder block (4) rotates with the shaft (1)
and the piston shoes (6) slide over the flat sur- 3 A 6 S 4 C
face «A».
The swash plate (3) moves over the cylindrical 1
surface «B»; the angle «α» between the axis of x
the shaft (1) and the axis X of the swash plate (3)
␣
can be changed to alter the stroke of the pistons.
Angle «α» is known as the «swash plate angle».
2 - When axis X of the swash plate (3) is at an angle
«α» to the shaft (1) and consequently also the
cylinder block (4), the surface «A» acts as cam
for the piston shoes (6). As a result, as the shaft
rotates, the pistons (5) stroke inside the cylinder
block (4), thereby creating a difference in the vol- B D
umes C and D and thus drawing in and discharg- Fig. 1
ing oil in a quantity equal to this difference in
volume (D -- C=delivery).
In other terms, when the cylinder block (4) ro-
tates, the volume of cylinder D is reduced, there-
by forcing out the oil, while the volume of cylinder
C is increased, thereby drawing oil into the bore.
(Fig. 1 shows the pump condition on completion
of the suction phase in cylinder D and the deliv- 3 4 C
ery phase in cylinder C).
3 - When the axis X of the swash plate (3) is parallel
to the axis of the cylinder block (4) (swash plate
angle «α»=0), the difference in volume between
C and D inside the cylinder block (6) is 0 and
therefore no oil is pumped (Fig. 2). x
(In reality, the swash plate «α» is never exactly
equal to zero 0).
4 - Pump delivery is therefore directly proportional
to the swash plate angle «α».
D
2. Pump delivery control Fig. 2 D0000530
• When the swash plate angle «α» is increased,

the difference between volumes C and D in-
creases and consequently so does the pump 8
delivery Q. 2 3 C
The swash plate angle is changed by the control
piston (8).
• The control piston (8) moves in accordance with
the pressure signals received from the Load
Sensing valve and the pressure control valve. ␣
The linear movement of the piston is transmitted
to the swash plate (3), which is supported by the
cylindrical surface of the pump housing (2); the
swash plate thus moves through a semicircular
arc (Fig. 3).
Fig. 3 D D0000620
10-23
LOAD SENSING VALVE, PRESSURE CONTROL VALVE
2. LOAD SENSING VALVE, PRESSURE CONTROL VALVE
2
1
PLS
⌬PLS 8
3
4 6 PP
D0000560
COMPONENTS
1. Load Sensing valve spool
2. Load sensing valve spring
3. Pessure control valve spool
4. Pessure control valve spring
5. Swash plate return spring
6. Control piston
7. Directional control valve
8. Actuator
10-24
2. OPERATING PRINCIPLE
Controls the angle of the pump swash plate
• The swash plate angle (and thus the pump delivery) is controlled in such a way that the pressure difference ∆PLS
between the pump delivery pressure PP and the pressure PLS at the work port of the directional control valve is
maintained at a constant value. (∆PLS = Pump delivery pressure PP -- PLS delivery pressure to actuator).
• If the pressure difference ∆PLS decreases relative to the pressure setting of the LS valve, the swash plate angle
will increase.
If the pressure difference ∆PLS increases, the swash plate angle will decrease.
★ For more detailed information on this mechanism, see the description of the «HYDRAULIC PUMP».
Control valve
T PLS
Pump delivery PP
Control piston
TP Valve
LS Valve
D0000631
10-25
2.1 LOAD SENSING (LS) VALVE

FUNCTION
• The LS valve controls the pump delivery according to the stroke of the directional control valve lever, i.e., according
to the demand for oil flow from the actuators.
• The LS valve determines the demand from the actuators by way of the pressure difference ∆PLS between the pump
delivery pressure PP and the pressure PLS at the outlet of the directional control valve; this difference is then used to
control the delivery Q of the hydraulic pump.
(PP, PLS and ∆PLS, are respectively: the pump delivery pressure, the pressure of the Load Sensing signal and the
pressure difference between these two values).
• In other terms, the LS valve determines the pressure difference ∆PLS, generated by the flow of oil through the pas-
sage opened up by the directional control valve spool and controls the pump delivery Q so as to maintain a constant
pressure difference.
The pump delivery can thus be said to be proportional to the demand from the directional control valve.
OPERATION
The operation of the pump can be described in four main stages:
1. When the directional control valve is in neutral position
2. When a control valve lever is operated
3. When the delivery stabilizes
4. When the system enters a state of “saturation”
10-26
1. When the directional control valve is in «NEUTRAL»
b 1 d e a 2
PP T PLS
PEN
PP Min Max
7
X
M 5 6
D0000460
• The pressure PLS of the LS from the control valve outlet enters the chamber a of theLS valve spring; the pump de-
livery pressure PP enters the chamber b on the opposite side of the spool.
• The position of the spool (1) is determined by the combination of the force created by the pressure PLS plus the force
exerted by the spring (2) and by the force exerted in the opposite direction by the pressure PP.
• Before the engine is started, the control piston (6) is pushed by the spring (5) to the right (corresponding to the max-
imum swash plate angle).
• When the engine is started, all the control valve spools are in «NEUTRAL», the pressure PLS of the LS signal remains
at 0 bar (0 psi) as no fluid is delivered from the control valve outlets and the signal is connected to drain.
At the same, the pump delivery pressure PP increases as there is no demand from the users.
When the force exerted by the pressure PP in chamber b balances the force exerted by the spring (2), the spool (1)
moves to the right and allows the fluid at pressure PP to flow into the chamber X of the piston (6) by connecting pas-
sages c and d.
• The force exerted by the fluid pressure on the piston (6) overcomes the force of the spring (5). The control piston is
thus pushed to the left, i.e. towards the minimum swash plate angle position.
• The pump delivery pressure PP stabilizes around the value of 18 bar (261 psi), which corresponds to the standby
pressure.
10-27
2. When a control valve lever is operated
b 1 d e a 2
PP T PLS
7 8
PEN
PP Min Max
f
X
M 5 6
D0000470
• When a control valve lever is shifted from the NEUTRAL position, this generates an LS signal corresponding to the
pressure PLS.
• The LS signal pressure in chamber a moves the spool to the left, thereby connecting passages d and e.
Chamber X is thus depressurised and the swash plate is moved to the maximum delivery position by the action of the
spring (5).
• System balance is restored when the pressure difference ∆PLS acting on the spool (1) balances the force exerted by
the spring (2) and thus re-opens the connection between passages c and d.
10-28
3. When the delivery stabilizes
d 1 2
c
d
PP T PLS
g
PEN
PP
X
M
D0000510
• When the pump delivery matches the demand from the directional control valve, the pump delivery pressure PP
present in chamber b of the LS valve balances the combination of the forces exerted by the pressure PLS of the LS
in chamber a and by the spring (6).
On reaching the state of balance, the piston (1) stops in an intermediate position.
• In this condition, the passage from chamber c to chamber d remains partially open so that the pressure is maintained
in chamber d.
A sufficient flow of fluid to balance the force exerted by the spring (5) enters the control piston (6).
• This state of balance is maintained by a stabilized flow of fluid from the choke g.
• The force of the spring (2) is regulated so that the piston (1) is balanced when
PP -- PLS = ∆PLS = 16 bar (232 psi).
• In effect, the pump delivery is made proportional to the opening of the directional control valve, maintaining the pressure
differential ∆PLS = 16 bar (232 psi).
• This state is maintained until there is a change in the operating conditions (for example, a change in the engine speed, an
increase or reduction in the demand for fluid flow or pressure, etc.).
10-29
4. When the system enters "saturation" state
b 1 d e a 2
PP T PLS
7 8
PEN
PP Min Max
f
X
M 5 6
D0000480
• When the engine speed is reduced while one or more hydraulic actuators are in operation, the pump delivery is also
reduced. Consequently the swash plate angle is changed to increase pump delivery.
• When the pump reaches its maximum displacement, and therefore the delivery can no longer be increased, the dif-
ference between the pump pressure PP and the pressure PLS of the LS (pressure difference ∆PLS) is reduced (“sat-
uration” condition).
• The pressure PLS in chamber a of the LS valve becomes almost equal to the pump pressure PP and the control pis-
ton (1) shifts to the left under the combined action of the pressure PLS and the spring (2).
The piston thus closes passage c and opens the connection between passages d and e.
• The pressurised oil in chamber X of the control piston (6) flows through passages d and e and into the drain chamber
of the pump; consequently the pressure in chamber X of the control piston (6) becomes equal to the drain pressure.
• The control piston (6) is therefore shifted to the right by the action of the spring (5), to the position corresponding to
the maximum swash plate angle.
10-30
2.2 PRESSURE CONTROL VALVE (TP)
FUNCTION
• The pressure control valve determines the maximum pump delivery pressure.
PP T PLS
PEN
PP
Min Max
D0000500
OPERATION
• The pressure control valve monitors the pump delivery pressure, and when this reaches the set pressure limit, it re-
duces the pump delivery to the minimum, by-passing the action of the LS valve.
• Pump delivery is then regulated at the minimum value to ensure internal lubrication of the main auxiliary services
pump and maximum pressure in the hydraulic system.
10-31
AUXILIARY SERVICES CONTROL VALVE (OPEN CENTRE)
FUNCTION
• The function of the auxiliary services control valve is to control the flow of pressurised fluid to the auxiliary services
and the rear lift.
• This is a parallel circuit control valve, which means that all the work ports receive oil simultaneously.
1
4
T R1 A
R
B
210 bar
3
1.2
1.2
190 ± 11 bar
A
A B A B T A B
REAR GEARBOX D0001320
DESCRIPTION
• The pressurised oil from the pump (1) enters the inlet manifold (2) from where it is distributed to the various valve el-
ements through internal ports.
• The inlet manifold is equipped with a pressure relief valve (3) that serves to protect the hydraulic components against
pressure surges.
• On the lift control element there is an antishock valve (4) (on the "raise" control side), which serves to prevent any ex-
cessive pressure surges caused by jolting of the implement.
10-32
DEFINITIONS OF VALVE ELEMENTS
NAME DESCRIPTION SYMBOL
Control element with mechanical spool retention and

DETENT
manual release.

KICK-OUT automatic release when user pressure reaches pre-set
level.
Control element that simultaneously connects the two

work ports to the exhaust passage, thereby allowing
FLOAT
the implement to "float".
NOTE: may also be used as a single-acting element.
This element includes a mechanically operated check

valve that ensures an effective seal and thus prevents
NR internal blowby from causing the cylinders to move.
The valve only allows oil to flow when the spool is
operated.
Control element with priority flow control valve.

This element controls the flow rate of oil to the valve
on which it is mounted, sending the surplus oil to the
FLOW CONTROL
other users.
The controlled flow rate is independent of the opera-
ting pressure.
10-33
CONTROL VALVE TYPES
6-WAY VERSION
HYDRAULIC DIAGRAM
3 5 4 6 7
8 4 6 8
T R1 A
A A A A R
210 bar
1 P
190 ± 11 bar
P
B
2
R
R1
1.2
1.2
A
B B B
9
A B A B A B
1 3 5 7 9
2 D0001330
1. Inlet manifold 6. Return manifold

2. Pressure relief valve 7. Lift control element
3. Detent element 8. Kick-out + float element
4. Kickout + float + NR element 9. End cover
5. Check valve
6-WAY VALVE WITH FLOW CONTROL
4 HYDRAULIC DIAGRAM
6 5 7 8
9 4 5 8 9
3 A A A T R1 A
A
R 210 bar
P
1 P
190 ± 11 bar
2 B
R
R1
1.2
1.2
B
B B
10 A
A B A B A B
1 3 6 7 10
2 D0001340
1. Inlet manifold 6. Check valve

2. Pressure relief valve 7. Return manifold
3. Detent element with flow control 8. Lift control element
4. Flow control 9. Kick-out + float element
5. Kick-out + float + NR element 10. Cover plate
10-34
8-WAY VERSION
5 4 6 7 8 9 HYDRAULIC DIAGRAM
4 8 9
3 A A A
T R1 A
A A
R
210 bar
P
190 ± 11 bar
1 P
2 B
1.2
1.2
1.2
R1
A
B B B B A B A B A B AB
1 3 5 6 7 10
10
2 D0001350

3. Detent element 8. Kick-out + float element
4. Kick-out + float + NR element 9. Kick-out + float element
5. Check valve 10. End cover
8-WAY VERSION WITH FLOW CONTROL
4
6 5 7 8 9 10 HYDRAULIC DIAGRAM
3 A A A A 4 5 9 10
A
T R1 A
1 P
R
P
190 ± 11 bar
B
R
2 210 bar
1.2
R1
1.2
1.2
1.2
B A
1.2
B B B
B
A B AB A B AB
11
1 3 6 7 8 11
2 D0001360

3. Detent element with flow control 9. Kick-out + float element
4. Flow control 10. Kick-out + float element
5. Kick-out + float + NR element 11. End cover
6. Check valve
10-35
DESCRIPTION OF COMPONENTS
DETENT ELEMENT
1 3 5 6
2 4
D0001670
1. Valve stem return spring 4. Valve stem detent ball

2. Valve stem detent spring 5. Cam
3. Ball 6. Valve stem
KICK-OUT ELEMENT
1 3 5 7
8
2 4 6
D0001680
1. Valve stem return spring 5. Cam

2. Valve stem detent spring 6. Spool
3. Slide 7. Ball
4. Valve stem detent ball 8. Valve stem
10-36
CHECK VALVE (NR)
3 4
5
D0001660
1. Slide 4. Valve seat

2. Ball 5. Spool
3. Check valve spring
FLOW CONTROL VALVE
1 2 3 4
D0001650
1. Adjustment knob 3. Flow regulator spool

2. Spring 4. Slide
10-37
AUXILIARY SERVICES CONTROL VALVE (LOAD SENSING)
FUNCTION
The function of the auxiliary services control valve is to control the flow of oil to the auxiliary services and the rear lift.
This control valve is of the parallel circuit Load Sensing type.
2 4
B A P T A R1 B A B A
210 bar
220 bar
Y
R
5 3 5 5 5
D0001930
REAR GEARBOX
DESCRIPTION
• The pressurised oil from the variable displacement pump (1) enters the manifold (2) from where it is distributed to the
valve elements through internal ports.
• The manifold (2) is equipped with an antishock valve (3) that prevents the pressure surges that are created when the
actuators reach the end of their stroke while the pump displacement is returned to zero.
• All the control valve elements, when operated, generate a pressure signal (Load Sensing signal) that is equal to the
pressure required at each work port.
The largest of the signals, selected by the bistable valve (5), is then sent to the variable displacement pump through
the Y port of the control valve.
• On the lift control element there is an anti-shock valve (4) (on the "raise" control side), which serves to prevent any ex-
cessive pressure surges caused by jolting of the implement.
10-38
DEFINITIONS OF VALVE ELEMENTS
NAME DESCRIPTION SYMBOL

DETENT
manual release.
Control element with mechanical spool retention and auto-

KICK-OUT
matic release when user pressure reaches pre-set level.
Control element that simultaneously connects the two

work ports to the exhaust passage, thereby allowing the
FLOAT
implement to "float".
NOTE: may also be used as a single-acting element.
This element includes a mechanically operated check

valve that ensures an effective seal and thus prevents
NR internal blowby from causing the cylinders to move.
The valve only allows oil to flow when the spool is ope-
rated.
Control element with priority flow control valve.

This element controls the flow rate of oil to the valve on
FLOW which it is mounted, sending the surplus oil to the other
CONTROL users.
The controlled flow rate is independent of the operating
pressure.
10-39
CONTROL VALVE TYPES
6-WAY VERSION
4 2 5 6 8 7 4 9 HYDRAULIC DIAGRAM
4
B
10
5 8 9
A A
3
A
BA P T A R BA B A 11
1 R1
1,2
210 bar
1,2
P
1
B T A B B
R P
11 Y
R
T
A
2 4 6 7 10
3 3 D0001920
1. End cover 7. Lift control element

2. Kick-out + float + NR element 8. Lift control antishock valve
3. Check valve 9. Detent element
4. Flow control 10. Kick-out + float + NR element
5. Manifold 11. Connection plate
6. Antishock valve
8-WAY VERSION
5 5 3 6 7 9 8 5 10 HYDRAULIC DIAGRAM
5
2 B
11 4 3 6 9 10 11
A A A A
R1 P BA BA P T A R BA B A
1 1 1,2 1,2 210 bar 1,2
T R
P
Y
R
B B A B B
12 T
A
2 5 7 8 12
D0001910
4 4 4
1. End cover 7. Pressure relief valve

2. Kick-out + float + NR element 8. Lift control element
4. Antishock valve 10. Detent element
5. Flow control valve 11. Kick out + float + NR element
10-40
8-WAY VERSION WITH PROPORTIONAL ELECTRICAL CONTROL
2 5 3 6 7 9 8 5 10
5 HYDRAULIC DIAGRAM
B
1 11 1 4 3 6 9 10 11
A A A A
P B A BA P T A R BA B A
R1 210 bar
1,2 1,2
F
2
0
1
T R c
d
X
P
Y
R
B B A B B
T
A
2 5 7 8 12
4 4
D0001900
4 12
1. End cover 7. Pressure relief valve

2. Electrically controlled element 8. Lift control element
4. Antishock valve 10. Detent element
5. Flow control 11. Kick out + float + NR element
10-41
DESCRIPTION OF COMPONENTS
MANIFOLD
The main functions of the manifold are to support the auxiliary service control valve stack, to distribute the oil flow from the
pump to the valve elements and to collect the return flows.
An antishock valve is installed in the manifold.
2 3
a 4
5
1
6
D0000580
c
COMPONENTS PORT CONNECTIONS

1. Manifold a. Port P - Fom LS hydraulic pump (Port B9)
2. Antishock valve seating b. Port T1 - From lift control element
3. Antishock valve spool (Port R1), or not utilised
4. Antishock valve spring c. Port T - Return to lift casing
5. Plug
6. Shims
10-42
POWER SHIFT CONTROL VALVE
B A
4 5 18
12
C
C
16
3 6
19
15
14 17
2
8
20
9 13
1
B
A-A B-B
11
A
D0001370
10
C-C
SOLENOID VALVES COMPONENTS 16. 1st gear engagement valve
1. 3rd gear control solenoid valve 6. Proportional solenoid valve 10. Reverse gear engagement valve 17. 2nd gear engagement valve
2. 2nd gear control solenoid valve for gear engagement modulation 11. Medium gear (M) engagement valve 18. Secondary pressure (P2) control valve
3. 1st gear control solenoid valve 7. Low gear (L) control solenoid valve 12. Forward gear engagement valve (setting 19 bar (275.5 psi))
4. Forward gear control solenoid valve 8. High gear (H) control solenoid valve 13. 3rd gear engagement valve 19. Main pressure (P1) control valve
5. Reverse gear control solenoid valve 9. Medium gear (M) control solenoid valve 14. High gear (H) engagement valve (setting 21 bar (304.6 psi))
15. Slow gear (L) engagement valve 20. Check valve
10-43
FUNCTION
The function of the Power Shift control is to pilot and control the engagement of the Power Shift gears.
The Power Shift control valve controls:
• engagement of forward and reverse gear (shuttle)
• engagement of 1st, 2nd and 3rd gear
• engagement of High, Medium and Low gear
This control valve also contains a pressure control valve (1) that maintains the Power Shift pressure (P1) and regulates the
operating pressure in the range gearbox control valves (2), the main clutch (3) and the services (4).
N H L 3° 2° 1° A B U2
ø2.5 ø2.5 ø2.5 ø2.5 ø2.5 3

4 bar 14 bar 14 bar 14 bar 14 bar 14 bar
ø2.5 ø2.5
12 bar 12 bar
L1
M3 19 bar
ø1.7
Hp. 21 bar
Md. 0..19 bar
U1
21 bar
0/19-19/0 bar
4
M2 T M1 P1
1
D0001380
10-44
OPERATION OF EACH CIRCUIT AND VALVE
HYDRAULIC DIAGRAM AND KEY TO VALVES
1. Power Shift pressure control valve:

L1 U1
U2 P1
21 bar (304.6 psi)
2. Pressure relief valve: 19 bar (275.5 psi)
ø2.5 1 21 bar
19 bar 3. Reverse gear engagement valve
3 12 bar
M1
B 4. Forward gear engagement valve
5. Proportional solenoid valve
ø2.5 2
12 bar for modulation of gear engagement
4
6. Shuttle control solenoid valve
A
0/19-19/0 bar
7. Check valve
6
0,3 bar 8. Gear engagement valve
5
9. 1st gear control solenoid valve
T
10. 2nd gear control solenoid valve
7 11. 3rd gear control solenoid valve
ø2.5
14 bar
8 9 0,3 bar
12. Low gear control solenoid valve

T P
1° A 13. High gear control solenoid valve

14. Medium gear disengagement valve
7 15. Medium gear control solenoid valve
ø2.5
0,3 bar
14 bar
8 10 T P
2° A
M2
7
ø2.5
0,3 bar
11
14 bar
8
Md. 0..19 bar
Hp. 21 bar
T P
3° A
7
ø2.5
0,3 bar
14 bar
8 12 T P
L A
7
ø2.5
14 bar
0,3 bar
8 13 T P
H A
14
4 bar
T P ø1.7
A
N 15
M3
D0001390
10-45
1. MAIN AND SECONDARY PRESSURE CONTROL VALVES
FUNCTION
The pressure control valves regulate the pressure of the fluid sent to the following circuits:
• main pressure control valve
a. range gearbox control
b. main clutch control
c. services control
d. gears and shuttle full engagement
• secondary pressure control valve:
a. gear engagement modulation (1st- 2nd-3rd-H-M-L)
b. shuttle engagement modulation
OPERATION
USERS
1
3
5
b
4 d
D0001400
• The pressurised oil from the pump (1) enters chamber a.

As long as there is no demand from any of the users, the oil remains in chamber a and the pressure starts to rise.
When the force exerted by the oil pressure on the spool (2) exceeds the force of the spring (3), the spool shifts to the left,
thereby connecting chamber a with chamber b and regulating the pressure in passage c to 21 bar (304.6 psi).
• As chamber b is closed, the oil pressure in the chamber increases.
• When the force generated by the oil pressure on the spool (4) exceeds the force of the spring (5), the spool shifts to the
left, thereby connectingchamber b with chamber d and regulating the pressure in chamber b and passage e to 19 bar
(275.5 psi).
10-46
2. GEAR ENGAGEMENT CONTROL SYSTEM (EXCLUDING M)
FUNCTION
The function of the gear engagement control system is to ensure correct and gradual gear shifts. The system comprises:
- Proportional solenoid valve (1)
- Gear control solenoid valves (2)
- Gear engagement valve (3)
The clutches (with the exception of the M gear clutch) are of the "positive" type: the clutch is engaged by the oil supply pres-
sure.
0/19-19/0 bar
0,3 bar
1
19 bar
P A
14 bar
ø2.5
21 bar
D0001410
TO USER
10-47
OPERATION
WHEN THE GEAR IS SELECTED

• The pressurised oil from the main pressure control valve P1 enters chamber a.
• When the solenoid valve (1) is energised, the oil from the proportional solenoid valve (2) flows through the check valve (3)
into chamber b and then through the stem of the solenoid valve (1) into chamber c.
At the same time, the oil is sent into chamber d to the engagement valve (4).
d 4 a 5
c
P1 (21 bar)
1
e
b
P2 (19 bar)
3 2 D0001420
Fig. 1 - Engagement stage

• The pressure increase piloted by the proportional solenoid valve (2) creates a force on the spool (4).
When the pressure exceeds 14 bar (203 psi) and the force acting on the spool (4) exceeds the force exerted by the spring (5),
the spool (4) shifts to the right.
• The pressurised oil in chamber a (21 bar (304.6 psi)) can thus flow through chambers d and c into the clutch control pas-
sage e.
At the same, the check valve (3) closes and the proportional solenoid valve is de-energised.
• The oil pressure in the circuit downstream of the check valve (4) is thus raised to 21 bar (304.6 psi) (main pressure P1).
d a 4 5
c
P1 (21 bar)
1
e
b
P2 (19 bar)
3 2 D0001430
Fig. 2 - Clutch engaged
10-48
WHEN THE GEAR IS DESELECTED

• When the gear is deselected, solenoid valve (1) is de-energised and the oil in chambers c and d is returned to the tank
through passage f.
• The oil pressure on the spool (4) is thus reduced and the spool is returned to the rest position under the action of the
spring (5).
• At the same time, the pressurised oil in the clutch control passage e is returned to tank and the clutch is disengaged.
d a 4 5
c
P1 (21 bar)
1
e
b
P2 (19 bar)
3 2 D0001440
Fig. 3 - Disengagement stage
10-49
3. ENGAGEMENT CONTROL SYSTEM FOR "M" GEAR
FUNCTION
The engagement control system for the M gear ensures correct and gradual engagement of the M gear. The system com-
prises:
- proportional solenoid valve (4)
- gear disengagement control solenoid valve (1)
- engagement valve (2)
The M clutch is of the "negative" type: the clutch is disengaged by the oil supply pressure.
P
ø1.7
21 bar A
T
0/19-19/0 bar
4 bar
4 P A
19 bar 1
T
D0002840
TO USER
WHEN "M" GEAR IS DESELECTED

• The pressurised oil from the main pressure control valve P1 enters chamber a.
• When gear is deselected, the solenoid valve (1) is energised and the oil in chamber a can flow into chamber b and from
there into the clutch control passage c.
• The pressure in passagec exerts a force on the spool (2) which overcomes the force of the spring (3) causing the spool
to shift to the right.
• This makes the connection between passage d and chamber e.
P2 (19 bar)
c
d
2 3
a P1 (19 bar) e b D0001450
10-50
MAIN CLUTCH CONTROL VALVE
WHEN "M" GEAR IS SELECTED
• When the gear is selected, the proportional solenoid valve (4) is energised. This valve sends oil to passage d at a pres-
sure of about 12 bar (174 psi).
After a slight delay, the solenoid valve (1) is de-energised. This connects chambers e and b, thereby allowing fluid to
flow between chambers c and d (Fig. 1).
P2 (19 bar)
4
c
d 2 3
a P1 (19 bar) e b
D0001460
Fig.1 - Engagement stage
• The proportional solenoid valve is piloted is such a way as to reduce the pressure and the oil in passage c is therefore
returned to tank through chambers b, and, d and proportional solenoid valve (4).
• The drop in pressure in passage c reduces the force exerted on the spool (2) so that the force of the spring (3) pushes
the spool to the left, thereby opening the connection between passages e and f and connecting the clutch supply line c to
the return to tank line (Fig. 2).
P2 (19 bar)
4
c
d
2 3
1
f
a e b
P1 (19 bar) D0001470
Fig. 2 - Clutch engaged
10-51
SERVICES CONTROL VALVE
MAIN CLUTCH CONTROL VALVE
A A
4 5 6 7 8
1 2 3
B-B
HYDRAULIC DIAGRAM
4 bar
REGOLATION BAND
2,5-14 bar
15 bar
21 bar 19 bar
A-A D0001060
1. Spool of heat exchanger by-pass valve 5. Piston

2. Spring of heat exchanger by-pass valve 6. Regulator spring
3. NC pressure switch (set to 4 bar (58 psi)) 7. Piston return spring
4. Push rod 8. Clutch control valve spool
10-52
RANGE GEARBOX CONTROL VALVE
SERVICES CONTROL VALVE
FUNCTION
The services control valve controls the following services:
• four-wheel drive engagement
• differential lock engagement
• engagement and braking of rear PTO
This control valve also mounts the low pressure sensor for the Power Shift control circuit.
HYDRAULIC DIAGRAM
4 3 2
B B B A B
1
A C A C A C P T
ø 1,2
21 bar 15 bar
2 1
5
D0001070
1. Solenoid valve for PTO engagement control

2. Solenoid valve for PTO neutral control
3. Solenoid valve for 4WD engagement control
4. Solenoid valve for differential lock control
5. NC pressure switch (set to 15 bar (217.5 psi))
10-53
FRONT SUSPENSION CONTROL VALVE
RANGE GEARBOX CONTROL VALVE
FUNCTION
The range gearbox control valve controls the operation of the range selector.
HYDRAULIC DIAGRAM
7 cm3 7 cm3
1 2
8,3-15 bar 8,3-15 bar
RH RM
6,3 cm3x 2
M12x1,5 M12x1,5
B B
A C A C
21 bar
1 2
D0001500
1. Solenoid valve for High range control

2. Solenoid valve for Low range control
10-54
PRIORITY VALVE (OC VERSION ONLY)
PRIORITY VALVE (For OC version only)
PP LS
EF CF
HYDRAULIC DIAGRAM
1 2
CF EF
LS
10 bar
D0001510
OPERATION
• The flow of oil from the pump is divided by the priority valve between the suspension control valve (1) (port CF) and the
other hydraulic components (2) (port EF)
• The division of the flow is determined by the position of the priority valve slide in accordance with:
a- the Load Sensing signal from the front axle suspension control valve (port LS);
b- the flow rate of oil from the pump;
c- the pressure in the front axle suspension circuit;
d- the pressure in the connected hydraulic circuit.
• The position of the slide ensures that the oil flow to the front axle suspension control valve always corresponds to the
actual demand.
10-55
POWER STEERING
POWER STEERING
L R
T P
HYDRAULIC DIAGRAM
150 bar
L
P
D0001520
OPERATION
• The power steering system consists of a control valve with a rotary spool; these components have hydrostatic op-
eration.
• When the steering wheel is turned, the rotary spool control valve sends the oil from the pump to one side or the other
of the steering cylinder.
The rotary spool ensures that that the volume of oil delivered to the cylinder is proportional to the angle through which
the steering wheel is turned.
• In the event of a malfunction of the power steering pump, the rotary spool valve automatically functions as a manual
pump to ensure emergency steering.
CHARACTERISTICS
• Pressure relief valve setting: 150÷155 bar (2175 -- 2248 psi)
• Maximum flow rate: 60 ᐉ/min (15.852 US.gpm)
10-56
TRAILER BRAKING VALVE
ITALY VERSION
FUNCTION
The trailer braking valve is fitted when hydraulic trailer braking is required.
OPERATION
3 P
2 B N 4
D0002850
1. Valve control lever in position “1”

• When the lever (1) is in position “1” (valve activated) and the brake pedals are not depressed, the pressure avail-
able at port B is 12.5 bar (181.3 psi).
• This pressure is constantly supplied to the trailer to release the parking brake.
In this condition, the pressure detected by the pressure switch (2) is higher than the pressure setting and con-
sequently the indicator light (3) on the instrument panel remains off.
• When the driver applies the handbrake, this operates the lever (4).
The pressure at port B is thus eliminated and the pressure switch (2), on detecting the lack of pressure, illuminates
the indicator light (3).
• The pressure at port B is directly proportional to the pressure present in the tractor braking circuit.
2. Valve control lever in position “O”

• When the lever (1) is in position “O” (valve deactivated), there is no pressure at port B.
The pressure switch (2) detects the lack of pressure and illuminates the indicator light (3) on the instrument panel.
In this condition, the pressure at port B remains null regardless of the pressure in the tractor braking circuit.
10-57
OC VERSION
Y1
P 0
1
N 0
E
Y2
B
T
HYDRAULIC DIAGRAM
P
Y1
Y2
N
E
B T D0001530
Port P - Oil supply to valve CHARACTERISTICS

Port N - To auxiliary services control valve • Maximum operating pressure at port N:
Port B - To trailer brake 200 bar (2900 psi)
Port Y1-Y2 - Connection to tractor braking system • Minimum constant pressure at port B:
Port T - Return 12.5±2 bar (181.3±29 psi)
Port E - Parking brake pressure switch • Maximum pressure at port B:
135±5 bar (1958±72.5 psi)
• Oil delivery flow rate:
20÷80 ᐉ/min (5.3 -- 79.7 US.gpm)
10-58
LS VERSION
Y1
LS
P o
1
o
N
E
Y2
B
HYDRAULIC DIAGRAM
P
Y1
Y2
N LS
E
B T D0001550

Port T - Return • Minimum constant pressure at port B:
Port Y1-Y2 - Connection to tractor braking system 12.5±2 bar (181.3±29 psi)
Port LS - Load Sensing signal • Maximum pressure at port B:
130±5 bar (1885±72.5 psi)
Port E - Parking brake pressure switch
20÷80 ᐉ/min (5.3 -- 79.7 US.gpm)
10-59
EXPORT VERSION
FUNCTION
The trailer braking valve is fitted when hydraulic trailer braking is required.
OPERATION
B N
D0002860
• When the brakes are not applied there is no pressure at port B.

• When the driver applies the tractor brakes, the pressure in the circuit pilots the braking valve and the pressure at port
B increases in proportion to the pressure in the tractor brakes circuit.
10-60
OC VERSION
Y1
Y2
B
HYDRAULIC DIAGRAM
P T
Y1
Y2
N B
D0001540

Port Y1-Y2 - Connection to tractor braking system • Minimum constant pressure at port B:
Port T - Return 0 bar (0 psi)
• Maximum pressure at port B:
135±5 bar (1958±72.5 psi)
20÷80 ᐉ/min (5.3 -- 79.7 US.gpm)
10-61
LS VERSION
Y1
Y2
LS B LS
HYDRAULIC DIAGRAM
P T
Y1
Y2
N B LS
D0001560

Port T - Return • Minimum constant pressure at port B:
Port Y1-Y2 - Connection to tractor braking system 0 bar (0 psi)
Port LS - Load Sensing signal • Maximum pressure at port B:
130 +0 5 bar (1885 +0 72.5 psi)
20÷80 ᐉ/min (5.3 -- 79.7 US.gpm)
10-62
POWER SHIFT TRANSMISSION
DESCRIPTION
The Power Shift transmission is an 18-speed gearbox with electronically controlled electro-hydraulic operation.
It comprises:
1- H-M-L unit
2- Main clutch
3- Intermediate gearbox
4- Rear gearbox
H-M-L UNIT INTERMEDIATE GEARBOX REAR GEARBOX
TABLE OF GEARS SHOWING CLUTCHES ENGAGED

❍ Gear engaged
— Gear disengaged
GEAR H-M-L CLUTCHES INTERMEDIATE GEARBOX CLUTCH

(As shown on display)
L RANGE V RANGE L M H 1st 2nd 3rd
01 10 ❍ — — ❍ — —
02 11 — ❍ — ❍ — —
03 12 — — ❍ ❍ — —
04 13 ❍ — — — ❍ —
05 14 — ❍ — — ❍ —
06 15 — — ❍ — ❍ —
07 16 ❍ — — — — ❍
08 17 — ❍ — — — ❍
09 18 — — ❍ — — ❍
10-63
1. H-M-L UNIT
DESCRIPTION
The H-M-L unit is comprised of a wet multiplate clutch that controls engagement of the H speeds and two single-plate
clutches that control engagement of the M and L speeds.
The M and L speeds are obtained through a double-ratio epicyclic reduction unit, while the H speed is obtained through a
direct connection between the driven shaft and the driving shaft.
3 4
D0001580
1 11 2 10 9 8
COMPONENTS
1- Drive shaft 7- L speed engagement clutch
2- H speed engagement clutch 8- L speed sun gear
3- Planet pinion 9- M speed sun gear
4- M speed engagement piston 10 - Driven shaft
5- M speed engagement clutch 11 - H speed engagement piston
6- L speed engagement piston
10-64
OPERATION
• L speed engagement
ECU
H M L
5 6 3 4 2 D0001590
• When L speed is selected, the electronic control unit energises the M and L solenoid valves and oil flows into the
chambers a and b of the H-M-L unit.
• This pushes the M and L clutch pistons (1) and (2) to the left, thereby disengaging the M speed clutch plate (3) and en-
gaging the L speed clutch plate (4).
• The L clutch plate (4) is thus locked with the housing of the H-M-L unit and the drive shaft (5) transmits drive to the driv-
en shaft (6).
10-65
• M speed engagement
★ The following description refers to the shift from L to M speed.
ECU
H M L
7 8
5 6 3 4 2 D0001600
• When M speed is selected, the electronic control unit de-energises both solenoid valves (M) and (L).
• The oil contained in chambers a and b is returned to tank and the pistons (1) and (2) are pushed to the right by springs (7)
and (8).
• As a result, the L clutch plate (4) is disengaged while the M clutch plate (3) is engaged.
• The M clutch plate (3) is thus locked with the housing of the H-M-L unit and the drive shaft (5) can transmit drive to the
driven shaft (6).
10-66
• H speed engagement
★ The following description refers to the shift from M to H speed.
ECU
H M L
5 9 10 6 3 D0001610
• When H speed is selected, the electronic control unit energises the solenoid valves H and M and oil flows into the
chambers a and c of the H-M-L unit.
• As a result, the piston (1) is pushed to left thereby disengaging the M clutch plate (3), while piston (9) is pushed to the
right, thereby engaging the H speed clutch plates (10).
• The drive shaft (5) is thus locked with the driven shaft (6).
10-67
2. MAIN CLUTCH
DESCRIPTION
The main clutch is a wet multiplate unit with hydraulic control.
When the shuttle is in neutral, the main clutch is disengaged.
Clutch engagement is controlled by a pilot valve controlled by the shuttle and is automatic.
The driver can however maintain full control of the vehicle and modulate clutch engagement by using the clutch pedal and
thus bypassing the automatic system.
3 4 1 1 A 6 7 8 9
2
A -A
5 11 10
A
D0001620
COMPONENTS
1- Manifold 7- Friction plate
2- Pilot valve 8- Drive plate
3- Spring 9- Hub
4- Choke (Ø 0.7 mm (0.0275 in.)) 10 - Driven shaft
5- Drive shaft 11 - Piston return spring
6- Main clutch engagement piston
10-68
CLUTCH CONTROL SCHEMATIC
D0001630
COMPONENTS
1 - Clutch control pedal
2 - Clutch control cable
3 - Main clutch control valve
4 - Shuttle control unit
5 - Main clutch manifold
6 - Main clutch
10-69
OPERATION
A. When the engine is started

• When the engine is switched off, the main clutch is disengaged by the action of the spring (1) as clutch pilot passage
a is connected with the drain port by the spool (2).
ECU a
3 4 b c d 1
D0001640
• When the engine is started, the pump (3) sends oil under pressure to the main clutch control valve (4).
• If the driver does not keep the clutch pedal depressed, the oil can flow through the control valve (4) into passage b.
• Chamber c is filled and the oil flows through passage d on the opposite side of the spool (2).
• As neither forward or reverse drive has been selected, chamber e is closed and spool (2) is held in position by spring (5).
10-70
B. When drive is selected (without use of the clutch pedal).
f x1 9 x 8
ECU a
6 7
c g 1
D0001690
• When forward or reverse drive is selected, the electronic control unit (6) energises the solenoid valve (7) that controls
the shuttle unit (8). The pressurised oil flows into chamber x of the shuttle unit and moves the piston (9), while the oil
in the opposite chamber x1 is returned to tank.
• As a result of the shifting of piston (9), the passage connecting line f and the return circuit is opened so the oil in cham-
ber e flows into the return circuit and the pressure is reduced.
• In chamber g the pressure remains unchanged and the force exerted overcomes the force of the spring (5) to move
the spool (2) upwards.
• Chamber c is thus connected with passage a and the clutch is engaged.
10-71
C. When the driver presses the clutch pedal when the tractor is moving
ECU a
3 4 b c
D0001700
• When the clutch pedal is partially depressed, some of the oil from the pump (3) is discharged from the main clutch
control valve (4).
• As a result the pressure is reduced in passage b, in chamber c and in passage a, thereby giving manual control.
ECU a
3 4 b c
D0001710
• If the driver fully depresses he clutch pedal, the pressurised oil in passage a is returned to tank.
• As a result the pressure in chamber g is eliminated, the spool (2) is pushed downwards by the force of the spring (5)
thereby making a connection between passages a and h and engaging the clutch.
10-72
3. INTERMEDIATE GEARBOX
DESCRIPTION
The intermediate gearbox allows selection of 1st, 2nd and 3rd speeds and the direction of travel.
The intermediate gearbox thus contains three wet multiplate clutches (for engagement of 1st, 2nd and 3rd speeds) and a
mechanically controlled forward/reverse shuttle with synchronizer.
The intermediate gearbox comprises:
1 - Primary shaft
2 - Secondary shaft
3 - Driven shaft
4 - Shuttle unit
2 4 D0001720
10-73
1 2 3 4 5 6
18 17 16 15 14 13 12 11 10 9 8 D0001730
COMPONENTS
1- Drive shaft (primary shaft) 7- Reverse travel idle gear 13 - 3rd speed clutch
2- 3rd speed driving gear 8- Driven shaft 14 - 3rd speed engagement piston
3- Foward travel driving gear 9- Reverse travel driven gear 15 - 1st speed engagement piston
4- Reverse travel driving gear 10 - Shuttle synchronizer 16 - 1st speed clutch
5- 2nd speed clutch 11 - Foward travel driven gear 17 - 1st speed driven gear
6- 2nd speed engagement piston 12 - 3rd speed driven gear 18 - Intermediate shaft (Secondary shaft)
10-74
3.1 PRIMARY SHAFT

4 5
1 13 10 6
14 2 12 3 11 9 8 7 D0001740
1. Drive shaft 8. Piston return spring

2. 3rd speed driving gear 9. Reverse travel driving gear
3. Foward travel driving gear 10. Hub
4. 2nd speed clutch 11. Roller cage
5. 2nd speed engagement piston 12. Thrust bearing
6. Distance piece 13. Taper roller bearing
7. Taper roller bearing 14. Self-aligning roller bearing
3.2 SECONDARY SHAFT
2 3 4 5
6 7
1
15
14
13 12 11 10 9 8 D0001750
1. Thrust washer 9. Taper roller bearing

2. Roller cage 10. 3rd speed piston return spring
3. 1st speed piston return spring 11. 1st speed engagement piston
4. 3rd speed engagement piston 12. 1st speed clutch
5. 3rd speed clutch 13. 1st speed driven gear
6. 3rd speed driven gear 14. Taper roller bearing
7. Roller cage 15. Intermediate shaft (Secondary shaft)
8. Foward travel driven gear
10-75
3.3 DRIVEN SHAFT AND SHUTTLE UNIT
2 4
3
1
7 9
11 10 8 12
15 14
13
D0001760
1. Ball 9. Bearing
2. Cylinder 10. Reverse travel driven gear
3. Spring 11. Synchronizer
4. Spring 12. Reverse travel idle gear
5. Push rod 13. Bearing
6. Lever 14. Shaft
7. Roller cage 15. Bushing
8. Driven shaft
10-76
4. REAR GEARBOX
DESCRIPTION
The rear gearbox serves to select the High speed (H) and the Low speed (L) ranges.
The rear gearbox also contains the 4WD drive engagement clutch and the parking brake unit.
The rear gearbox comprises:
1- Creeper unit
2 - Range control unit
3 - 4WD control clutch
4 - Parking brake unit
4 3 D0001770
10-77
4.1 CREEPER UNIT
10 11 12
13
2 3 14
1
4
5
8
D0001780
7 6
1. Ring gear carrier 8. Shim

2. Planet pinion 9. Bearing
3. Ring gear 10. Lever
4. Disc 11. Spacer
5. Hub 12. Control shaft
6. Flange 13. Selector rod
7. Planet carrier 14. Selector fork
10-78
4.2 RANGE CONTROL UNIT
12
13
14
15
11
16
1 2 3
4 18
17
10 5
9 6
7 7
D0001790
1. Bearing 10. Driving gear

2. Taper roller bearing 11. Range engagement sensor
3. Low range driven gear 12. Range gearbox control valve
4. Distance piece 13. Piston
5. Roller cage 14. Hub
6. Synchronizer 15. Roller cage
7. Taper roller bearing 16. Lever
8. Range gearbox idler gear 17. Selector fork
9. Thrust washer 18. Selector rod
10-79
4.3 4WD CONTROL UNIT AND PARKING BRAKE
3
1 2
14
6
7
16 8
15
13
12 11 10 D0001800
1. Oil seal 9. 4WD clutch

2. Taper roller bearing 10. Guide pin
3. 4WD driven gear (parking brake hub) 11. Brake pads
4. Plain discs 12. Parking brake control rod
5. 4WD driving gear 13. Parking brake control cam
6. 4WD engagement piston 14. Thrust washer
7. Taper roller bearing 15. Parking brake control lever
8. 4WD piston return spring 16. 4WD output shaft
10-80
FRONT AXLE
FRONT AXLE
1. HUB CARRIER AND FINAL REDUCTION UNIT
7
8
5 6
4
3
9
2
10
1
11
21
20
12
19
18
17 16 15 14 13 D0001810
1. Planet carrier 12. Roller cage

2. Pin 13. Lower kingpin
3. Planet pinion 14. Plain disc
4. Flange 15. Hub carrier
5. Brake disc 16. Oil seal
6. Brake piston 17. Flange
7. Steering sensor 18. Ring gear
8. Upper kingpin 19. Ball cage
9. Taper roller bearing 20. Oil seal
10. Half-shaft 21. Bearing
11. Oil seal 22. Roller cage
10-81
FRONT AXLE
2. DIFFERENTIAL
5 6
4
7 8
3 9
2
10
11
1
21
20
12
13
19
18
17 16 15 14 D0001820
1. Diferential housing 12. Distance piece

2. Crown wheel 13. Taper roller bearing
3. Cross pin 14. Spring
4. Flange 15. Flange
5. Planet pinion 16. Taper roller bearing
6. Taper roller bearing 17. Roller cage
7. Planet pinion 18. Differential lock piston
8. Differential cage 19. Cover
9. Taper roller bearing 20. Bearing
10. Oil seal 21. Diiferential lock clutch
11. Bevel pinion shaft
10-82
REAR AXLE
REAR AXLE
1. FINAL REDUCTION UNIT AND BRAKE
1 2 3 4 5 6 7 8 9 10
21
20 19 18 17 16 15 14 13 12 11
D0001950
1. Brake piston 12. Oil seal

2. Planet pin 13. Taper roller bearing
3. Planet pinion 14. Flange
4. Roller cage 15. Thrust plate
5. Planet carrier 16. Ring gear
6. Taper roller bearing 17. Brake housing
7. Oil seal 18. Brake disc
8. Axle casing 19. Intermediate disc
9. Distance piece 20. Flange
10. Cover 21. Half-shaft
11. Half-shaft
10-83
REAR AXLE
2. DIFFERENTIAL
1 2 3 4 5 6
15
10
11
14 13 12
D0001940
1. Taper roller bearing 9. Planet pinion

2. Differential cage 10. Differential lock clutch
3. Bushing 11. Planet pinion
4. Lock ring 12. Bevel pinion
5. Crown wheel 13. Taper roller bearing
6. Differential housing 14. Pin
7. Taper roller bearing 15. Planet pinion
8. Differential lock control piston
10-84
REAR PTO
REAR PTO
DESCRIPTION
The rear power take-off transmits torque from the engine to a mounted implement at a predetermined rotation speed.
Drive is taken directly from the engine and then reduced through a 2-speed gearbox with manual control.
PTO engagement is controlled by the PTO control clutch with electrohydraulic control.
2
1 3 4 5 6 7
A 9
17 10
16
23 22 21 20 19 18
11
A
15 14 13 12
A-A D0001960
COMPONENTS
1. Input shaft 13. Flange
2. PTO control clutch unit 14. High speed driven gear
3. Ball bearing 15. Low speed driven gear
4. Drive shaft 16. Driven shaft
5. Roller bearing 17. Roller bearing
6. High speed driving gear 18. Lever
7. Ball bearing 19. Spring
8. Cover 20. Shoe
9. Ball bearing 21. Key
10. Power take-off 22. Fork
11. Guard 23. Rod
12. Oil seal
10-85
REAR PTO
PTO CONTROL CLUTCH UNIT
4 B 5 A
7
3
6
B A-A A
9 10
11
8
12
16
13
15 B-B 14 D0001970
COMPONENTS
1. Accumulator piston 9. Lower brake piston
2. Spring 10. Upper brake piston
3. Cylinder 11. Housing
4. Pressure relief valve spool 12. Bearing
5. Pressure relief valve spring 13. Bearing
6. Clutch drum 14. Clutch engagement piston
7. Brake band 15. PTO engagement clutch
8. Piston return spring 16. Hub
10-86
REAR PTO
OPERATION
1. When the PTO is engaged
9 A B
8
d c
4
6
3
b
7 e
D0001980
• When the operator selects the PTO, solenoid valve (1A) is energised and the pressurised oil from the pump (2) can
flow into line a.
• The pressurised oil from solenoid valve (1) flows into chamber b of the accumulator (3) and into passage c of the pres-
sure relief valve (4).
• At the same time, the pressurised oil in line d is returned to tank, thereby releasing the brake.
• As the pressure increases in chamber b, the force on the piston (5) compresses the spring (6).
As the stroke of the piston (5) increases, there is a corresponding increase in the pressure in chamber b and in cham-
ber e of piston (7). As a result, clutch engagement pressure is modulated within a pressure range of 3 to 7 bar (43.5
and 101.5 psi).
• When the pressure in line a reaches 12 bar (174 psi), the force exerted on spool (8) overcomes the force of spring (9)
and spool (8) shifts upwards thereby opening the passage between line c and drain.
This regulates the hydraulic circuit pressure to 12 bar (174 psi).
10-87
REAR PTO
2. When the PTO is disengaged

When the operator disengages the PTO, there are two possibilities:
a. the operator selects disengagement and simultaneous braking of the PTO:
this solution is used when the implement coupled to the PTO has minimal inertial mass (e.g. a flail cutter).
b. the operator selects disengagement of the PTO allowing the PTO shaft to gradually come to a stop on its own (PTO
brake disengaged):
this solution is used when the implement coupled to the PTO has a high inertial mass (e.g.: a baler).
a. PTO disengagement with braking.
A B
12
f d c
2
11 1
10 7 e b D0001990
• On selecting PTO disengagement with braking, solenoid valve (1) is de-energised.

• The pressurised oil in line a is returned to tank through solenoid valve (1).
• As a result of the loss of pressure in line a, the piston (5) is pushed downwards by the spring and the piston (7) is shifted
to the right to the rest position by the spring (10).
• Simultaneously the pressurised oil from the pump (2) flows into line d and thus enters chamber f.
• The force of the pressure pushes pistons (11) and (12) respectively downwards (piston 11) and upwards (piston 12).
• The force exerted by the piston (11) and the brake band (13) on the clutch drum brakes the PTO.
10-88
REAR PTO
b. PTO disengagement without braking.
A B
A
10 7 D0002000
• On selecting PTO disengagement without braking, solenoid valve (1B) is energised.

• The pressurised oil in line a is returned to tank through the solenoid valve (1).
• As a result of the reduced pressure in line a, piston (5) is pushed downwards by the spring while piston (7) is shifted
to the right to the rest position by the spring (10).
10-89
REAR POWER LIFT
REAR POWER LIFT
A 13
1 2 3 4 5 6 7 8 9
B
B
A-A B-B
14 13 12 11 10 5
D0001840
COMPONENTS 8. Shaft
1. Connecting rod 9. Right lift arm
2. Seal 10. Right-hand bushes
3. Piston 11. Spring pin
4. Left lift arm 12. Left-hand bushes
5. Distance piece 13. Cam
6. Lift housing 14. Cylinder
7. Lever with ball seat
10-90
REAR POWER LIFT
POWER LIFT CONTROL UNIT (LS)
DESCRIPTION
• The power-lift control unit comprises a 1-way hydraulic control valve controlled by two proportional solenoid valves.
• It is equipped with an antishock valve that protects the hydraulic circuit against pressure surges caused by jolting of
the implement during work and transport.
HYDRAULIC DIAGRAM
P Y R
A 210 bar
P Y R
1 2 3 4 5 7
D0001830
11 10 9 8 6
COMPONENTS 7. "Lower" control solenoid

1. "Lift" control solenoid 8. Flow control valve spring
2. Check valve 9. Flow control valve spool
3. Check valve spring 10. Spring
4. Antishock valve 11. "Lift" control valve spool
5. Antishock valve spring
6. "Lower" control valve spool
10-91
REAR POWER LIFT
OPERATION
1. When the power lift is not operated (neutral position)
• The pressurised oil from the pump flows into chamber a and into passage b.
• At the same time, oil flows into chamber c of the flow control valve (1) through passage d.
• This causes the spool to shift to the right, thereby closing the communicating passage between chamber a and pas-
sage b.
• The pressure in chamber e caused by the weight of the mounted implement (e.g.: a plough), keeps the check valve (2)
closed, so that the power lift maintains its position.
• Chamber e is thus closed off and prevents any uncontrolled movement of the power lift.
• The pressure in chamber e also acts on the antishock valve (3) that protects against any pressure surges caused by
jolting of the implement during work or transport.
.
e 3
c b d a 1 D0001850
10-92
REAR POWER LIFT
2. When "Lift" is selected

• When "Lift" is selected, the power lift control unit energises the solenoid (4) which shifts the spool (5) to the right.
• The pressurised oil in passage b can thus flow through the check valve (2) into chamber e and from there into the pow-
er lift cylinders.
• At the same time, the pressurised oil in passage b can flow into passage f, and from there, through channel g into
chamber h of the flow control valve (1).
• As the force exerted by the oil pressure is the same on both sides of the spool, the spool shifts to the left under the
force of spring (6) and the oil can flow from chamber a into passage b.
e 2
4 5
D0001860
b 1 g a 6 h
10-93
REAR POWER LIFT
3. When "Lower" is selected

• During lifting and when the power lift is stationary, spool (8) is pushed to the right by spring (9).
• As a result, the passage between chambers m and n is closed, and the pressure in chamber p pushes spool (10) to
the right.
• When "lower" is selected, the power lift control unit energises solenoid (7), which moves spool (8) to the left.
• The pressurised oil in chamber n can flow into chamber m and the pressure in chamber p falls.
• At the same time, spool (8) pushes spool (10) to the left, thus opening the passage between chamber e and chamber
m, which is connected to the tank return circuit.
• As a result, the oil in the lift cylinders is returned to tank and the lift arms lowered.
• As the solenoid is of the proportional type, the greater the current supplied to the solenoid coil, the further the spool (8)
shifts to the left, thereby increasing the flow of oil, and the faster the lift descends.
• Float position is obtained when the lift control unit energises solenoid (7) to maintain the maximum aperture.
• As a result, the oil in the lift cylinders is returned to tank and the lift arms are free to move up and down and follow the
contours of the terrain.
10 e n m 9 8
p
7
D0001870
10-94
BRAKING SYSTEM
BRAKING SYSTEM
DESCRIPTION
The braking system comprises 4 brakes (1 per wheel) operated by two mechanically controlled hydraulic pumps.
Each pump supplies oil to the brakes on one side of the tractors (right-hand and left-hand side), thereby allowing the op-
erator to brake on one side only and thus reduce the turning radius.
The braking circuit incorporates a “Separate-Brakes” which allows braking of the rear wheel only when the operator brakes
on just one side.
1 2 3 4 5
D0002310
1. Front axle
2. Right-hand brake cylinder
3. Left-hand brake cylinder
4. Separate-Brakes valve
5. Rear axle
10-95
BRAKING SYSTEM
“SEPARATE-BRAKES” VALVE
FUNCTION
The “Separate-Brakes” valve has the function of excluding front wheel braking when only one of the two brake pedals is
pressed.
ON
OFF
HS
AR
AL AR
PL
PR
PL PR
L R
ON OFF
AL AR
L pedal OFF ON
HS
R pedal
PL PR
L R
Both pedals
D0002321
10-96
BRAKING SYSTEM
2 3 4
11
HS
10
5
5
6
6
7
7 AL AR
8
8
PL PR
9
9
L R
D0002330
COMPONENTS
1. Control rod 7. Push rod
2. End cover 8. Ball
3. Flange 9. Spring
4. Control knob 10. Spring
5. Piston 11. Ball
6. Spring
10-97
BRAKING SYSTEM
OPERATION
1. When the valve is not activated

★ The following explanation refers to the situation in which the operator depresses only one of the two brake pedals; the
operation of the valve is the same for either pedal.
HS
3
AL AR
PL PR
L R
D0002340
• When the valve is not activated, the piston (1) is in the low position and the springs (2) push the slide (3) downwards.
• When one of the brake pedals is depressed (e.g. the right-hand pedal), the oil pressure pushes the push-rod (3) up-
wards against the piston (1), leaving open the communicating passage between chambers a and b.
• As a result, the oil pressure can reach both brakes on the side corresponding to the pedal depressed.
10-98
BRAKING SYSTEM
2. When the valve is activated and only one of the brake pedals is depressed
b
AL AR
PL PR
L R
D0002350
• When the valve is activated, the pistons (1) are in the upper position.
• When one of the brake pedals is depressed (e.g. the left pedal), the oil pressure pushes the push-rod (3) upwards,
overcoming the force of the spring (2).
• At the same time, the ball (4) is pushed upwards by spring (5) to close the passage connecting chambers a and b.
• As a result, the pressurised oil from the brake cylinder is sent to the rear wheel brake only.
10-99
BRAKING SYSTEM
3. When the valve is activated and both brake pedals are depressed
c 2
d
3
3
AL AR
PL PR
L R
D0002360
• When the valve is activated and both brake pedals are depressed, the oil under pressure is sent to chambers c and d.
• As the pressure acting on the push-rods (3) is the same, they are both pushed downwards under the action of the
springs (2) alone.
• As a result, the oil from the brake cylinders reaches the front and rear brakes on both sides.
• If follows that, even if the operator forgets to deactivate the valve on completion of field work, full braking is still guar-
anteed on all four wheels when both pedals are depressed.
10-100
HYDRAULIC FRONT AXLE SUSPENSION
HYDRAULIC FRONT AXLE SUSPENSION
The hydraulic front axle suspension serves to smooth the ride over rough terrain and to maintain the tractor level during
road transport.
The system comprises:
• axle support arm (1)
• position sensor (2)
• 2 suspension cylinders (3)
• front suspension control valve (4)
• electronic control unit (5)
1 D0002870
10-101
FUNCTION
In addition to its primary function of controlling the suspension of the front axle by way of the charge in the hydraulic/pneu-
matic accumulators, the front suspension control valve also serves to control the raising and lowering of the front axle.
4
ASP1
T
7
SV1
1 A
BL2 RV3
8
DBV2 LS
LS-V
BL3
2 A 5
SV2 ASP2 B ZSP1
BL1
RV1
4 6
HYDRAULIC DIAGRAM ASP1
A LS
LS
LS-V P T
BL3
DBV1
ASP1 ASP2 T
BL2 S
DBV1 DBV2
SV1
AV
RV3
AV
210 bar 210 bar RV2
A
ZSP1 RV2
H
ASP2
SV2
RV1 BL1
B P
View A
D0002370
1. Solenoid valve controlling cylinder extension 5. Pressure discharge cock

2. LS signal control solenoid valve 6. Accumulator (setting 140 bar)
3. Solenoid valve controlling cylinder retraction 7. User A safety valve (setting 210 bar)
4. Accumulator (setting 65 bar) 8. User B safety valve (setting 210 bar)
10-102
OPERATION
1. When the suspension is deactivated
LS
A
LS 1
LS-V
BL3
P T 7
6 ASP1 ASP2 T
BL2 S
4
DBV1 DBV2
SV1
AV
RV3
A 210 bar 210 bar
3 ZSP1
RV2
5 2
H
b
SV2
BL1
B RV1 P
D0002380
• When the suspension is deactivated, the electronic control unit energises solenoid valve (1), sending an LS signal to
the priority valve in the OC version and to the variable displacement pump in the LS version.
• As a result, the pressurised oil from the pump (2) reaches line a and compresses the membrane of the accumulator (3)
up to the maximum circuit pressure.
• The oil is exhausted from the piston side via line B through solenoid valve (7), which is energised.
• Consequently, the cylinder piston (4) is pushed upwards to its end-of-stroke, thereby returning the system to the
fixed axle condition.
• The suspension system is deactivated by the operator pressing a switch.
10-103
2. When the suspension is activated
A
LS
LS
LS-V
P T
BL3
6 ASP1 ASP2 T
BL2 S
4
DBV1 DBV2
SV1
AV
RV3
5
A 210 bar 210 bar
ZSP1 RV2
2
b H
SV2
BL1
B RV1 P
D0002390
• When the operator presses the switch to activate the suspension, the control unit energises the solenoid valves (1)
and (5).
• As a result, the pressurised oil from the pump (2) enters passage b and starts to push piston (4) downwards.
• At the same time, the oil compresses the membranes of the accumulators and the oil in passages a and b.
• When the pressure in passage a reaches the pressure setting of the safety valve (8), the valve (8) opens allowing some
of the oil to return to tank.
• When the position sensor detects that the tractor is level, the electronic control unit de-energises the solenoid valves (1)
and (5) and the prefilled accumulator circuit is isolated from the rest of the system.
10-104
3. When the system is active

• When the tractor is moving and the wheels encounter an obstacle, the front axle is pushed upwards.
• As a result, the pressure P2 increases (the accumulators 3 are compressed) while the pressure P1 decreases (ac-
cumulator 2 is decompressed).
• The relationship between the two pressures is thus altered and the system (being closed) tries to restore the original
condition.
A
LS
LS
LS-V
P T
BL3
6 ASP1 ASP2 T
BL2 S
DBV1 DBV2
SV1
P2 AV
RV3
5
A 210 bar 210 bar
ZSP1 RV2
2
P1 H
SV2
BL1
B RV1 P
D0002880
P2 max
P2
t
P1
P1 min
t shock t damping t
D0002411
10-105
CONTENTS
SECTION 20
CONTENTS
SYSTEM FOR TESTING AND CALIBRATION OF ELECTRICAL DIAGRAMS

ELECTRONIC COMPONENTS • Functional diagram ................................................... 87
• System conformation.................................................. 1 • 0.011.5375.4 Suspended front axle wiring ............... 88
• Connection of the Tester to the ECU.......................... 2 • 0.011.5376.4 Suspended front axle cab wiring (1/2) 89
• Introductory screen..................................................... 3 • 0.011.5376.4 Suspended front axle cab wiring (2/2) 90
• 0.011.5445.4 Diagnostic wiring................................. 91
ENGINE ECU TESTER
• 0.011.7032.4 Wiring for press. cab (Germany) ......... 92
• Manual ........................................................................ 5
• 0.010.8700.4 Cab roof wiring (1/2)............................ 93
• List of alarm codes ................................................... 23
• 0.010.8700.4 Cab roof wiring (2/2)............................ 94
TRANSMISSION ECU TESTER • 0.010.8704.4 Cab FPS wiring (1/2) ........................... 95
• Manual ...................................................................... 27 • 0.010.8704.4 Cab FPS wiring (2/2) ........................... 96
• List of alarm codes ................................................... 41 • 0.010.8705.4 Front wiring (1/2) ................................. 97
• 0.010.8705.4 Front wiring (2/2) ................................. 98
LIFT ECU TESTER • 0.010.8707.4 Draft angle sensor wiring .................... 99
• Manual ...................................................................... 53
• 0.010.8708.4 HS subframe wiring (1/4)................... 100
• List of alarm codes ................................................... 68
• 0.010.8708.4 HS subframe wiring (2/4)................... 101
ARMREST ECU TESTER • 0.010.8708.4 HS subframe wiring (3/4)................... 102
• Manual ...................................................................... 71 • 0.010.8708.4 HS subframe wiring (4/4).................. 103
• List of alarm codes ................................................... 85 • 0.010.8710.4 HS central wiring (1/2)....................... 104
• 0.010.8710.4 HS central wiring (2/2)....................... 105
• 0.010.8711.4 Rear light cables ............................... 106
• 0.010.8712.4 Switches wiring (1/2) ......................... 107
• 0.010.8712.4 Switches wiring (2/2) ......................... 108
• 0.010.8714.4 Light cables....................................... 109
• 0.010.8715.4 Battery cables ................................... 110
• 0.010.8716.4 Rear wiring (1/2) ................................ 111
• 0.010.8716.4 Rear wiring (2/2) ................................ 112
• 0.010.8717.4 FPS wiring (1/2) ................................. 113
• 0.010.8717.4 FPS wiring (2/2) ................................. 114
• 0.010.9139.4/10 Manual climate control wiring...... 115
• 0.011.8454.4 A/C compressor wiring ..................... 116
• 0.011.8747.4 wiring with 3 relays for steering
column lights switch .................................................. 117
• 0.011.9643.4 35S Wiper timer wiring...................... 118
• 1.0442.6899 Brake wiring (Germany)...................... 119
• 2.8399.146.0/50 Instrument with computer L1....... 120
20-i
SYSTEM FOR TESTING AND CALIBRATION OF ELECTRONIC COMPONENTS
SYSTEM FOR TESTING AND CALIBRATION OF ELECTRONIC

COMPONENTS
SYSTEM CONFORMATION
Electronic components are calibrated using the same device as that used for retrieval of diagnostic information - the «ALL
ROUND TESTER ®», hereafter referred to with the abbreviation ART®.
This device is used to check the alarm codes that are displayed on the on-board computer and to enter or modify operating
parameters relative to:
• The engine and SBA Electronic Control Unit
• The transmission Electronic Control Unit
• The Lift Electronic Control Unit
• The armrest and console Electronic Control Unit
The transfer of data between the ECUs and the ART® is achieved by connecting the ART® to the diagnostics socket lo-
cated on the right-hand console or to the diagnostics socket located on the armrest.
The following section describes all the screen pages displayed on the ART® relative to each ECU, along with instructions
on which keys to press at each step in the programming procedures and the functions of each submenu. This information
should enable the technician to carry out the programming required for a specific tractor, to perform the necessary cal-
ibrations and to display lists of the alarms detected by the ECUs.
Each section dealing with a specific ECU is completed by a list of the alarm messages that may be displayed on the Tester,
along with the possible causes and the points to check, as well as the actions performed by the ECU on detecting the alarm
in question.
cod. 5.9030.730.0
cod. 011.5445.4 cod. 011.6178.4
cod. 011.5445.4
cod. 011.6178.4
cod. 011.5445.4
F0014020
20-1
CONNECTION OF THE TESTER TO THE ECU
CONNECTION OF THE TESTER TO THE ECU
1 - Before connecting the tester to one of the ECUs, switch

off the engine and remove the key from the ignition.
2 - Connect the cable (code. 011.5445.4) to the tester
(code 5.9030.730.0).
For the transmission, engine and lift ECUs

3 - Connect connector (1) to connector (2) located inside
the right-hand console.
1
F0014060
For the armrest and lift ECUs

4 - Connect connector (1) to wiring (2) (code 0.11.6178.4)
and connector (3) to the diagnostics socket (4) located
on the armrest.
5 - Check that all the connections are firm.
6 - Insert the starter key and turn it to position to switch
on the tester.
3 ★ Do not start the engine unless specifically requested
to do so by the Tester.
1
4
2
F0014070
20-2
INTRODUCTORY SCREEN
INTRODUCTORY SCREEN
S + L + H T E S T E R The introductory screen displays the version of ART® and a

message that the battery test is in progress.
= = = = = = = = = = = = = = = =
★ If the battery voltage is less than 10.5V, the Tester dis-
V E R S I O N 2 1 2 play an error message and emit a warning beep.
The Tester will automatically pass to the next screen.
B A T T E R Y T E S T To bring up the next screen more quickly, press any key on
I N P R O G R E S S the ART®.
V O L T A G E 1 2 . 5 V
C O P Y R I G H T 1 9 9 1
E L . E N . S A S
M I L A N O
= = = = = = = = = = = = = = = =
T E S T S MENU SELECTION
= = = = = = = = = = = = = = = = For the transmission, engine, lift
M E N U In this menu you can select the ECU you wish to test:
1 | 35S GEARBOX: transmission ECU
1 | 3 5 S T R A N S M I S S . 2 | ENGINE ECU: engine ECU
3 | REAR LIFT: rear lift ECU
2 | E N G I N E E C U To continue, press the corresponding numerical key on the
ART®.
3 | R E A R L I F T
S E L E C T
= = = = = = = = = = = = = = = =
20-3
INTRODUCTORY SCREEN
T E S T S For the armrest and lift

In this menu you can select connection to the CAN network:
= = = = = = = = = = = = = = = =
1 | CAN NETWORK
M E N U
To continue 1 .
1 | C A N N E T W O R K
S E L E C T
= = = = = = = = = = = = = = = =
T E S T S CAN NETWORK MENU

= = = = = = = = = = = = = = = = In this menu you can select the ECU to be tested.
M E N U 1 | ARMREST: armrest ECU
2 | REAR LIFT: lift ECU
1 | A R M R E S T To continue, press the corresponding numerical key on the
ART®.
2 | R E A R L I F T
S E L E C T
= = = = = = = = = = = = = = = =
20-4
ENGINE ECU
TESTER
MANUAL
F0014050
20-5
ENGINE ECU
★ Connect the ART® to the diagnostics socket of the electronic control units.
E n g i n e PRESENTATION PAGE
= = = = = = = = = = = = = = = = This screen page shows:
Version: software version.
V e r s i o n : Date: software issue date.
Type engine table.
D A T E Eng.: type of engine installed on the tractor.
- T Y P E : ( ) SK: hardware board batch.
LN: production launch.
- E N G : NOTE. If the control connectors are connected the wrong
way round, the following message will be displayed
- S K : - L N : on this page
C A B L E
C O N N E C T I O N
I N C O R R E C T
= = = = = = = = = = = = = = = =
Press any key to proceed.
P R E S S A N Y K E Y
M A I N M E N U MAIN MENU
= = = = = = = = = = = = = = = = From this page you can select the system you wish to work
1 | E N G I N E on:
2 | S B A 1 | Engine system.
3 | P R E H E A T I N G 2 | SBA system
4 | A L A R M S 3 | Preheating system.
5 | V I S 4 | Alarms system
NOTE. System 5 | VIS only appears for engines with power
outputs in the range 160 and 200 CV (117-144 kW).
For each of these systems you can choose the following op-
erations:
• Configuration.
• Testing.
C H O I C E • Display.
= = = = = = = = = = = = = = = = It is also possible to display the list of alarms detected by the
[ E ] E X I T electronic control unit.
If you select one of the systems by pressing the correspond-
ing numerical key on the ART®, you can access the menus
described below.
20-6
ENGINE ECU
1. ENGINE MENU
E N G I N E
From this page you can select
= = = = = = = = = = = = = = = =
1 | Configuration: to enter the characteristic parameters of
1 | C O N F I G U R A T I O N the engine.
2 | Setting: to enter operating parameters of the engine gov-
2 | S E T T I N G ernor.
3 | Display: to display the parameters of the engine gover-
3 | D I S P L A Y nor.
Select the required function using the numerical keys on the
ART®.
Press E to quit
C H O I C E
= = = = = = = = = = = = = = = =
[ E ] E X I T
1.1 CONFIGURATION
C O N F I G U A R T I O N
From this menu you can configure and calibrate:
= = = = = = = = = = = = = = = =
1 | Type of engine.
2 | Power signal: to enter the data required to obtain correct
1 | T Y P E O F E N G I N E information regarding engine power.
Select the required menu option using the numerical keys on
2 | P O W E R S I G N A L
the ART®.
Press E to quit
C H O I C E
= = = = = = = = = = = = = = = =
[ E ] E X I T
20-7
ENGINE ECU
1.1.1 TYPE OF ENGINE

T Y P E O F E N G I N E
This submenu displays a list of the engine types that can be
= = = = = = = = = = = = = = = = controlled by the ECU: to select the engine type, press the
1 | corresponding numerical key of the ART®.
2 | On selecting an engine type you will pass automatically to the
3 | next screen page.
4 | NOTE. To move to the next list, press 0 .
5 | Press E to quit
6 |
LIST OF ENGINE TYPES
7 |
CONTROL UNIT 35S
8 |
9 | POWER (CV/kW) ENGINE TYPE ASSOCIATED N°
0 | O T H E R 120/882 2V 120 CV WT1 1

135/100 2V 135 CV WT1 2
C H O I C E 150/110 2V 150 CV WTI1 3
= = = = = = = = = = = = = = = = 120/882 3V 120 CV WT3V 4
[ E ] E X I T
135/100 3V 135 CV WT3V 5
150/110 3V 150 CV WTI3V 6
NOTE. The meaning of the values displayed in this screen

P R O G R A M M I N G page is explained in the Settings Menu.
= = = = = = = = = = = = = = = =
- E N G
T Y P E O F E N G I N E
M I N . R P M X X X X
M A X . R P M X X X X
S T A T I S M X X X
M I N . C U R R E N T X X X X
[ C ] C O N F I R M
= = = = = = = = = = = = = = = =
[ E ] E X I T
20-8
ENGINE ECU
P O W E R S I G N A L 1.1.2 POWER SIGNAL

In this menu you can calibrate the engine power signal to
obtain an optimum Power Shift gear change and accurate in-
- D E A C T I V A T E T H E
formation on the power delivered by the engine.
D I S T R I B U T O R S Current: current supplied to engine governor.
- A N D V E N T I L A T I O N Value set: previously set current value.
C A B V E N T I L A T I O N Engine rpm: engine speed.
- T . G E A R B O X O I L Time set: time at which value was set.
7 0 / 7 8 To perform the calibration correctly, you must adhere to the
[ C ] C O N F I R M conditions given at the top of the screen:
= = = = = D I S P L A Y = = = = 1 - Hydraulic control valves in neutral position.
C U R R E N T X X X X M A 2 - Cab ventilation switched off.
M E M O R I S E D X X X X 3 - Gearbox oil temperature between 70°C (158°F) and
E N G I N E R P M X X X X 78°C (172.4 °F).
H O U R S E T T I N G X X X X 4 - On displaying this menu, the engine speed automati-
= = = = = = = = = = = = = = = = cally rises to 1400 rpm.
[ E ] E X I T 5 - Wait a few seconds for the engine speed to stabilise.
6 - Press C on the ART® to save the value of the current
supplied by the governor in memory.
P R O G R A M M E D ➔ NOTES. 1 - If the parameter is saved correctly, the ART®

displays the message on the left.
P A R A M E T E R
➔ 2 - If the electronic control unit is unable to save

E e P R O M E R R O R
the value correctly, the calibration operation is
not performed and the tester display the mes-
sage shown on the left.
Press E to exit this menu and pass to the next screen page
(Idle speed power calibration).
20-9
ENGINE ECU
M I N . R P M 1.1.3 IDLE SPEED POWER CALIBRATION

From this menu you can calibrate the power signal at the en-
gine idle speed.
- D E A C T I V A T E T H E
Engine rpm: value read by the engine speed pickup unit.
D I S T R I B U T O R S
Rpm difference: difference between the engine speed you
- A N D V E N T I L A T I O N wish to set and the actual engine speed.
C A B V E N T I L A T I O N Like the calibration of the power signal, this setting must also
- T . G E A R B O X O I L be made in the following conditions:
7 0 / 7 8 1 - Hydraulic control valves in neutral position.
[ C ] C O N F I R M 2 - Cab ventilation switched off.
= = = = = D I S P L A Y = = = = 3 - Gearbox oil temperature between 70°C (158°F) and
78°C (172.4 °F).
E N G I N E R P M X
4 - On displaying this menu, the engine automatically re-
R P M D E L T A X X X X turns to idle speed.
5 - Wait a few seconds for the engine speed to stabilise.
= = = = = = = = = = = = = = = =
[ E ] E X I T 6 - Press C on the ART® to save the value of the current
supplied by the governor in memory.
P A R A M E T E R displays the message on the left.
2 - If the “RPM DELTA” exceeds the value of 40,

R P M D E L T A > 4 0 ➔ the calibration will not be performed and the
tester will display the message on the left.
E e P R O M E R R O R ➔ 3 - If the electronic control unit is unable to save

the value correctly, the calibration operation is
20-10
ENGINE ECU
S E T T I N G 1.2 SETTING
In this menu you can change the operating parameters of the
B Y E N G I N E O N
engine control system; you can change:
1 | Min rpm: minimum engine speed.
1 | M I N . R P M X X X 2 | Min. Curr.: current supplied to the engine governor to
2 | M I N . C U R R . X X X maintain idle speed (mA).
3 | S T A T I S M X X X 3 | Statism: the parameter that regulates engine speed
variation according to the load.
A | R E S E T V A L U E The keys used are:
F | I N C R E A S E V A L U E B: to select the parameter to be modified, highlighted
D | D E C R E A S E V A L U E with a dark background.
B | C H O I C E P A R A M . F : to increase the parameter value selected with B .
C | C O N F I R M
D: to decrease the parameter value selected with B .
A: to return the selected parameter to the B original
value.
= = = = = = = = = = = = = = = =
[ E ] E X I T C: to save the new parameter value.
NOTES. 1 - If the parameter is saved correctly, the ART®
P R O G R A M M E D ➔
P A R A M E T E R
1.3 DISPLAY
This screen displays a summary of all the engine parameter
settings.
D I S P L A Y
Type of engine Engine code.
= = = = = = = = = = = = = = = =
Min. rpm Minimum engine speed contained in the
T Y P E O F E N G I N E N N engine characteristics table.
M I N . R P M N N N Max. rpm Maximum engine speed contained in the
M A X . R P M N N N N engine characteristics table (cannot be
M I N . C U R R E N T N N N modified).
M A X . C U R R E N T N N N N MIN. CURRENT Current supplied to the governor to main-
S T A T I S M N N N tain the engine at idle speed.
MAX. CURRENT Maximum current of the electronic control
unit (cannot be modified).
A C T U A L R P M N N N N
STATISM the parameter that regulates engine speed
I A C T U A T O R N N N N
variation according to the load.
A C C . P E D A L N N N N
Actual rpm Actual engine speed.
T E N G I N E N N N
I Actuator Curent supplied to the governor actuator
E N G I N E P O W E R N N N (mA).
B A T T E R Y N N N N N m V Acc. pedal Position of accelerator pedal.
[ E ] E X I T T engine Engine temperature.
Battery Battery voltage.
20-11
ENGINE ECU
2. SBA MENU
S B A
From this menu, you can configure, test and monitor the SBA
= = = = = = = = = = = = = = = = automatic system controlling engagement of the differential
1 | C O N F I G U R A T I O N locks and 4WD.
To select the required function press the corresponding nu-
2 | T E S T S merical key on the ART®.
Press E to quit
3 | D I S P L A Y
C H O I C E
= = = = = = = = = = = = = = = =
[ E ] E X I T
S T E R R I N G S E T T I N G 2.1 STEERING CONFIGURATION

From this submenu you can set the “straight-ahead” wheels
= = = = = = = = = = = = = = = =
position.
S T E E R : \ X X \ X X X X
Steer: the first numerical value (enclosed between
the two slashes) is the steering angle ex-
M E M O R Y : X X X X m V pressed in degrees.
The second numerical value represents the
P O S I T I O N T H E corresponding electrical value.
The slashes that enclose the steering angle give a visual rep-
W H E E L S S T R A I G H T
resentation of the position of the wheels :
A N D P R E S S
Wheels straight-ahead:
S T E E R : | 0 0 | X X X X
Wheels turned to left:

S T E E R : \ x x \ X X X X
[ C ] C O N F I R M
= = = = = = = = = = = = = = = = Wheels turned to right:
[ E ] E X I T S T E E R : / x x / X X X X
Memory: set value expressed in mV.
20-12
ENGINE ECU
STEERING SETTING
1 - Position the wheels straight-ahead and drive a short
distance corresponding to one full turn of the wheels.
2 - Press C on the ART® to save the value in memory.
P A R A M E T E R
2 - If the electronic control unit is unable to save
E e P R O M E R R O R ➔ the value correctly, the calibration operation is
T E S T S
2.2 TESTS
= = = = = = = = = = = = = = = = From this menu you can check the operation of the entire
S T E E R : \ X X \ X X X X S.B.A. system and directly analyse the operation of the in-
L T . B R A K E X X X dividual components.
R T . B R A K E X X X LT. brake: By pressing the left-hand pedal you can test
S B A B U T T O N X X X the electrical continuity, the mechanical in-
tegrity of the electrical switch and the oper-
D I F . B U T T O N X X X
ation of the electronic control unit.
D . T . B U T T O N X X X
On pressing the pedal:
1 | D I F . S O L X X X X m A L T . B R A K E O N
2 | D . T . S O L X X X X m A
On releasing the pedal:
L T . B R A K E O F F
= = = = = = = = = = = = = = = = RT. brake: By pressing the right-hand brake pedal, you

[ E ] E X I T can check the electrical continuity, the me-
chanical integrity of the electrical switch and
the operation of the electronic control unit.
On pressing the pedal:
R T . B R A K E O N
On releasing the pedal:

R T . B R A K E O F F
20-13
ENGINE ECU
T E S T S SBA Button: By pressing this button you can check the

electrical continuity and the mechanical in-
= = = = = = = = = = = = = = = =
tegrity of the pushbutton.
S T E E R : \ X X \ X X X X
L T . B R A K E X X X On pressing the button on the joystick:
R T . B R A K E X X X S B A B U T T O N O N
S B A B U T T O N X X X
With button released:
D . T . B U T T O N X X X S B A B U T T O N O F F
Dif. Button: By pressing this button you can check the

1 | D I F . S O L X X X X m A electrical continuity and the mechanical in-
2 | D . T . S O L X X X X m A tegrity of the button.
On pressing the button on the joystick:
D I F . B U T T O N O N
= = = = = = = = = = = = = = = = With the button released:

[ E ] E X I T
D I F . B U T T O N O F F
D.T. button: By pressing this button you can check the

electrical continuity and the mechanical in-
tegrity of the pushbutton.
On pressing the button on the joystick:
D . T . B U T T O N O N
With the button released:

D . T . B U T T O N O F F
Dif. Sol.: By pressing the button “1” on the tester you

can activate and deactivate the solenoid
valve that controls the differential. By press-
ing this key you can check the electrical con-
tinuity of the wiring, the integrity of the
solenoid valve and the operation of the elec-
tronic control unit.
Solenoid valve activated:
1 D I F . S O L X X X X m A
NOTE. The value xxxx must be greater than 800 mA.
Solenoid valve deactivated:

1 D I F . S O L X X X X m A
NOTE. The value xxxx must be 0.
20-14
ENGINE ECU
T E S T S D.T. Sol.: By pressing button “2” on the tester you can

activate and deactivate the solenoid valve
= = = = = = = = = = = = = = = =
that controls engagement of the 4WD. By
S T E E R : \ X X \ X X X X pressing this key you can check the electri-
L T . B R A K E X X X cal continuity of the wiring, the integrity of
R T . B R A K E X X X the solenoid valve and the operation of the
S B A B U T T O N X X X electronic control unit.
D I F . B U T T O N X X X Solenoid valve activated:
D . T . B U T T O N X X X 2 D . T . S O L X X X X m A
NOTE. The value xxxx must be 0.
1 | D I F . S O L X X X X m A
2 | D . T . S O L X X X X m A Solenoid valve deactivated:
2 D . T . S O L X X X X m A
NOTE. The value xxxx must be greater than 800 mA.
= = = = = = = = = = = = = = = =
[ E ] E X I T
D Y S P L A Y
2.3 DISPLAY
= = = = = = = = = = = = = = = = This menu allows you to check the general operating status
S T E E R : \ X X \ X X X X of the entire SBA system.
L T . B R A K E X X X Following the procedure described in «2.2 - TESTS», you can
R T . B R A K E X X X check the status of all devices with the exception of the so-
S B A B U T T O N X X X lenoid valves.
D . T . B U T T O N X X X
1 | D I F . S O L X X X X m A
2 | D . T . S O L X X X X m A
= = = = = = = = = = = = = = = =
[ E ] E X I T
20-15
ENGINE ECU
P R E H E A T I N G 3. PREHEATING
From this menu you can check configure, test and display the
= = = = = = = = = = = = = = = =
status of the preheating system.
1 | C O N F I G U R A T I O N
To select the required function press the corresponding nu-
merical key on the ART®.
2 | T E S T S
Press E to quit
3 | D Y S P L A Y
C H O I C E
= = = = = = = = = = = = = = = =
[ E ] E X I T
P R E H E A T . C O N F I G . 3.1 PREHEATING CONFIGURATION

In this screen you can enable or disable the preheating sys-
= = = = = = = = = = = = = = = =
tem.
G L O W P . S T A .
Press B to enable the system.
G L O W P . S T A .
Press F or D to disable preheating.
G L O W P . N . C .
B - P A R A M . Press C to confirm.
F - I N C R . D - D E C R .
Press E to quit
C C O N F I R M
C H O I C E
= = = = = = = = = = = = = = = =
[ E ] E X I T
20-16
ENGINE ECU
3.2 PREHEATING TESTS

P R E H E A T I N G
From this menu you can test the individual system compo-
T E S T S nents.
NOTE. All tests must be performed with the engine switched
T E M P . S E N S O R C off.
1 | G L O W P . R E L A Y Temp. Sensor.: engine temperature in °C.
2 | P R E H E A . S O L .
By selecting one of the components using the numerical keys
3 | P R E H E A . L A M P
of the ART®, you can change its status to obtain the following
indications.
T E S T S 1 | Glowp. relay (Glowplug relay)
B Y E N G I N E O F F
Disabled
1 G L O W P . R E L A Y
Enabled
1 G L O W P . R E L A Y
= = = = = = = = = = = = = = = =
[ E ] E X I T 2 | Prehea. sol. (Preheating solenoid)
Disabled
2 P R E H E A . S O L .
Enabled
2 P R E H E A . S O L .
3 | Preheat. lamp (preheating lamp)

Disabled:
3 P R E H E A . L A M P
Enabled:
3 P R E H E A . L A M P
Press E to quit
20-17
ENGINE ECU
3.3 DISPLAY
P R E H E A T I N G
This screen shows the operating status of the system com-
D I S P L A Y ponents.
The screen is identical to the screen «3.2 TESTS» but it is not
T E M P . S E N S O R possible to change the operating status of the various com-
G L O W P . R E L A Y ponents.
P R E H E A . S O L .
P R E H E A . L A M P
= = = = = = = = = = = = = = = =
[ E ] E X I T
A L A R M S
4. ALARMS
= = = = = = = = = = = = = = = = In this menu you can:
• Initialize the alarms;
1 | S T A R T - U P • Display the alarms log.
2 | D I S P L A Y
Select the required option using the numerical keys on the
ART®.
1 | Start-up: to check software compatibility.
2 | Display: to display and cancel alarms from the log.
ART®.
Press E to quit
C H O I C E
= = = = = = = = = = = = = = = =
[ E ] E X I T
20-18
ENGINE ECU
4.1 START-UP
A L A R M S
It is only necessary to perform the initialization procedure
= = = = = = = = = = = = = = = = when required by the putting into service standards, gener-
ally after installing new software versions.
E e P R O M O K If the software is compatible, the ART® displays the screen
shown on the left.
If the software is not compatible, the screen below appears.
In both cases, to exit press E .
= = = = = = = = = = = = = = = =
[ E ] E X I T
A L A R M S Press C on the ART® to reset the alarm. The control unit

= = = = = = = = = = = = = = = = confirms the alarm reset operation with the next screen.
P R E S S C T O
E L I M I N A T E I T
= = = = = = = = = = = = = = = =
[ E ] E X I T
20-19
ENGINE ECU
A L A R M S
= = = = = = = = = = = = = = = =
P R E S S C T O
E L I M I N A T E I T
R E S E T O K
S W I T C H E N G . O F F
= = = = = = = = = = = = = = = =
[ E ] E X I T
A L A R M S H I S T O R Y 4.2 DISPLAY (alarms log)

= = = = = = = = = = = = = = = = This screen shows the list of alarms detected by the system.
The most recent alarm is top of the list.
To cancel alarms from the list, press A on the ART®.
To exit, press E .
NOTE. A list of all the alarm conditions that can be diag-
nosed by the electronic control unit is given in the
paragraph «LIST OF ENGINE ECU ALARM CODES».
C . A . = C i r c . O p e n
C . C . = S h o r t C i r c .
A - R E S E T A L A . M E M .
= = = = = = = = = = = = = = = =
[ E ] E X I T
20-20
ENGINE ECU
5. VIS MENU (Variable Intake System)

V I S
= = = = = = = = = = = = = = = = NOTE. The Variable Intake System is only installed on 2-
valve engines with rated power in the range 160 to
1 | T E S T S
200CV (117 and 144 kW).
From this menu you can test and display the operating status
2 | D I S P L A Y of the system.
1 | Tests: to check that the system is functioning cor-
rectly.
2 | Display: to display the system operating status.
ART®.
Press E to quit
C H O I C E
= = = = = = = = = = = = = = = =
[ E ] E X I T
T E S T S
5.1 TESTS
= = = = = = = = = = = = = = = =
Menu for testing the operation of the VIS.
VIS Sol.: By pressing “1” on the tester you can acti-
vate and deactivate the solenoid that con-
trols the VIS valve; this operation also serves
to check the electrical continuity of the wir-
ing, the integrity of the solenoid and the op-
eration of the electronic control unit.
1 | V I S S O L . X X X X m A Solenoid activated:
1 V I S S O L . X X X X m A
Solenoid deactivated:
1 V I S S O L . X X X X m A
= = = = = = = = = = = = = = = =
Press E to quit
[ E ] E X I T
20-21
ENGINE ECU
5.2 DISPLAY
D I S P L A Y
Screen displaying the operating status of the VIS solenoid.
= = = = = = = = = = = = = = = =
The screen is identical to the screen «5.2 TESTS», the sole
difference being that it is not possible to control the solenoid
from this screen.
1 | V I S S O L . X X X X m A
= = = = = = = = = = = = = = = =
[ E ] E X I T
20-22
LIST OF ENGINE ECU ALARM CODES
N° Tester Message Cause of fault - Remedy Control unit action
• Engine speed >3200 rpm Actuator control

1 OVERSPEED
Restart the engine removed
• Actuator not connected
Actuator not
2 ACTUATOR OPEN • Wiring fault controlled
Check Pin [46], Pin [47]
• Actuator faulty
3 ACTUATOR Actuator control
SHOR.CIRC • Wiring fault removed
check Pin [46], Pin [47]
• Pickup not connected Actuator control
4 RPM Sen.n.c.
Check Pin [10] removed
• Pickup faulty
Actuator control
5 RPM Sen.inter. • Poor contact removed
Check Pin [10]
When the CAN is not
• Short circuit of pedal potentiometer active, engine remains
6 Acc.Ped.sh.cir. • Wiring fault at idle speed;
Check Pin [5] otherwise no effect
✽
When the CAN is not
• Pedal potentiometer not connected active, engine remains
7 Acc.Ped.n.c. • Wiring fault at idle speed;
Check Pin [5] otherwise no effect
✽
• Glowplug relay faulty (located in fuse holder)
8 Glowp.Rel. n.c. • No connection between the control unit (Pin [56]) and the Preheating inhibited
relay
• Glowplug not connected
Preheating inhibited
9 Glowplug n.c. • No connection between the relay and glowplug ✽
Check Pin [56] Pin [68]
• Glowplug relay faulty
• Wiring fault
10 Glowp.Rel. Faul. • No power to glowplug Preheating inhibited
Check fuse ✽
• Shortcircuit of glowplug
Check Pin [56] Pin [68]
• Preheating solenoid relay faulty (located in fuseholder)
11 Preh.Rel.n.c. Preheating inhibited
• No connection between control unit (Pin [58]) and relay
• Preheating solenoid not connected
Preheating inhibited
12 Preh.Sol. n.c. • Wiring fault ✽
• Preheating solenoid relay faulty
• Wiring fault
13 Prh.Sol.Re.C.fau • No power to solenoid Preheating inhibited
Check fuse ✽
• Short circuit of solenoid
20-23
Preheating sequence
still performed if no
• Temperature sensor not connected other faults present
14 Temp.Sen. n.c. • Wiring fault On engine start-up
Check Pin [3] the cold-starting pro-
cedure is performed
✽
Preheating sequence
still performed if no
• Temperature sensor faulty other faults present
15 Tem.Sen sh.cir. • Wiring fault On engine start-up
Check Pin [3] the cold-starting pro-
cedure is performed
✽
• Shortcircuit of 4WD solenoid valve Control to 4WD
solenoid removed
16 D.T.sol.sh.Circ. • Wiring fault
4WD solenoid valve
Check Pin [53] inhibited
• 4WD solenoid not connected Control to
4WD solenoid
• 4WD solenoid faulty removed
17 D.T.Sol.n.c.
• Wiring fault 4WD solenoid
Check Pin [53] inhibited ✽
Control to
• Shortcircuit of DIFF solenoid DIFF solenoid
18 Dif.Sol.sh.Circ. • Wiring fault removed
Check Pin [53] DIFF solenoid
inhibited
• DIFF solenoid not connected Control to
DIFF solenoid
• DIFF solenoid faulty removed
19 Dif.Sol.n.c.
• Wiring fault DIFF solenoid
Check Pin [53] inhibited ✽
• Shortcircuit of steering sensor
20 St.Sen.sh.Circ. • Wiring fault Not utilised
Check Pin [6]
• Steering sensor not connected
21 St.Sen.n.c. • Wiring fault Not utilised
Check Pin [6]
• Control unit faulty
Power to SBA
• 4WD and DIFF solenoid faulty solenoid removed
22 SBA Sol. Block
• Wiring fault SBA solenoid inhibited
Check Pin [52], Pin [53], Pin [55]
• Software error Engine speed cannot

23 Flash faulty exceed 1500 rpm
• Control unit faulty CAN inhibited
20-24
• Eeprom faulty Default parameters

24 Eeprom faulty • Old board with updated software for 120 CV engine
Re-program engine type used
Control to
25 Generic Alarm • Control unit faulty preheating relays
removed ✽
The intact bank
• Writing to Eeprom interrupted by power supply failure is copied to the
26 Err.B1&B2 EEP altered bank
(SME alarm)
27 Low Voltage • Battery voltage No action
28 ENGINE NOT SET • Current value not set Default value

used (1400mA)
The parameter value
outside the limits is
• Old board with updated software replaced with
29 EepromPar.out.L.
• Programmed value outside limits the default value
an d t h e Ee p rom is
updated
• Control unit connected in the place of another Control unit locked
30 FAULTY CONFIG. • Wiring fault with relative message
Check Pin [35], Pin [36], Pin [37] on tester
• Malfunction
31 VIS actuat.fault • Locked VIS not working
• Check pin 54
• VIS actuator not connected
• VIS actuator faulty
32 VIS Actuat.n.c. VIS not working
• Wiring fault
Check Pin [54]
• Shortcircuit of VIS actuator
33 VIS Actuat.sh.circ. • Wiring fault VIS not working
Check Pin [54]
• CAN faulty
• Wiring fault
199 Engine in local
• TC control unit not connected
• CAN faulty
• Wiring fault The SBA solenoids
201 CAN T.O. CCMSG2
Check Pin [30], Pin [31] are set to OFF
• CC control unit not connected
• CAN faulty
• Wiring fault
202 CAN T.O. CCMSG4
• CC not connected
20-25
• CAN faulty
• Wiring fault
220 CAN T.O. ICMSG1
• Instrument cluster not connected
• CAN faulty The engine speed
• Wiring fault control is determined
240 CAN T.O. TCTSC1 only by the position of
Check Pin [30], Pin [31] the accelerator pedal
• TC control unit not connected Pin [5]
• CAN faulty
• Wiring fault The SBA
242 CAN T.O. TCMSG1 system operates in
Check Pin [30], Pin [31] manual
• TC control unit not connected
✽ The control unit action only persists for as long as the alarm remains active
(if the missing component is reconnected the alarm will cease)
20-26
TRANSMISSION
ECU
TESTER MANUAL
F0014030
20-27
TRANSMISSION ECU
G E A R PRESENTATION SCREEN
= = = = = = = = = = = = = = = = This screen displays:
FW ver: Hardware version
H W V e r . : SW Ver: Software version
Date: Software issue date
S W V e r . : Settings: Clutch engagement settings
NOTE. If the ECU connectors are inadvertently swapped
D a t e : over, this screen will appear as follows
W I R I N G
L e g g i :
C O N N E C T I O N F A U L T
Press E to proceed with programming.
= = = = = = = = = = = = = = = =
[ E ] E x i t
= = = = = = = = = = = = = = = = This menu contains the options:
1 | C o n f i g u r a t i o n 1 | Configuration: to select the type of gearbox and to select
2 | C h e c k automatic or manual calibration.
3 | M o n i t o r 2 | Check: to test sensors and actuators.
4 | A l l a r m 3 | Monitor: to monitor operation of all the sensors.
4 | Alarm: to display the list of previous alarms (alarm log).
To select an option and pass to the next submenu press the
corresponding numerical key on the ART®.
= = = = = = = = = = = = = = = =
C h o o i s e
20-28
TRANSMISSION ECU
C O N F I G U R A T I O N 1. CONFIGURATION
= = = = = = = = = = = = = = = = From this menu you can configure the ECU according to the
type of gearbox installed on the tractor and calibrate the 1st,
1 | T y p e g e a r
2nd, 3rd gear clutches and the M clutch.
2 | C a l i b . F r i z .
| A u t o & M a n u a l To select the required option, press the corresponding nu-
3 | P a r a m e t e r merical key on the ART® or press E to exit.
= = = = = = = = = = = = = = = =
[ E ] E x i t
1.1 Gearbox type

T Y P E G E A R
From this menu you can enable the gearbox in accordance
= = = = = = = = = = = = = = = = with the type of tractor (Series 40 S: Range 160-180 cv).
1 | G e a r 4 0 S
1 = Press these keys to enable the gearbox
2 | E V P C l u t c h
2 = in the 40S version and the proportional solenoid
valve of the main clutch.
X = Enabled symbol (appears alongside the legends 40S
and EVP Clutch when the 40s version is selected).
-- = Disabled symbol (appears alongside the legends
40S and EVP Clutch when the 35S version is se-
= = = = = = = = = = = = = = = = lected).
L e g e n d a B = Press this key to save the gearbox type in memory
X = E n a b l e d (the relative display boxes will turn black).
-- = D i s a b l e d D = Press this key to restore the default values (35S gear-
[ B ] M e m o [ D ] D e f a u l box without proportional solenoid valve for main
[ E ] E x i t clutch).
E = Press to continue.
20-29
TRANSMISSION ECU
C A L I B R A T I O N C L U T C 1.2 Clutch calibration

= = = = = = = = = = = = = = = = From this menu you can perform the automatic or manual
calibration of the gearbox clutches.
T r a c t o r P l a n e
The information displayed is as follows:
7 0 T O i l 7 8 • Operating hours since last calibration (n°).
R a n g e L e n t a • Calibration coefficient of 1st speed clutch %.
B r e a k O F F • Calibration coefficient of 2nd speed clutch %.
C h o o s e C l u t c h • Calibration coefficient of 3rd speed clutch %.
h . c a l i b r x x
x x x x • Corrective parameter for M clutch (main) (bar). (This pa-
> 1 | C l u t c h 1 ^ .
x x x % rameter may also have a negative value).
2 | C l u t c h 2 ^ .
x x x % NOTES.1 - The calibration coefficients for the 1-2-3 speed
clutches are percentage values calculated au-
3 | C l u t c h 3 ^ .
x x x % tomatically by the ECU which modify:
C l u t c h M . b a r 1 - The filling end pressure.
= = = = = = = = = = = = = = = = 2 - The filling time.
[ A ] C h o i x [ D ] + [ C ] 3 - The modulation start pressure.
[ B ] S t o r e 4 - The modulation end pressure.
[ E ] E x i t 2 - If the ECU has never performed the automatic
calibration procedure for all the clutches, it will
signal an error code for each clutch that has not
been calibrated (See paragraph «ALARM
CODES»).
3 - The clutches that have been previously calibrat-
ed are indicated by the black background of the
box containing the clutch identification number.
C A L I B R A T I O N C L U T C In order to carry out the calibration procedure, the following

conditions must be satisfied:
= = = = = = = = = = = = = = = =
T r a c t o r P l a n e 1 - Engine running at idle speed.
7 0 T O i l 7 8 2 - Drive the tractor over a flat section of road, preferably
R a n g e L e n t a on asphalt or concrete.
B r e a k O F F 3 - The tractor must be free of all implements or ballast.
C h o o s e C l u t c h 4 - The tyres must be inflated to the optimum pressures.
h . c a l i b r 5 - None of the hydraulic systems must be activated (SBA,
> 1 | C l u t c h 1 ^ . 0 9 5 % 4WD, Lift, PTO, Steering).
2 | C l u t c h 2 ^ . 1 0 0 % 6 - The gearbox oil temperature must be within the range of
3 | C l u t c h 3 ^ . 0 8 7 % 70°C (158°F) to 78°C (172.4°F).
C l u t c h M . + 0 . 3 b a r 7 - Low range engaged.
= = = = = = = = = = = = = = = = 8 - Brakes off.
[ A ] C h o i x [ D ] + [ C ]
[ B ] S t o r e
[ E ] E x i t
20-30
TRANSMISSION ECU
C A L I B R A T I O N C L U T C Press the keys 1 2 3 to select the clutch to be cali-

brated.
= = = = = = = = = = = = = = = =
O i l T e m p C Press 1 to calibrate the 1st clutch.
R a n g e Press 2 to calibrate the 2nd clutch.
E n g i n e
Press 3 to calibrate the 3rd clutch.
= = = = = = = = = = = = = = = =
R i f e r m s If the conditions listed above are satisfied, the engine speed
M i s u r m s will automatically rise to 1400 rpm and the ART® will display
T i m e r m s the following information:
T e n t a • Oil Temp = Gearbox oil temperature (°C).
R u o t e • Range = Range engaged.
• Engine = Engine speed (rpm).
• Rifer = Reference time (ms).
• Misur = Time measured during calibration (ms).
= = = = = = = = = = = = = = = = • Timer = Chronometer for calibration time (ms).
[ E ] E x i t • Tenta = Number of attempts made.
• Ruote = Wheel rotation speed (rpm).
If you wish to quit the procedure, press E .
C A L I B R A T I O N C L U T C Calibration procedure
= = = = = = = = = = = = = = = = Engage forward drive (by pressing the armrest buttons «For-
ward» and «Enable» simultaneously); the tractor will move off
and after a few seconds the number of attempts displayed on
7 0 T O i l 7 8 the ART® will increase.
R a n g e L e n t a Select Neutral (button N on the armrest).
B r e a k O F F Re-engage drive until the number of attempts is reset to zero
C h o o s e C l u t c h (Tenta = 0); with the resetting of this parameter, the engine will
h . c a l i b r x x x x x x automatically return to idle speed (under control of the op-
> 1 | C l u t c h 1 ^ . x x x % erator) and the ART® will return to the display of the initial
«Clutch Calibration» screen.
2 | C l u t c h 2 ^ . x x x %
3 | C l u t c h 3 ^ . x x x %
C l u t c h M b a r
= = = = = = = = = = = = = = = =
[ A ] C h o i x [ D ] + [ C ]
[ B ] S t o r e
[ E ] E x i t
20-31
TRANSMISSION ECU
C A L I B R A T I O N C L U T C Manual corrections
= = = = = = = = = = = = = = = = (Max ±10% of the value calculated automatically by the
ECU)
7 0 T O i l 7 8 Clutches 1-2-3
R a n g e L e n t a • The individual calibration coefficients can only be perma-
B r e a k O F F nently modified after having carried out the automatic cal-
C h o o s e C l u t c h ibration procedure.
h . c a l i b r x x x x x x • If the automatic calibration procedure has not been per-
formed, any modifications to the values of individual co-
> 1 | C l u t c h 1 ^ . x x x %
efficients will not be saved in memory and the original
2 | C l u t c h 2 ^ . x x x % values will be restored each time the engine is stopped
3 | C l u t c h 3 ^ . x x x % and restarted.
C l u t c h M b a r
M Clutch
= = = = = = = = = = = = = = = =
• The corrective coefficient of the Medium clutch is a pres-
[ A ] C h o i x [ D ] + [ C ] sure value that is added to or subtracted from the pres-
[ B ] S t o r e su re valu es con ta ine d in th e fill ing law s for t he
[ E ] E x i t gearchanges involving the Medium clutch.
• This corrective value is to be determined experimentally
by the operator from an analysis of the gearchanges that
involve use of the Medium clutch with the gearbox oil tem-
perature greater than 60°C.
• The gearchanges affected are as follows:
1st Þ 2nd 3rd Þ 2nd
4th Þ 5th 6th Þ 5th
• The keys used on the ART® are:
A To select the clutch to be calibrated manually.
B To save in memory the value entered manually.
C To make the value negative (--).
D To make the value positive (+).
E To exit.
20-32
TRANSMISSION ECU
P a r a
m e t e r 1.3 Parameters
= = = = = = =
= = = = = = = = = In this screen are displayed the values of the parameters that
affect operation of the transmission ECU. These values can-
D i a m e t e
r x x x x m m
not be modified from this screen. The parameters are:
S p e e d m a
x x x x x k m / h Diameter = Wheel diameter (m/m).
C l o c k x x x x x : m m Speedmax = Maximum travel speed.
H e l p E n g . Clock = Tractor clock.
Help Eng. = Engine assistance control during gearchange.
The «Diameter» parameter may be modified from the
armrest controls using the «Performance monitor»;
the other parameters can be modified by connecting
the ART® to the armrest ECU.
Press E to exit.
= = = = = = = = = = = = = = = =
[ E ] E x i t
T E S T 2. TESTS
= = = = = = = = = = = = = = = = From this menu you can test the operation of all the sensors
pushbuttons and solenoid valves connected to the ECU.
1 | S e n s o r P u l s a n t
1 | Sensor pulsant: temperature sensor
range sensor
2 | E v o n - o f f forward/reverse button
3 | E v P r o p o r t i o n a l +/- gear pushbutton
2 | Ev on-off: Solenoid valves in the gearbox, re-
versing shuttle, range gearbox.
3 | Evproportional: Proportional solenoid valve for
modulation of gear engagement
pressure.
Select the required test by pressing the corresponding nu-

merical key or press E to exit.
= = = = = = = = = = = = = = = =
[ E ] E x i t
20-33
TRANSMISSION ECU
S e n s o r P u l s a n t If the 40S version was selected (and consequently the pro-

portional solenoid valve of the M clutch) as the «GEARBOX
= = = = = = = = = = = = = = = =
TYPE», the tests menu will also include the option:
R a n g g g g g g
4 | EvP Clutch: M clutch proportional solenoid valve.
— > — — > | — —
You may therefore also select this test or press E to exit.
T o i l t t t t t c a m b ø C
3 | E v P r o p o r t i o n a l
4 | E v P C l u t c h
= = = = = = = = = = = = = = = =
[ E ] E x i t
2.1 Sensors-Pushbuttons (main screen)

T E S T S
From this submenu you can test the operation of the push-
= = = = = = = = = = = = = = = = buttons and sensors connected to the transmission ECU.
1 | S e n s o r P u l s a n t
Rang: numerical value of the range position sensor and the
range engaged.
2 | E v o n - o f f
3 | E v P r o p o r t i o n a l <–>: Foward/Reverse pushbutton
Toil ...... cambio: Gearbox oil temperature
+/--: Shift up/down pushbutton.
Press E to exit.
= = = = = = = = = = = = = = = =
[ E ] E x i t
20-34
TRANSMISSION ECU
Minimum value Range selected Maximum value The functional tests which you can carry out are:
from 0 Error to 109 • Range sensor: located on the right-hand side of the
from 110 Fast to 212 tractor. On operating the range change, the display
from 213 Neutral to 419 shows the voltage detected by the sensor and the cor-
responding range selected. The voltages and example
from 420 Slow to 540
readout are shown on the left.
from 540 Creep to 928
from 929 Error to 1023
R a n g e 1 3 0 S P E E D
Enable + Forward
-- > -- -- > • Forward/Reverse button: by simultaneously pressing
the Enable button and the Forward/Reverse button you
Enable + Reverse can display the conditions shown on the left.
-- > -- --
Neutral (N button on armrest)

-- > -- --
If an error occurs
-- > E r r o r
T o i l 0 0 0 6 5 g e a r • Gearbox oil temperature sensor: displayed °C (Cel-

sius) as shown on left.
Shift up
+ | -- | + | • Shift up/down buttons: by holding pressed the shift up
or shift down button you can display the conditions
Shift down shown on the left. (The negative or positive sign disap-
pears accordingly).
+ | -- | -- |
If an error occurs
+ | -- E r r o r
20-35
TRANSMISSION ECU
E . V . O N / O F F 2.2 Ev ON-OFF
= = = = = = = = = = = = = = = = From this menu it is possible to manually energise the ON-
OFF solenoids of the gearbox, the range gearbox and the re-
| / | | / |
versing shuttle.
| / | | / | For each solenoid there is a corresponding a key on the
4 | E v -- A | E v -- > ART®:
-- -- -- -- -- -- -- -- -- --
Key Solenoid ECU Wiring
6 | E v . M | 3 | E v . 3 ART® controlled connector pin label
7 | E v . H | 1 | E v . 1 1 1st speed clutch 62 C1
5 | E v . L | 2 | E v . 2 2 2nd speed clutch 63 C2
-- -- -- -- -- -- -- -- -- -- 3 3rd speed clutch 64 C3
| / | | / | 4 Reverse 65 I
| / | | / | 5 Low clutch 59 L
| / | 9 | E v . H R | / | 6 Medium clutch 60 N
| / | 8 | E v . L R | / | 7 High clutch 61 H
= = = = = = = = = = = = = = = = 8 Medium range 18 RM
[ E ] E x i t 9 Fast range 19 RH
A Forward 17 AV
★ The display reflects the arrangement of the solenoid

valves on the tractor.
Press E to exit.
NOTES.1 - If the engine is running, it will not be possible to
control the solenoids manually, but you can still
display the status of the solenoids.
2 - With the key in position , you can control the
operation of the solenoids using the keys on the
ART®.
On pressing 1 on the ART®, the display boxes cor-
responding to the control and the designation of the rel- The possible displays are shown on the left using the 1st
ative solenoid valve (Ev1) are highlighted in black. clutch solenoid as an example.
7 | E v . H | 1 | E v . 1
On pressing 1 again, the display returns to its original

condition.
7 | E v . H | 1 | E v . 1
If a solenoid valve is malfunctioning, the relative display

boxes will start to flash.
7 | E v . H | 1 | E v . 1
➔
7 | E v . H | 1 | E v . 1
20-36
TRANSMISSION ECU
E v P r o p o r t i o n a l 2.3 Ev Proportional
= = = = = = = = = = = = = = = = From this menu you can test the operation of the proportional
solenoid valve that modulates the gear engagement pres-
1 / + C u r r e n t
sure.
2 / -- C u r r e n t • 1/ + Current: By pressing 1 on the ART® you increase
the current drawn by the solenoid.
= = = = = = = = = = = = = = = = • 2/ - Current: By pressing 2 on the ART® you decrease
I ( E v P ) x x x x m A the current drawn by the solenoid.
P W M % x x x • I (EvP.): Current draw of the solenoid (mA)
• PWM %: Percentage of P.W.M.
= = = = = = = = = = = = = = = = Press E to exit.
= = = = = = = = = = = = = = = =
[ E ] E x i t
L o w V o l t a g e The ECU automatically performs tests on the supply voltage

and the current draw of the solenoid.
If the battery voltage is less than 12V or if the current drawn by
E v P C o n n e c t the solenoid is less than 200 mA, the messages on the left will
be displayed.
20-37
TRANSMISSION ECU
E v P C l u t c h 2.4 EvP Clutch (40S version only)

= = = = = = = = = = = = = = = = From this menu you can test operation of the proportional so-
lenoid valve that controls the main clutch on the 40S version
C l u t c h P e d a l %
transmission.
P r e s x x x x x m b a r • Clutch pedal: percentage of clutch pedal travel.
I ( E v P ) x x x x m A Permitted range:
MIN. 0% - MAX 200%.
• Pres: requested pressure to the proportional
solenoid valve.
Permitted range:
MIN. 0 mbar - MAX 200 mbar.
• I (EvP): Current drawn by the proportional sole-
noid valve.
On depressing the pedal, the current
should rise continuously from the mini-
mum value to the maximum.
= = = = = = = = = = = = = = = = Press E to exit.
[ E ] E x i t
3. MONITOR
From this menu you can select the connection method used
M E N U M O N I T O R to acquire the information necessary during normal tractor
= = = = = = = = = = = = = = = = operation.
1 | M o n i t o r T e s t e r 1| Monitor Tester: Information managed directly by the
2 | M o n i t o r C . A . N . ECU.
2 | Monitor Can: Information managed by other electron-
ic units and transmitted via the CAN®
bus.
Press the numerical key on the ART® corresponding to the
type of information to be displayed or press E to quit.
C h o o i s e
= = = = = = = = = = = = = = = =
[ E ] U s c i t a
20-38
TRANSMISSION ECU
M o n i t o r 3.1 Monitor Tester

= = = = = = = = = = = = = = = = This screen displays all the data used to control tractor op-
eration:
R P M E n g i n e x x x x
• RPM Engine: engine speed (rpm).
R P M W h e e l x x x x
• RPM Wheel: wheel speed (rpm).
S p e e d x x , x k m / h
• Speed: groundspeed (km/h).
S k i d e d x x x
• Skided: wheelslip percentage (%).
T o l i o x x x
• T.olio: gearbox oil temperature (°C).
P r e s . I d r a u L
• Pres. IdrauL: service pressure pressostat.
P r e s . C l u t c h
• Pres. Clutch: main clutch pressostat.
S o g l i a
• Pres. Inver: reversing shuttle pressostat.
P o w e r x x x
• Soglia: Hard Soft power threshold calculated in ac-
V B a t t . x x , x cordance with the gear and engine speed.
• Power: engine power delivery (%).
• V Batt.: battery voltage (V).
= = = = = = = = = = = = = = = =
Press E to exit.
[ E ] E x i t
3.2 Monitor CAN

This screen lists the values that are transmitted and received
M o n i t o r C . A . N . via the CAN bus.
= = = = = = = = = = = = = = = =
Tester value Unit of Transmitted
C l u t c h message meas. from
D i r e z . D e s = Clutch Clutch pedal position % Armrest ECU
D i r e z . I n s = Forward
Direz. Des Direction requested →
Reverse ← Armrest ECU
Neutral ----
G e a r D e s =
Forward
G e a r I n s =
Direz. Ins Direction engaged →
R a n g e D e s . = Reverse← Transmission ECU
Neutral ----
R a n g e I n s . =
Gear Des Gear requested 1÷9 Armrest ECU
E n g . R e q =
Gear Ins Gear engaged 1÷9 Transmission ECU
E n g . M A N =
Neutral
Range Des Range requested Fast Armrest ECU
Slow
Medium
= = = = = = = = = = = = = = = = High
Range Ins Range engaged Low Transmission ECU
[ E ] E x i t Creep
Error
Engine speed requested
Eng. Req. 750÷2350 Transmission ECU
Engine speed 750÷2350 Armrest ECU

Eng. Man.
required by operator
20-39
TRANSMISSION ECU
A L L A R M L I S T 4. ALARMS
= = = = = = = = = = = = = = = =
➔ The most recent alarm
This screen lists the last 10 alarm signals to be detected.
The last line displays in succession all the currently active
alarms highlighted with a dark background.
= = = = = = = = = = = = = = = =
➔ Active alarms
Press D to cancel or E to exit.
= = = = = = = = = = = = = = = =
[ D ] D e l [ E ] E x i t
20-40
LIST OF TRANSMISSION ECU ALARM CODES
The ECU:
• Connected to wrong connector
1 Errore Configur Check connector ECU locked
• Wiring fault
Check electrical continuity Pin[34],Pin[35],Pin[36]
• ECU faulty No limitation of

2 Alim. 5v K.O. functional capacity of
Renew ECU tractor
• ECU faulty No limitation of

3 Alim. 6v8 K.O. functional capacity of
Renew ECU tractor
Service pressostat faulty:
• Gearbox oil level
Check gearbox oil level
No limitation of
• Wiring fault functional capacity of
4 Err.Pres.Service Check electrical continuity Pin[10] tractor
• Sensor faulty
Check integrity of pressostat
• ECU faulty
Check service pressostat using ART® Monitor function
Clutch pressostat faulty
• Wiring fault Gear shift and
Check electrical continuity Pin[54] forward/reverse shift
5 Err.Pres.Clutch • Sensor faulty with clutch pedal only
• ECU faulty
Check clutch pressostat using ART® Display
Direction pressostat faulty
• Wiring fault
Check electrical continuity Pin[16]
Gear shift and
• Sensor faulty forward/reverse shift
6 Err.Pres.Direzio Check integrity of pressostat with clutch pedal only
• Mechanical/hydraulic fault
Check
• ECU faulty
Check clutch pressostat using ART® Monitor
Pressure loss for 2 sec.
• Gearbox oil level
Check gearbox oil level
No limitation of func-
• Wiring fault tional capacity of
9 Main Press KO Check electrical continuity Pin[10] tractor
• Sensor faulty
• ECU faulty
Check clutch pressostat using ART® Monitor
20-41
Short-circuit of temperature sensor

• Wiring fault
10 C.C. Sens. Temp. Temperature forced
• Sensor faulty to 80 °C
Check integrity of sensor (N.T.C.)
• ECU faulty
Check temperature sensor using ART® Monitor
Temperature sensor disconnected:
• Wiring fault
No limitation of
Check electrical continuity Pin[46] functional capacity of
11 C.A. Sens. Temp. • Sensor faulty tractor
Check integrity of sensor (N.T.C.)
• ECU faulty
Check temperature sensor using ART® Monitor
No affect on operation
12 TOlio>130 gradi Gearbox oil temperature over 130 °C
Wheel speed sensor faulty:

• Wiring fault
Tractor speed limited
Check electrical continuity Pin[56] to 3 km/h
15 Err. Sens. Wheel • Sensor faulty Range change
Check integrity of wheel speed sensor inhibited
• ECU faulty
Check wheels RPM using ART® Monitor
Range sensor disconnected
• Wiring fault
Check electrical continuity Pin[3] Range change
17 Sens. Range Off • Sensor faulty inhibited
Check integrity of range sensor
• ECU faulty
Check Range sensor using ART® Monitor
Range sensor faulty
• Wiring fault
• Sensor faulty Range change
18 Sens.Range K.O. Check integrity of Range sensor inhibited
• Sensor incorrectly positioned

• ECU faulty
Check Range sensor using ART® Monitor
No limitation of
19 ErrRange Neutral Engagement of range neutral not controlled functional capacity of
tractor
20-42
Short-circuit of 1st gear solenoid not controlled

• Wiring fault With earlier software ver-
Check electrical continuity Pin[62] - Pin[41] sions, tractor operation
could be inhibited
20 C.C. Ev1 (L) • Solenoid faulty
Check integrity of solenoid With more recent
software versions,
• ECU faulty the tractor will operate in
Check using EV On-Off from Tests Menu on the ART® (with engine minimal safety conditions
switched off)
Short-circuit of 2nd gear solenoid not controlled With earlier software ver-
• Wiring fault sions, tractor operation
Check electrical continuity Pin[63] - Pin[41] could be inhibited
21 C.C. Ev2 (L) • Solenoid faulty With more recent
Check integrity of solenoid software,
• ECU faulty the tractor will
Check using EV On-Off from Tests Menu on the ART® (with engine operate in minimal
switched off) safety conditions
Short-circuit of 3rd gear solenoid not controlled With earlier software ver-
22 C.C. Ev3 (L) • Solenoid faulty With more recent
Check integrity of solenoid software,
• ECU faulty the tractor will
Check using EV On-Off from Tests Menu on the ART® (with engine operate in minimal
switched off) safety conditions
Short-circuit of L solenoid not controlled With earlier software ver-

24 C.C. EvL (L) • Solenoid faulty With more recent
Check integrity of solenoid software versions,
• ECU faulty the tractor will operate in
Check using EV On-Off from Tests Menu on the ART® (with engine minimal safety
switched off) conditions
Short-circuit of M solenoid not controlled With earlier software ver-

• Solenoid faulty With more recent
25 C.C. EvM (L) software versions
Check integrity of solenoid
the tractor will operate in
• ECU faulty minimal safety
Check using EV On-Off from Tests Menu on the ART® (with engine conditions
switched off)
Short-circuit of H solenoid not controlled With earlier software
• Wiring fault versions,
Check electrical continuity Pin[61] - Pin[40] tractor operation
• Solenoid faulty could be inhibited
26 C.C. EvH (L)
Check integrity of solenoid With more recent softwa-
• ECU faulty re, the tractor will operate
Check using EV On-Off from Tests menu on the ART® (with engine in minimal safety condi-
switched off) tions
20-43
Short-circuit of Reverse solenoid not controlled

With earlier software
27 C.C. Ev<- (L)
Check integrity of solenoid With more recent sof-
• ECU faulty tware, the tractor will
operate in minimal sa-
Check using EV On-Off from Tests menu on the ART® (with en- fety conditions
gine switched off)
Short-circuit of Forward solenoid not controlled
28 C.C. Ev-> (L)
gine switched off)
Short-circuit of Medium range solenoid not controlled
29 C.C. EvMR (L)
gine switched off)
Short-circuit of High range solenoid not controlled
30 C.C. EvHR (L)
gine switched off)
Short-circuit of 1st gear solenoid controlled
31 C.C. Ev1 (H)
gine switched off)
Short-circuit of 2nd gear solenoid controlled
32 C.C. Ev2 (H)
Check using EV On-Off from Tests Menu on the ART® (with en- fety conditions
gine switched off)
20-44
Short-circuit of 3rd gear solenoid controlled With earlier software

33 C.C. Ev3 (H)
Check using EV On-Off from Tests Menu on the ART® (with en- operate in minimal sa-
gine switched off) fety conditions
Short-circuit of Low clutch solenoid controlled With earlier software

35 C.C. EvL (H)
Short-circuit of Medium clutch solenoid controlled With earlier software

36 C.C. EvM (H)
Short-circuit of High clutch solenoid controlled With earlier software

37 C.C. EvH (H)
Check using EV On-Off from Tests menu on the ART® (with en- operate in minimal sa-
Short-circuit of Reverse solenoid controlled With earlier software

38 C.C. Ev<- (H)
Short-circuit of Forward solenoid controlled With earlier software

39 C.C. Ev-> (H)
20-45
Short-circuit of Medium range solenoid controlled

40 C.C. EvMR (H)
fety conditions
gine switched off)
Short-circuit of High range solenoid controlled
41 C.C. EvHR (H)
fety conditions
gine switched off)
Open-circuit - 1st clutch solenoid
42 C.A. Ev1
fety conditions
gine switched off)
Open-circuit - 2nd clutch solenoid
43 C.A. Ev2
fety conditions
gine switched off)
Open-circuit - 3rd clutch solenoid
44 C.A. Ev3
fety conditions
gine switched off)
Open-circuit - Low clutch solenoid
46 C.A. EvL
fety conditions
gine switched off)
20-46
Open-circuit - Medium clutch solenoid

47 C.A. EvM
gine switched off)
Open-circuit - High clutch solenoid
48 C.A. EvH
gine switched off)
Open-circuit - Reverse solenoid
49 C.A. Ev <-
gine switched off)
Open-circuit - Forward solenoid
50 C.A. Ev ->
gine switched off)
Open-circuit - Medium range solenoid
51 C.A. Ev MR
gine switched off)
Open-circuit - High range solenoid
52 C.A. Ev HR
gine switched off)
20-47
Control signal/status discrepancy - 1st clutch solenoid disconnected

53 Ev 1 Comand/State
gine switched off)
gine switched off)
gine switched off)
57 Ev L Comand/State
gine switched off)
Control signal/status discrepancy - 1st clutch solenoid disconnected With earlier software
versions,
• Wiring fault tractor operation
58 Ev M Comand/State • Solenoid faulty With more recent sof-
Check integrity of solenoid tware, the tractor will
• ECU faulty operate in minimal sa-
gine switched off)
59 Ev H Comand/State
gine switched off)
20-48
Control signal/status discrepancy - Reverse solenoid disconnected With earlier software

60 Ev <- Comand/Stato

61 Ev -> Comand/Stato

62 Ev MR Comand/Stato

63 Ev HR Comand/Stato
Current draw incorrect - 1st clutch solenoid

(solenoid disconnected or continuously energised) With earlier software
tractor operation
64 Ev 1 Comand/Corr. • Solenoid faulty
tware, the tractor will
gine switched off)
Current draw incorrect - 2nd clutch solenoid
tractor operation
65 Ev 2 Comand/Corr • Solenoid faulty
gine switched off)
20-49
Current draw incorrect - 3rd clutch solenoid

versions,
66 Ev 3 Comand/Corr • Solenoid faulty
gine switched off)
Current draw incorrect - Low clutch solenoid
versions,
68 Ev L Comand/Corr • Solenoid faulty
gine switched off)
Current draw incorrect - Medium clutch solenoid
versions,
69 Ev M Comand/Corr • Solenoid faulty
gine switched off)
Current draw incorrect - High clutch solenoid
versions,
70 Ev H Comand/Corr • Solenoid faulty
gine switched off)
Current draw incorrect - Reverse solenoid
versions,
71 Ev <- Comand/Corr • Solenoid faulty
gine switched off)
Current draw incorrect - Forward solenoid With earlier software
(E.V. disconnected or continuously energised) versions,
71 Ev -> Comand/Corr • Solenoid faulty With more recent sof-
Check integrity of solenoid tware, the tractor will
gine switched off)
20-50
Current draw incorrect - Medium Range solenoid

versions,
Check electrical continuity Pin[18] - Pin[40]
could be inhibited
73 Ev MR Comand/Corr • Solenoid faulty
gine switched off)
Current draw incorrect - High range solenoid
versions,
Check electrical continuity Pin[19] - Pin[40]
could be inhibited
74 Ev HR Comand/Corr • Solenoid faulty
gine switched off)
No limitation of
• 1st clutch not calibrated
75 FRIZ 1 NO CALIBR functional capacity of
Carry out automatic clutch calibration
tractor
No limitation of
• 2nd clutch not calibrated
tractor
No limitation of
• 3rd clutch not calibrated
tractor
Main clutch proportional solenoid valve continuously energised
78 Evp. Friz. Always ON • ECU faulty Speed limited
Check using the Test menu that the proportional solenoid val-
ve is continuously energised
Main clutch proportional solenoid valve never energised
• Wiring fault
Check electrical continuity
No limitation of
• Solenoid faulty
functional capacity of
79 Evp. Friz. Err C.A. tractor
• ECU faulty
Check proportional solenoid valve using Test menu on the
ART®
• Check ECU configuration
Check gearbox type configuration (35S/40S)
Proportional solenoid valve always energised
• ECU faulty Speed limited to
80 Evp. Always ON Check in Test menu that the proportional solenoid valve is 3 km/h
continuously energised
Proportional solenoid valve never energised

• Wiring fault
Check electrical continuity No limitation of
functional capacity of
81 Evp. Err C.A. • Solenoid faulty tractor
• ECU faulty
Check using EV on-off from Test menu on the ART® (with engine
switched off)
20-51
Calibration coefficient not set correctly No limitation of

82 COEFF FRIZ1 K.O. • ECU faulty functional capacity of
Renew the ECU tractor
Fault in EEprom area in which the system parameters are stored No limitation of
85 EEPROM SYSTEM • ECU faulty functional capacity of
Fault in EEprom area in which the Hard-Soft threshold parame-
ters are stored No limitation of
86 EEPROM POWER functional capacity of
• ECU faulty tractor
Renew the ECU
No limitation of
87 Error Watchdog • Operating anomaly of the ECU functional capacity of
tractor
No/bad connection with the armrest
• ECU faulty
200 CAN T.O. CCMsg1
Check using CAN Monitor menu on the ART®
• Wiring fault
• ECU faulty
201 CAN T.O. CCMsg2
• Wiring fault
• ECU faulty
210 CAN T.O. ECMsg1 Check using CAN Monitor menu on the ART®
• Wiring fault
No/bad connection with ECU
• ECU faulty
220 CAN T.O. ICMsg1
• Wiring fault
20-52
LIFT ECU
TESTER
MANUAL
F0014040
20-53
LIFT ECU
L I F T I N G A R M PRESENTATION SCREEN
= = = = = = = = = = = = = = = = This screen shows:
Software: the Software version and date of issue
S o f t w a r e N N N . C C
g g / m m / a a a a NOTE. If the connectors are connected the wrong way
round to the ECU, the following message will appear
on the screen:
C O N T R O L U N I T C O N
N E C T E D T O I N C O R R
E C T C O N N E C T O R
Press C to proceed or E to exit.
[ E ] C A N N E T W O R K
[ C ] C o n t i n u e d
= = = = = = = = = = = = = = = = This menu contains the following options:
1 | M o n i t o r s 1 | Monitor: to monitor the sensors and actuators connect-
2 | P a r a m e t e r s ed to the ECU.
3 | S e t t i n g 2 | Parameters: to configure the characteristics of the lift.
4 | A l a r m s l i s t 3 | Settings: to calibrate the sensors connected to the ECU.
4 | Alarms list: to view the alarm log.
To select one of the options and move to the next screen,
press the corresponding numerical key on the ART®.
Press E to exit.
= = = = = = = = = = = = = = = =
[ E ] E x i t
20-54
LIFT ECU
M O N I T O R S M E N U 1. MONITOR MENU
= = = = = = = = = = = = = = = = In this menu you can choose to display the status of devices
regarding the following:
1 - Lifting arm: rear lift.
2 - Console: armrest console.
1 - L i f t i n g a r m
3 - PTO: front and rear PTOs.
2 - C o n s o l e
4 - Power: supply voltage of the lift ECU.
3 - P T O
5 - Rx/Tx Can 1: number of messages transmitted and
4 - P o w e r
received by the ECU.
5 - R x / T x C a n 1
6 - Errors Can 1: number and type of errors detected on
6 - E r r o r s C a n 1 the CAN® bus.
To select the required option, press the corresponding nu-

merical key on the ART® or press E to quit.
= = = = = = = = = = = = = = = =
[ E ] E x i t
L I F T I N G A R M 1.1 Lift Monitor menu

= = = = = = = = = = = = = = = = State:
S t a t e . . . . . . $ $ $ $ $ indicates the active lift control mode: the possible modes are:
P o s i t i o n # # # . # %
L f S t r e s s R t
# # # # # # # # # # #
S l i d i g n # # # . # %
R a d a r k m h # # . #
W h e e l s k m h # # . #
M o d e - > $ $ $ $ $
S v u p $ $ $
S v d w $ $ $
P w m # # # # # # # # m A
[ E ] E x i t
20-55
LIFT ECU
Lock: On pressing the Lock button on the armrest,

S t a t e . . . . . . L o c k the lift status changes from Lock to Stop.
S t a t e . . . . . . S t o p
S t a t e . . . . . . S t o p CTRL: On pressing the Up/Down buttons on the joy-

stick, the lift status changes from Stop to
Control (CTRL)
S t a t e . . . . . . C T R L
S t a t e . . . . . . C T R L Float: On turning the position control potentiometer

on the armrest, the lift status changes from
Control to Float.
S t a t e . . . . . . F l o a t Holding pressed the Down button has the
same effect.
1- Lift being raised
S t a t e . . . . . . T o U p To Up: After pressing the Up button, while the lift is
being raised, the ART® displays message (1).
2- Lift at maximum height When the lift has reached the maximum
S t a t e . . . . . . S t o p height, message (2) appears.
S t a t e . . . . . . S t o p Safe: Safety condition in which normal lift operation

is inhibited; in some fault conditions the lift
may be operated by way of the pushbuttons.
Position:
Displays the reading from the position sensor mounted on
the lift arm; the values displayed are as follows:
0% minimum height condition
100% maximum height condition
Draft sensor:
Displays the draft sensor readings
Lt: left-hand draft sensor reading
Rt: right-hand draft sensor reading
Stress: calculated draft percentage
S l i d i g n # # # . # % Slidign:
Wheelslip calculated as the ratio between:
Theoretical speed Wheel speed
Actual speed Radar speed
The value is displayed as a percentage between 0% and
100% with accuracy to one decimal place.
Radar
Actual speed of tractor as measured by the Radar.
Wheels
Theoretical speed of the tractor as measured by the wheel
speed sensor.
20-56
LIFT ECU
Position Control
Mode
M o d e - > . . . . P o s By turning the control type selector knob you can vary the lift
Draft Control control mode.
M o d e - > . . . . D r a f t
Position/Draft Control
M o d e - > . . . . M i x
Solenoid not activated

S V u p O F F SV Up
Operating status of the Up Solenoid Valve.
Solenoid activated
S V u p O N
Solenoid not activated

S V d w O F F SV Dw
Operating status of the DOWN Solenoid Valve.
Solenoid activated
S V d w O N
P w m # # # # # # # # m A Pwm
Operating status of the proportional Up and Down solenoid
valves.
The following values are displayed on the Tester:
• P.W.M. percentage
• Current in mA absorbed by the activated solenoid valve.
20-57
LIFT ECU
C o n s o l e 1.2 Console Monitor

This screen displays the statuses and values of the push-
= = = = = = = = = = = = = = = =
buttons and potentiometers located on the armrest and the
L L > H L > statuses of the external lift control pushbuttons.
S p > # # # # M > # # # #
# # # # V > # # # S >
# # # # # #
I n t B U T T > e x t
$ $ $ U P $ $ $
$ $ $ D W $ $ $
$ $ $ L O C K - - -
[ E ] E x i t
Minimum condition
L L > H L > <LO> Minimum position potentiometer
S p > 0 0 0 0 M > # # # # On turning the maximum working depth control knob, the
value displayed on the Tester changes.
Maximum condition
L L > H L >
S p > 1 0 0 0 M > # # # #
Minimum condition
L L > H L > <Hi> Maximum lift height potentiometer
S p > # # # # M > 0 0 0 0 On turning the maximum lift height knob, the value displayed
on the Tester changes.
Maximum condition
L L > H L >
S p > # # # # M > 1 0 0 0
Minimum condition
S p > # # # # M > # # # # <Sp> Control level potentiometer
0 0 0 0 V > # # # S > On turning the control level knob, the value displayed on the
Tester changes.
Maximum condition
S p > # # # # M > # # # #
1 0 0 0 V > 2 5 0 S >
Minimum condition
S p > # # # # M > # # # # <M> Lift control type selector - MIXER
(Position -Draft-Wheelslip).
# # # # V > 0 0 0 S >
On turning the control selector knob, the value displayed on
Maximum condition the Tester changes.
S p > # # # # M > # # # #
# # # # V > 2 5 0 S >
20-58
LIFT ECU
Minimum condition
<V> Lowering speed control
# # # # V > # # # S >
On turning the lowering speed control knob, the value dis-
0 0 0 # # # played on the Tester changes.
Maximum condition
# # # # V > # # # S >
2 5 0 # # #
Minimum condition
# # # # V > # # # S > <S> Sensitivity control.
# # # 0 0 0 On turning the sensitivity control knob, the value displayed
on the Tester changes.
Maximum condition
# # # # V > # # # S >
# # # 1 0 0
• Internal pushbuttons Lift control pushbuttons.

Up button released By pressing the internal or external lift control buttons you
O F F U P can test their operation.
Up button depressed
O N U P
Down button released
O F F D W
Down button depressed
O N D W
• External pushbuttons
Up button released
U P O F F
Up button depressed
U P O N
Down button released
D W O F F
Down button depressed
D W O N
Lock button released
O F F L O C K
Lock button depressed
O N L O C K
20-59
LIFT ECU
P T O 1.3 PTO Monitor

This screen displays the status and values of the PTO control
= = = = = = = = = = = = = = = =
pushbuttons and potentiometers located on the armrest, on
R p m E n g i n e # # # # the console to the right of the driver's seat and outside the
P t o F r o n t $ $ $ cab.
P t o B a c k $ $ $ Rpm engine engine speed.
B a c k B r . B u t . R
E x t . B u t t o n R
S V F r . . . . m A # # # #
S V B r a . . . m A # # # #
S V B a c k m A # # # #
P t o $ $ $ $ $ r p m # # # #
P t o $ $ $ $ $ $ $ $ $ $
[ E ] E x i t
PTO on
P t o F r o n t O N Pto front operating status of the front PTO
(where present).
PTO off
P t o F r o n t O F F
PTO on
P t o B a c k O N Pto back Operating status of the rear PTO.
PTO off
P t o B a c k O F F
Button released
B a c k B r . B u t . R Back Br. But. Status of the rear PTO brake control button,
located on the right-hand console.
Button depressed
E x t . B u t t o n P
Button released
B a c k B r . B u t . R Ext. Button Status of external PTO button (1).
Button depressed
E x t . B u t t o n P
SV not activated
S V f r m A 0 0 0 0 SV fr Current absorbed by the Front PTO solenoid
valve.
SV activated (Where present)
S V f r m A NOTE: the current absorbed by the solenoid is normally
greater than 700 mA.
20-60
LIFT ECU
SV not activated
SV bra Current absorbed by the rear PTO brake so-
S V B r a . . . m A 0 0 0 0 lenoid.
SV activated NOTE: The current absorbed by the solenoid is normally
S V B r a . . . m A 1 X X X greater than 700 mA
SV not activated
S V B a c k m A 0 0 0 0 SVback Current absorbed by Rear PTO solenoid valve.
SV activated NOTE: the current absorbed by the solenoid valve is nor-
mally greater than 700 mA
S V B a c k m A 1 X X X
P t o N e u t r p m # # # # PTO Rear PTO rotation speed.
P t o 5 4 0 r p m # # # #
P t o 5 4 0 E r p m # # # #
P t o 1 0 0 0 r p m # # # #
P t o 1 0 0 0 E r p m # # # #
(1)
P t o A u t o O F F PTO Rear PTO operating mode.
• If automatic mode is disabled, message (1) is dis-
(2)
played
P t o A u t o O N • If automatic mode is enabled, message (2) is dis-
(3) played; only in this case will the operating status of
the PTO be displayed as follows:
P t o A u t o O n O N
• If the PTO is activated, message (3) is displayed.
(4) • If the PTO is not activated, message (4) is dis-
P t o A u t o O n O F F played.
20-61
LIFT ECU
P O W E R 1.4 Power Monitor

This screen displays the supply voltages of the ECU and the
= = = = = = = = = = = = = = = =
components connected to it.
+ 5 v . . . . . . . V # # . #
+ 6 v 8 . . . . . . V # # . #
+ 1 0 v . . . . . . V # # . #
B a t t e r y . . V # # . #
[ E ] E x i t
M S G S . C O U N T E R C A N 1.5 C.A.N. Monitor

This screen displays the number of messages received by or
= = = = = = = = = = = = = = = =
transmitted from the ECU, divided according the type of
* * T X * * message.
L C _ M S G 1 . . . . # # # # #
* * R X * *
C C _ M S G 1 . . . . # # # # #
C C _ M S G 2 . . . . # # # # #
C C _ M S G 3 . . . . # # # # #
E C _ M S G 1 . . . . # # # # #
T C _ M S G 1 . . . . # # # # #
I C _ M S G 1 . . . . # # # # #
[ E ] E x i t
20-62
LIFT ECU
E r r o r C o u n t . C A N 1.6 C.A.N. Errors Monitor

This screen displays the number and type of errors that the
= = = = = = = = = = = = = = = =
ECU has detected on the C.A.N.® bus.
A C K . . . . . . . . # # # # #
S T U F F . . . . . . # # # # #
F O R M . . . . . . . # # # # #
B I T 0 . . . . . . . # # # # #
B I T 1 . . . . . . . # # # # #
C R C . . . . . . . . # # # # #
W A R N I N G . . . . # # # # #
B U S O F F . . . . . # # # # #
[ E ] E x i t
P a r a m e t e r s M e n u 2. PARAMETERS MENU
From this menu you can set the lift parameters.
= = = = = = = = = = = = = = = =
1 - Speed Const.: Radar configuration.
Press 1 to continue or E to return to the previous menu.
1 - S p e e d C o n s t .
[ E ] E x i t
20-63
LIFT ECU
S p e e d C o n s t a n t s 2.1 Speed constants

From this menu you can specify the presence or absence of
= = = = = = = = = = = = = = = =
the radar.
Radar present
1 - R a d a r # # # #
• If the radar is present, enter the value 6500.
Radar absent
• If the radar is absent, enter the value 0000.
[ E ] E x i t
S e t t i n g M e n u 3. SETTING MENU
From this menu you can calibrate the lift position sensor and
= = = = = = = = = = = = = = = =
the lift lock speed.
1 - Min. Height: calibration of the minimum lift height.
2 - Max. Height: calibration of the maximum lift height.
1 - M i n . H e i g h t # # # #
3 - Front PTO.: presence of front PTO.
2 - M a x . H e i g h t # # # #
4 - Block Speed: lift lock speed.
3 - F r o n t P T O #
To select the required calibration, press the corresponding
4 - B l o c k S p e e d # #
numerical key on the ART® or press E to exit.
[ E ] E x i t
20-64
LIFT ECU
M i n . H e i g h t 3.1 Minimum height menu

From this menu you can set the minimum lift height.
= = = = = = = = = = = = = = = =
Procedure
1- Start the engine and run at idle speed.
1 - A c t u a l # # # # 2- Unlock the lift.
2 - N e w # # # # 3- Lower the lift completely using the button on the joy-
stick.
4- Press E to confirm the value.
[ D ] D e l e t e
[ E ] E x i t
M a x . H e i g h t 3.2 Maximum height menu

= = = = = = = = = = = = = = = = From this menu you can set the maximum lift height.
1- Start the engine and run at idle speed.
2- Unlock the lift.
1 - A c t u a l # # # # 3- Fully raise the lift using the button on the joystick.
2 - N e w # # # #
4- When the lift has reached its maximum height, lower it
by about 35 units and then press E to confirm the val-
ue.
[ D ] D e l e t e
[ E ] E x i t
20-65
LIFT ECU
F R O N T P T O 3.3 Front PTO menu

From this menu you can specify the absence or presence of
= = = = = = = = = = = = = = = =
the front PTO.
Press 0 if the front PTO is not installed.
1 - A c t u a l # Press 1 if the front PTO is installed.

2 - N e w # After making your selection, press E to continue.
[ D ] D e l e t e
[ E ] E x i t
3.4 Lock speed menu

L O C K S P E E D M E N U
In this menu you can set the tractor speed above which the
= = = = = = = = = = = = = = = = ECU will automatically engage the lift lock.
The lock will only be applied if the lift is in STOP condition.
Enter the new value using the numerical keys on the ART®;
1 - A c t u a l # # # # note that the value entered corresponds to the speed in km/h.
2 - N e w # # # # Press E to confirm the new value.
[ D ] D e l e t e
[ E ] E x i t
20-66
LIFT ECU
A L A R M S L I S T 4. ALARMS LIST
= = = = = = = = = = = = = = = =
➔ Most recent alarm
This screen displays the last 10 alarm signals to be gener-
ated.
All currently active alarms are displayed in succession on the
last line of the display, highlighted in reverse video.
[ D ] D e l e t e
[ E ] E x i t
20-67
LIST OF LIFT ECU ALARM CODES
N° Tester Message Cause of fault
11 This alarm is not logged Checksum EPROM program not valid

12 “Pow.Sens.Posit” Position sensor voltage incorrect
13 “ShortCircuit 1” Short-circuit of lift high solenoid (without solenoids activated)
14 “ShortCircuit 2” Low short-circuit
16 “Config.Error” ECU 1 connected to wrong connector
18 “Pos.Sen.disc.” Position sensor not connected
21 “ShortCirc.EVUP 1” High short-circuit of Up solenoid
22 “ShortCirc.EVUP 2” Low short-circuit of Up solenoid
23 “EvUpdiscon. 1” Up solenoid not connected (static test - SV Off)
24 “EvUpdiscon. 2” Up solenoid disconnected (dynamic test - SV On)
25 “EvUp Error” Up solenoid unidentifiable fault
31 “ShortCirc.EvDw 1” High short-circuit Down solenoid
32 “ShortCirc.EvDw 2” Low short-circuit Down solenoid
33 “EvDwSdiscon. 1” Down solenoid not connected (static test - SV off)
34 “EvDwdiscon. 2” Down solenoid not connected (dynamic test - SV on)
35 “EvDw Error” Down solenoid unidentifiable fault
41 “ShortCirc. PTO” PTO short-circuit
42 “EvFORW discon. 1” FRONT PTO SOLENOID not connected (static test - SV Off)
43 “EvFORW discon. 2” FRONT PTO SOLENOID not connected (dynamic test - SV On)
44 “EvFORW Error ON” FRONT PTO SOLENOID: command/logical status discrepancy
45 “EvFORW Error OFF” FRONT PTO SOLENOID: current detected in solenoid without active command
51 “EvBACK discon. 1” REAR PTO SOLENOID not connected (static test - SV Off)
52 “EvBACKScolleg. 2” REAR PTO SOLENOID not connected (dynamic test - SV On)
53 “EvBACK Error ON” REAR PTO SOLENOID: command/logical status discrepancy
54 “EvBACK Error OFF” REAR PTO SOLENOID: current detected in solenoid without active command
55 “EvBRAKEdiscon. 1” PTO BRAKE SOLENOID not connected (static test - SV Off)
56 “EvBRAKEdiscon. 2” PTO BRAKE SOLENOID not connected (dynamic test - SV On)
57 “EvBRAKE err ON” PTO BRAKE SOLENOID: command/logical status discrepancy
58 “EvBRAKE err OFF” PTO BRAKE SOLENOID: current detected in solenoid without active command
62 “RtForSen.discon.” RH draft sensor not connected
63 “LtForSen.discon” LH draft sensor not connected
65 “Radar discon.” Radar not connected
67 “Power 5V” 5V sensor power incorrect
68 “Power 10V” 10V sensor power incorrect
71 “Power 6V8” 6V8 sensor power incorrect
72 “C.C. ISO 11786” Short-circuit on ISO 11786 outputs
77 “EEPROM : SPEED” EEPROM checksum not correct - Parameters menu
78 “EEPROM : CALIB” EEPROM checksum not correct - Calibrations menu
20-68
N° Tester Message Cause of fault
81 “EEPROM : CTRL” EEPROM checksum not correct - Control menu

82 “EEPROM : PWM” EEPROM checksum not correct - PWM menu
83 “EEPROM : DRAFT” EEPROM checksum not correct - Draft menu
84 “EEPROM : SLIP” EEPROM checksum not correct - Slip menu
85 “EEPROM : POS” EEPROM checksum not correct - Position menu
86 “EEPROM : AD” EEPROM checksum not correct - Antidumping menu
87 “EEPROM : SFCFG” EEPROM checksum not correct - Draft config. menu
88 “EEPROM : SLCFG” EEPROM checksum not correct - Slip config. menu
201 “CAN T.O. CCMSG2” Message reception time-out - CAN CCMSG2 from armrest
242 “CAN T.O. TCMSG1” Message reception time-out - CAN TCMSG1 from armrest
243 “CAN T.O. ECMSG1” Message reception time-out - CAN ECMSG1 from armrest
20-69
PAGE INTENTIONALLY
LEFT BLANK
20-70
ARMREST
ECU
TESTER MANUAL
F0014080
F0014080
20-71
ARMREST ECU
3 5 S L I F T I N G A R M PRESENTATION SCREEN
= = = = = = = = = = = = = = = = This screen displays:
Software: Software version and date of issue
S o f t w a r e N N N . C C
g g / m m / a a a a
[ E ] C A N N E T W O R K
[ C ] C o n t i n u e d
= = = = = = = = = = = = = = = = From this menu you can select the following options:
1 | C o n f i g u r a t i o n 1 | Configurations: for calibration of the sensors used by the
2 | M o n i t o r ECU.
3 | P r e s e l e c t i o n s 2 | Monitor: for display of the sensor and actuator control
4 | T e s t s signal values.
5 | A l a r m s L i s t 3 | Preselections: for programming the characteristic pa-
rameters.
4 | Tests: to test operation of the control buttons and po-
tentiometers.
5 | Alarms list: alarm log.
To select the required option and pass to the next screen,
press the corresponding numerical key on the ART®.
Press E to exit.
= = = = = = = = = = = = = = = =
[ E ] E x i t
20-72
ARMREST ECU
C o n f i g u a t i o n s 1. CONFIGURATIONS MENU
= = = = = = = = = = = = = = = = From this menu you can calibrate the minimum and maxi-
mum positions for the position sensors of the:
• Clutch pedal.
• Accelerator pedal.
1 - C l u t M i n # # # #
• Hand throttle.
2 - C l u t M a x # # # #
3 - A c c e l M i n # # # # Calibration procedure
Select the required calibration using the numerical keys on
4 - A c c e l M a x # # # #
the ART®.
5 - H G a s - M i n # # # #
1- Calibration of the minimum clutch pedal position
6 - H G a s - M a x # # # # Fully depress the clutch pedal and save the value dis-
played following the instructions given on the ART®.
2- Calibration of the maximum clutch pedal position
Fully release the clutch pedal and save the value dis-
played following the instructions on the ART®.
= = = = = = = = = = = = = = = = 3- Calibration of the minimum accelerator pedal posi-
[ E ] E x i t tion:
Fully release the accelerator pedal and save the value
displayed following the instructions on the ART®.
4- Calibration of the maximum accelerator pedal po-
sition
Fully depress the accelerator pedal and save the value
displayed following the instructions on the ART®.
5- Calibration of the minimum hand throttle position:
Position the hand throttle, indicated with the number 8
in Appendix 1, in the minimum position and save the
= = = = = = = = = = = = = = = =
value displayed following the instructions on the ART®.
6- Calibration of the maximum hand throttle position:
Position the hand throttle (8) in the maximum position
A c t u a l # # # #
and save the value displayed following the instructions
on the ART®.
N e w # # # #
On pressing the numerical key to select the required calibra-
tion operation, the ART® screen will appear as shown on the
left.
On pressing E the following messages will be displayed on
the last two lines of the screen:
[ A ] A n n u l
[ C ] C o n f i r m
Press one of the indicated keys to save the value or to cancel

[ E ] E x i t the operation.
On saving or cancelling, the tester will return to display of the
CONFIGURATIONS screen.
20-73
ARMREST ECU
M o n i t o r s M e n u 2. MONITOR MENU
= = = = = = = = = = = = = = = = From this menu you can display all the operating statuses
and numerical values of the control functions:
1 - Engine: test: Accelerator pedal
Hand throttle
1 - E n g i n e Memory M1
2 - B a c k L i f t Memory M2
3 - F r o n t L i f t 2 - Rear lift:
4 - T r a n s m i s s i o n Test the adjustment and control potentiometers.
5 - M e s s a g e s C A N Display the lift operating status.
6 - E r r o r s C A N 3 - Front lift:
Test the adjustment and control potentiometers.
Display the operation status.
4 - Transmission:
display the status of the transmission ECU and the com-
mands given by the operator .
= = = = = = = = = = = = = = = = 5 - Messages CAN:
[ E ] E x i t messages received and transmitted over the CAN bus.
6 - Errors CAN: errors detected on the CAN bus.
E n g i n e 2.1 Engine
= = = = = = = = = = = = = = = = This screen displays all the commands relative to the engine
E n g i n e R P M ECU.
R e q u i r e m e n t s 1 - Engine speed command from the accelerator pedal.
As you press the pedal, the value displayed will vary con-
tinuously between minimum and maximum rpm.
P e d a l # # # #
2 - Engine speed command from the hand lever (hand
H a n d l e v e r # # # # throttle)
As you operate the hand throttle, the value displayed will
M e m o r y 1 O F F # # # # vary continuously between the minimum and maximum
M e m o r y 2 O F F # # # # rpm.
R P M R e q u i r e d 3 - Memory M1
If the Memory M1 is deactivated, the Tester display will be
# # # #
as follows:
E n g i n e R P M
M e m o r y 1 O F F # # # #
# # # #
= = = = = = = = = = = = = = = = On activating Memory M1, the display changes to:
[ E ] E x i t M e m o r y 1 O N n n n n
Where nnnn is any number between the minimum and
maximum permitted engine speed.
20-74
ARMREST ECU
4 - Memory M2
If Memory M2 is deactivated, the Tester display will be as
follows:
M e m o r y 2 O F F # # # #
On activating Memory M2, the display changes to:
M e m o r y 2 O N n n n n
Where nnnn is any number between the minimum and
maximum permitted engine speed.
5 - Rpm required
The required rpm is calculated by choosing the highest
value between the hand throttle, the accelerator pedal
and the activated memory (if selected).
6 - Engine rpm
Actual engine speed.
R E A R L I F T I N G A R M 2.2 Rear lift (rear lifting arm)

= = = = = = = = = = = = = = = = This screen displays the statuses of all the potentiometers,
the pushbuttons on the armrest and the external pushbut-
P o t e n t i o m e t e r s
tons mounted on the rear of the tractor.
S e t P o i n t . . . . # # # #
M i n . H e i g h t # # # #
M a x . H e i g h t # # # #
C o n t r o l # # # #
L o w . S p e e d # # # #
S e n s i t i v i t y # # # #
S t a t u s L i f t A r m
L O C K
= = = = = = = = = = = = = = = =
[ E ] E x i t
20-75
ARMREST ECU
Minimum condition
S e t P o i n t . . . . # # # # 1 - Set point potentiometer
Turning the potentiometer changes the value displayed
Maximum condition on the Tester.
S e t P o i n t . . . . # # # #
Minimum condition
M i n . H e i g h t # # # # 2 - Minimum height potentiometer:
Turning the potentiometer changes the minimum height
Maximum condition value.
M i n . H e i g h t # # # #
Minimum condition
M a x . H e i g h t # # # # 3 - Maximum height potentiometer:
Turning the potentiometer changes the maximum height
M a x . H e i g h t # # # #
Minimum condition
C o n t r o l # # # # 4 - Control selector potentiometer:
Turning the potentiometer varies the type and degree of lift
Maximum condition control (position, draft, draft and wheelslip).
C o n t r o l # # # #
Minimum condition
L o w . S p e e d # # # # 5 - Lowering sped potentiometer:
Turning the potentiometer changes the value displayed.
Maximum condition
L o w . S p e e d # # # #
Minimum condition
S e n s i t i v i t y # # # # 6 - Sensitivity potentiometer:
Turning the potentiometer changes the value displayed.
Maximum condition
S e n s i t i v i t y # # # #
Position control
M o d e - > P o s 7 - Lift type control:
By turning the knob located on the armrest you can
Draft control change lift control type.
M o d e - > D r a f t
Position/Draft control
M o d e - > M i x
8 - Lift Status
Pressing the LOCK button changes the rear lift status; the
possible statuses are: LOCK, STOP.
20-76
ARMREST ECU
F r o n t L i f t . A r m 2.3 Front lift

= = = = = = = = = = = = = = = = This screen displays the operating status of all the front lift
controls.
P o t e n t i o m e t e r
M i n . H e i g h t # # # #
M a x . H e i g h t # # # #
S t a t u s L i f t . A r m
L O C K
= = = = = = = = = = = = = = = =
[ E ] E x i t
Minimum condition
M i n . H e i g h t # # # # 1 - Minimum height potentiometer:
Turning the potentiometer changes the minimum height
M a x . H e i g h t # # # #
Minimum condition
M a x . H e i g h t # # # # 2 - Maximum height potentiometer:
Turning the potentiometer changes the maximum height
M a x . H e i g h t # # # #
T r a n s m i s s i o n 2.4 Transmission
= = = = = = = = = = = = = = = = This screen displays the status and values of all the armrest
buttons used to control the transmission ECU.
R e q . A c t . Req.: Requested.
F F NI V F F Act.: Actual.
N N R na g e N A FF: Gear.
C ul t NN: Range not engaged.
G e a r s E gn a g e d AV: Forward.
A v : # A tc : # I n : # IN: Reverse.
M a n u a l G: e a r b o x GEARBOX: Selected gearbox operation mode
(Manual, AUTO 1 - AUTO 2).
R e v e r s e G e a r s
Reverse gears: Reverse travel gears.
F a s t A V : # I N : #
Fast: High range (H).
S l o w A V : # I N : #
Slow: Medium range (M).
Press E to exit.
= = = = = = = = = = = = = = = =
[ E ] E x i t
20-77
ARMREST ECU
1- Requested and engaged gear/range:

These lines display the transmission status as regards
the gear and range actually engaged and the gear and
range requested:
R e q . A c t .
F F I N V F F
N N R a n g e N N
The first line indicates the requested gear and the en-
gaged gear, which can assume any value from 1 to 9 for
each range.
The requested range value, by pressing the relative
armrest buttons, can be changed as follows:
Super slow (L): Low range.
Slow (M): Medium range.
Fast(H): High range.
Error (E): range sensor disconnected or faulty.
Neutral (NN): range gearbox in neutral.
2- Reverse gear requested, engaged:
These lines display information similar to that which ap-
pears on the tractor instrument.
G e a r s E n g a g e d
A v : # A c t : # I n : #
3- Gearbox operating mode

This line indicates the transmission operating mode,
which may be as follows:
Manual: gearchanges are effected under the complete
control of the operator
Automatic: gearchanges are controlled by the ECU in
accordance with the operating conditions.
4- Programmed reverse gears
These lines indicate the four reverse gears pro-
grammed by the operator as follows:
20-78
ARMREST ECU
S e t t i n g s M e n u 3. PRESELECTIONS MENU
= = = = = = = = = = = = = = = = The Preselections menu contains all the armrest configura-
tion variables.
1 - Machine clock.
2 - Maintenance.
1 - M a c h i n e C l o c k
2 - M a i n t e n a n c e
P a s s w o r d
= = = = = = = = = = = = = = = =
[ E ] E x i t
T e s t s M e n u 4. TESTS MENU
This menu allows you to test the operation of all the push-
= = = = = = = = = = = = = = = =
buttons and potentiometers located on the armrest.
1- Joystick: test pushbuttons mounted on the joystick.
2- External console: test pushbuttons and controls on ex-
1 - J o y s t i c k
ternal console.
2 - C o n s o l e e x t .
3- Internal console: test pushbuttons and controls on in-
3 - C o n s o l e i n t . ternal console (protected).
4 - S e n s o r s
4- Sensors: test operation of sensors.
5 - L e d s
5- Leds: test all LEDs on armrest.
T e s t s M e n u
= = = = = = = = = = = = = = = =
[ E ] E x i t
20-79
ARMREST ECU
J o y s t i c k T e s t 4.1 Joystick
= = = = = = = = = = = = = = = = This screen displays the operating status of all the pushbut-
tons on the joystick.
F o r w a r d D i r e c t . R R: indicates that the pushbutton is Released.

R e v e r s e D i r e c t . R P: indicates that the pushbutton is Pressed.
N e u t r a l D i r e c t . R
1- Forward/Reverse direction:
C o n s e n t . . . R
When the shuttle button is released in the rest position, the
I n c r e a s e G e a r R Tester displays:
D e c r e a s e G e a r R F o r w a r d D i r e c t R
L i f t i n g A r m U p R R e v e r s e D i r e c t P
L i f t . A r m D o w n R
A c t i v a t i o n M 1 R On pressing the Forward direction, the Tester displays:
A c t i v a t i o n M 2 R F o r w a r d D i r e c t R
S E Q / S T O P . . . R R e v e r s e D i r e c t P
= = = = = = = = = = = = = = = =
On pressing the Reverse direction, the Tester displays:
[ E ] E x i t
F o r w a r d D i r e c t R
R e v e r s e D i r e c t P
2- Neutral Direction.
When the neutral button is released, the Tester dis-
plays:
N e u t r a l D i r e c t P
On pressing the button, the display changes to:

N e u t r a l D i r e c t P
3- Consent.
When the Consent button (green enabling button) is re-
leased, the Tester displays:
C o n s e n t . . . . P
On the pressing the button the display changes to:

C o n s e n t . . . . P
4- Increase/Decrease gear.
When the EPS button is left in the rest position, the Tester
displays:
I n c r e a s e G e a r R
D e c r e a s e G e a r R
On pressing "increase gear" (shift up), the Tester displays:
On pressing "decrease gear" (shift down), the Tester dis-
plays:
20-80
ARMREST ECU
5- Lift Up/Down.
When the lift control button is left in the rest position, the
Tester displays:
On pressing "Up", the Tester displays:
L i f t i n g A r m U p P
L i f t . A r m D o w n R
On pressing "Down", the Tester displays:
L i f t i n g A r m U p R
L i f t . A r m D o w n P
6- Activation memory M1.

When the M1button is released, the Tester displays:
A t c i v a t i o n M 1 R
On pressing the M1 button:

A t c i v a t i o n M 1 P
7- Activation memory M2.

When the M2 button (7) is released, the Tester displays:
A t c i v a t i o n M 2 R
On pressing the M2 button:

A t c i v a t i o n M 2 P
8- Sequence button.
When the SEQ is released, the Tester displays:
S E Q / S T O P . . . R
On pressing the SEQ button:

S E Q / S T O P . . . P
20-81
ARMREST ECU
E x t e r n a l C o n s o l e 4.2 External console

tons and potentiometers on the external console.
P T O C o n s e n t R
F R O N T R R E A R R R: indicates that the pushbutton is Released.
S B A A u t o R P: indicates that the pushbutton is Pressed.
D T R D i f f R
1- PTO consent.
R E A R L I F T I N G A R M
When the PTO consent (enable) button is in the rest po-
P o t C o n t r o l # # # # sition, the Tester displays:
L O C K R
P T O C o n s e n t R
F R O N T L I F T I N G A R M
M a x . H e i g h t # # # # On pressing the button:
M i n . H e i g h t # # # # P T O C o n s e n t P
S e l e c . P u s h b u t . R 2- Front PTO.
E N G I N E When the front PTO button is in the rest position, the
M a n u a l A c c . # # # # Tester displays:
[ E ] E x i t A n t R
On pressing the button:
A n t R
3- SBA.
When the SBA button is in the rest position, the Tester
displays:
S B A A u t o R
On pressing the button:
S B A A u t o P
I N T E R N A L C O N S O L E 4.3 Internal console

tons and potentiometers on the internal console.
B U T T O N S
On pressing the buttons and operating the potentiometers
listed in this screen, the display shows the changes in the log-
M e n u R ical status of the pushbuttons (R= Released, P= Pressed) and
I n v e r s e G e a r R the potentiometer values.
M a x i m u n G e a r R
A U T O / M A N R
R e s e t R
P O T . R E A R L I F T . A
S e l e c t M o d e # # # #
S e n s i b i l i t y # # # #
L o w e r . S p e e d # # # #
M a x . H e i g h t # # # #
M i n . H e i g h t # # # #
[ E ] E x i t
20-82
ARMREST ECU
E X T E R N A L S E N S O R S 4.4 External sensors

= = = = = = = = = = = = = = = = This screen displays the operating status of the components
of the armrest and the sensors to it.
R: indicates that the pushbutton is Released.
P: indicates that the pushbutton is Pressed.
O p . P o w e r m V # # # #
1- Power supply voltages in the armrest ECU.
S . P o w e r m V # # # #
Displays the supply voltage of certain internal compo-
A c c . P e d a l # # # # nents of the armrest ECU. :
C l u t c h P e d a l # # # #
O p . P o w e r m V # # # #
R i g h t B r a k e R
L e f t B r a k e R 2- Sensor power supply voltage.
Displays the voltage supplied to the sensors connected
to the armrest ECU:
S . P o w e r m V # # # #
3- Accelerator pedal:
[ E ] E x i t Displays the output voltage of the position sensor con-
nected to the accelerator pedal:
A c c . P e d a l # # # #
4- Clutch pedal:
Displays the output voltage of the position sensor con-
nected to the clutch pedal:
C l u t c h P e d a l # # # #
5- Right Brake Pedal:

Displays the status of the switch connected to the right
brake pedal:
Pedal released:
Pedal pressed:
R i g h t B r a k e P
6- Left brake pedal:

Displays the status of the switch connected to the left
brake pedal:
Pedal released:
Pedal pressed:
R i g h t B r a k e P
20-83
ARMREST ECU
L e d s T e s t s 4.5 LEDs test

= = = = = = = = = = = = = = = = From this menu you can test the operation of the LEDs on the
armrest.
Press 1 , 2 , 3 and 4 to test the LEDs:
Key 1 lock LED.

[ 1 ] L o c k
[ 2 ] L i f t . A r m U p Key 2 rear lift "up" LED.
[ 3 ] L i f t . A r m D o w n Key 3 rear lift "down" LED.
[ 4 ] L i g h t s
Key 4 Joystick backlight LED.
[ E ] E x i t
A l a r m s L i s t 5. ALARMS
= = = = = = = = = = = = = = = =
➔ Most recent alarm
This screen displays the 10 most recent alarm signals to be
detected.
The last line in reverse video shows all the currently active
alarms in succession.
= = = = = = = = = = = = = = = =
➔ Active alarms
[ D ] D e l e t e
[ E ] E x i t
20-84
ARMREST ECU ALARM CODES
LIST OF ARMREST ECU ALARM CODES
N° Tester Message Cause of fault Control unit action
1 L/A fault EEPROM EEPROM fault, total system lockup
2 A/L S/C; RPM MIN Hand throttle disconnected/short-circuit Hand throttle value
fixed at minimum RPM
CLUTCH=
3 CL dis/pot./S/C Clutch pedal disconnected or short-circuit of potentiometer minimum calibrated
value
4 A/P S/C; RPM MIN Accelerator pedal disconnected/short-circuit Pedal value fixed
at minimum RPM
Forced to default
5 EEPROM CHECK TYRE.” EEPROM malfunction alarms values
210 CAN T.O. ECMSG2 Connection timeout CAN ENGINE MSG 1
211 CAN T.O. ECMSG1 Connection timeout CAN ENGINE MSG 2
220 CAN T.O. ICMSG1 Connection timeout CAN INSTRUMENT
230 CAN T.O. LCMSG2 Connection timeout CAN REAR LIFT
242 CAN T.O. TCMSG2 Connection timeout CAN GEARBOX
20-85
PAGE INTENTIONALLY
LEFT BLANK
20-86
FUNCTIONAL DIAGRAM
9+9 Gears Full Power Shift ECU Engine Speed Control, Pre-Heating, Belt Alarm, SBA ECU Rear Lift Control, PTO, CAN Bridge
Codice scheda 0 0 1
Codice scheda 1 0 0 Codice scheda 1 0 1
61 40 60 42 59 43 19 38 18 7 62 41 63 8 64 65 2 17 26 22 68 44 45 23 24 25 1 53 52 51 9 6 54 29 10 16 33 28 3 4 5 56 27 49 15 16 58 46 12 57 39 47 48 37 36 35 34 14 13 32 31 30 11 22 13 14 5 31 14 47 46 49 51 32 29 2 27 10 59 3 58 56 23 44 45 65 68 1 25 24 53 52 55 34 36 37 28 6 34 36 21 68 22 29 66 40 41 64 65 61 50 51 52 6 2 23 44 45 1 24 25 10 27 46 7 8 47 28 48 55 56 57 15 16 13 14 32 30 31
Electrovalve "H"
Common Supply 1
Electrovalve "M"
Common Supply 3
Electrovalve "L"
Common Supply 4
Electrovalve Range "H"
GND
Electrovalve Range "M"
DIG_SP4
Electrovalve "1"
Common Supply 2
Electrovalve "2"
DIG_SP5
Electrovalve "3"
Electrovalve "Backw"
Sensor GND
Electrovalve Forward
Vpp (FLASH)
Ev+ Proportional "HML"
Ev- Proportional "HML"
Vcc
Vcc
Vcc
GND
Range Hi
Range Med
Range Lo
GAMMA H
GAMMA L
Clutch Pressure
ISO 9141
Main Pressure
Reverser Valve Pressure
Sensors GND
Sensors Supply (+5Vcc)
Range position
AN_SP2
AN_SP3
Wheel Speed
AN_SP4
AN_SP5
DIG_SP1
DIG_SP2
DIG_SP3
Oil Temperature
Freq 4
Freq 5
Ground Armrest
Forward & Reverse & Neutral
Speed Up & Speed Down
CONFIG2
CONFIG1
CONFIG0
CFG_GND
CAN_L
CAN_H
CAN-RES
CAN_L
CAN_H
Reverser Input Speed
Engine Speed Output

CAN_H
CAN_L
Throttle Pedal Position
CAN_L
CAN_H
Actuator GND
+12Vout
Sensor CHA
Sensor CHC
CAN RES
ISO 9141
Sensors GND
Alf duplex
Engine Speed Frequency
Engine Belt Frequency
Engine Temperature
Pre-Heating Glow Plug Relay

+VCC
Electrovalve presence
Glow Plug presence
GND
Electrovalve "4WD"
Common SBA
Electrovalve "DIFF"
Cfg Ground
+5Vcc OUT
Steering Angle
Rear EVP "LIFT DOWN"

Config 1
Config 2
Cfg Ground
Config 1
Rear EVP "LIFT UP"
Common Supply Rear Lift
ISO 9141
Electrovalve "FRONT PTO"
Common Supply PTO
Common Supply PTO
Electrovalve "BACK PTO clutch"
Electrovalve "BACK PTO Brake"
Rear PTO Brake/NoBrake
External Down Command

External Rear PTO ON/OFF
CAN_H2
CAN_H1
CAN_L1
Pre-Heating Electrovalve Relay
Rear PTO Brake/NoBrake light
External Up Command
Sensors GND
+VCC
GND
Radar Frequency
+10Vcc
Left Draft
CAN_L2
Right Draft
+5Vcc
Rear Lift Position
True Ground Speed OUT

Theoretical Ground Speed OUT
Rear PTO Rotational Speed OUT
Rear 3 point in/Out Work OUT
Rear 3 point Linkage position OUT
CAN_H1
CAN_L1
CAN-RES1
GND
GND
+ -
To Fuses Box
Fuses + -
Box
+12VCC
-VCC
1 2 1 2 1 2 1 2 1 2 1 2 1 1 2 1 2 1 2 1 3 2 1 3 2
Hydraulic F F 1 2 3 4 5 6 7
p
Main Circuit Sp Kg
ISO/DIS 11786
EV-H EV-L EV-RM EV-2 EV-I EVP-HML Ev UP Front PTO Back Radar Right Draft Connector
PTO brake Sensor Sensor
1 2 1 2 1 2 1 2 1 2 1 1 2 1 4 1 2 3 1 2 1 2 1 2 3 1 2 1 2 1 2 2 1 4 1 2 1 2 1 3 2 1 3 2
M F I I
p p I F I
F Kg
F t t To subst.wiring
EV-M EV-RH EV-1 EV-3 EV-AV Clutch Reverser Range Wheel Transmission Fuel Pumps Sensor Engine Ev 4WD Ev DIFF Steering Ev DWN Back +12Vcc Left Draft Rear Lift
Pressure Min. position Speed Temperature Actuator Temperature Angle PTO clutch Sensor Position
Pressure
Accelerator Clutch
Pedal Pedal
V V
+12V
To Fuses
2 1 4 2 1 4 Box
Instrument Cluster R L - +
Brakes
Switch Ter Full Armrest ECU
1 4 9 10 11 12 19 5 6 7 2 3 17 18 21 8 23 24 25 29 27 26 28 30 31 32 33 15 16 22 14 13 25 36 35 X10 X1
Battery Charge
Air Filter
Engine Oil Pressure
Trailer Brakes Pressure
Hydraulic Oil Filter
Gear Box Filter
PTO SYNCRO
PTO 540
PTO 1000
PTO ECO
Brake Oil Level
Hand Brake
Empty Lamp
Fuel Level
Spare 2
+Vcc direct (30)

+Vcc Switched (15)
GND
Sensors GND
Sensors +
Configuration
Engine Speed in
Radar Signal
Wheel Speed
Engine Pressure
Eng.Temperature
BackLight
High Beam Lights
Triler 2 Direction Lights
Triler 1 Direction Lights
Direction Lights
CAN RES
CAN_L
CAN_H
A2 A3 A4 A5 A6 A7 B2 B3 B4 B7 C2 B6 B5 16 7 2 1 11 8 3 10 9 6 18 17 19 20 4 5 15 14 12 13 7 9 12 10 15 17 8 14 13 16 20 3 19 1 4 3 2 5 6 32 31 29 27 37 39 40 28 30 34 36 38 35 33
Auto/Manual (gear box)
Front PTO
Back PTO
Lift Down
Sensors GND
CONSENT
Sequencer/Stop last manouvre
Memory M1
CAN_H
CAN_L
Left Brake SW
GND
VCC
ISO 9141
Accelerator pedal Out
Accelerator Pedal In
To Pot +5Vcc
TX TTL
Speed OUT
Reverser OUT
Menu
Rev Gear Set/P1
Forw. Gear Set/P2
RESET
DIGAUX 2
Backlight
Digital Ground
PTO Consent
Front Lift CTRL
4WD
Differentials Lock
SBA Auto
Lift Lock
Lock LED
Lift Up
Setpoint Pot
Pot Supply (+5Vcc)
Front Lift Max
Front Lift Min

Right Brake Sw
Clutch Pedal In
Hand Gas
Ground
Ground
Neutral
Memory M2
Forward
Backward
Speed-UP
Speed-DWN
Backlight
390R
Sensors GND
Min H. Pot
Pot Supply (+5Vcc)
Lov. Speed Pot
Sensitivity Pot
Max Heigh Pot
S. Level
Diagnostic
Connector
2 1 3 4 5
1K2
R
Rear Lift DW
Rear Lift UP
x x x x
1 1 1 + + -
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
To Fuses Box
p p p
Fuel Level Sensor
Air Filter Trailer Brakes Gear Box Filter Rear lift Front Lift Front Lift Hand Gas Minimum Lowering Sensitivity Maximum Lift Control
8K2
Depressure SW Pressure SW Depressure SW Setpoint Max Min Height Speed Height Mode
1 2
1 1 p
SERVICE 2 1
Engine CAN
p p Pressure
Engine Oil Hydraulic Filter

Pressure SW Depressure SW
FC3 FC13 FA2 FA1 FC1 FA7 FC2 FA8 FC7 FC8 FC10 FC9 FC4 FB11 FB12 FC14 FA5 FC11 FB16 FA6 FC15 FA4 FC16 FC12 FC6 FC5
30A 15A 5A 10A 40A 7.5A 30A 5A 30A 3A 30A 30A 15A 7.5A 7.5A 20A 5A 5A 20A 10A 15A 10A 15A 20A 25A 10A
30
R4A R2A R4B R3B
R3A DEVIO DX DEVIO SX 1
D+ B+ 1 3 17 18 -10
50 15 R2B R1A 5 3 2
R. Brake
L. Brake
CENTRALINA
3
G FB6 FB7 FB8 FB9 FB10
31B
Plafon. Spot
DIREZIONI
1 4 6
15A 10A 3A 3A 5A J I 2 5 8
Pressostato 53M R R R -7 2 -7 2 -7 2 -7 2 -7 2 -7 2 -7 2
30 50 Filtro dis. 53M I
I
M T T
B- Gruppo 53S 31
+ - + - + + - + - Clima 15 15 31 + + - + - + - DEVIO
R1B 15 31 82 B4 B3 6 7 1 2 3 4 +8 3 +8 3 +8 3 +8 3 +8 3 +8 3 +8 3
TEMPOR. SX 2
Engine DIN Power Lift Cluster Console Accend.
ECU Soket Shift ECU ECU Interr. Orologio Radio Sedile
+ FB5 Portiera Pneu. Sigar.
ECU 5A FB4 FB3 FB2 FB1
Comando 10A 10A 10A 10A
CONN. Clima
ISO FA13 PONTE
+ -
10A M SOSP.
11786 77
53 Presa
53A COMP.
- Lampegg.
31B SOSP.
31
Battery Luci STOP Elettrovalvola Candela Compressore Ventola Pompa A. Tergi P. Luci Dir. SX Luci Dir. DX tendina Fari lavoro Fari lavoro Fari lavoro Fari lavoro Fari lavoro
Preriscaldo Preriscaldo Condensatore Anteriori alti Posteriori alti Anteriori musetto Anteriori bassi Posteriori bassi
Presa rimorchio 1 3 4 5 6 7
Tergi A. Pompa P.
FUNCTIONAL DIAGRAM
D0002500
20-87
SUSPENDED FRONT AXLE WIRING
AL CAB. CABINA S GN 1.5

TO CAB. WIRING
2
DISCESA
M 1.5 DESCENT
1
LN 1.5
1
GN 1.5
2
VN 1.5 H LN 1.5
3
2
A 1.5
SALITA
4 M 1.5 CLIMB
1
B 1.5
5
Z 1.5
6
M 1.5 L VN 1.5
7
2
PROPORZIONALE
M 1.5 PROPORTIONAL
1
A 1.5
1
B 1.5
2
Z 1.5
3
SENSORE DI POSIZIONE
TO POSITION SENSOR
LN 1.5
1
GN 1.5
2
VN 1.5
3
A 1.5
4
B 1.5
5
Z 1.5
6
M 1.5
7
AL CAB. CABINA
TO CAB. WIRING
GN 1.5
VN 1.5
LN 1.5
M 1.5
M 1.5
M 1.5
B 1.5
A 1.5
Z 1.5
1 2 3 1 2 1 2 1 2
SENSORE DI POSIZIONE PROPORZIONALE SALITA DISCESA

TO POSITION SENSOR PROPORTIONAL CLIMB DESCENT
0.011.5375.4
SUSPENDED FRONT AXLE WIRING
d0002100
20-88
SUSPENDED FRONT AXLE CAB WIRING
BIANCO
WHITE
JY4
AL CENTRALE
TO CENTRAL FE2
JY3
NERO
BLACK
8 1 2 3
R FE1 P
1 2 3
4 5 6 7
8 9 10 11
12 13 14
0.011.5376.4
SHEET 1/2
D0002110
20-89
D0002120
V 1.5 4 +VCC +VCC
V 1.5 5 +VCC +VCC
M 1.5 20 -VCC -VCC
JX3
NA 1.5
NERO
1 UP UP
BLACK
NG 1.5 2 DW DW
TO U.E.
NM 1.5
11 4WDT 4WDT
ALLA CENTRALINA
G 1.5
13 FRENI BRAKE
NA 1.5 AB 1
SALITA LIFT UP 1 22 DIAGNOSTIC. DIAGNOSTIC.L
NG 1.5 AG 1
DISCESA LIFT DW 2 15 DIAGNOSTIC. DIAGNOSTIC.K
NV 1.5 NV 1.5
PROPORZ. PROPORZ. 3 2 EV PROPORZ. EV PROP.
A 1.5 A 1.5
FE
GND POSIZ. GND POSI. 4 17 GND POS. GND POS.
B 1.5 B 1.5
JX4
WHITE
SEGNALE POSIZ. SIGNAL POS. 5 14 SEGNALE POS. POS. SIGNAL

Z 1.5 Z 1.5
AL CARRO
BIANCO
+ POSIZIONE + POS. 6 9 + POS. + POS.
TO TRAILER
M 1.5 HV 1.5
GND GND 7 19 V. VEICOLO VEICLE SPEED
H1
8 SPIA DIAL LAMP
R 1.5
12 PULSANTE SWITCH
R 1.5
3 PULSANTE SWITCH
M 1.5
7 -VCC -VCC
P
V 1.5
2 +VCC +VCC
3 2 1 8
H1
8 SPIA DIAL LAMP
TO SWITCH
AL PULSANTE
+ 12VCC + 12VCC V1
GND GND M 1.5

G 1.5
FRENI BRAKE 30
R
M 1.5
GND GND 85
X
+ FRENI + BRAKE
SWAP RELAY
86
20-90
V 1.5
RELE A SCAMBIO 2 +VCC +VCC
SHEET 2/2
M 1.5
1 GND GND
0.011.5376.4
D
AG 1.5
13 K LINEE K LINEE
AB 1.5
14 L LINEE L LINEE
DIAGNOSTIC
DIAGNOSTICA
X
+ FRENI + BRAKE 1
2 NM 1.5
4WDT 4WDT
V 1.5
+ 12VCC + 12VCC 3
FE1
HG 1.5
V. VEICOLO SPEED VEICLE 5
M 1.5
GND GND 8
TO SUBSTRUCTURE
AL SOTTOSTRUTTURA
DIAGNOSTIC WIRING
CONNETTORE AMP HDP 20

CONTATTI AMP 5-166051-
6 VIE 070 P.F. CORAZZA AMP 745122-1
N N
1 ISO 4191 GND 15 ISO 4191 GND
Z Z
2 ISO 4191 VCC 14 ISO 4191 VCC
A A
3 ISO 4191 H.D. SOLL.-LIFT 13 ISO 4191 H.D. SOLL.-LIFT
GM GM
4 ISO 4191 H.D. FPS 11 ISO 4191 H.D. FPS
BR BR
5 ISO 4191 H.D. MOTORE ENGINE 12 ISO 4191 H.D. MOTORE ENGINE
0.011.5445.4
DIAGNOSTIC WIRING
D0002130
20-91
CAB PRESS. WIRING (GERMANY)
G05
AL CAB. ILLUMINAZIONE STRUMENTO

TO WIRING INSTRUMENT LIGHTING
N05
1 BR05
2 G05
3 N053
4 RN05 N05
N05
INDICATORE PRESSIONE FRENI

BR05 BRAKE PRESS. INDICATOR
RN05
1 BR05
2 G05
AL CAB.
TO WIRING
3 N053
4 RN05
RN05
BR05
G05
N05
N05
N05
INDICATORE PRESSIONE FRENI ILLUMINAZIONE STRUMENTO
BRAKE PRESS. INDICATOR INSTRUMENT LIGHTING
0.011.7032.4
CAB PRESS. WIRING (GERMANY)
D0002140
20-92
CAB ROOF WIRING
8VIE 6VIE 4VIE

E3 E2 E1
NOTA 1
AL CENTRALE
POS1
POS2
TO CENTRAL WIRING
POS1
POS2
A11
GND GROUND 1
N1 070 12VIE P.M.
AMP. 282371
GND GROUND 2 N1
E1
N1
NZ 1
MN1
VG1
MV1
MB1
HR1
HN1
HR1
HV1
VN1
NZ1
NZ1
NZ1
LN1
GND GROUND 3
M1
M1
G1
H1
V1
B1
B1
(GND)
(AZZ.)
GND GROUND 4 N1
1 2 1 2 070 12VIE P.F. 1 2 1 2
AZZ.TERGI AZZ.WIPER V1 (+MOT) (+AZZ)

AMP. 282367
N1
1
AMP
AMP
AMP
AMP
F F1 HB1 AN1
F2 F3
4
3
2
1
+AZZ.TERGI +AZZ.WIPER 2
AN1
M1
+DIRETTO RADIO +RADIO 30
T S A4 A5 A6 A7 A8 A9 O P I L
E2
MN1
MV1
MB1
HN1
VN1
CN1
CN1
M1
CB1
CB1
+DIRETTO +BATTERY 4
N1
N1
N1
N1
NZ1 NZ1
MASSA RADIO GND RADIO 5
N1 NZ1 TERGI SPOT ALTOPARLANTI DX ALTOPARLANTI SX OROLOGIO PLAFONIERA INT. PORTIERA
GND GROUND 6
NZ1 FARO FARO POST RH LOUDSPEAKER LH LOUDSPEAKER
5 4 3 2 1 RADIO CLOCK LIGHT CAB DOOR SWITCH FARO FARO LAMPADA
ANT.DX POST.DX REAR
12 11 10 9 8 7 6
A10 ANT.SX POST.SX ROTANTE
HR1.5 HR1
+SOTTO CHIAVE +KEY 1 RH RH WIPER LH LH LIGHT
HR1
HV1
NZ1
LN1
G1 HR1
M1
H1
+LUCI +LIGHT 2
VG1
FRONT REAR FRONT REAR ROTATING
LAMPADA ROTANTE ROTARY LIGHT 3
CB1 LIGHT LIGHT LIGHT LIGHT
E3
FARI ANT.ALTI FRONT LIGHT H 4

FARI ANT.ALTI FRONT LIGHT H 5 CB1
FARI POST.ALTI REAR LIGHT H 6 CN1
FARI POST.ALTI REAR LIGHT H 7 CN1
+MOT.TERGI +WIPER 8 HB1
NOTA 1 FORNIRE BLOCCHETTO, 070 P.M. AMP.282371 CON CAVI INTESTATI

NOTE 1 SUPPLY THE CONNECTORS WITH WIRES AMP 28237182371
HN1 5 12
MV1 4 11
HR1
070 12VIE P.M.
+
M1
AMP. 282371
10
-
9
NZ1
VN1 3 8
HV1
MB1 LN1
2 7
MN1 1 6
H1
+ - + - + - + -
SX DX
0.010.8700.4
CAB ROOF WIRING
SHEET 1/2
D0002150
20-93
CAB ROOF WIRING
AL CENTRALE
TO CENTRAL WIRING
N1
GND GROUND 1
N1
GND GROUND 2
E1 N1
GND GROUND 3
N1
GND GROUND 4
V1
AZZ.TERGI AZZ.WIPER 1
AN1
M1
+DIRETTO RADIO +RADIO 30 3
E2 +DIRETTO +BATTERY 4
M1
NZ1
N1
GND GROUND 6
HR1
+SOTTO CHIAVE +KEY 1
G1
+LUCI +LIGHT 2
VG1
CB1
E3 FARI ANT.ALTI FRONT LIGHT H 4
CB1 GND GROUND 9
NZ1
FARI ANT.ALTI FRONT LIGHT H 5 M1
CN1 +DIRETTO +BATTERY 10
FARI POST.ALTI REAR LIGHT H 6 HR1
CN1 +SOTTO CHIAVE +KEY 15 11
FARI POST.ALTI REAR LIGHT H 7 MN1
HB1 -ALTOP.SX POST. -REAR LEFT LAUDSP. 1
+MOT.TERGI +WIPER 8 MB1
+ALTOP.SX POST. +REAR LEFT LAUDSP. 2
VN1
-ALTOP.SX ANT. -FRONT LEFT LAUDSP. 3
MV1
+ALTOP.SX ANT. +FRONT LEFT LAUDSP. 4
HN1
-ALTOP.DX POST. -REAR RIGHT LAUDSP. 5
H1
+ALTOP.DX POST. +REAR RIGHT 6
LN1
-ALTOP.DX ANT. -FRONT RIGHT LAUDSP. 7
HV1
+ALTOP.DX ANT. +FRONT RIGHT LAUDSP. 8
MN1
MV1
MB1
CN1
CN1
VG1
HR1
HN1
CB1
HB1
AN1
CB1
HV1
VN1
NZ1
NZ1
LN1
M1
N1
H1
HR1
NZ1
M1
G1
1 2 1 2 1 2 1 2
AMP
AMP
AMP
AMP
4
3
2
1
F F1 T F2 F3 L S O P I A10 A4 A5 A6 A7 A8 A9
FARO FARO TERGI POST. FARO FARO LAMPADA SPOT OROLOGIO PLAFONIERA INT. PORTIERA RADIO ALTOPARLANTI DX ALTOPARLANTI SX
ANT.DX POST.DX REAR WIP. ANT.DX POST.DX ROTANTE SPOT CLOCK LIGHT CAB DOOR SWITCH RADIO RIGHT LOUDSPEAKER LEFT LOUDSPEAKER
LIGHT LIGHT LIGHT LIGHT LIGHT
RIGHT FRONT RIGHT REAR LEFT FRONT LEFT REAR ROTATING
0.010.8700.4
CAB ROOF WIRING
SHEET 2/2
D0002160
20-94
CAB FPS WIRING
N2.5 N1.5 1 -VCC

X3 N1
24 -VCC
N1
25 -VCC
MN05 2 SENSOR GND
BN1 3 RANGE SENSOR
V05 6 PRESSURE GAMMA M
Z05
9 PRESSURE GAMMA H
LR05 10 HYDRAULIC PRESSURE
A05 1 48
11 INGRESSO VELOCITA' MOTORE
24
V1 13 CAN H OUTPUT
G1 14 CAN L OUTPUT
B1 16 PRESSURE REVERSER RM
AN1 17 ELECTROVALVE FORWARD
HB1 18 ELECTROVALVE RANGE M
HV1 19 ELECTROVALVE RANGE H
CB1 22 EV + PROPORTIONAL HML

FP CAMBIO
GEARBOX
MV1 27 PEDALE FRIZIONE
HL1 28 SENSOR SUPPLY +5V
ZB05 29 ISO 9141
V1 30 CAN H INPUT
G1 31 CAN L INPUT
MN1 33 SENSOR GND
N1 34 CFG GND
N1
X1 35 CONFIG 0
N1 36 CONFIG 1
47
68
23
VN1 39 MASSA SENSORI FRIZ.-ACC.
HN1 40 COM SUPPLY 1
M1 41 COM SUPPLY 2
HR1 44 +12V
HR2.5 X2 HR1 45 +12V
HR1 HR1.5 23 +12V CENTRALINA FPS
R05 46 TRASMISSION TEMPERATURE ELECTRONIC CONTROL
BG05
BV05
47 COMANDOO NEUTRO AV-IND. UNIT (ECU)
48 VELOCITA' UP-DW
S05 51 RANGE L
L05 52 RANGE M
C05 53 RANGE H AL SOTTOSTRUTTURA
A1 54 PRESSURE FORWARD AV TO SUBSTRUCTURE
ISO 9141 A2
ZB05
SG05 56 WHEEL SPEED A3
A B C
+12V A1
HR2.5
SN1 59 ELECTROVALVE L BV05
1 VELOCITA' UP-DW A4
LN1 60 ELECTROVALVE M 2 A05
INGRESSO VEL.MOTORE A5
CN1 61 ELECTROVALVE H
3
N2.5
4 -VCC A8
GN1
VG1
62 ELECTROVALVE 1 5
6
F G1
63 ELECTROVALVE 2 7 CAN L C2
RG1 64 ELECTROVALVE 3 V1
8 CAN H C3
GH1 65 ELECTROVALVE BACKW MN05
SENSOR GND B2
PEDALE FRIZIONE B3
MV1
CV1 68 EV - PROPORTIONAL HML VN1
MASSA SENSORI FRIZ.-ACC. B4
BG05
MARRONE COMANDO NEUTRO AV-IND. B5
G1
BROWN CAN L C4
V1
CAN H C5
31
30
ELECTROVALVE FORWARD 29 AN1
PRESSURE REVERSER RM 28 B1
PRESSURE FORWARD AV 27
A1
26
EV - PROPORTIONAL HML 25
CV1
EV + PROPORTIONAL HML 24
CB1
ELECTROVALVE H 23
CN1
ELECTROVALVE M 22
LN1
ELECTROVALVE L 21
SN1
CAMBIO TRASMISSION TEMPERATURE 20
R05
BN1
RANGE SENSOR 19
SENSOR SUPPLY +5 VCC 18
HL1
M1
COM SUPPLY 2 17
FPS ELECTROVALVE BACKW 16
GH1
RG1
ELECTROVALVE 3 15
VG1
ELECTROVALVE 2 14
ELECTROVALVE 1 13
GN1
SG05
WHEEL SPEED 12
31 20 MN1
30 8 21 SENSOR GND 11
19 9
SENSOR SUPPLY +12V 10
HR1
18 2 10
29 7 3 22
17 1 11 HN1
28 6 4 23 COM SUPPLY 1 9
16 5 12
HB1
ELECTROVALVE RANGE M 8
15 13
ELECTROVALVE RANGE H 7
HV1
27 14 24
26 25
RANGE H 6
C05
RANGE M 5
L05
S05
RANGE L 4
AL CAMBIO FPS PRESSURE GAMMA H 3
Z05
TO GEAR FPS PRESSURE GAMMA M 2
V05
HYDRAULIC PRESSURE 1
LR05
0.010.8704.4
CAB FPS WIRING
SHEET 1/2
D0002170
20-95
D0002180
31 67 EV -PROPORTIONAL 1234
30 21 EV +PROPORTIONAL 1234
AN1 AN1
ELECTROVALVE FORWARD 29 17 ELECTROVALVE FORWARD
FP
B1 B1
PRESSURE REVERSER RM 28 16 PRESSURE REVERSER RM
20-96
A1 A1
PRESSURE FORWARD AV 27 54 PRESSURE FORWARD AV
SN05
SHEET 2/2
REVERSER OUT.SPEED 26 55
0.010.8704.4
CV1 CV1
EV - PROPORTIONAL HML 25 68 EV - PROPORTIONAL HML
CB1 CB1
EV + PROPORTIONAL HML 24 22 EV + PROPORTIONAL HML
CN1 CN1
ELECTROVALVE H 23 61 ELECTROVALVE H
CAB FPS WIRING

LN1 LN1
ELECTROVALVE M 22 60 ELECTROVALVE M
SN1 SN1
ELECTROVALVE L 21 59 ELECTROVALVE L
R05 R05
TRANSMISSION TEMPERATURE 20 46 TRASMISSION TEMPERATURE
BN1 BN1
28
29
RANGE SENSOR 19 3 RANGE SENSOR

/20 HL1 HL1
27
30
16
17
18
SENSOR SUPPLY +5 VCC 18 28 SENSOR SUPPLY +5 VCC

6
7
26
15
19
31
M1 M1
5
2
8
14
COM SUPPLY 2 17 41 COM SUPPLY 2

GH1 GH1
4
3
9
25
20
13
ELECTROVALVE BACKW 16
23
65 ELECTROVALVE BACKW
68
RG1 RG1
47
10
11
24
21
12
ELECTROVALVE 3 15 64 ELECTROVALVE 3
VG1 VG1
23
22
GN1 GN1
SG05 SG05
WHEEL SPEED 12 56 WHEEL SPEED
MN1 MN1
SENSOR GND 11 33 SENSOR GND
FPS
HR1
SENSOR SUPPLY +12V 10
HN1 HN1
COM SUPPLY 1 9 40 COM SUPPLY 1
AL CARRO
HB1 HB1
ELECTROVALVE RANGE M 8 18 ELECTROVALVE RANGE M
ALLA CENTRALINA FPS
ELECTROVALVE RANGE H HV1 HV1

7 19 ELECTROVALVE RANGE H
C05 C05
TO FPS ELECTRONIC UNIT
RANGE H 6 53 RANGE H
TO REAR WIRING
RANGE M L05 L05

5 52 RANGE M
RANGE L S05 S05
4 51 RANGE L
Z05 Z05
PRESSURE GAMMA H 3 9 PRESSURE GAMMA H
V05 V05
PRESSURE GAMMA M 2 6 PRESSURE GAMMA M
LR05 LR05
HYDRAULIC PRESSURE 1 10 HYDRAULIC PRESSURE
N1
34 CFG GND
24
N1
X1 35 CONFIG 0
48
1
N1
36 CONFIG 1
ZB05 ZB05
ISO 9141 A2 29 ISO 9141
A3
HR2.5 HR1
+12V A1 44 +12V
X2 HR1
45 +12V
HR1.5
23 +12V
N2.5 N1.5
-VCC A8 1 -VCC
X3 N1
24 -VCC
N1
25 -VCC
A
BROWN
MN05 MN05
B
SENSOR GND B2 2 SENSOR GND

C
MV1 MV1
MARRONE
PEDALE FRIZIONE B3 27 PEDALE FRIZIONE

8
7
6
5
4
3
2
1
VN1 VN1
MASSA SENSORI FRIZ.-ACC. B4 39 MASSA SENSORI FRIZ.-ACC.
F
BG05 BG05
COMANDOO NEUTRO AV-IND. B5 47 COMANDOO NEUTRO AV-IND.
BV05 BV05
VELOCITA' UP-DW A4 48 VELOCITA' UP-DW
AL SOTTOSTRUTTURA
A05 A05
INGRESSO VEL. MOTORE A5 11 INGRESSO INVERSORE
G1 CAVO TWISTATO V1
CAN L C2 30 CAN H
V1 G1
CAN H C3 31 CAN L
TO SUBSTRUCTURE WIRING
G1 CAVO TWISTATO V1
CAN L C4 13 CAN H
V1 G1
CAN H C5 14 CAN L
CAB FPS WIRING
FRONT WIRING
34
AN
47 35
46 33 20 36
8
3 2
3 1 9 2
MOTORE
1 2 1
3 7 3 2
4 1 1 3
1
2 6 4 2
4 1 5 1 3
4 2 1 1 2 3
1
4 2 2 4
4
AL CABL. SOTTOSTRUTTURA
H1
22 ANABBAGLIANTI LOW BEAM
23 ANABBAGLIANTI LOW BEAM
H1
37 ABBAGLIANTI HIGH BEAM VN 1
39 FARI MUSETTO CORNER LIGHT HV1

40 FARI MUSETTO CORNER LIGHT HV1 1
Z1 1 2 1 2 3 1 2 3 1 2
41 CLACSON HORN
AMP
2 2
AMP
AMP
AMP
AMP
8 FILTRO 17 BAR 17 BAR FILTER AN 1
1 3 1 3
34 COMPRESSORE COMPRESSOR V 1.5
42 VENTOLA CONDIZ. CONDITIONER FAN A1 M
RN1.5
RN1.5
A1
MV1
AG1
NZ 1
VN1
HV1
VN1
HV1
N1.5
N1.5
35 VENTOLA CONDIZ. CONDITIONER FAN
A2.5
A2.5
RN1
CB1
SN1
BR1
BN1
AN1
RV1
V05
V05
N1
N1
H1
N1
N1
H1
N1
MASSA
N1
N1
N1
S1
B1
Z1
L1
43 VENTOLA CONDIZ. CONDITIONER FAN A1
GRID
RN 1.5
A1 F6 P G W S A2 F1 F F5 F4 F3 F3 C L1 L3 L2 L4 P3
4 PRERISCALDO COLD START
ALTERNATOR SIGNAL
CORNER LIGHT
CORNER LIGHT
ATTUATORE
LIVELLO OLIO FRENI
CANDELETTA
SEGN. ALTERNATORE
SENSORE SBA
EV PRERISCALDO
CONDITIONER F.
FILTRO ARIA
VENTOLA C.
VENTOLA C.
CALCSON
HEAD LIGHTS
FARI MUSETTO
HEAD LIGHTS
FARI MUSETTO
PTO ANTERIORE
LIGHT GENERATOR
SPIA GENERATORE
SPARK PLUG
RN 1.5
ACTUATOR
5 PRERISCALDO COLD START
BRAKES OIL LEVEL
SBA SENSOR
PREHEATING EV
AIR FILTER
FILTRO COND.
1 START START HN 1.5
HORN
HN 1.5
FRONT PTO
6 START START
FAN C.
FAN C.
15 IND.PRESS. OIL PRESS.IND. VG1
16 PRESS.OLIO MOT. ENGINE OIL PRESS. M1
FARI
FARI
17 INT.FILTRO ARIA OB.AIR FILTER B1
18 TEMPERATURE TEMPERATURE R1
19 ALTERNATORE GENERATOR L1
20 LIV.OLIO FRENI BRAKES OIL LEV. NZ 1

21 ALIMENTAZIONE PTO SUPPLY PTO MV1
45 COMANDO PTO ANT. FRONT PTO AG1
47 SENSORE CHC SENSORE CHC SG1
46 SENSORE CHB SENSORE CHB HN1

32 SENSORE CHA SENSORE CHA VB1 SN1
RN1 SN1
33 ATTUATORE +12V ATTUATORE +12V
S1 SN1
31 ATTUATORE GND ATTUATORE GND
24 SENSORE GND SENSORE GND SN1 X1 SN1
2 W W BR1
29 SEGN.PICK-UP PICK-UP SIGN. C1
30 ALL.VENTOLE FAN ALARM

25 +5VCC SBA +5VCC SBA
CB1
26 SEGNALE SBA SEGNALE SBA RV1
27 EV PRERISCALDO EV PREHEATING BN1
10 FILTRO 2/27BAR TRINARY

V05 1 2 1 2 3
V05
AMP
11 FILTRO 2/27BAR TRINARY
CONN.42 POLI SITZE 20 E 5 POLI SITZE 16

TAPPI 34/SITZE16
12 13 14 28 42 43 44/SITZE20
HN1.5
HN1.5
V1.5
VG1
SN1
SN1
M1
R1
C1
T A P1 P2 F2 A3
MOTORINO AVV.
PRESS. OLIO MOTORE
IND.PRESSIONE MOTORE
TEMPERATURA
COMPRESSORE
PIK UP MOTORE
TEMPERATURE
START ENGINE
COMPRESSOR
ENGINE PK
OIL PRESSURE IND.
OIL PRESSURE
0.010.8705.4
FRONT WIRING
SHEET 1/2
D0002190
20-97
FRONT WIRING
22 ANABBAGLIANTI LOW BEAM H1
23 ANABBAGLIANTI LOW BEAM H1
41 CLACSON HORN Z1
10 FILTRO 2-27 BAR TRINARY V05
11 FILTRO 2-27 BAR TRINARY V05
8 FILTRO 17 BAR 17 BAR FILTER AN1
34 COMPRESSORE COMPRESSOR V1.5
4 PRERISCALDO COLD START RN 1.5
5 PRERISCALDO COLD START RN 1.5
15 IND.PRESS. OIL PRESS.IND. VG1
16 PRESS.OLIO MOT. ENGINE OIL PRESS. M1
17 INT.FILTRO ARIA OB.AIR FILTER B1
18 TEMPERATURE TEMPERATURE R1
19 ALTERNATORE GENERATOR L1
20 LIV.OLIO FRENI BRAKES FLUID LEV. NZ 1
21 ALIMENTAZIONE PTO SUPPLY PTO MV1
45 COMANDO PTO ANT. FRONT PTO AG1
47 SENSORE CHC SENSOR CHC SG1
46 SENSORE CHB SENSOR CHB HN1
32 SENSORE CHA SENSOR CHA VB1
33 ATTUATORE +12V ACTUATOR +12V RN1

S1
31 ATTUATORE GND ACTUATOR GND
24 SENSORE GND SENSOR GND SN1 X1
2 W W BR1
28 +12 VOLT +12 VOLT
29 SEGN.PICK-UP PICK-UP SIGN. C1
30 ALL.VENTOLE FAN ALARM
25 +5VCC SBA +5VCC SBA CB1
26 SEGNALE SBA SIGNAL SBA RV1
27 EV PRERISCALDO EV PREHEATING BN1

MN1
SG1
SN1
VB1
AL CABL. CENTRALE
HN1.5
HN1.5
RN1.5
RN1.5
V05
TO CENTRAL WIRING
N1.5
N1.5
MV1
A2.5
A2.5
V1.5
RN1
AG1
VG1
BN1
CB1
SN1
BR1
SN1
AN1
HV1
VN1
VN1
RV1
NZ1
HV1
ZB1
V05
M1
C1
N1
R1
N1
N1
N1
N1
N1
N1
H1
N1
H1
S1
B1
Z1
L1
1
1 2 3 1 2 1 2 1 2 3
1 2 3
AMP
AN 2 2
AMP
AMP
AMP
AMP
AMP
1 2
1 3 1 3
A2 S A3 A1 P3 F6 W G T F5 F4 P1 P2 A P M F3 F4 F2 F F1 C L3 L4 L1 L2
BRAKE FLUID LEVEL
CORNER LIGHT
LIVELLO OLIO FRENI
LIGHT GENERATOR
PTO ANTERIORE
PRESS. OLIO MOTORE

EV PRERISCALDO
SENSORE SBA
PIK UP MOTORE
ATTUATORE
SPIA GENERATORE
FILTRO ARIA
IND.PRESSIONE MOTORE
MOTORINO AVV.
CANDELETTA
MASSA
VENTOLA C.
VENTOLA C.
COMPRESSORE
FILTRO CONDIZIONATORE
CLACSON
FARI MUSETTO
HEAD LIGHTS
TEMPERATURA
TEMPERATURE
SPARK PLUG
ACTUATOR
START ENGINE
COMPRESSOR
SBA SENSOR
PREHEATING EV
AIR FILTER
GND
HORN
CONDITIONER FILTER
FRONT PTO
ENGINE PK
FAN C.
FAN C.
OIL PRESSURE IND.
OIL PRESSURE
FARI
0.010.8705.4
FRONT WIRING
SHEET 2/2
D0002200
20-98
DRAFT ANGLE SENSOR WIRING
V1 (s)
4 V 1 (s)
3
3
SN1 (-)
AMP 1 CB 1 (+)
2
2
1
1
CB1 (+)
2 SN 1 (-)
0.010.8707.4
DRAFT ANGLE SENSOR WIRING
D0002210
20-99
HS SUBFRAME WIRING
1 1
24
48
ALLA CENTRALINA MOTORE ALLA CENTRALINA SOLLEVATORE 24
48
TO ECU ENGINE TO ECU LIFT

MOTORE SOLLEV
M S
47 47
68 68
23 23
MOTORE
ANTERIORE AN
C1 POSTERIORE
SOLLEV.
FRONT
REAR
E
BIANCO(white)
DIAGNOSTICA
TEST D4 D3 PRESA ISO
ISO SOCKET
FRENATURA GERMANIA FG 1 LAMPEGGIATORE A

GERMANY BRAKE D5
FLASHING LIGHT VERDE (green)
PS
CENTRALE
CENTRAL
BRACCIOLO LS B
B1 BLU (blue)
HAND COMAND
FAN.ANTER. FL MS
FRONT LIGHT NERO
MASSA C
GROUND GIALLO (yellow)
D3
PRESA DIN
CHECK
CHECK CK AGLI INTERRUTTORI
I1 TO SWITCH
MARRONE
GRIGIO
1 2 3 1 2 3 1 2 3
AMP
AMP
AMP
1
D1 D2 F R1 R2 ST
HNO5
1 2 3 1 2 3 1 2 3
HR1
VN1
2
(GND) (AZZ.)
3
DEVIOGUIDA CABLAGGIO FPS GRUPPO RISCALD. ALLA BRIGLIA
N1 AB1 STEERING COLUMN FPS WIRING HEATING CAB TO SUB.WIRING
TAPPO
(+MOT) (+AZZ)
BNO5
MV05
1 4
LR05
LR05
LB05
LB05
A1 VG1
N1
B1
T F1 F2 FS FD
TERGI POT FRIZIONE FRENI
WIPER RESIST. CLUTCH BRAKE
0.010.8708.4
HS SUBFRAME WIRING
SHEET 1/4
D0002220
20-100
HS SUBFRAME WIRING
LR 0.5 1 STOP
COLORE 2 +12VCC COM.CAB.
COLORE 3 +12VCC COM.CAB.
PS
CENTRALE
HN0.5 5 VELOCITA' SPEED
CENTRAL
COLORE 1.5
+12 LOW SENSING +12 LOW SENSING E 1
COLORE 1.5 N 1.5
+12 PONTE SOSP. +12 FRONT SUSP. E 2 8 GND
R 1.5
+12 COMP. CAB. +12 CAB.COMP. E 3 COLORE 1.5
+12 V (30) +12 V (30) E 10 R6 1 LOW SENSING
VN 2.5 N1
FUS.COMP. FUS.COMP. E 11 2 GND
FUS.COMP. FUS.COMP. E 12 V 2.5 LS
G1
CAN L CAN L 14
V1
CAN H CAN H 13
POSIZ. PEDALE TROTTLE P.P. 5 NZ05
EV DT 4WD ELECTROV. 53 AB1 ZB05
MOTORE EV DIFF DIFF ELECTROV. 55 HR1
M1
4
2
ISO 9141 FPS
+12V
M1
ENGINE COM.EV DT/DF
ATTUATORE +12V
EV DT/DIFF
ACTUATOR +12V
52
46 RN1 N05 1 -VCC D4
S1 MB05 3 ISO 9141 SOLL.
ATTUATORE GND ACTUATOR 47
VB1 M05
VALVOLA VIS
SENSORE CHB
VIS ELECTROVALVE
SENSOR CHB
54
50 HN1 H1
5
6
ISO 9141 MOTORE
ALF-DUPLEX MOTORE
DIAGNOSTICA
SG1
RELE'EV PRER. 58 AB05
+5VCC SBA +5VCC SBA 28 CB05
SENSORE GND SENSOR GND 2 SN1
SEGN.PICK-UP PICK-UP SIGN. 10 C05
CN05 MR1
CENTRALE
ALL.VENTOLE FAN ALARM 59 13 I1 +TENDINA
R05 HR2.5
TEMPERATURE TEMPERATURE 3 5 A +12V FPS
CENTRAL
RV05 BG05
M SEGNALE SBA
+12VCC
SEGNALE SBA
+12VCC POWER
6
45 ZB1 MN1
16
11
C
I1
FRENO PTO
MASSA SENSORI
RELE' PRER. PREHITING RELE' 56 BR05 LB05
10 I1 COMANDO SALITA
USCITA VELOCITA' ENGINE SPEED OUT. 22 A1 AR05 9 I1 COMANDO DISCESA
-VCC GND POWER 1 N1 MN1
N1 2 C -VCC ISO SOLL
-VCC GND POWER 24 MV1
N1 5 C +12 VCC ISO SOLL
-VCC GND POWER 25 B4
V1 10 A +12VCC 30DIN
CAN H CAN H 30 BR1
G1 8 C +12 VCC 15DIN
CAN L CAN L 31
ZB1
+12VCC +12VCC POWER 44 LR1.5
+12VCC +12VCC POWER 23 ZB1 LUCI STOP STOP LIGHT A1
M05 GN1 POSIZIONI POSITIONS A2
ISO 9141 ISO 9141 29
CONFIG GROUND CONFIG GROUND 34 M05 G1
M05 POSIZIONI POSITIONS A3
A1.5
ALLA BRIGLIA SOTTOST

CONFIG 1 CONFIG 1 36 M05 DIREZIONI DX TURN DX A4
CONFIG 2 CONFIG 2 37 RN05 AN1.5
DIREZIONI SX TURN SX A5
PRES.CANDELETTA PRES.GLOW PLUG 68 BN05 VG1
PRES.EV PRER. PRES.EV COLD.ST. 65 H1 FARO LAVORO DX LIGHT JOB DX A6
VG1
ALF-DUPLEX ALF-DUPLEX 27 FARO LAVORO SX LIGHT JOB SX A7
TO SUBST. WIRING.
N4 MASSA LUCI LIGHT GROUND A8
+12V DIR.CHECK C 1 M1 N 2.5 MASSA SERVIZI SERVICE GROUND B1
+12 V 15CHECK C 3 MB1 RV1 POMPA TRGI A PUMP WIPER F. B2
+VCC BRACIOLO C 4 RV1 SG1 POMPA TERGI P. PUMP WIPER R. B3
R1
TERGI A +12V C 6
VG1
AN1 RV05
+12V SEDILE P.
SPIA F. MANO
+12V SEAT
LIGHT HAND BRAKE
B4
B5
ST
TERGI P +12V C 7 MN1
COMUNE PULSANTI COM. SWITCH B6
RN1
PRESS.FRENI BRAKE PRESS B7
RELE' PRER. PREHITING RELE' C 10 BR05 BR1.5 ACCENDISIGARI +12V CIG-LIGHTER B8
VENTOLA CONDIZ. CONDITIONER FAN C 11 A1.5 B1
A1.5 PRESS.FRENI BRAKE PRESS C1
VENTOLA CONDIZ. CONDITIONER FAN C 12 AR05
AN 05 SOLLEVATORE DW LIFT DW. C2
FILTRO 17 BAR 17 BAR FILTER C 13 LB05
AB05 SOLLEVATORE UP LIFT UP C3
RELE'EV PRER. C 14
BN1 GR05 PULSANTE PTO PTO SWITCH C4
EV PRERISCALDO C 15
SPIA FRENO PTO LIGHT PTO BRAKE C 9 B05 HV05
HB1 SEGNALE PEDALE ACC. SIGNAL C5
TERGI P VEL. C 17 VN05
V1 MASSA PEDALE ACC. GROUND C6
TERGI P AZZE. C 18 HR1
+ 5 VOLT + 5 VOLT C7
+ACCENDISIGARI B 14 BR1.5 C8
B VN 1
ABBAGLIANTI HIGH BEAM 2
ABBAGLIANTI HIGH BEAM B 3 VN 1
ANABBAGLIANTI LOW BEAM B 4 H1
H1 N1 1 GND
ANABBAGLIANTI LOW BEAM B 5 Z05
LB0.5 3 II RIMORCHIO II TRAILER
+12VCC FRENI B 1
R1.5 AR1
+12V LUCI
OUT FRENI
B
B
13
16
LR05 RN05
2 I RIMORCHIO I TRAILER D5
GN1.5 5 SPIA DIREZ.
POSIZIONI F.A.SX B 6 RN1.5
+12V DIREZ. B 18
RN1.5
LR1.5 B1.5
6
4
+12V ING.
+12V OUT.
CENT.DIREZIONI
LUCI STOP B 17
CENTRALE
G1
POSIZIONI F.A.DX. B 15 BR1
R1 15 +12V 15
CENTRAL
+SEDILE B 10 B1.5
R1.5 82 +12V 30
+LUCI
+CLACSON
B
B
12
11
R1.5 B1.5 82 +12V 30 D1
N1.5 31 -VCC
ANABB. DEVIO L.B.STEERIN C. A 3
HN1.5
G1.5
N1.5 31 -VCC PRESA DIN
POSIZ. DEVIO LIGHT STEERIN C. A 4
N2.5 G1
GND A 11 C2 CAN L INPUT
V1
GND A 12 N4 C3 CAN H INPUT
ZB05
A2 ISO 9141
START START A 6 HN 1.5 HR2.5
A1 +12V
HN 1.5 VN1
ZB1.5 B4 GND FRIZ. ACC.
+12V MOTORE +12V ENGINE A 1 CB1
RN 4 A3 TRAS.TEMPERATURE
PRERISCALDO COLD START A 8 BV05
VN1.5
ABB. DEVIO
+12 VCC SOLL.
H.B STEERIN C. A 2
A 7 M2.5
A1
A4
A5
VELOCITA'UP-DW
ING.VEL.MOTORE
F
A 9 C4 MV1
+12VOLT RIS
MN1
B3
B2
PEDALE FRIZ.
SENS.GND
CAB.FPS
VG1 G1 C4 CAN L OUTPUT
FARO LAV.P.B. I1 5 V1
FARO LAV.P.B. I1 6 VG1 BG1
C5 CAN H OUTPUT
FARI L.BASSI I1 7 CV1 B5 NEUTRO AV.IND.
CV1 N2.5
FARI L.BASSI I1 8 A8 -VCC
A1.5 V05 2 TRINARY
DIREZIONI DX I1 1
DIREZIONI SX I1 2 AN1.5
V05
1 TRINARY R2
FARI MUSETTO CORNER LIGHT I1 3 HV1 VN 2.5
3 COMPRESS.
FARI MUSETTO CORNER LIGHT I1 4 HV1 G1
4 +LUCI
GRUPPO
COM.DIREZ. I1 12 B1.5 C4
C +12VOLT(15)
RISCALD.
N4
N1 R6
B GND R1
A +12V (30)
N 1.5
N 2.5
MN1 BR 1
MS N 2.5 G1
1 +12Vcc (15) +12Vcc (15)
FRENATURA GERMANIA
MASSA N4 N1
2 POSIZIONI LIGHT
FG1
GROUND
N4
N 2.5
N 2.5
RN 1
3
4
GND
PRESS.FRENI
GND
BRAKE PRESS.
GERMANY BRAKE
N1
N 2.5
HN05
VELOCITA'REALE GROUND SPEED 55
SN05
VELOCITA'TEORICA THEOR. SPEED 56
HG05
VEL.PTO POS. REAR PTO SPEED 57
SOLLEVATORE LAVORO 3 PUNTO 3 POINT WORK 15 HR05
S05
LIFT POS. 3 PUNTO
CAN L
REAR 3 P.POS.
CAN L
16
14
G1
V1
CAN H CAN H 13
+10VCC +10VCC 27 GR05
SFORZO DX RIGHT DRAFT 47 GV05
G1
V1
+5VCC +5VCC 28
SEG.POSIZ.POST. REAR LIFT POS 48 HV05
Z1
HN1.5
EVP UP POST. EVP UP REAR 21
VN1.5
AN1.5
HG05
1 LB0.5
2 LB0.5
HN05
HR05
HN05
BG05
HV05
BN05
SN05
2 BN05
BV05
NZ05
LR05
1 LR05
R1
G1.5
MN1
R1.5
R1.5
R1.5
MV1
GN1
B1.5
A1.5
HR1
4 VG1
VG1
SG1
VN1
AN1
CV1
CV1
HB1
AN1
AN1
RV1
RV1
3 AB1
AB1
S05
COMUNE EV COM EV 68
Z1
G1
G1
N1
N1
N1
N1
2 N1
B1
V1
A1
3 B1
1 A1
A1
V1
H1
EVP DW POST. EVP DW REAR 22
V05
C2
A3
A4
A5
A6
A7
B2
B3
B4
B5
B6
B7
SEGNALE RADAR RADAR SIGNAL 10
A2
10
10
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
9
3
6
4
1
2
3
9
8
7
1
5
2
4
3
6
7
9
8
MV1
ALIMENT. PTO SUPPLY PTO 40
RG1
COM. FREN PTO REAR BRAKE PTO 65
TERGI P AZZERAMENTO
TERGI A AZZERAMENTO
TERGI A AZZERAMENTO
+12V LAVAVETRO POST

S COM. PTO POST.
COM. PTO ANT.
REAR PTO
FRONT PTO
64
66
VG1
AG1
VELOCITA'TEORICA
GND F.L.BASSO DX
GND F.L.BASSO SX
MN1
FARO L.BASSO DX
FARO L.BASSO SX
LAVAVETRO POST
OUT POS PEDALE
LAVORO 3 PUNTO
MASSA SENSORI GND SENSOR 2
AVANTI/INDIETRO
VELOCITA'REALE
TERGI A. MASSA
ANABBAGLIANTI
BG05
5VCC SENSORI
INT.FRENO PTO SWITCH BRAKE PTO 50
+12VCC FRENI
+12VCC FRENI
GND SENSORI
POS. 3 PUNTO
VEL.PTO POS.
GR05
COMUNE DIR.
DIREZIONI DX
LAVAVETRO A
DIREZIONI SX
TERGI P +12V
ABBAGLIANTI
TERGI A +12V
TERGI A +12V
TERGI P VEL.
TERGI A VEL.
TERGI A VEL.
SEG.PEDALE
PULSANTE PTO PTO SWITCH 6
VELOCITA'+/-
AR05
+CALCSON
OUT FRENI
OUT FRENI
COMANDO DISC. E.DW COMMAND 52
FRENO DX
FRENO DX
FRENO SX
FRENO SX
POSIZIONI
SEG.FRIZ.
CLACSON
DIREZ.DX
POSIZ.DX
DIREZ.SX
POSIZ.SX
LB05
COMANDO SAL. E.UP COMMAND 51
+12VCC
M1
CAN H
+12 VCC +12VCC 23
CAN L
+LUCI
+LUCI
+VCC
-VCC
-VCC
M1
GND
+12 VCC +12VCC 44
+12 VCC +12VCC 45 M1
MB05
ISO 9141 ISO 9141 29
ALIMENT. PTO SUPPLY PTO 41 MV1
G1
CAN L CAN L 31
CAN H CAN H 30 V1
MASSA GND 25 N1
N1
D1 D2 B1 D3 FL
MASSA GND 24
MASSA
CFG GROUND
GND 1
34
N1
M05 FS FD T
CONFIG.1
SFORZO SX LEFT DRAFT
36
46 GN05 FRENI TERGI DEVIOGUIDA BRACCIOLO PRESA ISO FAN.ANT.
SPIA FRENO PTO PTO BRAKE LIGHT 61
B05 BRAKE WIPER STEERING COLUMN HAND COMMAND ISO SOCKET FRONT LIGHT
/30
RN1.5
RN1.5
HN1.5
HN1.5
GN05
HG05
GN05
GR05
HG05
GV05
RN05
HN05
CN05
GV05
OIL PRESS.IND. GV05
HN05
HN05
HR05
AN05
AR05
VN05
HV05
VN05
AN05
VN05
AN05
CB05
AR05
RV05
RV05
BV05
BRAKES OIL LEV. NZ05
NZ05
BV05
R 1.5
M1.5
N1.5
MN1
MB1
V2.5
MV1
MV1
RG1
MV1
MB1
CN1
AG1
HN1
ACTUATOR +12V RN1
AG1
CN1
AG1
HR1
VG1
VN1
AR1
ENG OIL PRESS. M05
CB1
ENG OIL PRESS. M05
VN1
VN1
CORNER LIGHT HV1
HV1
SN1
BN1
G05
VB1
VB1
AB1
VB1
C05
ZB1
C05
R05
C05
B05
V05
B05
V05
Z05
L05
L05
MR
A1
A1
Z1
M1
M1
M1
G1
N1
H1
R1
N1
H1
H1
V1
A1
A1
A1
ACTUATOR GND S1
V0
Z1
30
29
28
27
26
19
22
21
25
18
17
15
14
13
12
16
24
31
BRAKES OIL LEV.
23
11
20
10
EV PREHEATING
2
3
4
1
2
7
5
6
3
1
2
9
8
4
CORNER LIGHT
OIL PRESS.IND.
OB.AIR FILTER
OB.AIR FILTER
PICK-UP SIGN.
SENSORECHB
SENSOR GND
GENERATOR
GENERATOR
COLD START
COLD START
SUPPLY PTO
+12VCC DIR.
+12VCC S.C.
COMUNE ELETTROVALVOLE UP/DW

SIGNAL SBA
DISPLAY 3/4
FRONT PTO
HIGH BEAM
HIGH BEAM
FAN ALARM
+5VCC SBA
COND. FAN
COND. FAN
COND. FAN
COND. FAN
LOW BEAM
LOW BEAM
ELECT VIS
ELECT VIS
SENSOR +
CLEANER
+12 VOLT
CAN RES
START
START
SPIA FRENATURA RIMORCHIO

CAN H
CAN L
HORN
TEMP
SFORZO SINISTRO SEGNALE
INTASAMENTO OLIO SERVIZI

SPIA RISERVA CARBURANTE
GND
GND
ELETTROVALVOLA DISCESA
SFORZO DESTRO SEGNALE
INDICATORE CARBURANTE
ELETTROVALVOLA SALITA
INTASAMENTO OLIO SAC

+12 VCC COMP.CABINA
SPIA CARBURANTE
VENTOLA CONDIZ.
VENTOLA CONDIZ.
VENTOLA CONDIZ.
VENTOLA CONDIZ.
IND.CARBURANTE
FREN.RIMORCHIO
ELECTROVALVE DIFF.
SEGNALE POSIZIONE
EV PRERISCALDO
PRESS.OLIO MOT.
PRESS.OLIO MOT.
ATTUATORE +12V
PTO ECONOMICA
ATTUATORE GND
INT.OLIO SERVIZI
ANABBAGLIANTI
ANABBAGLIANTI
COMPRESSORE
TEMPERAT.CAMBIO
INT.FILTRO ARIA
INT.FILTRO ARIA
ELECTROVALVE DT
GND CARBURANTE
FRENO A MANO
TEMPERATURE
SENSORE GND
FARI MUSETTO
FARI MUSETTO
LIV.OLIO FRENI
LIV.OLIO FRENI
COM. PTO ANT.

SENSORE CHB
PEDALE FRIZIONE
ALTERNATORE
ALTERNATORE
PRERISCALDO
PRERISCALDO
SEGN.PICK-UP
SEGNALE SBA
FILTRO 17BAR
SEGNALE RADAR
PTO ECONOMICA
ALIMENT. PTO
+12VCC DIR.
EV INNESTO PTO
ALL.VENTOLE
II RIMORCHIO
MASSA SENSORI
ABBAGLIANTI
COM EV DT DIFF.
ABBAGLIANTI
ABBAGLIANTI
INT.OLIO SAC
I RIMORCHIO
VALVOLA VIS
VALVOLA VIS
PTO SINCRO
+12VCC S.C.
5VCC SENSORI
EV FRENO PTO
IND.PRESS.
IND.PRESS.
+5VCC SBA
GND SENSORI
COMUNE PTO
POSIZIONI
DIREZIONI
0.010.8708.4
CLACSON
+VCC RADAR
PTO SINCRO
PTO 1000
+12 VOLT
CAN RES
TENDINA
TRINARY
TRINARY
GND CONS.
PTO 540
SEG.FRIZ.
START
START
CAN H
CAN L
PTO 1000
GND
PTO 540
GND
+10VCC
+12VCC
MASSA
HS SUBFRAME WIRING
34
42
43
20
16
15
17
19
22
36
23
37
38
39
40
35
28
26
18
30
29
24
25
27
47
46
32
31
33
10
21
45
41
12
27
29
21
23
24
34
25
36
35
15
16
22
14
13
19
10
12
18
17
32
11
11
1
4
5
6
8
8
3
7
5
6
1
4
9
2
AN C1 SHEET 2/4
CHECK CK ANTERIORE POSTERIORE F2 F1
FRONT REAR FRIZIONE
D0002490
20-101
HS SUBFRAME WIRING
AL CAB. SOTTOSTRUTTURA
A B C
1
2
3
4
5
6
7
8
ST
1 2 3 4 1 2 1 2
AMP
AMP
A D4 D3 S4 S3 S5 FM S2
ACCELERATORE DESTRO SINISTR0 FRENO A MANO SEDILE

ACCEL. RIGHT LEFT HAND BRAKE SEAT FG T1 T2 SA S1
ANT. POST. ACCENDISIGARI
FRONT REAR CIGARETTE LIGHTER
FANALI POSTERIORI
REAR LIGHT FG2 LAVAVETRI
LUCI STOP STOP LIGHT A1 LR1,5 WIPER
POSIZIONI POSITIONS A2 GN1
POSIZIONI POSITIONS A3 G1
DIREZIONI DX TURN DX A4 A1.5 S6 TR

DIREZIONI SX TURN SX A5 AN1.5 LUCE TARGA RIMORCHIO
FARO LAVORO DX LIGHT JOB DX A6 VG1 PLATE LIGHT TRAILER
FARO LAVORO SX LIGHT JOB SX A7 VG1
MASSA LUCI LIGHT GROUND A8 N4
MASSA SERVIZI SERVICE GROUND B1 N 2.5
POMPA TRGI A PUMP WIPER F. B2 RV1
POMPA TERGI P. PUMP WIPER R. B3 SG1
+12V SEDILE P. +12V SEAT B4 R1
SPIA F. MANO LIGHT HAND BRAKE B5 RV05
COMUNE PULSANTI COM. SWITCH B6 MN1
PRESS. FRENI BRAKE PRESSURE B7 RN1
ACCENDISIGARI +12V CIG-LIGHTER B8 BR1.5
EV FREN.GERM. EV GERM.BRAKE C1 B1
SOLLEVATORE DW LIFT DW. C2 AR05
SOLLEVATORE UP LIFT UP C3 BL05
PULSANTE PTO PTO SWITCH C4 RG05
SEGNALE PEDALE ACC. SIGNAL C5 HV05
MASSA GROUND C6 VN0.5
+ 5 VOLT + 5 VOLT C7 HR1
C8
0.010.8708.4
HS SUBFRAME WIRING
SHEET 3/4
D0002230
20-102
HS SUBFRAME WIRING
LUCI STOP STOP LIGHT A1 LR1.5 X1
POSIZIONI POSITIONS A2 GN1 X2
POSIZIONI POSITIONS A3 G1 X3
DIREZIONI DX TURN DX A1.5 X4

A4
DIREZIONI SX TURN SX A5 AN1.5 X5
FARO LAVORO DX LIGHT JOB DX A6 VG1
FARO LAVORO SX LIGHT JOB SX A7 VG1
MASSA LUCI LIGHT GROUND N4 X7

A8
MASSA SERVIZI SERVICE GROUND B1 N 2.5 X8
POMPA TRGI A PUMP WIPER F. RV1

B2
POMPA TERGI P. PUMP WIPER R. SG1

B3
+12V SEDILE P. +12V SEAT R1
B4
B5 RV05
SPIA F. MANO LIGHT HAND BRAKE
COMUNE PULSANTI COM. SWITCH MN1 X6

B6
RN1
PRESS.FRENI BRAKE PRESSURE B7
ACCENDISIGARI +12V CIG-LIGHTER BR1.5

B8
EV FREN.GERM. EV GERM.BRAKE C1 B1
SOLLEVATORE DW LIFT DW. C2 AR05 X9
SOLLEVATORE UP LIFT UP BL05 X10

C3
PULSANTE PTO PTO SWITCH C4 GR05
SEGNALE PEDALE ACC. SIGNAL C5 HV05
MASSA GROUND C6 VN05
+ 5 VOLT + 5 VOLT C7 HR0.5
C8
A B C
2
3
4
1 2 3 4
5
6
+LUCI
7
+12V
-VCC
8
FG
GR05
AR05
AR05
BL05
BL05
N1.5
N1.5
MN1
MN1
GN1
VG1
VG1
AN1
LR1
LR1
G1
A1
HR0.5
BR1.5
VN05
HV05
N1.5
N1.5
GN1
SG1
AN1
RV1
LR1
G1
G1
N1
N1
N1
R1
A1
1
2
4
3
1
2
3
4
1
2
3
4
1
2
3
4
1
7
1
3
6
1
2
4
4
FG2
COMUNE SOLLEVATORE
COMUNE SOLLEVATORE
SOLLEVATORE DW
SOLLEVATORE DW
RV05
SOLLEVATORE UP
SOLLEVATORE UP
N05
G1
N1
PULSANTE PTO
DIREZIONE DX
FARO LAVORO
FARO LAVORO
DIREZIONE SX
1 2 1 2 FRENATURA GER.
SEGNALE
POSIZIONI
POSIZIONI
GERMANY BRAKING
COMUNE
COMUNE
+5 VOLT
DIR.DX
DIR.SX
AMP
AMP
+LUCI
+LUCI
STOP
STOP
STOP
GND
GND
A T1 T2 D5 S1 SA S2 TR S6 FM
ACC.PEDALE LAVAV.ANT. LAVAV.POST. ACCEND. SEDILE RIMORCHIO LUCE TARGA FRENO A MANO
ACCELERATOR FRONT WIPER REAR WIPER CIG-LIGHTER SEAT TRAILER PLATE LIGHT HAND BRAKE
D3 D4 S3 S4 S5
FANALI POSTERIORI
REAR LIGHT
0.010.8708.4
HS SUBFRAME WIRING
SHEET 4/4
D0002240
20-103
HS CENTRAL WIRING
IMPIANTO AEREO CABINA

CAB WIRING STAFFA MASCHIO
4VIE 6VIE 8VIE MALE SUPPORT
E1 E2 E3
R
20 A 7.5 A
15 A
20 A
10 A
R4
R4
A
5A 7.5 A
30 A 5 A ISO
+12V
30 A 3A
F6B F7B
F8B F9B
15 A
10 A
F10B
5A
R3
R3
R2A-R3A-R4A
3A CHECK 3A CHECK 5A R1B-R2B
30 A 10 A 7.5 DIN
A ELECT.
HN4 25 A 15 A FPS 10 A
50
R2
R2
10 A 5A ISO 5A
R4
20 A
10 A
20 A
30
K 20 A 10 A 10 A
L6 30 A 10 A 10A
15
FREON
STOP
STOP
7.5 A
7.5 A
15 A
STOP
R1
R1
30 A DIN 10 A 5A
QUADRO AVVIAMENTO F
START KEY 40 A 10 A 10 A
STAFFA FEMMINA E D C B A I
FEMALE SUPPORT
BIANCO (WHITE)
ROSSO (RED)
GIALLO (YELLOW)
BLU (BLUE)
VERDE (GREEN)
STAFFA METALLICA
METAL SUPPORT
CONNETTORE Connector
F FUSIBILIERA MTA COMPLETA (MTA FUSEBOX)
I CORPO FISSO BIANCO (fixed body white) FCI 211BL059004

CORPO VOLANTE BIANCO (free body white) FCI 211BC059004
E 12 VIE BIANCO (white connector 12 wires)
D 18 VIE ROSSO (red connector 18 wires) FCI 211PL182S2004
C 18 VIE GIALLO (yellow connector 18 wires) FCI 211PL182S4004
B 18 VIE BLU (blue connector 18 wires) FCI 211PL182S6004
A 12 VIE VERDE (green connector 12 wires) FCI 211PL123S5004
K CONNETTORE MERIT STAFFA MASCHIO
A OCCHIELLO D.8 mm MALE SUPPORT
E1 070 P.F.4VIE
E2 070 P.F.6VIE
E3 070 P.F.8VIE
STAFFA FEMMINA
FEMALE SUPPORT
STAFFA METALLICA
METAL SUPPORT
0.010.8710.4
HS CENTRAL WIRING
SHEET 1/2
D0002250
20-104
HS CENTRAL WIRING
N1
GND GROUND 1
N1
E1
GND GROUND 2
N1
GND GROUND 3
AEREO CABINA
N1
GND GROUND 4
V1
AZZ.TERGI AZZ.WIPER 1
AN1
M1
+DIRETTO RADIO +RADIO 30 3
E2
M1
+DIRETTO +BATTERY 4
NZ1
N1
GND GROUND 6
HR1.5
+SOTTO CHIAVE +KEY 1
G1
+LUCI +LIGHT 2
VG1
CB1.5
E3
CB1.5
CN1.5
FARI POST.ALTI REAR LIGHT H 6
CN1.5
FARI POST.ALTI REAR LIGHT H 7
HB1
+MOT.TERGI +WIPER 8
E BIANCO 12VIE WHITE(COLORE) 1.5

LOW SENSING LOW SENSING E 1
(COLORE) 1.5
PONTE SOSP. FRONT.SUSP. E 2
R 1.5
COMP. CABINA CAB. COMP. E 3
R6
+12 BATTERIA VENT. +12 BATTERY VENT. E 10
VN 2.5
COMPRESSORE COMPRESSOR E 11
V 2.5
COMPRESSORE COMPRESSOR E 12
A VERDE 12VIE GREEN ZB1.5

+12V MOTORE +12V ENGINE A 1
M2.5
+12VCC SOLL. +12VCC CONT.LIFT A 7
HR2.5
+12V FPS A 5
C4
+12VOLT RIS. A 9
B4
+12V 30DIN A 10
VN1.5
ABB. DEVIO A 2
HN1.5
ANAB. DEVIO A 3
G1.5
POS. DEVIO A 4
HN 4
START START A 6
RN 4
PRERISCALDO COLD START A 8
N1.5
MASSA GROUND A 11
SOTTOSTRUTTURA
N1.5
N4
MASSA GROUND A 12
SUBSTRUCTURE
B BLU 18VIE BLUE

LB0.5
+12VCC FRENI +12V BRAKE B 1
RN1.5
+12V DIREZ B 18
G1
POS.F.A.DX B 15
GN1.5
POS.F.A.SX B 6
VN 1
ABBAGLIANTI HIGH BEAM B 2
VN 1
ABBAGLIANTI HIGH BEAM B 3
H1
ANABBAGLIANTI LOW BEAM B 4
H1
ANABBAGLIANTI LOW BEAM B 5
LR05
OUT FRENI OUT BRAKE B 16
LR1.5
LUCI STOP B 17
R1.5
+LUCI B 11
R1.5
+12V LUCI B 12
R1.5
+CALCSON B 13
R1.5
+SEDILE B 10
BR1.5
+ACCENDISIGARI +CIG-LIGHTER B 14
C GIALLO 18VIE YELLOW

BR05
RELE'CAND. PRER. PREHITING RELE' C 10
AB0.5
RELE'EV PRER C 14
BN1
EV PRERIS. EV COLD START C 15
BG05
INT.FRENO PTO SWITCH BRAKE PTO C 16
AN0.5
FILTRO 17 BAR 17 BAR FILTER C 13
A 1.5
VENTOLA CONDIZ. CONDITIONER FAN C 11
A 1.5
VENTOLA CONDIZ. CONDITIONER FAN C 12
B05
SPIA FRENO PTO LIGHT BRAKE PTO C 9
AN1
TERGI P +12V C 7
HB1
TERGI P VEL. C 17
V1
TERGI P AZZE. C 18
VG1
TERGI A +12V C 6
MB1
+12VCC CHECK C 3
+12V DIR.CHECK C 1 M1.5
RV1
+VCC BRACIOLO C 4
MV1
+12 VCC ISO SOLL +12VCC ISO C 5
MN05
-VCC ISO SOLL -VCC ISO C 2
BR1
+12V 15DIN C 8
HN4
AVV. 50
R4
K +12VOLT
OUT S.CH.
30
15
L6
QUADRO
AVVIAMENTO
CN1.5
CB1.5
HR1.5
RN1.5
CN1.5
CB1.5
BG05
M1.5
M1.5
C1.5
C1.5
C1.5
R1.5
VG1
15A
20A
30A
30A
B05
5A
G1
3A
N1
7.5A
7.5A
7.5A
10 A
10 A
30A
25A
10A
15A
30A
30A
40A
15A
20A
20A
20A
15A
10A
15A
10A
10A
10A
10A
10A
10A
10A
10A
10A
10A
+12 BAT. VENTILAZIONE
10
15
13
12
16
14
17
18
11
5A
3A
3A
5A
5A
5A
5A
5
6
7
8
4
1
3
2
9
+12v LAMP.ROTANTE
HR1 RADIO/PLAFONIERA
LAMPADA ROTANTE
RADIO/OROLOGIO
RELE' ELETTRON.
RELE' CONDENS.
FC15 BR1.5 ACCENDISIGARI
ANABBAGLIANTI
ANABBAGLIANTI
ANABBAGLIANTI
LAMPEGGIANTE
87 R2A AN2.5 +12V RELE'CAB.
LOW SENSISNG
+ELETTRONICA
RELE'FARI R1B
RELE'FARI R2B
SOLLEVATORE
PRERISCALDO
CAND.PRERIS.
RELE' CABINA
COMP.CABINA
FARI POST.ALTI
FARI POST.ALTI
ABBAGLIANTI
ABBAGLIANTI
ABBAGLIANTI
PONTE SOSP.
+FARI L.BASSI
+FARI L.BASSI
+FARI L.BASSI
EMERGENZA
STRUMENTO
87 RELE'R4A
CAMBIO FPS
FARI ANT.ALTI
FARI ANT.ALTI
TERGI POST.
VENT.COND.
VENT.COND.
AN0.5 FILTRO DIS.
TERGI ANT.
LR05 OUT FRENI

BOB.RELE'
BRACIOLO
FRENO PTO
CHIAVE 30
CHIAVE 15
POSIZIONI
POSIZIONI
POSIZIONI
HR1.5 DIREZIONI
CHECK 30
FARI L.ALTI
FARI L.ALTI
DIN/3-R3B
GEN.LUCI
BN1 EV PRER.
+12VCC 15
+12VCC 30
OUT. +12V
SPIA PTO
ENGINE
AB0.5 ENGINE
BR05 ENGINE
SEDILE
COMP.
AN2.5 TERGI
FA13 VN 2.5 COMP.
VENT.
STOP
STOP
LR1.5 STOP
+ISO
-ISO
+12V BR1 FC6
FC1
+12V RN4 FB1
-VCC
FA7
FA5
FA4
DIN
GN1.5
HR2.5
DEVIO HN1.5
DEVIO VN1.5
MN05
FA13 V 2.5
LB0.5
FC8 M1.5
M2.5
M1.5
M1.5
M1.5
G1.5
DEVIO G1.5
FC16 R1.5
FC4 A2.5
FC14 R2.5
C1.5
C1.5
C1.5
MB1
+12V A2.5
A1.5
A1.5
MV1
FC1 RN4
FC13 L1.5
FB16 VG1
FB16 VG1
VG1
RN4
AN1
BR1
+12V L1.5
FB1 VN1
FB1 VN1
RV1
ZB1
+12V
+12V
+12V
+12V
+12V
FC12 M 4
+12V M 4
FC11 M1
+12V M1
+12V M1
+12V M1
+12V M1
+12V M1
+12V M1
+12V M1
FC5 G1
FC10 H4
FC9 R6
FC6 C4
FC3 R4
FC2 B4
H1
H1
+12V C4
+12V H4
C4
B4
FC7 V4
+12V V4
L
FB12
FB10
FB11
F1-8
FB9
FB8
FB7
FB6
FB5
FB4
FB3
FB2
FA8
FA7
FA6
FA5
FA4
FA3
FA2
FA1
B4
INTERR. ROSSO D
A
R1B R2B R3B R4B R3A R2A R4A R1A
FC16 FC15 FC14 FC13
N1
+12v N1 0.010.8710.4
HS CENTRAL WIRING
SHEET 2/2
D0002260
20-105
REAR LIGHT CABLES
DIREZIONI DIREZIONI
POSIZIONI POSIZIONI
DIRECTION DIRECTION
INDICATORS FARO DI LAVORO INDICATORS FARO DI LAVORO
SIDELIGHTS STOP WORK LIGHT SIDELIGHTS STOP WORK LIGHT
VG1
LR1
G1
N1
N1
N1
A1
GN1
VG1
AN1
LR1
N1
N1
N1
SX DX
LH RH
STOP
STOP
UP DW
UP DW
S5
MN1
MN1
AR1
MN1
MN1
MN1
RG1
BL1
AR1
BL1
VG1
FARO LAVORO WORK LIGHT 1
S5 N1
PTO SOLLEVATORE SOLLEVATORE SOLLEVATORE SOLLEVATORE D3 N1
UP DW UP DW N1.5 N1 D3
COMUNE COM. 1
LIFT LIFT S3 LIFT LIFT COMUNE SOLLEVATORE COM. LIFT 2 MN1 MN1
RG1 MN1 SOLLEVATORE UP LIFT UP 3 BL1 MN1
PULSANTE PTO PTO SWITCH 1
AR1
AI FARI POSTERIORI MN1 S3 AI FARI POSTERIORI SOLLEVATORE DW LIFT DW 4
MN1 MN1
TO REAR LIGHTS COMUNE COM. 2 TO REAR LIGHT D4
SOLLEVATORE UP LIFT UP 3 BL1
SOLLEVATORE DW LIFT DW 4
AR1 D4 D4
POSIZIONI POS. 1 G1
S4 DIREZIONE DX DIR. RH 2
A1
N1 STOP STOP 3 LR1
N1 VG1
S4 FARO LAVORO WORK LIGHT 4
N1.5 N1
COMUNE COM. 1
GN1
POSIZIONI POS. 2
AN1 AL SOTTOSTRUTTURA AL SOTTOSTRUTTURA
DIREZIONE SX DIR. LH 3
STOP STOP 4 LR1 TO SUBSTRUCTURE TO SUBSTRUCTURE
0.010.8711.4
REAR LIGHT CABLES
D0002270
20-106
SWITCHES WIRING
N05
N05
HR1
D N05
HR1.5 HR1 N05
+12VCC 15 +12VCC 15 D 1 1B 1C
G1 N05
+12VCC LAMPADA ROTANTE +12VCC LIGHT ROTATING D 2
R1.5 N05 FARI ANT.BASSI FARI ANGOLO
+12VCC 30 +12VCC 30 D 3 LIGHT FRONT LOW CORNER LIGHT
N1 N05 7 4 5 6 10 3 2 1 8
-VCC GROUND D 4
+12VCC 2 C1.5 +12VCC 2 C1.5
C1.5 N05
+12V FARI L.BASSI +12V LIGHT JOB LOW D 5
N05 OUT 3 CV1.5 OUT 3 HV1.5
+12V FARI L.BASSI +12V LIGHT JOB LOW D 6 C1.5 8 1 2 3 18 17 5
+12V FARI L.BASSI +12V LIGHT JOB LOW D 7 C1.5

+SPIA (LIGHT) 8 CV1 +SPIA (LIGHT) 8 HV05
BG05
FRENO PTO PTO BRAKE D 8
LATO INGRESSO CAVI -SPIA (LIGHT) 7 N05 -SPIA (LIGHT) 7 N05
OUT. +12V OUT. +12V D 9 RN1.5
INPUT SIDE CABLE
+12V FARI L.ALTI +12V LIGHT JOB HIGH D 10 M1.5
LAMPADA ROTANTE LIGHT ROTATING D 12 VG1
FARI ANT.ALTI FRONT LIGHT JOB HIGH D 13 CB1 CB1.5

CB1 CB1
1B 1C
FARI ANT.ALTI FRONT LIGHT JOB HIGH D 14
CN1 CN1.5
FARI POST.ALTI LIGHT JOB HIGH D 15
FARI POST.ALTI LIGHT JOB HIGH D 16 CN1 CN1
B05 3 2 1 8 5 17 18
SPIA FRENO PTO BRAKE PTO LIGHT D 17
ROSSO
RED
SOLL UP 3
AL CENTRALE
TO CENTRAL
)
AL SOTTOSTRUTTURA T
(
TO SUBSTRUCTURE
8 1 2 3 8 1 2 3 8 1 2 3 8 1 2 3 8 1 2 3 8 1 2 3 8 1 2 3 8 1 2 3
1T 1S 1F 2E 1P 1R 1L 1A
I1
DIR. DX DIR. RIGHT I1 1 A1.5
AN1.5 1T 1S 1F 2E 1P 1R 1L 1A
DIR.SX DIR.LEFT I1 2
HV1.5 HV05 TENDINA SOLLEVATORE FRENO PTO EMERGENZA FARI POST.BASSI FARI POST.ALTI LAMP.ROTANTE FARI ANT.ALTI
CORNER LIGHT CORNER LIGHT I1 3
CLEAN LIFT BREAK PTO EMERGENCY LIGHT REAR LOW LIGHT REAR UP ROTATING LAMP LIGHT FRONT UP
HV1.5 HV1.5
GV1.5 GV05 HR1 SOLL DW 1 AR05 +12VCC 30 3 R1.5 C1.5 M1.5 G1 M1.5
FARI POST.BASSI LIGHT JOB LOW I1 5 +ING. 2 +12VCC 2 +12VCC 2 +12VCC 2 +12VCC 2
GV1.5 GV1.5 MN1 COMUNE 2 MN05 FRENO PTO 3 BG05 +12VCC 15 1 HR1.5 OUT 3 GV1.5 OUT CN1.5 VG1 CB1.5
FARI POST.BASSI LIGHT JOB LOW I1 6 +OUT 3 3 OUT 3 OUT 3
CV1.5 CV05 MN05 MN05
FARI ANT.BASSI FRONT LIGHT JOB LOW I1 7 COM 2
CV1.5 CV1.5 SPIA TEND. 8 MN1 3 LB05 SPIA FRENO PTO 7 B05 OUT 12V 2 RN1.5 +SPIA 8 GV05 +SPIA 8 CN05 +SPIA 8 GV05 +SPIA 8 CB1
FARI ANT.BASSI FRONT LIGHT JOB LOW I1 8
AR05 -SPIA 7 N05 +SPIA 8 HR1 DIR DX 5 A1.5 -SPIA 7 N05 -SPIA N05 N05 -SPIA 7 N05
SOLL.DW LIFT.DW I1 9 7 -SPIA 7
LB05 DIR SX 18 AN1.5
SOLL.UP LIFT.UP I1 10
MN05 B1.5
COM. GND COM. GND I1 11 COM.DIR 17
B1.5 -SPIA 10 N05
COM. DIREZ. COM. DIREZ. I1 12
+TENDINA CLEAN I1 13 MN1
0.010.8712.4
SWITCHES WIRING
SHEET 1/2
D0002280
20-107
SWITCHES WIRING
+12VCC 15 +12VCC 15 D 1 HR1.5

G1
+12VCC LAMPADA ROTANTE +12VCC LIGHT ROTATING D 2
R1.5
+12VCC 30 +12VCC 30 D 3
D
N1 X1
-VCC GROUND D 4
C1.5
+12V FARI L.BASSI +12V LIGHT JOB LOW D 7
BG05
FRENO PTO PTO BRAKE D 8
OUT. +12V OUT. +12V D 9 RN1.5
LAMPADA ROTANTE LIGHT ROTATING D 12 VG1

CB1 X6
FARI ANT.ALTI FRONT LIGHT JOB HIGH D 13
FARI ANT.ALTI FRONT LIGHT JOB HIGH D 14 CB1

CN1 X5
FARI POST.ALTI LIGHT JOB HIGH D 15
FARI POST.ALTI LIGHT JOB HIGH D 16 CN1
SPIA FRENO PTO LIGHT BRAKE PTO D 17 B05
SPIA FRENO PTO LIGHT BRAKE PTO I1 13 MN1
DIR. DX DIR. RIGHT I1 1 A1.5
AN1.5
DIR.SX DIR.LEFT I1 2
HV1.5
HV1.5 X4
FARI POST.BASSI LIGHT JOB LOW I1 5 GV1.5
GV1.5 X3
I1 FARI POST.BASSI LIGHT JOB LOW I1 6
CV1.5
CV1.5 X2
AR05
SOLL.DW LIFT.DW I1 9
SOLL.UP LIFT.UP I1 10 LB05
MN05
COM. GND COM. GND I1 11
B1.5
COM. DIREZ. COM. DIREZ. I1 12
X7
HR1.5
RN1.5
GV1.5
CN1.5
AN1.5
HV1.5
CV1.5
CB1.5
MN05
MN05
GV05
GV05
CN05
BG05
BG05
HV05
CB05
AR05
BL05
M1.5
M1.5
R1.5
C1.5
C1.5
C1.5
MN1
MN1
A1.5
B1.5
VG1
HR1
HR1
CV1
N05
N05
N05
N05
N05
N05
N05
N05
B05
G1
18
17
10
3
8
7
7
8
7
FARI POST.BASSI
SPIA FRENO PTO

LAMP.ROTANTE
FRONT LIGHT JOB LOW FARI ANT.BASSI

CORNER LIGHT
REAR LIGHT JOB HIGHT FARI POST.ALTI
SOLLEVATORE
FRONT LIGHT JOB HIGHT FARI ANT.ALTI
EMERGENZA
FRENO PTO
FRENO PTO
FRENO PTO
+12VCC 30
+12VCC 15
SOLL DW
COMUNE
COM.DIR
TENDINA
SOLL UP
OUT 12V
+12VCC
+12VCC
+12VCC
+12VCC
+12VCC
+12VCC
+12VCC
DIR DX
DIR SX
+SPIA
+SPIA
+SPIA
+SPIA
+SPIA
+SPIA
+SPIA
+SPIA
-SPIA
-SPIA
-SPIA
-SPIA
-SPIA
-SPIA
-SPIA
-SPIA
COM
OUT
OUT
OUT
OUT
OUT
OUT
OUT
REAR LIGHT JOB LOW
LIGHT BRAKE PTO

ROTATING LIGHT
CORNER LIGHT
COPTO BRAKE
CONTROL LIFT
EMERGENCY
PTO BRAKE
PTO BRAKE
+12VCC 30
+12VCC 15
DIR RIGHT
DIR. LEFT
COMUNE
COM.DIR
OUT 12V
LIFT DW
+12VCC
+12VCC
+12VCC
+12VCC
+12VCC
+12VCC
+12VCC
LIFT UP
+LIGHT
+LIGHT
+LIGHT
+LIGHT
+LIGHT
+LIGHT
+LIGHT
CLEAN
-LIGHT
-LIGHT
-LIGHT
-LIGHT
-LIGHT
-LIGHT
-LIGHT
COM
OUT
OUT
OUT
OUT
OUT
OUT
OUT
2E 1L 1C 1B 1A 1P 1R 1F 1S 1T
0.010.8712.4
SWITCHES WIRING
SHEET 2/2
D0002290
20-108
LIGHT CABLES
N1
N1 N1
GND GND 1
DIREZ.SX DIR.LH 2
AN1
POSIZ.DX POS.RH 3 GN1
FARO L.BASSO SX LIGHT JOB LOW LH 4 CV1
GND F.L.BASSO SX GND LIGHT JOB LOW LH 5 NZ1
A1
DIREZ.DX DIR.RH 6
G1
POSIZ.SX POS.LH 7
FARO L.BASSO DX LIGHT JOB LOW RH 8
CV1
N1
GND F.L.BASSO DX GND LIGHT JOB LOW RH 9
FL
FAN.ANT.
FARI B.ANT.
FRONT LIGHTS
FRONT WORK LIGHTS
CONNESSIONE SUL FARO LAVORO
CONNECTION ON WORKING LIGHT
P.M. (GND) (GND)
G1 N1 N1
+FARO LAV.
+WORK LIGHT
GB 1
-FARO LAV.
-WORK LIGHT
AN1 CV1 AN1 CV1

DIREZ.SX FARO L.BASSO SX DIREZ.DX FARO L.BASSO DX
DIR.LH LIGHT JOB LOW LH DIR.RH LIGHT JOB LOW RH
G1 NZ1 G1 NZ1
POSIZ.SX GND F.L.BASSO SX POSIZ.DX GND F.L.BASSO DX
POS.LH GND LIGHT JOB LOW LH POS.RH GND LIGHT JOB LOW RH
LS LD
FARO L.BASSO SX FARO L.BASSO DX
LIGHT JOB LOW LH LIGHT JOB LOW RH
0.010.8714.4
LIGHT CABLES
D0002440
20-109
BATTERY CABLES
TERMINALE ø 14 TERMINALE ø 10
TERMINALE ø 8
2
CAVO SEZ. 35 mm
2
CAVO SEZ. 25 mm COLORE NERO (BLACK COLOR CABLE)
2
MORSETTO POSITIVO BATTERIA (POSITIVE BATTERY)
CAPPUCCIO-COVER
TERM. INTEGRALE ø 10.5 (INTEGRAL CONTACT.)
CAPPUCCIO ISOLANTE (COVER)
CAVIS A 223
LITTLEL FUSE CAPPUCCIO-COVER
100 AMP
2
TERMINALE ø 8 (CONTACT)
TERMINALE INTEGRALE ø 12 (INTEGRAL CONTACT)
2
MORSETTO NEGATIVO BATTERIA (NEGATIVE BATTERY)
GTR
CONNETTORE-CONNECTOR ITT TERMINALE ø 8 (CONTACT)
2
0.010.8715.4
BATTERY CABLES
D0002450
20-110
REAR WIRING
31 20
30 8 21
19 9
18 2 10
29 7 3 22
17 1 11
28 6 4 23
16 5 12
15 13
27 14 24
26 25
AL SOTTOSTRUTTURA
TO SUBSTRUCTURE CORAZZA BLU
BLUE COLOR
SOLLEV.
DX
SX
+VCC RADAR +VCC RADAR 31 M1
SIGNAL RADAR SEGNALE RADAR 30 V1
L
5/1
D
H1
U
F
EV DOWN ELETTROVALVOLA DISCESA 29 R1
COM EV UP/DW COMUNE EV UP/DW 28 R1 X6
R1
EV UP ELETTROVALVOLA SALITA 27 Z1
HV05
R
SIGNAL POSITION SEGNALE POSIZIONE 26 MN1

R 1.5
CAB. COMP. COMP.CAB. 25 MN1
MN1
GROUND SENSOR MASSA SENSORI 24 MN1 X5
MN1
GV1 1 2 1 2 1 2 1 2 1 2 3 1 2 3 1 2
RIGHT STRANGE SIGNAL SFORZO DESTRO SEGNALE 23 GR1
X4 AMP 1 2 1 2 1 2 1 2 1 2 1 2 3 1 2 3 1 2 3
AMP
AMP
AMP
AMP
AMP
AMP
+10VCC +10VCC 22 GR05
AMP
AMP
GR1
GN1
LEFT STRANGE SIGNAL SFORZO SINISTRO SEGNALE 21 GR1
1 2 3
CN1
AMP
GND SENSOR FUEL MASSA SENSORE CARBURANTE 19 HN1
HV05
BV05
HN1
MN1
MN1
MN1
RG1
MV1
MV1
GR1
GN1
GR1
GR1
HR1
GV1
AG1
HN1
CN1
GV1
VN1
AN1
AN1
AR1
AR1
AB1
LIGHT RESERVE FUEL SPIA RISERVA CARBURANTE 18 HN1

M1
M1
N1
N1
N1
N1
C1
N1
R1
H1
R1
A1
Z1
C1 X8
LEVEL FUEL INDICATORE CARBURANTE 17
+12VCC +12VCC 16
VN1
MN1
PTO 1000 PTO 1000 15

D T P4 P3 P5 A1 A L L1 F G FR UP DW DX SX
M1
P2
V1
PTO 540 PTO 540 14 AG1 AR1

OBSTRUCTION SAC OIL INTASAMENTO OLIO SAC 13 AR1 AR1
DIFF. DT PTO PTO PTO FILTRO C.C AUS. SOLL.FILTRO C.C FILTRO PAL GALL. RIMORCHIO ELETTROVALVOLE RH LH
OBSTRUCTION SERVICE OIL INTASAMENTO OLIO SERVIZI 12 AN1 AN1
LIGHT TRAILER BRAKE SPIA FRENATURA RIMORCHIO 11

BV05 AN1 R FRENO FRIZIONE AUS. SOLL. TRAILER SFORZO
N1 RADAR BRAKE CLUTCH
N1
N1
GROUND MASSA 10 N1.5 X3
N1
9 N1
8 N1.5
M1.5 X2 M1
COM EV DT DIFF. COM EV DT DIFF. 7
AB1 M1
ELECTROVALVE DT ELECTROVALVE DT 6
ELECTROVALVE DIFF. ELECTROVALVE DIFF. 5 HR1
A1
OBSTRUCTION OIL TRASMISSION INTAS.FILTRO TRASM. 4
VG1
Z
EV PTO EV INNESTO PTO 3 MV1
MV1 X1
COM. PTO COMUNE PTO 2 MV1
RG1
EV BRAKE PTO EV FRENO PTO 1
2 1
R 1.5
N 1.5
SOSPENSIONE PNEUMATICA
PNEUMATIC SUSPENSION
0.010.8716.4
REAR WIRING
SHEET 1/2
D0002460
20-111
REAR WIRING
+VCC RADAR 31 M1
+VCC RADAR
V1
SIGNAL RADAR SEGNALE RADAR 30
H1
EV DOWN ELETTROVALVOLA DISCESA 29
R1 X6
COM EV UP/DW COMUNE EV UP/DW 28
Z1
EV UP ELETTROVALVOLA SALITA 27
HV05
SIGNAL POSITION SEGNALE POSIZIONE 26
R 1.5
CAB.COMP. COMP. CAB. 25
MN1 X5
GROUND SENSOR MASSA SENSORI 24
VG1
RIGHT STRANGE SIGNAL SFORZO DESTRO SEGNALE 23
GR05 X4
+10VCC +10VCC 22
GN1
LEFT STRANGE SIGNAL SFORZO SINISTRO SEGNALE 21
LEFT STRANGE SIGNAL SFORZO SINISTRO SEGNALE 20
CN1
GND LEVEL FUEL MASSA LIVELLO CARBURANTE 19
HN1
LIGHT RESERVE FUEL SPIA RISERVA CARBURANTE 18
C1
FUEL GAUGE INDICATORE CARBURANTE 17
+12VCC +12VCC 16
VN1
PTO 1000 PTO 1000 15
AG1
PTO 540 PTO 540 14
AR1
OBSTRUCTIONS SAC OIL INTASAMENTO OLIO SAC 13 X10
AN1
OBSTRUCTIONS SERVICE OIL INTASAMENTO OLIO SERVIZI 12 X9
BV05
LIGHT TRAILER BRAKE SPIA FRENATURA RIMORCHIO 11
N1.5 X3
GROUND MASSA 10
SYNCRO PTO PTO SINCRO 9
ECONOMY PTO PTO ECONOMICA 8
M1.5 X2
COM EV DT DIFF. COM EV DT DIFF. 7
AB1
ELECTROVALVE DT ELECTROVALVE DT 6
HR1
ELECTROVALVE DIFF. ELECTROVALVE DIFF. 5
A1
OBSTRUCTION OIL TRASM. INTASAMENTO OLIO TRASM. 4
MN1
MN1
MN1
MN1
GN1
RG1
RG1
RG1
VG1
HV1
VG1
M1
R1
H1
R1
EV PTO EV INNESTO PTO 3
V1
Z1
MV1 X1
COM. PTO COMUNE PTO 2
RG1
EV BRAKE PTO EV FRENO PTO 1
1 2 3
1 2 3 1 2 3 1 2 3 1 2 1 2
AMP
SX DX P2 UP DW R
SFORZO SX
SFORZO DX
POSIZIONE
EV SALITA
EV DISCESA
RADAR
31 20
BV05
R 1.5
N 1.5
RG1
MV1
MV1
GV1
HR1
AG1
HN1
CN1
AN1
AN1
AR1
AR1
VN1
AB1
M1
M1
30 8 21
N1
N1
N1
N1
N1
C1
19 9 A1
18 2 10
1 2 1 2 1 2 1 2 1 1 1 2 1 2 3 1 2 3
29 7 3 22
17 1 11 1 2 1 2 1 2
AMP
AMP
AMP
AMP
AMP
AMP
AMP
AMP
AMP
28 6 4 23
16 5 12
15 13
27 14 24
26 25 P4 P3 D T A A1 F L1 L FR P5 G
DOUBLE TRACTION
PTO BRAKE
FRENO PTO
INSERIMENTO PTO
DIFFERENZIALE
FILTRO PAL
INTAS.FILTRO OLIO
LIVELLO GASOLIO
DOPPIA TRAZIONE
SOLLEVAMENTO C.C.
FRENI RIMORCHIO
PTO 540/1000
PAL FILTER
PNEUMATIC SUSP.
DIFFERENTIAL
OBSTRUCTION OIL FILTER
TRAILER BRAKE
OBSTRUCTION OIL FILTER
INTAS.FILTRO OLIO
SOLLEVAMENTO
PTO INSERTED
SERVIZI AUSILIARI C.C.
FUEL LEVEL
SOSP.PNEU
INTAS.FILTRO OLIO
INTAS.FILTRO OLIO
SERVIZI AUSILIARI
0.010.8716.4
REAR WIRING
SHEET 2/2
D0002470
20-112
FPS WIRING
31 20
30 8 21
19 9
18 2 10
29 7 3 22
17 1 11
28 6 4 23
16 5 12
15 13
27 14 24
26 25
CAMBIO
AL FPS CABINA
TO FPS CAB
31
30
ELECTROVALVE FORWARD 29 AN1
WH
RM
RH
C1
C2
C3
AV
IN
H
P
R
L
PRESSURE REVERSER RM B1
28
PRESSURE FORWARD AV 27 A1
IN
S
FR
26
T
EV - PROPORTIONAL HML 25 CV1
EV + PROPORTIONAL HML 24 CB1

ELECTROVALVE H 23 CN1
ELECTROVALVE M 22 LN1
1 2 1 2 1 2 3 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
ELECTROVALVE L 21 SN1 1 2 3
1 2
AMP
AMP
AMP
AMP
AMP
AMP
AMP
AMP
AMP
AMP
AMP
TEMPERATURE 20 R1
AMP
AMP
AMP
1 2
RANGE SENSOR 19 BN1
+5 VCC 18 HL1 M1
M1
M1.5 X1 M1
LR05
COM SUPPLY 2 17
MN1
MN1
MN1
GH1
GN1
RG1
HN1
HN1
HR1
SG1
HN1
HN1
CN1
HN1
VG1
HV1
HB1
BN1
AN1
CB1
CV1
SN1
HL1
LN1
M1
M1
M1
M1
M1
R1
B1
A1
ELECTROVALVE BACKW 16 GH1 M1
ELECTROVALVE 3 15 RG1 M1
VG1
HR RM S IN R WH A I P L MG HG FR T C1 C2 C3
ELECTROVALVE 2 14
ELECTROVALVE 1 13 GN1
WHEEL SPEED 12 SG1 MN1 GAMME SERVICE GAMME VELOCITA' INVERSORE MARCE
SENSOR GND 11 MN1 MN1 RANGE RANGE SPEED REVERSING GEAR
SENSOR SUPPLY +12V 10 HR1
COM SUPPLY 1 9 HN1.5 X2 HN1
ELECTROVALVE RANGE M HB1 HN1

8
ELECTROVALVE RANGE H HV1 HN1
7
RANGE H 6 HN1
RANGE M HN1
5
RANGE L 4
PRESSURE GAMMA H 3
PRESSURE GAMMA M 2
HYDRAULIC PRESSURE 1 LR05
0.010.8717.4
FPS WIRING
SHEET 1/2
D0002300
20-113
FPS WIRING
31
30
AN1
ELECTROVALVE FORWARD 29
B1
PRESSURE REVERSER RM 28
A1
PRESSURE FORWARD AV 27
REVERSER OUT.SPEED 26
EV - PROPORTIONAL HML 25 CV1
EV + PROPORTIONAL HML 24 CB1
CN1
ELECTROVALVE H 23
ELECTROVALVE M 22 LN1
ELECTROVALVE L 21 SN1
TEMPERATURE 20 R1
RANGE SENSOR 19 BN1
+ 5 VCC 18 HL1
COM SUPPLY 2 17 M1.5 M1.5 X1

GH1
ELECTROVALVE BACKW 16
RG1
ELECTROVALVE 3 15
ELECTROVALVE 2 14 VG1
GN1
ELECTROVALVE 1 13
WHEEL SPEED 12 SG1
SENSOR GND 11 MN1
SENSOR SUPPLY +12V 10 HR1

HN1.5 HN1.5 X2
COM SUPPLY 1 9
ELECTROVALVE RANGE M 8 HB1
ELECTROVALVE RANGE H 7 HV1
RANGE H 6
RANGE M 5
RANGE L 4
PRESSURE GAMMA H 3
PRESSURE GAMMA M 2
HYDRAULIC PRESSURE 1 LR05
FPS
31 20
30 8 21
19 9
18 2 10
29 7 3 22
17 1 11
28 6 4 23
LR05
MN1
MN1
MN1
GN1
RG1
GH1
HR1
SG1
HN1
HN1
VG1
HN1
HN1
CN1
HN1
BN1
HV1
HB1
SN1
CB1
CV1
AN1
16 5 12
HL1
LN1
M1
M1
M1
M1
M1
R1
A1
B1
15 13
27 14 24
26 25
1 1 1 2 3 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 1 2 1 2
1 2 3 1 2 1 2
AMP
AMP
AMP
AMP
AMP
AMP
AMP
AMP
AMP
AMP
AMP
AMP
AMP
AMP
S FR R WH T HR MR C1 C2 C3 LG MG HG P IN AV I
CONTROLLI GAMME MARCE INVERSORE

CONTROL RANGE GEARS REVERSING
0.010.8717.4
FPS WIRING
SHEET 2/2
D0002430
20-114
MANUAL CLIMATE CONTROL
RELE' COM. III

VEL. ELETTROVALVOLA
ELETTROVENTILATORE SX RESISTORE SX RELE' (PER MAX. VEL.) COMP. STAGE III GND
FAN LH RESISTOR LH RELAY (FOR MAX SPEED) SOLENOID RELAY
M
+ BATTERIA + CHIAVE
+ BATTERY + KEYSWITCH
87b 87 86 85 30 87b 87 86 85 30
BR2.5
R2.5
N0.5
S1
R6
GL2
AR2
N0.5
A1
R4
GIUNTO CON CAVO PLANCIA
BR2.5
N2.5
BR2
GL2
LR1.5
V1
C B A
(CHIAVE + BATTERIA)
CONNECTION WITH CONSOLE WIRING
(KEYSWITCH + BATTERY)
R6
N6
C2.5
GIUNTO CON CAVO PLANCIA (PRESSOSTATO E
COMANDO COMPRESSORE)
CONNECTION WITH CONSOLE WIRING
(PRESSOSTAT AND COMPRESSOR CONTROL)
+ LUCI
+ LIGHTS
5
GN0.5
4
CB1
3
PRESSOSTATO
PRESSOSTAT
V0.5
2
B0.5
1
FUS. 7.,5A
C0.5
N0.5
GN0.5
V0.5
CB1
N0.5
VN0.5
C2
V1
C0.5
C2.5
LR2
V1
A1
S1
R2.5
N2.5
LR1.5
AR2
R2
VN0.5
V1
LN0.5
2 3 4 5 1
B0.5
30 85 86 87 87b
1 2 3 4 5
1 2
4 3 2 1
1 2 3 4 C C B A
ELETTROVENTILATORE DX RESISTORE DX COMMUTATORE RELE' COMPRESS. INTERRUTTORE TERMOSTATO ILLUMINAZIONE

FAN RH RESISTOR RH SWITCH E INSER. I VELOCITA' INSERIMENTO A/C ELETTRONICO COMANDI
COMPRESSOR AND A/C SWITCH ELECTRONIC LIGHTS FOR CONTROLS
STAGE I RELAY THERMOSTAT
D0002630
0.010.9139.4/10
MANUAL CLIMATE CONTROL
D0002630
20-115
A/C COMPRESSOR WIRING
N.OPEN RELE'
R2 R1
85 V1
86 N1 FUSE 30A
87 M4
30 R4
R4 R4
AL CAVO + C
TO CABLE
N1
N1
R1 P
M4
R1 P
M4
N4
N4 AL CAB.0.010.8716.4
AL CAB.0.010.8716.4
AL COMPRESSORE
AL COMPRESSORE TO COMPRESSOR
TO COMPRESSOR
R1
1
AL PRESSOSTATO
AMP 2 V1
TO PRESSOSTAT
R1
V1
N4
AL PRESSOSTATO
TO PRESSOSTAT
R4
FUSE 30A
N4
-VCC
+VCC
R4
AI MORSETTI BATTERIA
TO BATTERY TERMINALS
0.011.8454.4
A/C COMPRESSOR WIRING
D0002590
20-116
WIRING WITH 3 RELAYS FOR STEERING COLUMN LIGHTS SWITCH
R3
GND
R2 R1
D1
R2
R3 R2 R1 R3
R1
D2
N.APERTO 30A N.APERTO 30A N.APERTO 30A
R1 R2 R3
30 86 85 87 30 86 85 87 30 86 85 87
N1
N1
N1 GND AL CABLAGGIO
TO WIRING
R1.5 R1.5
+LUCI +LIGHT 1 1 +LUCI +LIGHT
R1.5 R1.5
+LUCI +LIGHT 5 5 +LUCI +LIGHT
G1.5 G1.5
POSIZIONI DIMS 2 2 POSIZIONI DIMS
HN1.5 HN1.5
ANABBAGLIANTI LOW BEAM 4 4 ANABBAGLIANTI LOW BEAM
VN1.5 VN1.5
ABBAGLIANTI HIGH BEAM 3 3 ABBAGLIANTI HIGH BEAM
Z1
AL DEVIOGUIDA CLACSON HORN 10
Z1 10 CLACSON HORN D1
TO STEERING COLUMN D2 +CLACSON +HORN 6
R1.5 R1.5
6 +CLACSON +HORN
B1.5 B1.5
COMUNE DIR. DIRECTION COMB. 7 7 COMUNE DIR. DIRECTION COMB.
AN1.5 AN1.5
DIREZIONI SX DIRECTION LH 9 9 DIREZIONI SX DIRECTION LH
A1.5 A1.5
DIREZIONI DX DIRECTION RH 8 8 DIREZIONI DX DIRECTION RH
0.011.8747.4
WIRING WITH 3 RELAYS FOR STEERING COLUMN LIGHTS
SWITCH
D0002610
20-117
35S WIPER TIMER WIRING
AL TEMPORIZZATORE
TO TIMER
N1
D5
M1
6 1 4 LB1
AB1 VG1
3 4 5
RV1
VG1 +12V VG1

A1
AL CABLAGGIO D3
TO WIRING AZZ. LB1 D4 AL TERGI
TO WIPER
N1 GND N1
VG1 VG1
+12V TERGI A. 1 1 +12V TERGI A.
RV1 RV1
LAVAVETRO ANTER. 2 2 LAVAVETRO ANTER.
HB1 HB1
TERGI POST.VEL. 3 3 TERGI POST.VEL.
A1
TERGI A. VEL. 4 4 TERGI A. VEL.
M1
TERGI A.TEMP. 5 5
AB1 AL CABLAGGIO
TERGI A AZZ. 6 6 TERGI A AZZ. D1 TO WIRING
AL DEVIOGUIDA AN1 AN1
TO STEERING COLUMN D2
+12V LAV.POST 7 7 +12V LAV.POST
SG1 SG1
LAVAVETRO POST. 8 8 LAVAVETRO POST.
AN1 AN1
+12V TERGI POST. 9 9 +12V TERGI POST.
V1 V1
TERGI P. AZZ. 10 10 TERGI P. AZZ.
VISTE CONNETTORI LATO INGRESSO CAVI

WIEW CONNECTOR FOR SIDE IMPUT WIRES
D5
D3 D4
D2 D1
0.011.9643.4
35S WIPER TIMER WIRING
D0002600
20-118
BRAKE WIRING (GERMANY)
FG 4
3
AMP S
2
1
AL CAB SOTTOSTRUTTURA
EV
FG
4
B1
3
AMP G1
2
M1
1
M1
G1
B1
B1
EV S
1.0442.6899
BRAKE WIRING (GERMANY)
D0002480
20-119
D0002620
+Vcc
CONNECTOR
I/O Interface & Microprocessor
Battery Charge
1
Dig1
Brake Oil Level
2
Dig2
Hand Brake
3
Dig3
Air Filter
4
Dig4
PTO 540
5
Dig5
PTO 1000
6
Dig6
PTO ECO
7
Dig7
PTO Syncro
Dig14
Engine Oil Pressure
Dig9
Trailer Brakes Pressure
Dig10
Hydraulic Oil Filter
Dig11
Gear Box Filter
19 9 10 11 12
Dig12
GND
High Beam Lights
Direction Lights
Trailer 1 Direction Lights
Trailer 2 Direction Lights

CAN Or Direct Link Controlled Devices
BackLight
16 13 14 22 15
Light
Back
Dig8
Empty Lamp
x
Dig13
Fuel Level
x
An1
17 18
Sensor
x
Fuel Level
Spare 1
x
Dig15
Spare 2
An2
20 21
+Vcc direct (30)
+
+Vcc dir
+Vcc Switched (15)

25.8
+
6981
0963
Box
GND
Fuses
+Vcc sw
Sensors GND
GND
8 23 24 29
m
Configuration
RPM
Config
26
Km/h
1000
Engine Speed
F
1
Sp1
Sensors GND
Speed
2
Engine
28 29
Sp
20-120
x
F
2.8339.146.0/50
x
Radar Signal
x
Sp2
30
Sp
RADAR Sensor
Wheel Speed
F
1
Sp3
31
Wheel
Speed
Sp
Engine Pressure
1
An3
32
Engine
Pressure
INSTRUMENT WITH COMPUTER L1
Engine Temperature
1
An4
33
Engine
t
2
Temperature
An5
Display Keyboard
CAN RES
P4
CAN Controlled Devices
120R
CAN H
330R
1
CAN L
CAN L
2
34 25 35 36
CAN H
CAN Bus
P3
560R
P2
1K2
P1
6K8
+Vcc
Instrument Cluster
INSTRUMENT WITH COMPUTER L1
CONTENTS
SECTION 30
CONTENTS
ENGINE HOOD, SIDE PANELS AND GRILLE RADIATOR

• Removal ...................................................................... 1 • Removal .................................................................... 22
• Adjustment.................................................................. 1 • Refitting..................................................................... 24
STARTER MOTOR EXPANSION TANK
• Removal ...................................................................... 3 • Removal .................................................................... 25
• Refitting....................................................................... 3 • Refitting..................................................................... 25
ALTERNATOR THERMOSTAT VALVES
• Removal ...................................................................... 4 • Removal .................................................................... 26
• Refitting...................................................................... 4 • Refitting..................................................................... 26
TENSIONING AND RENEWAL OF THE COOLANT PUMP
ALTERNATOR DRIVEBELT ........................................ 5 • Removal .................................................................... 27
• Refitting..................................................................... 29
AIR COMPRESSOR
(for air trailer braking) OIL PRESSURE SENSOR AND SENDER UNIT
• Removal ...................................................................... 7 • Inspection and renewal ............................................. 30
• Refitting....................................................................... 8 ELECTRONIC ACTUATOR
TRAILER AIR BRAKING UNITS AND • Removal .................................................................... 31
THE CAB SUSPENSION • Refitting..................................................................... 31
(EXPORT D Version) • Calibration................................................................. 32
• Removal ...................................................................... 9 INJECTION PUMPS
• Refitting..................................................................... 11 • Removal .................................................................... 33
AIR CONDITIONING SYSTEM • Refitting..................................................................... 34
• Operation .................................................................. 13 EXHAUST PIPE AND SILENCER
• Servicing ................................................................... 14 • Removal .................................................................... 35
CONDENSER COOLING FANS • Refitting..................................................................... 35
• Tensioning................................................................. 14 TURBOCHARGER
DISCHARGING, FLUSHING AND RECHARGING • Removal .................................................................... 36
THE AIR CONDITIONING SYSTEM........................... 15 • Refitting..................................................................... 37
AIR CONDITIONING COMPRESSOR ROCKER COVERS
• Removal .................................................................... 16 • Removal .................................................................... 38
• Refitting..................................................................... 16 • Refitting..................................................................... 40
CONDENSER COOLING FANS ENGINE SPEED SENSOR (PICK-UP UNIT)
• Removal .................................................................... 18 • Removal .................................................................... 41
RECEIVER-DRIER FRONT CRANKSHAFT SEAL
• Removal .................................................................... 19 • Renewal .................................................................... 42
CONDENSER ASSEMBLY BRAKE PUMPS
• Removal .................................................................... 20 • Removal .................................................................... 46
GEARBOX OIL COOLER BRAKE PEDALS AND MICROSWITCHES
(Models 120 - 135) • Adjustment and alignment ........................................ 47
• Removal .................................................................... 21
• Refitting..................................................................... 21
30-i
CONTENTS
BRAKING SYSTEM FRONT AXLE SUPPORT BUSHINGS

• Bleeding.....................................................................48 • Renewal .................................................................. 129
POWER STEERING • Assembly ................................................................ 130
• Checking....................................................................49 ADJUSTING END FLOAT OF
• Removal.....................................................................50 FRONT AXLE MOUNTINGS..................................... 131
• Dismantling ................................................................52 FRONT CARRIER
• Assembly ...................................................................59 (Version with front suspension)
FRONT WHEELS • Removal .................................................................. 133
• Removal.....................................................................69 • Refitting................................................................... 135
• Refitting .....................................................................69 FRONT PTO
FRONT BRAKES • Removal .................................................................. 136
• Overhaul ....................................................................70 • Refitting................................................................... 138
• Assembly ...................................................................73 • Dismantling ............................................................. 139
EPICYLIC REDUCTION UNITS OF THE FRONT AXLE • Assembly ............................................................... 151
• Dismantling ................................................................74 ANTISHOCK VALVE AND ACCUMULATORS
• Assembly ...................................................................78 OF THE FRONT LIFT (models 120 - 135)
STUB AXLE HOUSINGS AND FRONT HALFSHAFTS • Removal .................................................................. 161
• Dismantling ................................................................79 • Refitting................................................................... 161
• Assembly ...................................................................85 BATTERY SUPPORT
STEERING SENSOR • Removal .................................................................. 162
• Refitting .....................................................................90 FUEL TANKS
STEERING CYLINDERS (Normal and supplementary)
• Removal.....................................................................91 • Removal .................................................................. 164
• Refitting .....................................................................91 • Refitting................................................................... 166
FRONT LIFT CYLINDERS AND ROCKERS PROPELLER SHAFTS
• Removal.....................................................................92 • Removal .................................................................. 167
• Refitting .....................................................................93 • Refitting................................................................... 167
FRONT SUSPENSION SOLENOID VALVES RENEWAL OF THE FRONT AXLE PINION OIL SEAL
• Removal.....................................................................94 • Renewal .................................................................. 168
• Refitting .....................................................................94 CLUTCH CONTROL UNIT
FRONT SUSPENSION CYLINDERS (when fitted) • Removal .................................................................. 169
• Refitting .....................................................................96 • Dismantling ............................................................. 171
• Assembly ................................................................ 172
STEERING CYLINDERS AND FRONT SUSPENSION
• Dismantling and assembly.........................................97 REAR WHEELS
• Removal .................................................................. 173
FRONT AXLE AND SUPPORT ASSEMBLY
• Refitting................................................................... 173
(Version with front suspension)
• Removal...................................................................101 COMPLETE PUMP ASSEMBLY
• Refitting ...................................................................103 • Removal .................................................................. 174
• Refitting................................................................... 174
FRONT SUSPENSION POSITION SENSOR
• Positioning ...............................................................104 TESTING THE AUXILIARY SERVICES PUMP ........ 175
FRONT AXLE DIFFERENTIAL PUMPS (Version LS)
• Dismantling ..............................................................105 • Removal .................................................................. 176
• Assembly .................................................................116 • Refitting................................................................... 180
FILTERS (OC Version)
• Removal .................................................................. 181
• Refitting................................................................... 182
30-ii
CONTENTS
PUMPS (OC Version) INSTRUMENT PANEL SHROUD

• Removal .................................................................. 183 • Removal .................................................................. 234
• Refitting................................................................... 185 • Refitting................................................................... 235
PUMP DRIVE RIGHT-HAND CONSOLE
• Dismantling ............................................................. 186 • Removal .................................................................. 236
• Assembly ................................................................ 188 • Refitting................................................................... 239
POWER SHIFT CONTROL VALVE LEFT-HAND CONSOLE
• Removal .................................................................. 189 • Removal .................................................................. 240
• Dismantling ............................................................. 190 ELECTRONIC CONTROL UNITS
• Assembly ................................................................ 194 • Removal .................................................................. 242
SHUTTLE ASSEMBLY • Refitting................................................................... 242
• Removal and dismantling ....................................... 195 FUSE BLOCK
• Assembly and refitting ............................................ 197 • Removal .................................................................. 243
• Dismantling and adjustment ................................... 198 • Refitting................................................................... 243
• Assembly ................................................................ 203
ACCELERATOR POTENTIOMETER
RANGE GEARBOX CONTROL UNIT • Renewal .................................................................. 244
• Removal .................................................................. 204 • Refitting................................................................... 244
• Refitting................................................................... 204
• Dismantling ............................................................. 205 CLUTCH PEDAL AND CONNECTED DEVICES...... 245
• Assembly ................................................................ 208 CONTROL CABLES OF THE AUXILIARY
AUXILIARY CONTROL VALVE ASSEMBLY SERVICE VALVES
(LS Version) • Renewal .................................................................. 247
• Refitting................................................................... 211 PUSHBUTTON PANEL AND CONTROL LEVERS
AUXILIARY CONTROL VALVE ASSEMBLY FOR AUXILIARY SERVICE VALVES
(OC Version) • Removal .................................................................. 249
• Refitting................................................................... 213 HEATER VALVE
• Assembly ................................................................ 218 • Refitting................................................................... 251
SUPPLEMENTARY LIFT CYLINDERS HEATER MATRIX
• Dismantling and assembly...................................... 219 • Removal .................................................................. 252
LIFT DRAFT SENSOR • Refitting................................................................... 254
• Removal .................................................................. 220 AIR CONDITIONING EVAPORATOR
• Refitting................................................................... 220 • Removal .................................................................. 255
• Refitting................................................................... 256
LIFT
• Removal .................................................................. 221 RIGHT-HAND BLOWER OF THE
• Refitting................................................................... 224 AIR CONDITIONING SYSTEM
• Assembly ............................................................... 230 • Refitting................................................................... 257
ARM-REST CONTROLS LEFT-HAND BLOWER OF THE
• Removal .................................................................. 231 AIR CONDITIONING SYSTEM
• Refitting................................................................... 258
STEERING WHEEL, STEERING COLUMN
SWITCH UNIT, INSTRUMENT PANEL WINDSCREEN WIPERS
• Removal .................................................................. 232 • Removal .................................................................. 259
iii
ENGINE HOOD, SIDE PANELS AND GRILLE
REMOVAL AND ADJUSTMENT OF ENGINE HOOD, SIDE PANELS

AND GRILLE
1. Removal of the upper hood
2 2
1 - Open the hood (1).
2 - While supporting the hood in the raised position, re-
move the pin screws (2) and detach the hood from the 3
gas springs (3). 3
F0001360
3 - Loosen and remove the hinge retaining screws (4) and

remove the hood. 4
1.1 Refitting the engine hood

• Refit the hood following the removal operations in re-
verse order. F0001370
1.2 Adjustment of the hood catch.

5
★ To adjust the catch, the front grille must be fitted and
the gas springs disconnected.
1 - Close the hood and check that the striker (5) engages
the centre of bush (6) in the front frame (7). 7
6 D0000081
2 - If the striker (5) does not enter the bush (6) centrally,
loosen nuts 4, move the hood and then re-tighten nuts 1
(4).
Nuts: 14.5 --16 Nm (10.7 -- 11.8 lb.ft.)
D0000110
30-1
ENGINE HOOD, SIDE PANELS AND GRILLE
3 - Check that the spring (8) is seated correctly on release

button (9) and that it engages the striker (5).
If necessary, adjust the protrusion depth of the striker 10
by means of nut (10).
9 5
8 D0000080
2. Removal of the front grille

12 14
1 - Loosen and remove the quick-release catches (11).
2 - Tilt the front grill (12) forwards and disconnect low
beam and main beam connectors (13) and (14). 13
11
3 - Raise and remove the front grille (12).
14
F0001131
3. Removal of the side panels

15
1 - Lift the side panel (15).
B
2 - Pull the side panel (15) away from clips (16). 16
17
3.1 Adjustment of the side panels
18
1 - Fit the side panels and align them with the front grille
(12) and the hood by loosening the locknuts (18) and
adjusting the pins (17). D0000090
30-2
STARTER MOTOR
REMOVAL OF THE STARTER MOTOR
Remove the battery cover and disconnect the lead

from the negative (--) battery terminal. 1
1 - Peel back sleeve (1) and remove nut (2) and shroud (3).
3
2
F0001420
2 - Peel back sleeve (1) and remove nut (2) and shroud (3).
4
5
F0001430
3 - Disconnect terminals (6) and (7).

4 - Undo and remove locknut (8) and screw (9) with the 7
relative washers; remove the starter motor (10).
F0001440
REFITTING THE STARTER MOTOR

• Refit the starter motor following the removal opera-
8
tions in reverse order.
9
10
F0001450
30-3
ALTERNATOR
REMOVAL AND RENEWAL OF THE ALTERNATOR

from the negative battery terminal (--).
1
1 - Remove the RH fan guard (1).
F0001070
2 - Loosen the alternator retaining screws (2) and nut (3).

3 - Loosen locknut (5) and turn adjuster screw (6) coun- 4
ter-clockwise in order to remove the drivebelt (7).
2
12
13
F0001381
4 - Disconnect connector (8), lead (9) and leads (10) from

the alternator.
6
5 - Remove screws (2) nut (3) and spacer (11); remove the 7
alternator (4). 5
★ Recover the shims (12) installed between the
mountings (13) and (14) and the alternator (4).
11
14
F0001391
REFITTING THE ALTERNATOR

8
• Refit the alternator by following the removal opera- 9
tions in reverse order, but without tightening down the
alternator retaining bolts.
1 - Align the drivebelt (7).
(For details, see next paragraph). 10
2 - Adjust the tension of the drivebelt.
(For details see «TENSIONING THE ALTERNATOR
DRIVEBELT»).
F0001410
30-4
ALTERNATOR DRIVEBELT
TENSIONING AND RENEWAL OF THE ALTERNATOR DRIVEBELT

from the negative (--) battery terminal.
1
1 - Remove the RH guard (1).
F0001070
2 - Loosen the screw (2) and nut (3) securing the alterna-
tor (4).
4
3 - Loosen locknut (5) of the tension adjuster screw (6).
4 - To tension the belt, turn the adjuster screw (6) clock- 2
wise to obtain a deflection of 5÷7 mm (0.1968 -- 0.2755
in.), when a load of 10 kg (22 lb.) is applied at the mid-
point of the run between the fan and alternator.
★ Before adjusting the tension, inspect the drivebelt 3
(7) carefully for signs of wear.
The drivebelt should be renewed immediately at
the first sign of cracks, fraying or cuts.
F0001380
5 - Tighten the alternator in position.

6
6 - If the drivebelt (7) is to be renewed, turn adjuster screw
(6) counter-clockwise in order to release the drivebelt 7
5
from the pulleys.
F0001390
7 - Remove the worn drivebelt (7), guiding it between the

blades of the cooling fan (8) and the cooling fan cowl-
ing (9) while slowly rotating the fan.
8 - Fit the new belt in the same way, and tension it as de- 8
scribed in points 4 and 5. 7
The tension of new drivebelts should be 9
checked after 50 operating hours.
9 - Refit the RH guard (1).
F0001400
30-5
ALTERNATOR DRIVEBELT
Alignment of the alternator drivebelt

13 12
★ This operation must be carried out with the drivebelt 4
under slight tension and without installing the spacers 2
under the belt tensioner.
1 - Check the alignment between the alternator pulley
and the crankshaft pulley by placing a metal straighte-
dge “ A” across the face of the alternator pulley.
A
2 - Insert shims (12) between the alternator (4) and the
mountings (13) and (14) to correct the alignment. 3
★ Max. alignment error: 1.5 mm (0.6 in.)
3 - Fix the longitudinal position of the alternator slightly
tightening screw (2) and nut (3).
4 - Tension the drivebelt.
14 12 MAX 1,5 mm
(For details see « TENSIONING THE ALTERNATOR

DRIVEBELT»).
D0000070
30-6
AIR COMPRESSOR (for air trailer braking)
REMOVAL OF THE AIR COMPRESSOR (for air trailer braking)
For models with suspended front axles only

1 - Deactivate front axle suspension by pressing the rel-
ative pushbutton.
2 - Eliminate all residual pressure in the rear accumulator 1
by opening the check valve (1 - marked AV) a few
turns.
F0010000
3 - Remove the clamps (2) from pipes (3) and (4).

4 - Disconnect the delivery (3) and return lines (4) from the
axle suspension valve block; position them so as to
free the compressor.
★ Plug the ends of the pipes and open fittings to pre-
vent the entry of contaminants.
3
2
4 F0001870
20
For all models
5 - Remove the heat shield (5) form the air conditioning
compressor.
F0001880
6 - Disconnect the compressor lubrication pipe (6).

★ Plug the end of the pipe and the open fitting to pre-
F0001811
30-7
AIR COMPRESSOR (for air trailer braking)
7 - Disconnect the inlet (7) and outlet (8) from the air com-
pressor. 7
★ Move the pipes to one side and plug the ends; also
plug the open fittings of the compressor.
8 - Remove the three nuts (9) and bolt (10) complete with 10
washers and remove the complete compressor.
1
8
9
F0001890
9 - Remove the intermediate spacer (11).

2
11
F0010200
REFITTING THE AIR COMPRESSOR

• Refit following the removal operations in reverse or-
der.
1
★ First install bolt (10) while holding the compressor
raised from the mounting face, then fit nuts (9).
★ Tighten the bolt and nuts in a crosswise pattern.
2
Engine block and compressor flange mounting
faces: Loctite 510
30-8
TRAILER AIR BRAKING UNITS AND THE CAB SUSPENSION (EXPORT D Version)
REMOVAL OF THE TRAILER AIR BRAKING UNITS AND THE

CAB SUSPENSION (EXPORT D Version)
1. Park the tractor on firm, level ground and position
chocks under the right rear wheel. 2
Discharge the pressure from the compressed air
reservoir.
1 - Remove the rear wheel from the side of the unit to be
removed.
(For details see « REMOVAL OF THE REAR
WHEELS»).
1
2 - Disconnect the delivery line (1) to trailer brake control
units from the compressed air reservoir (2). F0004560
2. Removal of the pressure control valve

1 - Disconnect pipes (2) and (4) from the valve (3). 5
★ Plug the ends of the pipes to prevent the entry of
contaminants.
2
2 - Remove screws (5) and remove the valve. 1
4 3
F0004570
3. Removal of the service brakes valve

1 - Disconnect the parking brake control cable (6).
F0004580
2 - Disconnect the pressure switch connector (7). 7
3 - Disconnect the rear braking system pipe (9) from the 9

valve (8). 2
★ Plug the end of the pipe to prevent the entry of con-
taminants.
F0004590
30-9
4 - Disconnect the pipes of the pneumatic and braking

systems (10). 8
contaminants.
5 - Remove the screws and remove the valve (8).
10
F0004600
4. Removal of the solenoid valve

11
1 - Disconnect the solenoid valve connector (11). 12
2 - Disconnect pipes (12) and (13).

contaminants.
3 - Remove screws(14) and remove the solenoid valve
(11).
14 13
F0004610
5. Removal of the parking brake valve

1 - Disconnect the four pipes (16) from the valve (15).
contaminants. 16
2 - Remove screws(17) and remove valve (15). 15
17 16
F0004620
6. Removal of the cab suspension valve.

1 - Disconnect the valve operating linkage (18).
20
2 - Disconnect the two supply and delivery pipes (19).

★ Label the pipes to avoid confusion on re-assem-
bly.
19
3 - Remove valve (20). 3 18
F0004630
30-10
REFITTING THE TRAILER AIR BRAKING UNITS AND THE

CAB SUSPENSION
• Refit the units following the removal operations in re-
verse order.
1 2
★ Start the engine, recharge the reservoir and check
that the operating pressure is maintained and
there are no leaks.
★ Pressure: 7.8± 0.2 bar (113.1±2.9 psi)
2
★ Bleed the braking system.
1
(For details see « BLEEDING THE BRAKING SYS-
TEM»). F0013550
3
★ When the reservoir is pressurised, check the cab
suspension system by measuring the distance be-
tween the buffer mounting plate (1)and the cab 2
support plate (2).
• If the distance is greater than the maximum limit,
shorten the length of the valve control linkage. 2,83±0,12 in.
72±3 mm
• If the distance is less than the minimum limit,

lengthen the valve control linkage.
1
D0000410
3
3
F0012490
30-11
AIR CONDITIONING SYSTEM
2
Low pressure gas
14÷17 bar
(203÷246,5 psi)
High pressure gas
3 bar 28 bar
(43,5 psi) (406 psi)
High pressure liquid
10
4
1a
3 1
9
CAB INTERIOR
D0000120
1- Compressor with electromagnetic clutch TECHNICAL SPECIFICATIONS

2- Condenser • Minimum and maximum safety pressures:
3- Receiver-drier 3 -- 28 bar (43.5 -- 406 psi)
4- 2-stage pressure switch controlling engagement/ • Refrigerant type: R134a
disengagement of compressor clutch • Quantity of refrigerant: 1600 g
5- Expansion valve • Quantity of moisture-free oil added at first charge :
6- Evaporator 300 g
7- Electronic evaporator temperature sensor
8- Blowers for circulating air inside cab
9- Air ducting
10 - Condenser cooling fans.
30-12
OPERATION OF THE AIR CONDITIONING SYSTEM
The compressor (1) is driven from the crankshaft via a belt. The temperature of the air flow generated by the centrif-
The belt drives a pulley that is engaged to the compressor ugal blowers (8) that flows over the evaporator (6) is sig-
by an electromagnetic clutch (1a), this being controlled nificantly higher than -- 8° C (17.6° F), and so the air gives up
from a switch on the console. heat to the refrigerant, causing to boil and completely
For safety purposes, the system is equipped with a pres- evaporate.
sure switch which performs the following functions: On leaving the evaporator (6), the low-pressure vapour is
1 - To inhibit engagement of the electromagnetic clutch returned to the inlet side of the compressor (1) to repeat
(1a) when the system pressure falls below 3 bar (43.5 the cycle.
psi) as a result of incomplete charging or leakage of The removal of heat from the environment around the
refrigerant. evaporator causes condensation of the moisture in the air
2 - To disengage the clutch (1a) and thus stop the com- and thus dehumidification. This condensation forms on
pressor when the pressure exceeds the maximum the fins of the evaporator where, if it is not kept above 0° C
permissible limit of 28 bar (406 psi) (usually as a result (32° F), it will freeze and prevent correct operation of the
of overheating). evaporator.
A further contact controls operation of the cooling fans The task of maintaining the temperature of the evaporator
(10) of the condenser (2) to maintain the normal operation above 0° C (32° F) (and within the optimum range for heat
pressure within the limits of 14--17 bar (203--246.5 psi). exchange) is performed by an electronic temperature sen-
sor (7). This sensor disengages the compressor clutch (1a)
The refrigerant (in vapour form) is drawn in by the com-
when the temperature falls to the lower limit mite and en-
pressor where it is compressed, thereby causing an in-
gages the clutch when the evaporator reaches the upper
crease in its temperature; the heated vapour then flows to
temperature limit.
the condenser (2), where it loses heat due to the effect of
the air flow generated by the condenser cooling fans (10) The condensate that forms on the fins of the evaporator (6)
and thus condenses from a vapour to a liquid under pres- also contains an amount of dust, pollen or other particles
sure. suspended in the air; the continuous condensation thus
The refrigerant then passes to the receiver-drier (3), which has a air purifying action, and the condensate is dis-
performs 3 functions: it filters out impurities, absorbs charged to the exterior through two pipes.
moisture contained in the refrigerant and acts as a tem- A small fixed quantity of moisture-free oil is added to the
porary storage container for the refrigerant. refrigerant in order to lubricate the seals and mechanical
The refrigerant in its liquid state then passes on to the components of the system. Some of this oil constantly cir-
evaporator (6) through an expansion valve (5), which con- culates in an atomised state throughout the entire system,
stantly meters the quantity of fluid delivered to the evap- lubricating the compressor (pistons and bearings) and the
orator to ensure optimum evaporation. expansion valve.
Inside the evaporator the fluid undergoes expansion to the
critical point of evaporation and to a temperature of ap-
proximately -- 8° C (17.6° F).
30-13
MAINTENANCE OF THE AIR CONDITIONING SYSTEM
The checks and servicing operations required for the air 5 - Removal of the condenser cooling fans.
conditioning system are as follows:
6 - Removal and renewal of the receiver-drier.
1 - Checking the tension of the compressor drive belt.
7 - Removal and renewal of the condenser.
2 - Discharging, flushing and recharging of the system
using a dedicated service machine and R134a re- 8 - Removal of the evaporator and the electronic tem-
frigerant. perature sensor.
(For details, see « REMOVAL OF THE AIR CONDI-
3 - Removal and renewal of the compressor. TIONING EVAPORATOR»).
4 - Inspection and renewal of the magnetic clutch pul-
ley.
ADJUSTING THE TENSION OF THE COMPRESSOR DRIVEBELT

★ Before adjusting the tension, carefully examine the
drivebelt for signs of wear.
The belt must be renewed immediately if any cracks, 1
fraying or cuts rare found.
If a new belt is fitted, adjust the tension again after
approx. 50 operating hours.
1 - Remove the grille (1).
F0001070
2 - Loosen the screw (2) and nut (3) securing the com-
pressor (4). 2 4
3 - Loosen nut (5) and screw in screw (6) to obtain a de-
flection of 10--15 mm (0.4 --0.6 in.) when a load of 10 kg
(22 lb.) is applied at the mid-point of either of the two
runs.
★ In the case of a new belt the deflection should be
7--9 mm (0.276 -- 0.355 in.). 6
4 - Secure screw (6) with locknut (5).
3
5 - Fix the compressor (4) and re-check the tension.
5 F0001080
6 - Refit grille (1).
After fitting a new drivebelt, re-check the tension after
50 operating hours.
30-14
DISCHARGING, FLUSHING AND RECHARGING

THE AIR CONDITIONING SYSTEM
1 - Before discharging, flushing and recharging the d - Separation of the moisture-free oil from the
air conditioning system, inspect the system for liquid refrigerant and determination of its
leaks using a suitable leak detector. quantity by weight.
2 - In order to carry out the system servicing oper- e - Recharging the system with exactly the same
ations you will require a dedicated servicing ma- amounts of refrigerant and oil as those recov-
chine capable of performing the following tasks: ered.
a -Aspiration of the refrigerant fluid. f - Measuring the system delivery line pressure
b - Creation of a high vacuum to purge the sys- and return pressure (low pressure).
tem of contaminants.
c - Filtration of the recovered refrigerant.
1. Discharging the system

1 - Connect the service machine to the high pressure
service valve (1) and follow the specific instructions for
the service machine to discharge the system.
2 - Disconnect the system component to be renewed or
overhauled immediately when the service machine 1
stops; immediately seal the open ends of the sys-
tem pipes. 2
2. Flushing and recharging the system

F0001090
Before each recharging, the system must be purged of all
air, moisture and contaminants (oxides, deposits).
This entails creating a high vacuum within the system to
evaporate any moisture present. The vapour, when extract-
ed, draws with it any contaminants in the system.
★ For the flushing and recharging operations, the serv-
ice machine must be connected to the high (1) and low
(2) pressure service valves.
“Maximum vacuum" must be maintained for at least
10 minutes
After flushing, the moisture-free oil recovered during the
discharging operation must be re-introduced into the sys-
tem, followed by the refrigerant.
Quantity of refrigerant (R134a): 1600 g

Quantity of oil: the quantity recovered.
If the system has to be discharged and flushed in or-
der to renew a system component, the quantity of oil
in the replaced component must be measured and
the same amount of new oil must added to that re-
covered with the refrigerant.
For details of the oil and refrigerant recharging pro-
cedure, refer to the instructions supplied with the
service machine.
30-15
AIR CONDITIONING COMPRESSOR
REMOVAL OF THE AIR CONDITIONING COMPRESSOR
1 - Remove the left fan guard (1).

2 - Discharge the liquid refrigerant from the system.
(For details, see « DISCHARGING, FLUSHING AND 1
RECHARGING THE AIR CONDITIONING SYSTEM»).
F0001100
3 - Remove the heat shield (2).

4 - Disconnect the lines (3), (4) connecting the compres-
sor (5) to the evaporator and the receiver-drier.
5 2
Immediately plug the open fittings to prevent the en- 3
try of air and moisture.
F0001110
5 - Loosen screw (6) and nut (7) securing the compressor

(5). 6
6 - Loosen nut (8) and turn screw (9) counter-clockwise in 12
order to remove the drivebelt (14). 11
7 - Unplug connector (10). 13
8 - Remove nut (11) and the relative washer and remove
the screw (12) securing pipe (13). 9 8
9 - Remove screw (6), nut (7) and the compressor (5).
★ Recover the spacers installed between the belt ten- 7 10
sioner and the guide bracket. 14
F0001081
REFITTING THE COMPRESSOR

• Refit the compressor following the removal opera-
tions in reverse order, but without tightening the com-
pressor mountings.
1 - Align drivebelt (14).
(For details, see following paragraph).
30-16
AIR CONDITIONING COMPRESSOR
2 - Adjust the compressor drivebelt.

(For details see « ADJUSTING THE TENSION OF THE 6
COMPRESSOR DRIVEBELT»).
Aligning the compressor drivebelt 15

★ This operation must be carried out with the drivebelt
under slight tension and without installing the spacers
under the belt tensioner. 16
1 - Loosen screw (6) and check the alignment of the pul- 7

leys using a metal straight edge “ A” across the face of
F0001082
the crankshaft pulley.
2 - Screw the compressor support bush (15) in or out to

align the compressor and crankshaft pulleys. 15
★ Alignment error: max. 1.5 mm (0.06 in.).
3 - Fix the position of the compressor about its longitu-
dinal axis by tightening screw (6). 17
4 - Eliminate the play between the tensioner (16) and the
guide bracket (17) by installing spacers (18).
5 - Tighten nut (7) and adjust the drivebelt tension.
(For details see « ADJUSTING THE TENSION OF THE
COMPRESSOR DRIVEBELT»). 18
MAX 1,5 mm
D0000150
18
7
16
F0001120
30-17
CONDENSER COOLING FANS
REMOVAL OF THE CONDENSER COOLING FANS

1 - Turn catches (1) counter-clockwise to release the
front grille (2). 1 4
2
2 - Disconnect the connectors (3) of the worklights (side).
3 - Disconnect the connectors (4) of the headlights (cen-
tral).
4 - Remove the front grille (2).
5- Unplug connectors (5) and the remove the individual 3
fans (6). F0001130
Removal of the complete fan assembly

5 7
6 - Unplug connectors (5) and (8) of the fans and (6) and 5
horn (7).
6
F0001140
7 - Detach the inlet hose (10) and the discharge pipe (11)
from the air cleaner (9). 11
★ On versions with air trailer braking, first disconnect
hose (12).
8 - Remove the four screws (13) and remove the air clean-
12
er (9).
10
9
13
F0001150
9 - Remove the condenser retaining bolts and washers

(14).
10 - Remove the nuts and washers (15) remove the com-
plete fan assembly (16). 14
★ Record the position of the earth lead (17).
16
REFITTING THE CONDENSER
COOLING FANS 14
• Reftit the fans following the removal operations in re-
verse order. 15 17
F0001160
30-18
RECEIVER-DRIER
REMOVAL OF THE RECEIVER-DRIER
1 - Recover the refrigerant from the system.

2 - Unplug connectors (1) and (2).
F0001170
3 - Disconnect the inlet and outlet lines (3) and (4).

4
1
★ Plug the open fittings on the receiver-drier and the
ends of the lines immediately to prevent entry of air
and moisture. 3
4 - Loosen screw (5) of retaining clamp (6); remove the re- 7
ceiver-drier unit (7).
If a new receiver-drier is to installed, measure the
quantity of oil contained in the old unit in order to de- 6
termine the quantity of new oil to be added to the sys- 5
tem. F0001180
REFITTING THE RECEIVER-

DRIER
• Refit the unit following the removal operations in re-
verse order.
1
★ Remove the end plugs and immediately connect the
lines, fully tightening the fittings to prevent air and
moisture from getting into the system.
1 - Flush and recharge the system.
(For details see « FLUSHING AND RECHARGING THE
SYSTEM»).
30-19
CONDENSER ASSEMBLY
REMOVAL OF THE CONDENSER ASSEMBLY

4
1 - Recover the refrigerant from the system.
2 - Disconnect from the condenser (1) the inlet line (2) and 3 5
the outlet line (3) from the receiver-drier (4).
1
★ Immediately plug the ends of the lines and the 6
open fittings on the condenser and receiver-drier
to prevent air and moisture from getting into the 1
system.
2
3 - Unplug connectors (5) and (6). F0001190
4 - Remove screws (7) and remove the complete con-

denser assembly (8).
If a new condenser is to be fitted, measure the quantity
7
of oil contained in the assembly in order to determine
the quantity of new oil that must be added to the sys-
tem.
8
F0001161
REFITTING THE CONDENSER

• Refit the condenser following the removal operations
in reverse order.
1
★ Remove the plugs and immediately connect the lines,
tightening the fittings fully to prevent air and moisture
from getting into the system.
1 - Flush and recharge the system.
SYSTEM»).
30-20
GEARBOX OIL COOLER (Models 120 - 135)
REMOVAL OF THE GEARBOX OIL COOLER (Models 120 - 135)
1 - Disconnect the discharge pipe (1) and place it on one

side.
2 - Label and disconnect pipes (2), (3); place the ends of
the pipes in suitable container to drain off the oil from
the cooler.
★ Plugs the ends of the pipes to prevent oil drips and 2
the ingress of contaminants. 1 3
F0001460
3 - Remove the upper and lower retaining screws (4) and

(5). 4
F0001470
4 - Remove the retaining pin (6).

7
5 - Pull the handle to withdraw the oil cooler (7).
6
F0001480
REFITING THE OIL COOLER

★ Before refitting, remove all traces of oil from the oil
cooler and the surrounding area (condenser, radiator,
intercooler, etc.).
• Refit the oil cooler following the removal operations in
reverse order.
1 - Start the engine and run for a few minutes (without
moving the tractor) to allow the oil cooler to fill with oil;
check fittings for leaks.
2 - Stop the engine and top up the gearbox oil level.
30-21
RADIATOR
REMOVAL OF THE RADIATOR

1 2
1 - Drain off the engine coolant.
Engine coolant: approx. 18 (5 US gal.)

2 - Remove the right and left fan guards (1) and (2).
F0001510
3 - Remove the air inlet (3) and disconnect the discharge

pipe (5) from the air cleaner (4). 3
5
hose (6).
4 - Remove the condenser cooling fan assembly (7) com-
plete with the air cleaner (4). 6
★ Record the position of the earth lead.
5 - Remove the condenser assembly complete with the
receiver-drier.
(For details see « REMOVAL OF THE AIR CONDITION-
ING CONDENSER»). 4 7
F0001151
6 - Remove the oil cooler.

(For details see « REMOVAL OF THE OIL COOLER»).
7 - For versions with front lift only.
Disconnect the lift pipes (8) and plug the ends to pre-
8
7a -Remove the antishock valve, the accumulators and
the accumulator support cover.
(For details see « REMOVAL OF THE ANTISHOCK
VALVE AND THE ACCUMULATORS OF THE FRONT
LIFT»).
F0001261
8 - Remove the bulkhead fittings and withdraw pipes (9)

and (10) and the outer wiring sheath (11) towards the
9 11
rear of the tractor.
10
F0001520
30-22
RADIATOR
9 - Disconnect the gearbox oil delivery and return pipes

(12) from the bulkhead fittings; plug the ends of the
pipes to prevent the entry of contaminants.
★ Clearly label the pipes to avoid confusion during
re-assembly.
12
F0001530
10 - Disconnect the inlet hose (13) and the outlet hose (14)
from the radiator.
13
14
F0001540
11 - Disconnect the bottom pipe (15) and the thermostatic

valve connection pipe (16) from the expansion tank.
★ Release all the pipes from their retaining straps
and guides.
16
15
F0001550
12 - Remove screws (17) to detach the radiator from

bracket (18).
17
18
F0001560
30-23
RADIATOR
13 - Attach the radiator (19) to a suitable hoist, remove

screws (20) and remove the radiator complete with the
expansion tank. 20 19 20
F0001570
REFITTING THE RADIATOR

• Refit the radiator following the removal operations in
reverse order.
1 - Flush and recharge the air conditioning system.
AIR CONDITIONING SYSTEM»).
2 - Fill the engine cooling system.
Engine coolant: approx. 18 (5 US.gal.)

3 - Start the engine and run for a few minutes to circulate
the coolant and check for leaks.
4 - Stop the engine, check the coolant level in the expan-
sion tank and top up if necessary.
5 - For versions with front lift only.
raise and lower the front lift repeatedly to eliminate any
air from the system.
30-24
EXPANSION TANK
REMOVAL OF THE EXPANSION TANK
1 - Partially drain the engine cooling liquid.
Engine coolant: approx. 9 (2.5 US gal.)

2 - Disconnect the bottom pipe (1) to the coolant pump 2
and pipe (2) to the thermostatic valves.
F0001490
3 - Disconnect the radiator connection pipe (3) and the

breather pipe (4) from the expansion tank. 3
4 - Undo screws (5) and remove the expansion tank (6).

5
4
6 5
F0001500
REFITTING THE EXPANSION

TANK
• Refit the tank following the removal operations in re-
verse order.
1 - Top up the engine cooling system.
Engine coolant: approx. 9 (2.5 US gal.)
2 - Start the engine and run for a few minutes to allow the
coolant to circulate.
3 - Stop the engine, check the level in the expansion tank
and top up if necessary.
30-25
THERMOSTAT VALVES
REMOVAL AND CHECKING OF THE THERMOSTAT VALVES
1 - Partially drain off the engine coolant.
Engine coolant: approx. 8 (2 US gal.) 1

2 - Disconnect the radiator connection pipe (1).
3 - Remove screws (2).
4 - Using a soft-faced mallet, remove cover (3). 1
5 - Withdraw the thermostat valves (4) for checking or re-
newal.
F0001640
Checking the thermostat valves

1 -Fully immerse the thermostat valve in a container “ A” 2
containing engine coolant.
2 - Heat the coolant, checking the temperature with a
thermometer “ B” .
3 - Check that valve aperture is 0.1 mm (0.004 in.) when
the temperature of the coolant is 79±2 ° C (174.2±35.6
° F) and 7 mm (0.276 in.) when the temperature reach-
es 94 ° C (201.2 ° F). 3
If the actual measurements do not correspond to
the above values, the thermostat valve must be F0001650
renewed.
Do not attempt to calibrate the valves.
REFITTING THE THERMOSTAT

VALVES
• Refit the valves following the removal operations in re-
verse order.
F0001660
1
Cover mating surface: Loctite 510
B
★ Make sure to apply the sealant also around the fixing
holes.
1 - Fill the engine cooling system. A
2 - Start the engine and run for a few minutes to circulate 4
the coolant.
3 - Stop the engine, check the level in the expansion tank
and top up if necessary.
D0000100
30-26
COOLANT PUMP
REMOVAL OF THE COOLANT PUMP
1. Removal of the pump

Remove the battery cover and disconnect the lead 1 2
1 - Drain the engine cooling system.
2 - Remove the right and left fan guards (1) and (2).
F0001510
3 - Remove the air inlet (3) and disconnect the discharge

pipe (5) from the air cleaner (4). 3
5
hose (6).
4
F0001152
4 - Remove the condenser cooling fan assembly (7) com-

plete with the air cleaner (4). 4
★ Record the position of the earth lead.
5 - Remove the condenser assembly complete with the 7
receiver-drier.
For details see « REMOVAL OF THE CONDENSER AS-
SEMBLY»)
6 - Remove the antishock valve and the accumulators of
the front lift and the lower support cover.
(For details see « REMOVAL OF THE ANTISHOCK
VALVE AND ACCUMULATORS OF THE FRONT
LIFT»). F0001580
7 - Remove the radiator assembly complete with the oil

cooler.
(For details see « REMOVAL OF THE RADIATOR»). 8
8 - Remove the radiator fan (8) and the relative spacer (9)
1 9
NOTE. On model 150, the spacer is a single compo-
nent.
On models 120 and 135, the spacer compris-
es two shims.
F0001590
30-27
COOLANT PUMP
9 - Remove compressor and alternator drivebelts (10),

(11).
2 12
13
10
11
F0001600
10 - Remove pump drive pulley (14) and the shims (15) for
adjusting the alignment between the pump pulley and
14 15
the crankshaft pulley. 3
11 - Remove the air conditioning compressor.
(For details see «REMOVAL OF THE AIR CONDITION-
ING COMPRESSOR»).
F0001610
12 - Remove the compressor mounting (16).

13 - Loosen the screws (17) securing the alternator (13); re- 13
move the topmost screw and turn the alternator out- 17
wards.
16
17
F0001620
14 - Disconnect from the pump the pipes and hoses con-

necting the pump to the radiator (18), to the heat ex- 21
22
changer (19), to the thermostat unit (20), to the
expansion tank (21) and to the cab heater (22).
20
19
18
F0001621
30-28
COOLANT PUMP
15 - Remove the screws, remove the alternator mounting

(23) and coolant pump (24). 23
★ The pump flange gasket must be renewed at each re-

fitting.
3 4
24
F0001630
REFITTING THE COOLANT PUMP

• Refit the coolant pump following the removal opera-
1
★ The radiator fan must be installed so that the marking
S+L+H and the number can be seen from the front of
the tractor.
2
★ Tension and re-align the drivebelts.
(For details see « REMOVAL AND RENEWAL OF THE
ALTERNATOR » and « REMOVAL OF THE AIR CON-
DITIONING COMPRESSOR»).
3
★ If fitting a new pump, check the alignment between the
pump pulley and the crankshaft pulley; adjust align-
ment by installing shims (15).
4
Pump mounting bolts: 49--54 Nm (36--40 lb.ft.)
1 - Flush and recharge the air conditioning system.
AIR CONDITIONING SYSTEM»).
2 - Refill the engine cooling system.

3 - Start the engine and run for a few minutes to circulate
the coolant and check for leaks.
4 - Stop the engine, check the coolant level in the expan-
sion tank and top up if necessary.
30-29
OIL PRESSURE SENSOR AND SENDER UNIT
CHECKING AND RENEWAL OF THE ENGINE OIL PRESSURE SENSOR

AND SENDER UNIT
1. Checking the sensor
1 - With engine off, turn the ignition key to position to 1
connect power to the instrument panel.
2 - Check that engine oil pressure warning light (1) illu-

minates.
If not, the sensor (2) is faulty and must be replaced. 2
F0001900
2. Checking the sender unit

1 - Start the engine and run it at idle speed. 1
2 - Check that the oil pressure warning light (1) goes out
and that the pressure gauge (3) indicates pressure.
If the gauge (3) indicates zero pressure, check the wir-
ing and check that pressure is present by fitting a
pressure gauge in place of the sender unit.
If pressure is present, the sender unit (4) is faulty and
must be renewed. 4
3
F0001910
3. Renewal of the sensor and sender unit

5
1 - Remove cover (5).
2 - Disconnect the sensor connector (6) or the sender
connector (7).
7
3 - Remove the faulty component and fit the new one.
4
6
2
F0001761
30-30
ELECTRONIC ACTUATOR
REMOVAL OF THE ELECTRONIC ACTUATOR
★ The following procedure refers to the removal and

subsequent refitting of the same actuator; if a new ac-
tuator is fitted, it must then be calibrated.
(For details see « CALIBRATION OF THE ELECTRON-
2
IC ACTUATOR»).
1 - Remove screws (1) and remove the injector cover (2)
1
1
F0001920
2 - Disconnect the fuel return line (3) from injector n° 6.

3 - Remove screws (4) and remove the inspection cover 7 6
(5).
4 - Unplug connector (6) and release the wiring from the
retaining strap (7). 3
5 - Loosen and fully unscrew the screws (8) securing the

actuator (9). 4
F0001930
6 - Force a paper plug “ A” into the inspection hole in order

to hold plate (10) in position.
9 10
7 - Raise the actuator (9) vertically and remove it.
★ Renew gasket (11) on each reassembly.
1 8
★ Take care not to allow plate (10) to fall.
If the plate does fall, it will be necessary to re-
move the oil sump to recover it. 11
A
F0001940
REFITTING THE ACTUATOR

der.
1
★ Degrease the mating surfaces of the engine block
and the governor.
Apply Silastic 738 sealant to the mating sur-
faces.
30-31
ELECTRONIC ACTUATOR
CALIBRATION OF THE ELECTRONIC ACTUATOR
★ This procedure is only to be carried out in the case of

renewal of the actuator.
2
★ The calibration operation must be carried out in con-
ditions of safety, with the tractor parked on a level sur-
face and the parking brake on.
★ During the calibration operation, do not operate any of
the hydraulic or mechanical systems (SBA, 4WD, Lift,
PTO, steering.
1
F0012530
1 - After renewal of the electronic actuator (1), remove the

plug (2) to gain access to the adjuster screw (3).
2 - Start the engine and allow it to reach normal operating
temperature.
3 - Set the engine speed to 2100±10 rpm using the hand
throttle.
F0012540
4 - Slowly screw out the adjuster screw (3) until you first
detect a slight fall in the engine speed.
★ This operation reduces the fuel flow rate; wait a few
seconds for the flow rate to stabilise.
2 3
5 - Screw out the adjuster screw (3) a further few degrees
and again wait for the fuel flow to stabilise.
6 - Repeat the above procedure a number of times,
screwing the adjuster screw out by a few degrees
each time until the engine stops.
7 - When the engine has stopped, slowly screw in the ad- D0002640
juster screw (3) the number of turns indicated in the ta-

ble on the right.
★ Do not force the plug (2) against the screw (3).
N° of screw turns
8 - Apply a small quantity of low-strength threadlocker to CHAMPION Mod.
(turns + degrees)
the plug (2) and screw it into the bore in the actuator
until rests against the adjuster screw (3). 120 cv 4.5 (4+180° )
★ Adhere to the indications for tightening the screw.
135 cv 4.65 (4+234° )
Plug Loctite 222.
150 cv 4.5 (4+180° )
★ Only use low-strength threadlockers for precision
fixings.
30-32
INJECTION PUMPS
REMOVAL OF THE INJECTION PUMPS
★ This operation is to be carried out whenever it is nec-

essary to inspect or overhaul one or more injection
pumps.
★ After refitting, check the injection pump timing (for de-
tails see Section 40-14 « ENGINE TESTS»).
Remove the key from the ignition.
1 - Remove screws (1) and remove the injection pumps

cover (2).
1
1
F0001920
2 - Detach the fuel delivery (4) and return (5) pipe fittings
from the injection pumps (3); remove the pipes. 3
3
4 5
F0012550
3 - Remove high-pressure fuel lines (6) to the injectors.

★ Hold the fitting on the pump steady and loosen the
fitting on the pipe.
4 - Remove screws and the inspection cover (7) over the 6
actuator - control rod coupling.
F0012560
30-33
INJECTION PUMPS
5 - Mark the positions of the injection pumps (3) and the

relative shims (8) to ensure that they are refitted in the
original positions.
Remove the nuts and washers, and then, after moving
3
the control rod to mid-stroke position, remove the in-
jection pumps (3) and the shim packs (8).
★ If necessary, turn the crankshaft over by hand to 8
facilitate removal of the pumps.
★ If the shims or the pumps are mixed up and not fit-
ted in their original positions, then it will be nec-
essary to carry out the timing procedure on all the
pumps. (For details see Section 40 - ENGINE AS-
SEMBLY). F0010661
REFITTING THE INJECTION

PUMPS
1 - Refit the pumps following the procedure indicated in
Section 40 - ENGINE ASSEMBLY - paragraphs 11.1-
11.2-11.3.
2 - Re-assemble parts following the dismantling opera-
3 - Carry out the injection pump timing procedure.
(For details, see Section 40 - 15. ENGINE TESTS).
30-34
EXHAUST PIPE AND SILENCER
REMOVAL OF THE EXHAUST PIPE AND SILENCER
Remove the key from the ignition switch.

1
1 - Place a wooden or plastic support block under the si-
lencer (1).
F0001670
2 - Disconnect the discharge pipe (3) from the exhaust

pipe (2). 5
6
3 - Remove silencer mounting bolts (4) and washers. 2
4 - Remove the three screws and washers (5) securing
the exhaust pipe (2) to the bulkhead (6); do not remove
the top screw for safety reasons.
3
5 - While supporting the exhaust pipe, remove the top
screw and washer and then remove the pipe complete 4
with the flange gasket.
★ The gasket must be replaced after each removal
operation. F0001680
6 - Remove the silencer (1) in a longitudinal direction.

★ Take care not to damage the seal segment.
1
1 F0001690
REFITTING THE EXHAUST PIPE

AND SILENCER
der.
1
★ Before refitting the silencer, carefully clean the con-
nection socket and the seat of the seal segments.
★ Tighten the seal segments by hand until the insertion
of leading taper.
30-35
TURBOCHARGER
REMOVAL OF THE TURBOCHARGER
1 - Remove the left fan guard (1).

2 - Remove the air inlet hose (2).
hose (3). 2 3
1
F0001700
3 - Remove bracket (4) and clamp (5); disconnect the lu-

brication oil delivery pipe (6) and the exhaust pipe.
4 - Remove the exhaust pipe and silencer.
(For details see « REMOVAL OF THE EXHAUST PIPE
4
AND SILENCER»).
5
F0001710
5 - Remove bolts (7) and (8) and remove the manifold (9).
9
F0001720
6 - Disconnect the outlet pipe (10) from the turbocharger

(11). 11
10
F0001730
30-36
TURBOCHARGER
7 - Remove the turbocharger retaining nuts (12) and the

relative washers. 11
12
F0001740
8 - Remove the turbocharger (11) and gasket (13).

★ Renew the gasket after each removal. 11
13
F0001750
REFITTING THE TURBOCHARGER

der.
30-37
ROCKER COVERS
REMOVAL OF THE ROCKER COVERS

1 - Remove the exhaust pipe and silencer.
(For details see « REMOVAL OF THE EXHAUST PIPE
AND SILENCER»).
2
2 - Remove the hose clamps and disconnect hose (1)
from manifold pipe (2). 1
F0001731
3 - Disconnect the feed pipe (3) of the glow plug (4) and
electrical lead (5).
5
F0001950
4 - Remove the screws and remove the plenum chamber

(6) and the relative gaskets. 6
★ First remove the inlet manifold connection plate
"A".
F0001960
5 - Remove screws (7) and remove injector cover (8).
7 F0001921
30-38
ROCKER COVERS
6 - Remove the support brackets (9) of the injector cover

(8) and the nuts (10) securing the inlet manifolds (11). 11
10
9
F0001970
7 - Remove the fuel feed pipes (12). 1
12
F0001931
8 - Remove the radiator stay (13).
13
13
F0001980
9 - Remove the bolts (14) of the exhaust side feed pipes

(15). 15
10 - Remove the inlet manifolds (11) from the injection
pump side.
14
11
F0001990
30-39
ROCKER COVERS
11 - Disconnect the breather pipe (16) from the rocker cov-

er (17). 16
17 18
12 - Remove nuts (18) with relative washers; remove the
rocker covers (17). 2
★ Lift the rocker covers together, keeping them par-
allel to the cylinder head so as not to damage the
O-ring seals.
Check all seals and gaskets; if in any doubt about
their condition, renew them.
F0002000
REFITTING THE ROCKER COVERS

• Refit the following the removal operations in reverse
order.
1
Pipe retaining nuts: 2.5 -- 2.9 Nm
(1.8 -- 2.1 lb.ft.)
2
Cover retaining nuts: 10 -- 11.5 Nm
(7.4 -- 8.5 lb.ft.)
30-40
ENGINE SPEED SENSOR (PICK-UP UNIT)
REMOVAL OF THE ENGINE SPEED SENSOR (PICK-UP UNIT)
Remove the key from the ignition switch before start-

ing work.
1 - Remove the left fan guard (1). 1
F0001100
2 - Unplug the connector (2).
3 - Loosen and remove screw (3), spring washer (4) and

plain washer (5). 1 F0001760
4 - Remove the pick-up unit (6) by withdrawing it verti-

cally from its housing. 2
3 4 5
REFITTING THE ENGINE SPEED

SENSOR
• Refit following the removal operation in reverse order.
1
6
Screw: Loctite 242
F0001770
Screw: 6 Nm (4.4 lb.ft.)
2
★ Check that the clearance "A" between the sensor and 7 (cod. 011.1207.0)
the pulse wheel is 0.35 - 0.75 mm (0.014-0.030 in.).

★ If the clearance between the sensor and the pulse
wheel is less than 0.35 mm, turn the crankshaft
through 180° ; if the clearance decreases, remove
the sensor and raise it by fitting a shim of thickness 6
0.2 mm (0.008 in.) (7) code 011.1207.0.
After refitting the sensor, test its operation using the All A
Round Tester.
D0000140
30-41
FRONT CRANKSHAFT SEAL
RENEWAL OF THE FRONT CRANKSHAFT SEAL

4
1 - Remove the coolant pump. 3
(For details see « REMOVAL OF THE COOLANT
PUMP»).
2 - Remove the bolts (1) and remove the crankshaft pulley
(2), shim (3) and the vibration damper (4) with the rel-
ative shims.
2
1
F0001780
3 - Loosen the clamps to release hose (5); disconnect

pipe (6) and remove the coolant pump connection
pipe (7).
5
6
7 F0001790
4 - Remove the fuel lift pump (AC pump) (8).
F0001800
5 - Remove the cover (9) of the compressor drive take-off

compartment.
F0009390
30-42
5a -For versions with air trailer braking only.

Remove the air compressor (10).
(For details see « REMOVAL OF THE AIR COMPRES-
SOR»).
10
F0001810
6 - Remove bolt (11) and washer (12) and remove the

pulse wheel (13).
11 12
13
F0001820
7 - Remove the engine speed sensor (14) and place it on

one side.
14
8 - Remove screws (15) and cover plate (16).
15
16
F0001830
9 - Remove bolts (17) and studs (18); remove the timing

cover (19) and gasket (20). 17 20
★ Record the positions of the studs (18).
★ Renew the gasket at each re-assembly.
18
19
F0001840
30-43
10 - Remove oil seal (21).

★ Notethecorrectorientationofthesealforreassembly.
1
★ Take care not to damage the seal housing.
21
F0009400
FITTING THE FRONT SEAL

1 - Using a suitable tool mounted in a press, insert the
21
seal (21) in the cover (19).
★ Install the seal with the centring notches facing the
inside of the cover. 19
F0009410
2 - Fit, in sequence, the gasket (20), cover (19) and bolts

(17).
20
★ Do not tighten the bolts yet.
19
F0001850
3 - Temporarily fit the pulse wheel (13) and tighten it down 17

with bolt (11) and washer (12) applying a tightening
torque of approx. 30 Nm (22.1 lb.ft).
13
12
11
F0001860
30-44
4 - Align the cover (19) with block using tool T24 (code
5.9030.634.0); tighten the bolts (A - B - C) in sequence. A
Bolts: 24.5 Nm (18 lb.ft.) T24
5 - Tighten the remaining bolts to the same torque value
following a triangular pattern.
20
6 - Remove tool T24 (code 5.9030.634.0) and trim off the
excess gasket that protrudes into the gear housing.
C B
D0000130
7 - Remove the pulse wheel (13) and fit the plastic cover
(16).
14
15
16
F0001830
8 - Refit the pulse wheel (13) and secure with bolt (11) and
washer (12). 12
★ Lubricate bolt (11), washer (12) and the threaded 13
11
bore in the crankshaft with engine oil.
★ Tighten the bolt (11) in two stages.
Crankshaft bolt and washer: gearbox oil
1st tightening: 60 -- 70 Nm (44.2 -- 51.6 lb.ft.)

2nd tightening: 320 --350 Nm (235.8 -- 258 lb.ft.)
9 - Complete the reassembly following the removal op-
erations in reverse order.
F0012570
30-45
BRAKE PUMPS
REMOVAL OF THE BRAKE MASTER CYLINDERS

1
1 - Remove the instrument panel shroud. (For details, see
« REMOVAL OF THE INSTRUMENT PANEL
SHROUD»).
2 - Remove the engine hood, side panels and front grille. 2
(For details, see « REMOVAL OF THE ENGINE HOOD,
SIDE PANELS AND FRONT GRILLE»).
3 - Undo the screws and remove the insulation panel (1).
4 - Remove screws (2) and move the engine hood gasket 3
F0000410
(3) towards the front of the tractor.
5 - Disconnect the connector (4) of the brake fluid level

warning light. 5
6 - Remove cap (5) and draw off the fluid contained in the
brake fluid reservoir (6). 6
4
7
7 - Disconnect the feed pipes (7) from the master cylin-

ders. F0000420
8 - Disconnect the outlet pipes (8).

★ Plug the ends of the pipes to prevent the ingress of
contaminants.
9 - Disconnect the lower by-pass pipe (9) between the
two master cylinders.
10 - Remove pins (10) to detach the pedals (11) from cle-
9 8
vises (12).
11 - Remove screws (13) and the relative washers and then
remove the master cylinders (14).
14
F0000430
REFITTING THE BRAKE MASTER

CYLINDERS
• Refit the master cylinders following the removal op-
1 - Fill the brake fluid reservoirs to the maximum level.
10
2 - Check the positioning of the brake pedals.
(For details, see « ADJUSTMENT AND ALIGNMENT 12
OF BRAKE PEDALS AND MICROSWITCHES»). 11
13
3 - Bleed the air from the hydraulic braking system.
(For details, see « BLEEDING THE BRAKING SYSTEM»).
F0000440
30-46
ADJUSTMENT AND ALIGNMENT OF BRAKE PEDALS AND MICROSWITCHES
ADJUSTMENT AND ALIGNMENT OF BRAKE PEDALS AND

MICROSWITCHES
★ The pedals must be adjusted separately.
1 - Remove the rubber pedal covers and the floor mat.
2 - Check that the pedal (1) is fully raised and that the dis-
tance between the lower edge of the pedal and the m
m
cab floor is as specified. 10
★ Height of lower edge of pedal: 212 mm (8.353 in.)
205 mm
212 mm
D0000030
3 - If the pedal height requires adjustment, loosen locknut

(2) and rotate pushrod (3) to obtain the correct height;
tighten locknut (2) to secure in position.
4
F0000450
4 - Check that the pedal latch pin (4) slides freely to con-
nect the two pedals.
5 - Check that the microswitches closeat a pedal travel of 2 3
10 mm (0.394 in.) corresponding to height of the lower
edge of the pedal of 205 mm (8.077 in.).
6 - If the microswitch does not close in the specified ped-
al travel position, adjust the position of the micro-
switch support bracket (5).
7 - Replace the rubber shrouds (6) ensuring that they are
5 6
correctly located on the master cylinder collars.
F0000460
30-47
BLEEDING THE BRAKING SYSTEM
BLEEDING THE BRAKING SYSTEM
1 - Turn the knob (1) of the braking system dividing valve

(2) to ON (vertical) (braking on rear brakes only).
ON
2
2 - Disconnect the two brake pedals (3) be releasing the
latch pin (4).
1 4 3
F0000470
3 - For tractors with hydraulic or air trailer braking

OFF
★ Bleed the trailer braking valve before bleeding the
service brake system. 2
4 - Bleed the left rear brake.

5 - Bleed the right rear brake.
6 - Turn knob (1) of valve (2) to OFF (horizontal) to select
both front and rear braking.
7 - Bleed the two front brakes in sequence. 1
F0000480
Brake bleeding method

While bleeding the brakes, ensure that the level in the
A
brake fluid reservoir is always above minimum.
★ Remove the dust cap and attach a transparent bleed
tube “ A” to the bleed screw. 5
1 - Fully depress the pedal corresponding the brake to be
bled.
2 - Slowly open the bleed screw (5) and allow the fluid and
air to flow throughout the entire pedal travel.
3 - While holding the pedal fully depressed, tighten the F0000490
bleed screw; release pedal.
4 - Repeat the operation until the fluid flowing from the
bleed screw is entirely free of air bubbles.
5 - Bleed all the remaining brakes in the same way.
★ After bleeding, replace the bleed screw dust caps (5).
30-48
POWER STEERING
TESTING THE POWER STEERING
1. Testing
1 - Remove the supply fitting from one of the steering cyl- A 200 25
0
300
inders (1) and replace it with fitting "B" connected to a 150
350
100
400 bar pressure gauge "A". 50
bar
400
B
0
2 - Start the engine and repeatedly turn the steering

wheel to full lock position to eliminate all the air from
the system.
3 - Force the steering to the full lock position towards the
side on which the pressure gauge "A" is connected 1
and read off the maximum continuous pressure on the
gauge. D0002650
★ Maximum permissible pressure:

150 +5 0 bar (2175.6 +72.5
0 psi)
4 - If the pressure is outside the permissible range, it will 3
be necessary to calibrate the power steering pressure
relief valve). 4
2. Calibration
1 - Remove the power steering unit (2). 5
(For details see « REMOVAL OF THE POWER STEER-
ING UNIT»).
2 - Remove plug (3) and its seal (4).
3 - Insert a hex wrench in the hole and adjust the maxi- F0012580
mum pressure by turning the screw (5).

• To INCREASE the pressure, turn the screw
CLOCKWISE.
• To REDUCE the pressure, turn the screw COUN-
TER-CLOCKWISE.
4 - Replace plug (3), making sure that the seal (4) is cor-
rectly seated.
Plug: 50÷60 Nm (36.9 -- 44.2 lb.ft.)
30-49
POWER STEERING
REMOVAL OF THE POWER STEERING UNIT

SHROUD»).
1
2 - Mark pipes (1) and disconnect them from the power
steering unit (2).
★ Plug the ends of the pipes to prevent the ingress of
contaminants.
1
2
F0000071
3 - Remove screws (3) and the internal spacers and de-

tach the release unit (5) from the pedal support (4).
7
4 - Remove the four screws (6) securing the steering col-
umn assembly (7). 6
4
5
3
F0000540
5 - Remove the steering column-power steering unit as-

sembly (7). 10
6 - Remove screws (8), washers (9) and steering column
(10). 8 9
2
7
F0000550
7 - Remove the rubber vibration dampers (10), spacers

(11), damper housings (12), plate (13) and the rubber 10 13
spacer (14).
14
11
12
F0000560
30-50
POWER STEERING
REFITTING THE POWER STEERING UNIT
• Refit the power steering unit following the removal op-

1
Pipe fittings: 59 Nm (43.5 lb.ft.)
2
★ If the pipe fittings have been undone, fit new seals
and tighten the fittings to a torque of 78.5 -- 88.2
Nm (57.8 -- 65 lb.ft.).
1 - Start the engine and turn the steering wheel in both di-
rections to eliminate air from the power steering sys-
tem.
2 - Check the pipe fittings for leaks.
30-51
POWER STEERING
DISMANTLING THE POWER STEERING UNIT
26
27
28
29
15
31 14
24 18 13
32 "ç
"çb
33 "ça 19
34
35 21
20
22
16
&)a
&)b
12
10
17
"'a
"'b
"' "'a
8 ça
7 6
11
9
2
5 1
D0001200
30-52
POWER STEERING
Dismantling the power steering unit

1 - Loosen and remove the screws (1) and (3) and wash- 3
1 2
ers (2) securing the cover (4) (6 bolts plus 1 special
screw).
F0009470
2 - Remove the cover (4) by sliding it off sideways.

4
F0009480
3 - Lift off the rotor assembly (5) complete with O-rings (6)
and distance piece (7). 5
6 7
F0009490
4 - Remove the shaft (8).
F0009500
30-53
POWER STEERING
5 - Remove the distributor plate (9).
F0009510
6 - Remove the stop bushing (10) of the safety valve.
10
F0009520
7 - Remove the O-ring (11).
11
F0009530
8 - Withdraw the ball (12) of the check valve, the valve

stems (14), the springs (14) and the balls (15) of the
anti-cavitation valves.
15 14
14
12 13
F0009540
30-54
POWER STEERING
9 - Checking through the central hole of the spool valve,

ensure that the pin (16) connecting the inner and outer
sleeves of the spool is positioned horizontally.
Push the entire spool assembly (17) and the bearing
out of the steering unit housing (18).
17
18
F0009550
10 - Remove the outer thrust washer (19), the inner thrust

washer (20) and the needle roller bearing (21) from the
spool; remove also ring (22).
★ The inner thrust washer (20) (thin) can sometimes
remain inside the housing; check that it is re- 22 20
moved.
21
19
F0009560
11 - Remove the trim spin (16), outer sleeve (17b) and the
inner sleeve (17a).
★ Use the special cover bolt (3).
17b
3 16
17a
F0009570
12 - Carefully slide the inner sleeve (17a) out of the outer

sleeve (17b).
17b
17a
F0009580
30-55
POWER STEERING
13 - Push the springs (23) into the neutral position and

withdraw them from the inner sleeve (17a).
23
17a
F0009590
14 - Remove the dust seal (24) and the composite seal (25)
(O-ring + gasket).
25
24
F0009600
15 - Remove the plugs (26) of the anti-shock valve.
26
F0009610
16 - Remove the seals (27).
27
F0009620
30-56
POWER STEERING
17 - Remove the calibration screws (28).
28
F0009630
18 - Remove the springs (29) and the two balls (30).

★ The valve seats are force fit in power steering unit
and cannot be removed.
29
30
F0009640
19 - Check that all the valve parts are present as show in

the photo. 30 29 28 27 26
30 29 28 27 26
F0009650
Removal of the safety valve

20 - Remove the plug (31) and the relative seal.
31
F0009660
30-57
POWER STEERING
21 - Remove the maximum pressure adjustment screw

(33).
33
F0009670
22 - Turn the power steering unit upside down and remove

the spring (34) and valve (35).
★ The valve seat is a force fit in the power steering
housing and cannot be removed.
35
34
F0009680
30-58
POWER STEERING
ASSEMBLY OF THE POWER STEERING UNIT
★ Before assembly, lubricate all components with gear-

box oil.
1 - Insert the two flat springs (23a) and position them cen-
23b
trally relative to the diameter of inner sleeve of the
23a
spool (17a). Insert the four curved springs (23b), ar-
ranged in pairs, between the two flat springs (23a) and
push them in fully.
23b 23a 17a
F0009690
2 - Align the springs (23).
23
F0009700
3 - Insert the inner sleeve (17a) in outer sleeve (17b).

★ Check that the relative positions of the inner and 17b
outer sleeve are as described in stage 1.
17a
F0009580
4 - Simultaneously push the springs (23) and the inner

sleeve (17a) so that the springs locate in the outer
sleeve (17b). 23
17a
17b
F0009710
30-59
POWER STEERING
5 - Align the springs (23) and position them centrally rel-

ative to the diameter of the outer sleeve (17b).
23
17b
F0009720
6 - Fit the ring (22) on to its seating on the outer sleeve

(17b).
★ The ring (22) must rotate freely without interfer-
ence with the springs (23). 22
17b
F0009730
7 - Insert the trim pin (16).
16
F0009740
8 - Fit the thrust bearing parts in the order indicated in the

assembly diagram in point 9.
20
19 21 F0009750
30-60
POWER STEERING
9 - Bearing assembly diagram

17a -Inner sleeve 22
17b -Outer sleeve
21- Needle roller bearing 21
20 -Outer thrust washer 20
22 -Inner thrust washer X
The chamfer "X" of the outer thrust washer
must be oriented towards the shoulder on the 17a
inner sleeve.
17b
D0001180
10 - Position the steering unit (18) so that the central bore is

horizontal.
Insert the guide of tool T30 (code 5.9030.480.0) into
the bore of the inner/outer sleeve assembly.
T30
18
F0009760
11 - Oil the seal (25a) and O-ring (25b) and fit them on the
plunger of tool T30 (code 5.9030.480.0). T30
25a 25b
T30 F0009770
12 - Assemble tool T30 (code 5.9030.480.0) and insert it in

the guide previously inserted in the central bore of the
power steering unit.
25
T30
F0009780
30-61
POWER STEERING
13 - Push the seal (25) into the seating in the power steer-
ing unit (18), turning it slightly to ensure correct posi-
tioning.
18
F0009790
14 - Withdraw the tool T30 (code 5.9030.480.0) and the

guide from the steering unit housing, leaving the seal
installer plunger in place. T30
18
F0009800
15 - Insert the spool assembly (17) in the bore of the power

steering unit (18), turning its slightly to assist insertion.
★ Insert the assembly while keeping the trim pin in a 17
horizontal position.
18
F0009810
16 - Push the spool assembly (17) fully home in order to ex-

pel the seal installer plunger left in the bore in step 14. 18
17
F0009820
30-62
POWER STEERING
17 - Turn over the power steering housing (18) so that the

central bore is vertical.
Insert the ball (12) of the safety valve in the hole indi- 12
cated in the photo.
18
F0009830
18 - Screw the stop bush (10) into the safety valve hole.
★ The top of the bush must be positioned lower than
the face of the steering unit housing (18).
10
18
F0009521
Assembly of the anti-cavitation valve

19 - Insert the balls (15) into the two holes indicated by the
arrows.
15
F0010310
20 - Insert the valve stems (13) complete with springs (14)

into the same holes.
13
14
F0009840
30-63
POWER STEERING
21 - Oil the O-ring (11) and fit it in its seat.

11
O-ring: gearbox oil
F0009850
22 - Position the distributor plate (9) so that its holes are

aligned with those in the power steering housing (18). 9
18
F0009860
23 - Insert the shaft (8) in to the central bore so that en-

gages the trim pin; check that trim pin engagement is
parallel to the face of the power steering unit by which
it is attached to the steering column.
8
F0009870
24 - Position the shaft vertically and hold it in place using

the specific tool.
F0009880
30-64
POWER STEERING
25 - Oil the two O-rings (6) and install them in the two seats
in the rotor assembly (5). 6
O-rings: gearbox oil
8
F0009890
Fit the inner rotor (5a) on the shaft (8) so that the lowest
part between two lobes of the rotor is aligned with the
trim pin groove on the shaft. The rotate the outer rotor
(5) to align the fixing holes.
5a
F0009900
26 - Fit the distance piece (7).

7
F0009910
27 - Fit the cover (4).
F0009920
30-65
POWER STEERING
28 - Insert the special screw (3) complete with washer (2) in

the hole shown in the photo.
F0009930
29 - Insert the six screws (1) with washers (2).

Tighten the screws(1) and (3) in crosswise pattern to a 3
torque of 30±6 Nm (22.1±4.4 lb.ft.). 1 2
F0009471
Assembly of the pressure relief valve

30 - Insert the valve (35).
35
F0009940
31 - Insert the spring (34).
34
F0009950
30-66
POWER STEERING
32 - Fit the pressure adjuster screw (33).

★ Set the maximum operating pressure on a test
bench.
★ Pressure: 150 +0 5 bar (2175.5 +0 72.5 psi)
33
F0009670
33 - Fit plug (31) complete with seal.
Plug: 50±10 Nm (36.8±7.4 lb.ft.)
31
F0009960
34 - Position the dust seal (24) in the power steering unit

housing (18). 24
18
F0009970
35 - Drive the dust seal (24) into its seating using a suitable
drift and a plastic mallet.
F0009980
30-67
POWER STEERING
36 - Close the holes of the hydraulic ports with plastic

plugs to prevent ingress of impurities.
★ Push the plugs in by hand; do not use a mallet.
F0009990
30-68
FRONT WHEELS
REMOVAL OF FRONT WHEELS
On tractors with front suspension, before switching

off the engine and proceeding with the removal of
the front wheels, deactivate the front axle suspen-
sion by pressing the relative pushbutton in the cab.
1 - Apply the parking brake.
For normal front axles

A
2 - Position under the differential case a trolley jack “ A”
with a minimum lifting capacity of 15 tons and maxi-
mum lift height of at least 15 cm (6 in.).
★ Drive safety wedges between the axle and the axle F0013560
carrier.
For suspended front axles

2 - Place under the centre of the carrier a jack "A", with a
minimum lifting capacity of 15 tonnes and with a max-
imum lifting height of at least 15 cm (6 in.)
1
3 - Raise the front end of the tractor sufficiently to elim-
inate flexing of the tyre walls and to lift the wheels by
approximately 2 cm (0.8 in.).
4 - Position two jacks “ B” under the axle; lower the trolley B
jack so that the axle is supported on the jacks with the
wheels off the ground and then remove trolley jack A B F0001300
“ A” .
★ Jack lifting capacity: 2 tonnes minimum.
5 - Slacken off all the wheel nuts (2); remove the wheel
nuts leaving one (for safety) at the top of the wheel.
1 3
6 - While holding the wheel perpendicular, remove the 2
last nut and remove the wheel (3).
7 - Repeat the above operations to remove the other
wheel.
F0009420
FITTING THE FRONT WHEELS

• Fitting is the reverse of removal.
1
Wheel nuts for 2WD: 490 Nm (361 lb.ft.)
Wheel nuts for 4WD: 360 Nm (265.3 lb.ft.)
★ Tighten the wheel nuts gradually in a crosswise se-
quence.
30-69
OVERHAUL OF THE FRONT BRAKES
15
17
14
12
16
13
1
11
6
4
10 9 5
3
8
7
D0001000
30-70
1. Disassembly of the hub units

★ The following descriptions refer to the left-hand side
of the tractor; however, the same procedure also ap-
plies to the right-hand side.
1 - Remove the front wheels.
( For d etai ls, see « REMOVAL OF THE FRONT
WHEELS»). 2
1
2 - Remove bolt (1) and remove breather cover (2).
F0007970
3 - Unscrew and remove the cover (3).

4 - Remove circlip (4).
3
4
F0007980
5 - Using the slide hammer puller T6 (code 5.9030.618.4/

10), remove the bearing cover plate (5).
T6 5 6
F0007990
7 - Remove the retaining nuts (7) and washers of the epi-

cyclic gear unit (8).
1
F0008000
30-71
8 - Position a bracket “ A” attached to a hoist and screw

the two M12x60 service bolts “ B” into the extraction
holes. A
Put the bracket under slight tension and screw in bolts
“ B” alternately until you can remove the epicyclic gear 9
unit (8).
★ Recover O-ring (9). 8
B
F0008010
9 - Undo bolts (10) and remove flange (11).

1
11
10
F0008020
10 - Remove the two friction discs (12) and smooth plate

(13).
2
12
12 13 F0008030
11 - Screw a slide hammer puller into alternate holes of the

piston (14) and remove the piston.
3
14 14
F0008040
30-72
12 - Remove O-rings (16) and (17) from stub axle housing

(15).
15
4
16 17
F0008050
ASSEMBLY OF FRONT BRAKES

• Assemble the front brake units following the disman-
tling operations in reverse order.
1
Bolts: 128 -- 142 Nm (94.4-- 104.7 lb.ft)
2
Locate the smooth plates with lock teeth opposed to
each other.
3
★ Insert the piston by tapping it gently around the cir-
cumference with a soft mallet.
4
★ Stretch the O-ring (16) so that it remains in its seat-
ing.
O-rings: grease
1 - Bleed the braking system.
(For details, see « BLEEDING THE BRAKING SYS-
TEM»).
30-73
EPICYLIC REDUCTION UNITS OF THE FRONT AXLE
DISMANTLING THE EPICYLIC REDUCTION UNITS OF THE FRONT

AXLE
2 1
4 5
7
9
10 1
17
15
16
3
19
11
18
13 14
12
D0000990
30-74
1 - Remove the complete epicyclic gear unit (1).

(For details, see first section of « OVERHAUL OF THE 2
FRONT BRAKES»).
2 - Remove O-ring (2).
★ Check the condition of the O-ring; if it is deformed,
renew it.
1
F0008080
3 - Using a narrow chisel, partially raise the edge of the oil

seal (3) and apply pressure at intervals of approx. 30
mm (1.182 in.) around the outer edge.
Withdraw the oil seal (3) with the aid of a lever.
★ Take care not to damage the sealing surfaces of
3
the oil seal.
1
F0008090
4 - Turn over the unit (1) and remove bolts (4), flange (5)
and, if present, shims (6). 2 5
6
1
F0008100
5 - Support the unit (1) on wooden blocks and, using a

copper mallet, withdraw the planet carrier assembly in
order to release thrust plate (7). 7
★ Tap gently and evenly all around the circumfer-
ence.
3
1
F0008110
30-75
6 - Remove inner thrust plate (7) and ball cage (8).

7
F0008120
7 - Lift up the annulus (9) and place it to one side..
F0008130
8 - Withdraw the planet pins (1) from the planet carrier

(10). T6
★ If necessary, use slide hammer puller slide ham-
mer puller T6 (code 5.9030.618.4/10) screwed into
11 10
the central hole.
F0008140
9 - Withdraw the planet pinions (12) and the relative roller

cages (13).
13
12
F0008150
30-76
10 - Remove the second ball cage (14).
14
F0008160
11 - Only if necessary
Turn over planet carrier (9) and using a punch, remove
the second internal thrust plate (15) from the planet
carrier (9).
★ Tap gently and evenly around the circumference.
10
4
15
F0008170
12 - Remove inner O-ring (16).

★ This O-ring must be renewed at each re-assembly.
16
F0008180
13 - Turn over the planet carrier (9) and, using a drift, re-
move bush (17).
17
10
F0008190
30-77
14 - Remove bearing (18) and circlip (19).
19
F0010030
ASSEMBLY OF THE EPICYCLIC

REDUCTION UNIT
T1
• Assemble the unit following the dismantling opera-
3
1
★ Locate the oil seal (3) and drive it into its seat using
tool T1 (code 5.9030.648.0).
★ Tighten the bolts gradually and alternately.
2
★ Tighten the bolts gradually in a cross-wise pattern. D0002890
3
★ Seat the thrust plate (7) by tapping gently and
evenly around its circumference with a soft mallet.
The final position of the plate is obtained after fit-
ting flange (5) and tightening the bolts gradually
and alternately.
4
★ Fit the thrust plate (15) by tapping it gently and
evenly with a soft mallet.
★ Make sure that the plate is seated tight up against
the planet carrier.
30-78
STUB AXLE HOUSINGS AND FRONT HALFSHAFTS
REMOVAL OF THE STUB AXLE HOUSINGS AND FRONT HALFSHAFTS
37 38 37 STANDARD
39
36
35
31
2
16
17
18
20
19
8 25
9 23
27
10
29
11
32 33 32 30
31
11
22 1
WATER PROOF
7 28
24 21
6
26
15
14
4 12
3 13
D0000980
30-79
★ The description below refers to the left-hand side of

the machine; however, the same procedure also ap-
plies to the right-hand side, with the exception of the 2
operations relative to the steering sensor.
1
1 - Removal of the steering sensor.
(For details, see « REMOVAL OF THE STEERING SEN-
SOR»).
2 - Disconnect braking system pipe (1).
taminants.
3 - Remove the steering sensor cover (2). F0008210
4 - Remove the epicyclic reduction unit.

(For details, see « OVERHAUL OF THE FRONT
BRAKES»).
5 - Remove cotter pin (3) and remove slotted nut (4).
★ Renew the cotter pin at each re-assembly.
4 4
3
F0008410
6 - Using a puller, detach the ball joint (6) from the stub
axle housing (5) and detach steering arm (7). 6
7
5
F0008230
7 - Remove bolt (8) and withdraw the pivot pin (9) of the
steering cylinder (10).
8
8 - Detach the steering cylinder and recover covers (11).
9
11
10
F0008240
30-80
9 - Screw two long eyebolts into the stub axle housing (5)
and attach them to the slings of a hoist; put the slings
under slight tension.
10 - Remove the bolts (12) and washers(13) securing the 5
lower pivot pin (14); insert two screws in the extraction
holes.
12 13
F0008250
11 - Remove the complete pin (14) and spacer (15).
15
14
F0008260
12 - Remove the bolts (16) and washers (17) the upper piv-
ot pin (18); insert two screws in the extraction holes.
18
17 16
F0008270
13 - Remove the upper pin (18) and the spacers (19).

14 - Remove coupling (20).
18
20
19
F0008280
30-81
15 - Remove the stub axle housing (5) complete with the oil
seal (21) of halfshaft (22).
★ Leave halfshaft (22) in position.
5
22
F0008290
16 - Remove the halfshaft oil seal (21) from the stub axle
housing.
★ Renew the oil seal at each re-assembly. 21
★ Note which way round the oil seal is installed.
21
F0008300
17 - Remove the upper (23) and lower (24) oil seals.

23
24
D0002660
18 - Using a puller, withdraw the upper (25) and lower (26)

rings. 25
26
D0002670
30-82
19 - Remove the upper (27) and lower (28) bearings.

20 - Using a bearing puller, remove the outer races of the
lower and upper bearings (27).
27
F0008310

★ Renew this O-ring at each re-assembly. 29
22 - Only if to be renewed
Remove plate (30).
30
29
F0008320
23 - Withdraw the complete halfshaft (22).
22
F0008330
24 - Remove oil seal (31) from the axle housing.

STANDARD WATER PROOF

31 31
F0008340
30-83
Version with waterproof oil seal

26 - Withdraw roller bearing (33).
Remove inner circlip (34).
32 34
33
D0000730
Version with standard oil seal

29 - Withdraw the bushing (36) complete with circlips (37) 35 36 39
and roller bearing (38).
Remove inner circlip (39).
37 37
38
D0000740
30-84
ASSEMBLY OF THE STUB AXLE HOUSINGS AND

FRONT HALFSHAFTS
Version with waterproof oil seal
1 - Locate roller bearing (33), circlip (32) and oil seal (31) in
the axle housing. 1 mm
(0.04 in.)
★ Check the depth of insertion.
34
31 32 33
D0000910
Version with standard oil seal

2 - Locate bushing (36) complete with roller bearing (38)
LOCTITE 601
and circlips (37) in the axle housing. 31 35 36 39
Outside surface of bushing: Loctite 601.
3 - Locate circlip (35) and oil seal (31).
37
37 38
D0000920
4 - Lubrificate the bearing and oil seal and fully insert the
halfshaft (22).
Halfshaft: Gearbox oil.

★ Turn the halfshaft in both directions in order to lo-
cate it in the side gear.
22
F0008330
5 - Only if removed
Apply sealant to surface "C" and fit the plate (30).
Sealant: Loctite 601

30
★ The machined face "B" must be oriented as shown
in the figure.
C 30
★ Allow the sealant to cure for at least 30 minutes. B
90° ± 2°
F0012410
30-85
6 - Locate O-ring (29).

O-ring: Grease.
29
F0008321
7 - Using suitable drifts fit the outer races of bearings (27)

and (28) in the axle housing.
27 28
F0008350
8 - Fit bearings (27) and (28) and, with suitable drifts, up-
per ring (25) and lower ring (26).
Rings (25) and (26): Loctite 601.

27 28
25
F0008360
9 - Fit the upper oil seal (23) and lower oil seal (24).
23
24
D0002660
30-86
10 - Using a suitable drift, install oil seal (21) in the stub axle
housing (5).
★ Take care to install the oil seal the right way round.
★ Check that the oils seal is fully seated in its housing.
21
5
F0008370
11 - Fit the stub axle housing (5) to the axle housing and in-
stall the lower pivot pin (14) complete with a shim (15)
of fixed thickness 0.6 mm.
★ Lubricate the halfshaft in the area around the seat
of oil seal (21).
Halfshaft: Grease.
15
14
F0008260
12 - Secure lower pin (14) with bolts(12) and washers (13).
14 12 13 F0008380
13 - Fit the upper pivot pin (18) and secure it with bolts (16)
and washers (17).
16 17
18
F0013570
30-87
For the right-hand stub axle housing

14 - Remove the central grease nipple of the pivot pin (18)
and fit a screw of the same thread in its place; fully
tighten the screw.
A
For the left-hand stub axle housing
14a- Carry out the above operation on the lower pivot pin
(14).
15 - Tighten the screws, and then check using a spring- 5
type torque wrench "A" (on the central screw) that the 18
torque require to rotate the stub axle housing (5) is 12-
17 Nm (8.8 - 12.5 lb.ft.). 16
★ Tighten the screws (16) evenly and gradually. F0013580
16 - Using a feeler gauge, measure the clearance “ X” be-

tween the flange of the upper pin (18) and the sub axle
18
housing (5).
(Example: 0.8 mm (0.032 in.)
5
F0013590
17 - Form a shim pack (19) of thickness “ X” , rounded down

to nearest 0.05 mm (0.002 in.).
Example (mm): 0.8 -- 0.05 = 0.75
(in.): 0.032 -- 0.002 = 0.030 19
F0013600
18 - Loosen bolts (16), lift the upper pin (18) by a few mil-
limetres, insert shims (19) and tighten bolts (16) to the
specified torque. 19
18
F0013610
30-88
19 - Check that the torque required to rotate the stub axle

housing is within the range of 12 -- 20 Nm (8.8 -- 14.7
lb.ft.).
20 - Remove the temporary screw used for checking the
A
rotation torque and replace the grease nipple.
F0013581
21 - Connect the steering cylinder (10) replacing the cov-

ers (11) and pin (9).
10
11 9
F0008390
22 - Connect the steering arm (7) and tighten the retaining

nut (4) of ball joint (6).
7
Nut: Minimum 160 Nm (118 lb.ft.) 6
★ Check that the slot in the nut coincides with the

hole for the cotter pin.
If the slot and hole are not aligned, further tighten
the nut.
F0008400
23 - Insert cotter pin (3).

★ Always fit a new cotter pin.
24 - Fit the epicyclic reduction unit and the steering sen-
sor.
(For details, see « OVERHAUL OF THE FRONT
BRAKES» and « REMOVAL OF THE STEERING SEN-
SOR»).
TEM»). 3
F0008220
30-89
STEERING SENSOR
REMOVAL OF THE STEERING SENSOR

1 - Remove the mudguard and remove support (1). 1
F0002010
2 - Remove the cover (2) from the protective casing (3).
3
F0002020
3 - Undo the screws and remove the sensor (4).

4 - Unplug connector (5). 4
5
4
F0002030
REFITTING THE STEERING

SENSOR
der.
30-90
STEERING CYLINDERS
REMOVAL OF THE STEERING CYLINDERS
★ The removal procedure described here refers to the

1 2
left cylinder; however, the operations are identical for
the right cylinder.
6
Remove the key from the ignition switch. 3
1 - Disconnect pipes (1) and (2).

★ Plug the ends of the pipes and the open fittings to
prevent entry of contaminants.
2 - Undo bolt (3) to remove the piston pivot pin (4). 7 5
3 - Loosen the nut and unscrew the grubscrew (5) to re- 4
lease the cylinder pivot pin.
F0002040
4 - Withdraw the piston pivot pin (4) by driving it upwar-

dsand the cylinder pivot pin (6) by driving it down-
wards.
5 - Remove the cylinder (7), covers (8) and spacers (9).
REFITTING THE STEERING

CYLINDERS 8
1 - Position the cylinder and connect to the axle by in- 9
serting the cylinder pivot pin (6); secure the pin with
the grubscrew (5) and the nut.
2 - Connect pipes (1) and (2). F0010020
3 - Start the engine and run it at idle sped and slowly turn
the steering wheel in order to centre the piston pivot
pin (4).
Do not insert your fingers in the holes to check
alignment.
4 - Insert pin (5) and secure it with the bolt (3) and the rel-
ative washer.
5 - Turn the steering wheel repeatedly to full lock in both
directions in order to eliminate any air from the sys-
tem; check for leaks.
6 - Stop the engine, check the oil level and top up if nec-
essary.
30-91
FRONT LIFT CYLINDERS AND ROCKERS
REMOVAL OF THE FRONT LIFT CYLINDERS AND ROCKERS
★ These components can only be removed after first re-

moving the link arms of he front 3-point hitch.
1 - Start the engine and raise the front rocker (1) to its
maximum height; support the rocker using suitable
lifting equipment “ A” and stop the engine.
2 - Remove the front lift valve and accumulators and the 1
guard. (For details see « REMOVAL OF THE AN-
TISHOCK VALVE AND ACUMULATORS OF THE
FRONT LIFT»).
A
F0001200
3 - Loosen nuts (2) and unscrew the grub screws (3) se-
curing the piston pivot pins (4). 1
4 - Extract the pins (4) using a drift. 5 2 3
★ before withdrawing the drift, support the cylinders
(5) and rest them on the front carrier.
F0001210
5 - Withdraw the pivot pins (6), lower the rocker and re-
move it.
1 F0001220
6 - Disconnect pipes (7) and (8) from the cylinders (5).

★ Plug the open ends of the pipes and the cylinders
to prevent the entry of contaminants.
8 8
7 7
5 5
F0001230
30-92
FRONT LIFT CYLINDERS AND ROCKERS
7 - Loosen nuts (9) and unscrew the grubscrews (10) se-

curing the cylinder pivot pins (11). 1
8 - Extract the pins (11) using a drift (11).
★ Support the cylinders before withdrawing the drift.
9 10
9 - Withdraw the cylinders (5) and bushes (12).
12
5
REFITTING THE FRONT LIFT
CYLINDERS AND ROCKERS F0001240

der.
1
★ Check that the tips of the grubscrews engage the lo- 11
cations in the shaft.
1 - Start the engine and raise and lower the front lift a
number of times in order to expel any air from the cyl-
inders.
2 - Stop the engine and check the oil level; top up if nec-
essary.
F0001250
30-93
FRONT SUSPENSION SOLENOID VALVES
REMOVAL OF THE FRONT SUSPENSION SOLENOID VALVES
Before stopping the engine, deactivate the front axle

suspension by pressing the relative pushbutton in the
cab.
from the negative battery terminal (--). 1
1 - Discharge the residual system pressure by opening
valve (1) two full turns.
★ Reclose the valve after having discharged the
pressure.
F0010000
2 - Unplug the connectors (2) of the solenoid valves (3).

★ Label the connectors and valves to prevent con-
fusion on reassembly.
2
3
F0002130
3 - Disconnect the five connecting pipes (4).

5
4 - Remove nuts (5) and remove the valve block (6). 6
4
4
F0002140
REFITTING THE FRONT

SUSPENSION SOLENOID VALVES
der.
1 - Start the engine and repeatedly press the pushbutton
to activate and deactivate the front suspension in or-
der to eliminate air from the system and check for
leaks.
essary.
30-94
FRONT SUSPENSION CYLINDERS (when fitted)
REMOVAL OF THE FRONT SUSPENSION CYLINDERS (when fitted)
★ The removal procedure for the left cylinder is de-

scribed; however, the removal operations are the
same also for the right cylinder.
Before turning off the engine, deactivate the front axle
suspension by pressing the pushbutton in the cab. 1
Apply the parking brake.
1 - Discharge the residual system pressure by opening
valve (1) two full turns.
★ Reclose the valve after having discharged the pres-
sure.
F0010000
2 - Disconnect the front propeller shaft.

(For details see « REMOVAL OF THE PROPELLER
SHAFTS»).
3 - Using a hydraulic jack “ A” , raise the front wheelsby
about 10 -- 15 cm (4 -- 6 in.).
★ Minimum jack capacity: 15 tonnes
B
4 - Position a jack “ B” and a non-slip block under the oil
sump pan; lower the tractor.
A
F0002150
5 - Position the jack "A" under the carrier (2) at the front.
★ Ensure that the jack can be lowered through ap-
prox. 10 -- 15 cm (4 -- 6 in.).
F0002160
6 - Disconnect pipes (3) and (4) from the cylinder.

★ Plug the end of the pipes and open fittings to pre-
vent the entry of contaminants. 4
F0002170
30-95
FRONT SUSPENSION CYLINDERS (when fitted)
7 - Remove the centre screw of the piston pivot pin (5)

and remove the pivot pin.
★ Use a suitable drift if necessary.
8 - Lower the jack down to the lower travel limit of the
6
support.
7
9 - Remove the centre screw of the cylinder pivot pin (6),
support the cylinder and remove the pivot pin and the
cylinder (7).
★ Use a suitable drift if necessary.
5
F0002180
REFITTING THE FRONT

SUSPENSION CYLINDERS
der.
1 - Start the engine and activate the front axle suspension
by pressing the relative pushbutton in the cab.
2 - Wait a few seconds, then deactivate the suspension.
3 - Repeat this operation a number of times to eliminate
all the air from the system.
essary.
30-96
DISMANTLING AND ASSEMBLY OF THE STEERING CYLINDERS AND

FRONT SUSPENSION
1. Dismantling of the suspension cylinders, front
lift and steering.
1 - Loosen the rod end ring nut (1) by 5 turns. 1
1
F0009110
2 - Using a soft mallet, tap gently on the ring nut (1) to re-
cess the end cap (2) by approx.3 mm (0.118 in.).
1 2
F0009120
3 - Remove ring nut (1) and remove the circlip (3) securing
the end cap (2).
3
F0009130
4 - Withdraw the complete piston assembly (4).
F0009140
30-97
5 - Loosen and remove the self-locking nut (5) and re-

move the piston (6).
6 - Slide the end cap (2) off the rod (7).
7 2
6
F0009150
7 - Remove outer O-ring (8), rod wiper (9) and rod seal
(10). 8
10 2
D0000800
8 - Remove outer seal (11) and the inner seal (12) from the
piston (6). 11
12
D0000810
2. Assembly of the suspension, front lift and

steering cylinders 8
10 2
1 - Fit rod seal (10) and rod wiper (9) to the end cap (2).
★ Check that seal (10) is installed the right way round.
2 - Fit O-ring (8). 9
D0000800
30-98
3 - Fit a suitable seal installation tool on to the piston (6)

and manually fit piston seal O-ring (12).
4 - Fit the outer piston seal (11) on the installation tool.
12 6
F0009160
5 - Using the elastic installer drive seal (11) into its seat.
11
F0009170
6 - Using the gauge and a suitable support, calibrate the

seal (11) by sliding the gauge over the full length of the
piston (6).
F0009180
7 - Fit end cap (2) and piston (6) to rod (7); secure the pis-
ton (6) with self-locking nut (5).
End cap: Gearbox oil.

7 2
Nut: 80 Nm (59 lb.ft.) 6
F0009150
30-99
8 - Lubricate the piston and end cap seals; insert the rod
assembly into the cylinder taking care not to damage
the seals. 2
Seals: Gearbox oil.
★ Insert the end cap (2) approx. 2 mm (0.08 in.) be-
yond the seat of circlip (3).
F0009190
9 - Fit circlip (3) and tighten ring nut (1).
Ring nut: 100 Nm (74 lb.ft.)

3
F0009130
30-100
FRONT AXLE AND SUPPORT ASSEMBLY (Version with front suspension)
REMOVAL OF THE FRONT AXLE AND SUPPORT ASSEMBLY

Before turning off the engine, deactivate the front axle

suspension by pressing the pushbutton in the cab.
1
Discharge the residual pressure in suspension system
by opening valve (1) by about two turns.
★ Close the valve after having discharged the pres-
sure.
1 - Remove the front wheels.

F0010000
(For details see « REMOVAL OF THE FRONT
WHEELS»).
★Position a jack under the engine oil sump and re-
move the stands.
2 - Disconnect the drive shaft.
(For details see « REMOVAL OF THE PROPELLER
SHAFT»).
3 - Only when fitted
Remove the lower link arms and top link of the front lift;
2
remove the rocker.
(For details see « REMOVAL OF THE FRONT LIFT
ROCKER»).
4 - Unplug the connector (2) of the steering angle sensor. F0002050
5 - Remove cover (3) and oscillation sensor mounting

bracket (4) and place it to one side.
6 - Disconnect the position sensor connector (5).
3 4
1
5 F0002060
7 - Disconnect pipes (6) of the steering cylinders (7); plug

the ends of the pipes and open fittings on the cylinders 6
to prevent the entry of contaminants.
★ Clearly label the pipes to avoid confusion on re-
assembly.
2
7
F0002070
30-101
8 - Disconnect the pipes (8) of the braking system and the

differential lock; plug the ends of all the pipes and the 9
open fittings to prevent the entry of contaminants.
9 - Remove the bracket (9) supporting the pipes of the
braking system and differential lock.
3
8
F0002080
10 - Disconnect the pipes (11) of the suspension cylinders

10
(12) from the rigid pipes (10).
contaminants. 11
2
12
F0002090
11 - Position a safety jack “ A” under the rear part of the

swinging axle support. 13
12 - Using a jack and wooden blocks, support the axle and
remove the pivot pins (13) of the support (14).
★ Keep the axle suspension points apart in order to
facilitate the subsequent removal operation.
14
F0002100
13 - Remove the mounting pins(15) of the pistons (12).

15
12
F0002110
30-102
14 - Remove the safety jack “ A” , lower the axle support as-

sembly and remove it. Rest the axle support (14) on a
flat surface.
15 - Undo bolts (17) and remove the cardan shaft (18).
17
18 14 16
F0002120
16 - Undo and remove nuts (19), spring washers (20) and

shoulders (21).
19
20
21
F0009081
17 - Remove the axle (16) complete with swinging suppor-

ts (22).
REFITTING THE FRONT AXLE AND

22
SUPPORT ASSEMBLY
der.
1 - Start the engine and check the seals.
1
★ Check the position of the position sensor. (For de- F0010010
tails, see « POSITIONING THE FRONT SUSPEN-

SION POSITION SENSOR»)
2
★ Bleed the air from the steering system and front
suspension circuits by repeatedly turning the
steering wheel to the full lock positions and acti-
vating and deactivating the suspension.
3
★ Bleed the braking system. (For details, see
« BLEEDING THE BRAKING SYSTEM»).
30-103
FRONT SUSPENSION POSITION SENSOR
POSITIONING THE FRONT SUSPENSION POSITION SENSOR
1. Positioning the sensor

1 - Start the engine. Fully extend the front suspension cyl-
inders and fit the sensor (1) on bracket (2).
2 - Push the sensor (1) in direction "X" until the sensor tip
(3) is fully retracted.
2
4 1
5
F0013620
3 - While holding the sensor tip in position, screw nuts (4)

and (5) up to the bracket to secure the sensor.
3 4 5 1 2
4 - Back off nut (4) by one full turn and tighten nut (5) to
lock the sensor (1) in position.
★ This prevents the possibility of impact as the sen-
sor tip reaches the end of its stroke.
Nuts: 30±6 Nm (22.1±4.4 lb.ft.).
D0002920
2. Testing the sensor

1 - Connect the lead T9 (code 5.9030.860.0) between the
sensor (1) and the wiring (6); using a multimeter, test
the voltage when the cylinders are fully extended and
fully retracted.
1 T9 6
★ Voltage with cylinders fully extended = 6V
Voltage with cylinders fully retracted =2V
2 - Stop the engine, disconnect lead T9 (code
5.9030.860.0) and connect the wiring to the sensor.
3 - Refit the sensor cover
F0013630
30-104
FRONT AXLE DIFFERENTIAL
DISMANTLING THE FRONT AXLE DIFFERENTIAL
9
10
4
11
2
1
11
14
13 15
17 8
19 34 35
36
23
31 32
12 21
33 37
25
24 22 20
29
26
28 27
30
16
18
D0000970
30-105
41 42
49
44 45 48
46
50
51
39
43 47
48
49 40
38
39
62
55
61
61
58
63
60
60 59
39
56
53 52
64
57
54
65 66
D0000960
30-106
1. Dismantling the unit

1 - Remove the stub axle housing and the halfshafts from
the front axle. 1
(For details, see «REMOVAL OF STUB AXLE HOU-
SINGS AND FRONT HALFSHAFTS»).
2 - Remove the front axle.
(For details, see «REMOVAL OF THE FRONT AXLE»).
3 - Remove the front support (1) complete with oil seal (2)
from the front axle.
★ Check the condition of the oil seal: if damaged or if 2
the seal lips have lost their elasticity, the seal must F0008420
be renewed.
4 - 4 -Support the axle on two stands so that axle may be
rotated about the wheel axis.
5 - For front suspension versions only

Remove the propeller shaft flange (3). 3
4
6 - Remove the complete rear support (4) and thrust plate
(5).
F0008430
7 - Remove the pipe guard (6) and disconnect the differ-

ential lock pipe (7).
taminants.
F0008440
8 - Relieve the staking on the tabs of ring nut (8).
F0008450
30-107
9 - With a pin wrench and special wrench T3 (code

5.9030.861.0), slacken off ring nut (8) by a few turns.
★ Do not remove the ring nut at this stage. T3
F0008460
10 - Remove the nuts (9) and washers (10) securing the

crown wheel-bevel pinion assembly (11).
11 9 10
F0008470
11 - Screw an eyebolt into the central hole of the pinion

shaft (12) and attach the eyebolt to a hoist.
12
12 - Withdraw the crown wheel-pinion assembly from the
axle (11).
11
13
F0008480
13 - Remove bolts (13) and remove the flange (14) and spa-
cers (15) from the crown wheel side.
14
15
F0008490
30-108
14 - Mark the relative positions of the bracket (16) and car-

rier (17); remove bolts (18) and remove bracket (16).
17
18
16
F0008500
15 - Insert the jaws of a puller “ A” in the recesses provided

in carrier (17) and remove bearing (19).
A
19
17
F0008510
16 - Turn the unit over and remove circlip (20) and thrust
washer (21).
20 21
F0008520
17 - Remove bearing (22).
22
F0008530
30-109
18 - Remove bolts (23) and remove the complete flange

(24) and spacers (25).
24
25
F0008540
19 - Screw a slide hammer puller into plug (26); withdraw

plug (26) complete with O-rings (27), (28) and (29). 27
★ Check the condition of the O-rings; if deformed,
they must be renewed.
28
26
29
F0008550
20 - Withdraw the complete differential unit (30) from the

carrier (17). 17
30
F0008560
2. Removal of the bevel pinion

1 - Remove the previously loosened ring nut (8). 8
★ The ring nut must be renewed at each re-assembly.
F0008570
30-110
2 - Position the carrier (17) in a press and withdraw the

pinion shaft (12) complete with inner bearing (31), 12
spacer (32) and shims (33).
17
F0008580
3 - Remove spacer (34) and oil seal (35) from the carrier
(17).
34 35
★ Take care not to damage the oil seal bore in the
process.
★ Make a note of which way round the oil seal is in-
stalled.
17
F0008590
4 - Remove outer bearing (36).
36
17
F0008600
5 - Using a bearing separator, remove the inner bearing

(31) from the pinion shaft (12).
12
31
F0008610
30-111
6 - Using a punch, drive the outer races of bearings (31)

and (36) out of the carrier (17). 17 17
★ Recover the shims (37) located under the outer
race of bearing (31).
F0008620
7 - Record the thickness of the shims (37).

Example: Shim pack = 1.9 mm (0.075 in.).
★ This thickness will be required to calculate the
thickness of the shim pack to be installed under the 37
outer race of bearing (31) for the new pinion.
F0007262
3. Dismantling the differential

38
1 - Remove circlip (38). 39
2 - Remove the complete differential lock unit (39).
F0008630
3 - Remove bearing (40).
40
F0008640
30-112
4 - Turn the differential unit over.

Remove bolts (41) and remove the crown wheel (42)
from the differential housing (43). 42
41
43
F0008650
5 - Remove thrust plate (44) and side gear (45).

44
45
F0008660
6 - With a pin punch, remove spring pin (46).
46
F0008670
7 - Withdraw cross-pin (47), first planet pinion (48), thrust

plate (49), second planet pinion (48) and thrust washer 49
(49).
48
48
49
47
F0008680
30-113
8 - Remove the second side gear (50) and thrust washer

(51).
50
51
F0008690
9 - With a punch, remove the outer races of bearings (19)

and (22) from flanges (14) and (24).
19 22 14 24
F0008700
4. Dismantling the differential lock unit (39)

1 - Remove the complete cylinder assembly (52) and re-
move thrust washer (53).
52
2 - Remove the thrust roller bearing (54). 54
39
53
F0008710
3 - While maintaining manual pressure on the clutch pack

(55), remove circlip (56).
4 - Release the pressure and remove plate (57), spring 58
guide (58) and spring (59).
★ Make a note of which way round the plate (57) is in- 56
stalled. 57
59
55 F0008720
30-114
5 - Remove the six friction plates (60) and the five inter-
mediate smooth plates (61).
★ If the clutch pack is not be renewed, remove it with-
out altering the order of the plates.
60 62
6 - Remove the final smooth plate (63) from the hub (62).
★ Note that this final plate is thicker than the others. 63
61
F0008730
★ Make reference marks to indicate the relative posi-

tions of the cylinder (52) and the piston (64).
7 - Direct compressed air into the cylinder (52) to expel
the piston (64).
64
52
F0013100
8 - Remove O-rings (65) and (66).

★ These O-rings must be renewed at each re-assembly.
64
66
65
F0013640
30-115
ASSEMBLY OF FRONT AXLE DIFFERENTIAL
1. Assembly of the differential lock unit

1 - Fit O-rings (65) and (66) to piston (64).
O-rings: Grease.
2 - Fit piston (64) in cylinder (52). 64
★ Lubricate the chamber surfaces.
★ Align the reference marks made previously during
dismantling.
Surfaces: Grease 66
65
F0013640
3 - Fit the final smooth plate (63) to hub (62).

4 - Fit the friction plates (60) and intermediate smooth
plates (61).
★ Lubricate the friction plates. 62 60
Friction plates: Gearbox oil. 63
61
F0008740
5 - Locate spring (59), spring guide (58) and plate (57).

★ Check that plate (57) is installed the right way
round. 58
6 - Compress spring (59) and fit circlip (56).
56
57
59
F0008750
7 - Locate thrust bearing (54) and thrust washer (53).
Bearing: Gearbox oil.

8 - Fit the complete cylinder assembly (52) on the clutch 52
unit. 54
53
F0008760
30-116
2. Assembly of the differential

1 - Fit thrust washer (51) and side gear (50) in the differ- 50
ential housing (43).
Thrust washer: Gearbox oil.

51
43
F0008691
2 - Insert cross-pin (47) and fit thrust washer (49), planet

pinion (48), second planet pinion (48) and thrust washer
49
(49).
48
Thrust washers: Gearbox oil. 48
49
47
F0008770
3 - Fully insert cross-pin (47) and secure with spring pin

(46).
46
47
F0008671
4 - Fit side gear (45) and thrust washer (44). 44

Thrust washer: Gearbox oil.
45
F0008660
30-117
5 - Fit crown wheel (42) to differential housing (43) and se-

cure it with bolts (41).
Bolts: Loctite 242
41
Bolts: 126 -- 140 Nm (92.8 -- 139.2 lb.ft.)
43
42
F0008780
6 - Turn over the differential unit (30) and locate the dif-
ferential lock assembly (39).
39
30
F0008790
3. Assembly and adjustment pinion

1 - Heat inner bearing (31) to approx. 80° C (176 ° F) and fit
it to pinion shaft (12).
★ Make sure that the bearing is seated against the 31
pinion shoulder.
12
F0008800
2 - Calculate thickness “ S” to be added or subtracted

from the original shim pack installed under the outer PINION REMOVED PINION TO BE FITTED
race of bearing (31). +0
,15 -- 0
,20
Thickness “ S” is obtained by subtracting the value
stamped on the tooth new pinion (12) from that of the
original pinion.
Example 1: S=+ 0,15 --(--0,20 )=+0,35 mm
S=+0.006 --(--0.008 )=+0.014 in.
--0
,20 +
0,1
5
Example 2: S=--0,20 --(+0,15 )= -- 0,35 mm

S= --0.006 --(+0.008 )=--0.014 in. D0000221
30-118
3 - To the thickness of the original shim pack, measured

during dismantling (Example: 1.9 mm (0.075 in.)), add
the thickness 0.35 mm (0.014 in.) if the result is pos- 37
itive (Example 1); or subtract 0.35 mm (0.014 in.) if the
result is negative (Example 2).
The value thus obtained is the final thickness of the
shim pack (37).
D0000770
4 - Insert a shim pack (37) of the calculated thickness in

carrier (17) and, using a drift, install the outer race of
bearing (31).
★ Make sure that shim pack (37) and the bearing race
(31) are correctly seated against the shoulder in the 37
17
carrier (17).
31
F0008810
5 - Insert the outer race of bearing (36) in the carrier (17).

★ Make sure that the outer race of bearing (36) is cor-
rectly seated in the carrier (17).
36
17
F0008820
6 - Fit the pinion shaft (12) complete with inner bearing

(31) in carrier (17), fit spacer (32) and service spacer T5
(code 5.9030.863.0) (2±0.01 mm (0.0788±0.0004 in.)). 17
12
31 32 T5
D0000771
30-119
7 - Heat the outer bearing (36) to approx. 80° C (176 ° F)

and fit it to the pinion shaft (12).
★ Lubricate the bearing when it has cooled. 36
12
F0008830
8 - Fit spacer (34) and a new ring nut (8).
34 8
F0008840
9 - Using a pin wrench and special wrench T3 (code

5.9030.861.0), tighten ring nut (8).
Ring nut: 250 -- 280 Nm (184.3 -- 206.4 lb.ft.)

T3
10 - Rotate the pinion several times in both directions to
help seat the bearings. 8
F0008850
11 Position a dial gauge with magnetic stand “ C” as

shown, with the contact point resting on the end face
of the pinion shaft (12).
Preload the dial gauge by approx. 2 mm (0.0788) and
then zero set it. 12
C
12 Use a lever to move the pinion shaft and measure the
end float.
★ Make a note of the end float
(Example 1.23 mm (0.0484 in.)).
F0008860
30-120
13 Calculate the final shim pack thickness (33) by sub-

tracting the measured end float from the service shim
thickness (2 mm (0.0788 in.)) rounding the value ob-
tained up to the nearest 0.05 mm. 33
Example: (mm):2.00 -- 1.23 = 0.77
rounded up to 0.80
(in.): 0.0788 -- 0.0484= 0.0304
rounded up to 0.0315 in.
F0007263
14 Remove service shim T3 (code. 5.9030.861.0), fit the

calculated shim pack (33) and finally tighten ring nut
(8).
Ring nut: 250 -- 280 Nm (184.3 -- 206.4 lb.ft.) T3
F0008851
15 - Using tool T4 (code 5.9030.862.0), install the oil seal

STANDARD
(35) in the support (17).
★ Check that the seal is installed the right way round.
WATER PROOF
35 T4
17
F0012400
4. Final assembly
1 - Using suitable drifts fit the outer races of bearings (19)
and (22) in flanges (14) and (24).
14 24
★ Take care to insert the bearing races the right way
round. 19
22
D0000780
30-121
2 - Fit flange (24), bearing (22) and circlip (20) to the dif-
ferential lock unit. X
3 - Using a U-shaper adapter resting on the flange, insert

the clutch pack and, with a feeler gauge, measure the
clearance “ X” between circlip (20) and bearing (22). 20
24
22
F0008870
4 - From the available shims, choose a shim (21) of the

next thickness down from the measured clearance.
Example: Unit of measurement mm (in)

Measured distance “X” Thickness to be used
21
5.2 mm (0.205 in.) 5.0 mm (0.197 in.)
5.8 mm (0.229 in.) 5.5 mm (0.217 in.)
D0002520
5 - Remove circlip (20), bearing (22) and flange (24).

6 - Fit bearing (40) in differential housing (43).
40
43
F0008641
7 - Fit the differential lock unit (39). 38

8 - Fit circlip (38).
39
F0008880
30-122
9 - Fit the differential unit (30) in carrier (17).

17
30
F0008560
10 - Heat bearing (19) to approx. 80 ° C (176° F) and fit it to

crown wheel (42).
★ Make sure that the bearing is seated correctly. 19
42
F0008890
11 - Provisionally fit flange (14) on the crown wheel side

and secure it with bolts (13). 14
Bolts: 30 Nm (22.1 lb.ft.)
★ Do not fit shims at this stage.
F0008900
12 - Fit bracket (16) to carrier (17) and secure with bolts

(18).
★ Make sure that assembly marks are aligned. 17
16
F0008910
30-123
13 - Insert plug (26) complete with O-rings (27), (28) and

(29). 27
O-rings: Gearbox oil.
★ Insert the fitting flush with the flange face. 28
26
29
F0008550
14 - Fit a temporary shim pack "A" of thickness 2.2 mm

(0.0867 in.) and the flange (24) on the side opposite to
the crown wheel.
15 - Provisionally tighten down the flange with bolts (23). 24
F0008541
16 - Fit bearing (22).
22
F0008530
17 - Install the shim thickness (21) calculated in step 4.

21 20
F0008920
30-124
19 - Position the dial gauge with magnetic stand “ C” as

shown, with the contact point on the hub of the dif-
ferential.
C
Preload the gauge by approx. 3 mm and zeroset it.
20 - Apply a lever under the crown wheel (17) to measure
the end float.
★ Record the end float.
Example: end float = 0.67 mm (0.0264 in.)
17
F0008930
21 - Calculate the total shim thickness to be installed un-

der the flanges (14) and (24) by subtracting the mea-
sured end float from the initial thickness 2.2 mm Example (mm): 2.2 -- 0.67 = 1.53
(0.0867 in.). (in.): 0.0867 -- 0.0264 = 0.0603
22 - From this value subtract 0 --0.04 mm (0 --0.002 in.) and

round the resulting value down to the nearest 0.05 mm
(0.002 in.). Example (mm): 1.53 -- 0.03 = 1,50
(in): 0.0603 -- 0.002 =0.0601
23 - Divide the calculated thickness into two equal packs

and install the packs under flanges (14) and (24). 23 24
Tighten down the flanges using bolts (13) and (23) and
a torque wrench.
Bolts: Loctite 242
Bolts: 39 -- 43 Nm (28.7 -- 31.7 lb.ft.)
13 14
F0013650
24 - Position a dial gauge with magnetic stand “ C” and po-

sition the contact point perpendicular to the side of
crown wheel teeth on the outside diameter.
Preload the dial gauge by approx. 4 mm and measure
the backlash “ Z” between the pinion and crown wheel
by turning the differential in both directions (30)
C
★ Normal backlash “ Z” : 0.18 -- 0.24 mm
(0.007 -- 0.009 in.) 30
★ Calculate the average of four readings taken at 90°
intervals.
F0008940
30-125
25 - If the backlash “ Z” is less than 0.18 mm (0.007 in.),

take one of the shims (15) from under the crown wheel
side flange (14) and install it under the flange (24) on
the opposite side.
If the backlash “ Z” is greater than 0.24 mm (0.009 in.) 25 15 14
take one of the shims (25) from under the flange (24) on 24
the opposite side to the crown wheel and install it un-
der flange (14).
D0000790
26 - Recheck backlash “ Z” .
★ If necessary, repeat the shim transfer procedure
until the backlash is within the permitted range.
30
F0008940
27 - Check the measurement stamped on the teeth of the

installed pinion (12) and add it (if positive) or subtract it
(if negative) to the theoretical value of 2.75 mm (0.108
in.) to obtain the value “ Y” . +0 -- 0
,10 ,15
Example 1: Example 2:
(mm) 2.75+0.10=2.85=Y (mm) 2.75--0.15=2.60=Y
(in.) 0.108 + 0.004 =0.112=Y (in.) 0.108 -- 0.006=0.102=Y
D0000241
28 - Using a feeler gauge, check that the clearance be-

tween the differential housing (43) and the end face of
the pinion (12) corresponds to the calculated value “ Y” 12
±0.10 mm (±0.004 in.).
43
F0008950
30-126
29 - Stake the ring nut (8) on the pinion shaft (12).
12
8
F0008451
5. Installing the unit on the axle

1 - Check that the mating surfaces of the differential unit
(11) and the axle housing are free from indentations.
2 - Apply sealant to the mating surface of the axle housing 11
(67).
Sealant: Silastic 738.

★ Make sure that the sealant forms a continuous film 67
around the studs.
F0008481
3 - Fit the differential (11) and tighten it down with nuts (9)
and washers (10).
★ Tighten the nuts evenly in a cross-wise pattern.
11
9 10
F0008960
4 - Connect the differential lock pipe (7).

5 - Fit the pipe guard (6).
F0008440
30-127
6 - Fit thrust plate (5) and rear support (4).

7 - For versions with front suspension only.
Fit the propeller shaft mounting flange (3) and secure it 70
3
with washer (68), spring washer (69) and bolt (70). 69
4
Bolt: Loctite 242.
68
Bolt: 48 -- 53 Nm (35.4 -- 39 lb.ft.)
5
F0008970
8 - Fit the front support (1) complete with oil seal (2) to the
axle (67).
9 - Screw the grease nipple into the front support (1). 1
67 2
F0008421
10 - Fit the axle and lubricate it.

(For details, see « REFITTING THE FRONT AXLE»).
11 - Fit the halfshafts and stub axle housings.
(For details, see « REMOVAL OF THE STUB AXLE
HOUSINGS AND THE FRONT HALFSHAFTS»).
(For details, see « BLEED THE BRAKING SYSTEM»).
30-128
FRONT AXLE SUPPORT BUSHINGS
RENEWAL OF FRONT AXLE SUPPORT BUSHINGS
1 - Remove the front axle.

(For details, see « REMOVAL OF THE FRONT AXLE»).
1
2 - Remove grease nipple (1) from the front support (2). 4 2
3 - Remove front support (1) and oil seal (4) from the axle.
★ Check the condition of the oil seal; if it is damaged
or if the seal lips have lost their elasticity, the seal
must be renewed.
3
F0008422
4 - For versions with front suspension only.

Remove bolt (5), washer (6) and spring washer (7) and
remove propeller shaft mounting flange (8).
5
5 - Remove the rear support (9) from the axle (3).
9
8
3
6 7
F0008431

★ This O-ring must be renewed at each re-assembly.
10
F0009020
7 - Using a narrow-bladed chisel, bend inwards a lip of

the bushing (11) of the front support (1).
With pliers, continue bending the lip inwards until the
bushing can be withdrawn.
11
F0009030
30-129
FRONT AXLE SUPPORT BUSHINGS
8 - Using a punch, remove bushing (12) from the rear sup-

port (9).
★ Use the drift all around the circumference, taking
great care not to damage the bore.
12
9
F0009040
INSTALLING FRONT AXLE 45°

SUPPORT BUSHINGS
1 - Lubricate the bore of the front support (1) and using a
suitable drift, install the bushing(11).
Bore: grease.
★ Locate the cut in the bushing at 45° from the top
position.
1 11
F0009050
2 - Lubricate the bore of the rear support (9) and, using a

suitable drift and a press, install bushing (12).
Bore: grease.
★ Poisition the bushing so that the lube hole is 12
aligned with the hole of the grease nipple.
9
★ After installing the bushing, check the internal di-
ameter.
★ If necessary, carry out surface grinding of the pivot
pin and ream the bushing.
3 - Fit O-ring (10) in rear support (9).
F0009060
10
F0009020
30-130
ADJUSTING END FLOAT OF FRONT AXLE MOUNTINGS
1 - On the rear side of the axle (1), fit thrust plate (2) and
support (3). 4
5
2 - On the front side of the axle (1), fit O-ring (4) and sup- 3
port (5).
1 2 1
F0009070
3 - Fit the axle assembly on the tractor and secure it with

washers (6), spring washers (7) and nuts (8).
★ For versions with front suspension 8
Install the axle on the swinging support.
9
6
F0009080
4 - Loosen by half a turn the retaining nuts (10) of the front

pin (11) and remove the existing shims (12). 1
10
12
11
F0009090
5 - Insert a lever between the front pin (11) and the axle
housing (1) to force the axle against the rear support
5 1
and front pin (11) against front support (5).
11
F0009100
30-131
6 - Measure the clearance between the front pin (11) and

the axle housing (1).
11
F0012590
7 - Insert shims (12) between the axle housing (1) and

front pin (11) to reduce the end float to within the per- 1
10
missible limits. 12
★ End float: 0.1 -- 0.4 mm (0.004 -- 0.016 in.).
★ Position the shims on both sides.
8 - Tighten down the front pin (11).
11
F0009090
30-132
FRONT CARRIER (Version with front suspension)
REMOVAL OF THE FRONT CARRIER

Before stopping the engine, deactivate the front axle

suspension by pressing the relative pushbutton in the
cab.
Remove the battery cover and disconnect the lead 2
1 - Remove the radiator.
(For details see « REMOVAL OF THE RADIATOR»).
2 - Remove the front axle and carrier. (For details, see
« REMOVAL OF THE FRONT AXLE AND SWINGING
SUPPORT»). 1
3 - Disconnect the support bracket (1) for the steering F0002190
pipes (2).
4 - Remove the front lift cylinders.
(For details see « REMOVAL OF THE FRONT LIFT 5
CYLINDERS»).
3
5 - Disconnect the front suspension cylinder pipes (4)
from the rigid pipes (3).
★ Plug the ends of the pipes to prevent entry of im-
purities.
4
6 - Remove the pipe retaining bracket (5).
9
F0002200
7 - Remove the retaining bolts (6) of the counterframes

(7).
1
★ Recover and record the position of the shims;
keep left- and right-hand shims separate. 6
F0002071
8 - Connect a hoist to two lifting eyebolts screwed into

the front carrier (8) and put the slings under slight ten-
8
sion.
9 - Fully retract the front suspension cylinders (9); secure
the cylinders in this position with wire or straps.
9
F0002210
30-133
10 - Slightly loosen all the carrier retaining bolts (10) and

nuts (11); remove the six lower bolts and the two low-
er nuts. 2
★ For safety purposes, do not remove the two upper
nuts (11) yet.
11 - Remove the two upper nuts (11) and move the front
carrier (8) towards the front of the tractor.
★ Recover and record the positions of the shims in-
11 11
stalled between the engine sump and the carrier;
keep the left- and right-hand shims separate.
3 10 10
F0002220
12 - Remove the carrier and rest it on non-slip blocks ap-

prox. 10 cm of thick.
F0002230
30-134
REFITTING THE FRONT CARRIER

der.
1
★ If a new engine is to be fitted or if the original shims
have been lost or mixed up, install new shims as fol-
lows:
1 - Fit the counterframes, securing them at the rear
end only.
2 - Check the distance between the right and left
counterframe and the front carrier.
3 - Install shims to obtain a clearance of less than 0.2 MAX 0,2 mm
mm. D0000160
4 - Bolt the counterframes to the carrier. Normal front carrier
Bolt: 228 -- 252 Nm (168 -- 186 lb.ft.)
2 2
★ Tighten the nuts and bolts in the following se-
quence:
Sequence 1: 285 -- 315 Nm (210 -- 232 lb.ft.)
Sequence 2: 285 -- 315 Nm (210 -- 232 lb.ft.)
Sequence 3: 228 -- 252 Nm (168 -- 186 lb.ft.)

1 1
D0000660
Front carrier for suspended front axle
1 1
3
★ If the original shims have been lost or mixed up, fit new D0000670
shims as follows:
1 - Before fitting the front carrier, place a straightedge
across the face of the engine block, and using a
feeler gauge, measure the distance between this
face and the face of the sump.
2 - Prepare a shim pack to obtain a maximum align-
ment error of ± 0.1 mm (0.004 in.).
3 - Tighten the carrier bolts in an alternate sequence.
1 - Start the engine and check the seals for leaks; bleed
the air from the steering, suspension and braking sys-
tem by repeatedly turning the steering to full lock and
activating and deactivating the front suspension. MAX ⫾ 0,1 mm
D0000170
30-135
FRONT PTO
REMOVAL OF THE FRONT PTO
1 - For tractors with front lifts only.

Before switching off the engine, remove the ballast (if
present) and fully lower the lift rocker. 1
2 - Remove the condenser cooling fans.
(For details, see « REMOVAL OF THE CONDENSER
COOLING FANS».
3 - Remove the condenser assembly. 2
(For details, see « REMOVAL OF THE CONDENSER 3
ASSEMBLY».
★ Also unplug the connector of the PTO solenoid valve.
F0007380
4 - Remove the top link mounting plate (1), PTO shield (2) 6 4
and PTO shaft cover (3).
5 - Disconnect pipe (6) from valve (4) and accumulator (5).
5
6 - Disconnect pipe (8) from accumulator (7).
7 - Disconnect PTO pipes (9), (10), (11) and (12). 10
contaminants. 8
7 9
12
11 F0007390
8 - Remove the PTO oil cooler assembly.
F0007400
9 - Remove cover (13) complete with accumulators (5)

and (7), after having removed the cable entry fitting
(14) and routed connector (15) under the cover. 5 7
13 14 15
F0007410
30-136
FRONT PTO
10 - Move the gearbox oil cooler outwards (16).

11 - Remove the support brackets (17) of cover (13).
16
17
17
F0007420
12 - Remove bolt (18) and lock washer of the propeller

shaft (19). 18
Move the propeller shaft (19) forwards to disengage it 19
from flange (21).
F0007430
13 - Remove bolts (20) and flange (21).

WARNING. If coupling (22) is not to be renewed, leave
it in position.
20
14 - Withdraw the propeller shaft (19). 21
22
F0007440
15 - By tightening two nuts against each other, remove the

PTO mounting studs (23).
23
24
F0007450
30-137
FRONT PTO
16 - Partially raise the PTO assembly (24) and fit two eye-
bolts with nuts. 24
Attach the eyebolts to a hoist and remove the PTO
(24).
★ Take care not to damage the radiator.
F0007460
REFITTING THE FRONT PTO

• Refit the PTO following the removal operations in re-
verse order.
1 - Fill the unit with oil.
2 - Start the engine and engage/disengage the front PTO
a few times in order to expel any air from the control
circuit.
3 - Raise and lower the front lift to its full height a few
times in order to expel any air from the front lift circuit.
30-138
FRONT PTO
DISMANTLING THE FRONT PTO
12
13
22
23 41
28
40
24
20 77
42 78
6 14
39
43 7 79
15 5
16
27 4
26
1
3
2
25
21
19
10
18
8 17
11
9
D0000940
30-139
FRONT PTO
28
33
38
35 36
24 29
47
44
45
48
46 37
32 34
30
31
46B
46A
24
52
51
54
50
75 73
74 59 64
49
60 53
57 62 55
71
69 75
70 68
67 66
63 61
76
58 65
56
D0000950
30-140
FRONT PTO
1. Dismantling
3
1 - Remove bolts (1) and washers (2); remove the com-
plete cover (3).
F0007470
2 - Remove bolts (4) and remove solenoid valve (5).

3 - Using a service screw, withdraw extensions (6) com-
plete with O-rings (7).
F0007480
4 - Remove nuts (8) and washers (9); remove the com-

plete cover (10).
5 - Remove oil seal (11).
10
★ Note which way round seal (11) is fitted.
11
F0007490
6 - Undo and remove bolt (12) of input shaft (13).

7 - Lift oil seal (14).
NOTE. This oil seal must be renewed at each re-as-
sembly. 13
14
12
F0007500
30-141
FRONT PTO
8 - Withdraw the complete input shaft (13).
13
F0007510
9 - With a lever, dislodge shaft (15) complete with outer

bearing (16).
10 - Withdraw shaft (15).
15
16
15
F0007520
11 - Withdraw the PTO shaft (17) complete with bearing

(18).
★ Use a copper mallet if necessary.
17
F0010210
12 - Withdraw gear (19).

19 20
13 - Withdraw bearings (20) and (21).
★ Note the shoulder on the inner race of bearings (21)
is oriented towards the output side of the PTO
shaft.
21
F0007530
30-142
FRONT PTO
14 - Undo and remove nut (22) complete with gasket (23) to

release the clutch assembly (24). 24
23
22
F0008060
15 - Withdraw the complete clutch assembly (24) from the

PTO housing (25).
25
24
F0007550
16 - Remove plug (26). 1

17 - Withdraw the mesh filter (27).
26
27
F0007560
18 - Withdraw the complete pump unit (28).
28
F0007570
30-143
FRONT PTO
2. Dismantling the pump unit (28)

29
1 - Remove bolts (29) and remove suction pipe (30). 29
NOTE. Recover and check the condition of the O-
rings (31) and (32) from the suction flange and the
mesh filter.
30
32 31
30
F0007580
2 - Mark the relative positions of the pump housing (33)

and the cover (34).
Remove bolts (35) and washers (36) and remove the 34
pump cover (34).
35 36
34
33 F0007590
3 - Remove gears (37) and (38).
37
38
33
F0007600
3. Dismantling the input shaft (13)

2 - Only if necessary. Remove circlip (40).
3 - Using a puller, remove bearing (41).
41
39
40
F0007610
30-144
FRONT PTO
4 - Withdraw the oil seal (14).

NOTE. 1- Note which way round the oil seal is installed.
2- The oil seal must be renewed on each re-as-
sembly of the input shaft.
14
F0007620
4. Dismantling the PTO shaft (17)

1 - Put the shaft (17) in a press and withdraw the inner
race of roller bearing (18)
17
18
F0007630
5. Dismantling the PTO drive shaft

(15)
1 - Using a puller, remove bearing (16).
42
16
15
F0007640
3 - Only in the case of renewal

Using an internal puller and the slide hammer puller T6
(code 5.9030.618.4/10), remove bushing (43) from the
shaft (15). 43
T6
15
F0007650
30-145
FRONT PTO
6. Dismantling the clutch-brake unit (24)

1 - Remove circlip (44) and shim (45). 44
45
F0010220
2 - Remove the complete clutch pack (46) along with hub

(47).
48 47
★ Note that the top plate (48) is thicker than the oth-
49
ers.
3 - Recover the thrust plate (49) located between the hub
(47) and the clutch housing (50).
46
50
F0007660
4 - Using a puller (or a press) and a U-shaped adapter

“ A” , compress the piston return spring (51) and with-
draw circlip (52).
52 A
51
52
F0007670
5 - Release the spring (51) and withdraw, in order, spring

guide (53) and spring (51). 53
51
F0010230
30-146
FRONT PTO
6 - Direct compressed air at low pressure into the upper

hole in the control valve in order to expel the piston
(54).
★ Piston (54) may be expelled at high speed and
therefore should be restrained to prevent damage.
54
F0007680
7 - Withdraw piston (54) and O-ring (55).
54
55
F0007690
8 - Turn the unit over and remove bolts (56) and brake
cover plate (57).
56
57
F0007700
9 - Remove the brake disc (58).
58
59
F0007710
30-147
FRONT PTO
10 - Direct compressed air at low pressure into the control

valve body (59) in order to expel the brake piston (60).
★ The piston may be expelled at high speed and
therefore should be restrained to prevent damage.
59
F0007720
11 - Withdraw piston (60) and O-ring (61).
61
60
F0007730
12 - Remove circlip (62) and thrust plate (63).

63
62
F0007740
13 - Remove the control valve body (59) and remove the

seals (64) from the clutch housing (50).
64
59
50
F0007750
30-148
FRONT PTO
14 - Using special wrench T8 (code 5.9030.859.0), remove

the complete damper unit (65). T8
65
59
F0007760
15 - With a press, compress the damper (65) and remove

circlip (66).
66
65
F0007770
16 - Release the damper and withdraw, in order, thrust

plate (67), spring (68) and piston (69) complete with O-
ring (70).
★ Renew O-ring (70) at each re-assembly.
70 69 71
68
66 67
F0007780
17 - Remove plug (72) from the control valve body (59) and
remove spring (73) and plunger (74). 59
73
72 74
F0010240
30-149
FRONT PTO
18 - Remove O-rings (75) and (76) from clutch piston (54)

and brake piston (60).
75
F0010250
7. Dismantling the solenoid valve block

77
1 - Remove retaining nut (77) and withdraw the solenoid
(78).
★ Recover the O-rings.
78
F0007790
2 - Loosen and withdraw the solenoid valve spool (79).
79
F0007800
30-150
FRONT PTO
ASSEMBLY OF THE FRONT PTO
1. Assembly of the clutch-brake unit

1 -Fit O-rings (75) and (76) to the clutch piston (54) and
brake piston (60). 75
F0010250
2 - Fit plunger (74), spring (73) and plug (72) in the control
valve body (59). 59
73
74 72
F0010260
3 - Assemble the damper (65) following the dismantling

operations in reverse order.
★ Lubricate the damper body (71) and O-ring (70).
Damper and O-ring: Gearbox oil 66
65
F0007770
4 - Fit the damper (65) to the control valve body (59).

T8
Damper: Loctite 242
65
59
F0007760
30-151
FRONT PTO
5 - Fit seals (64) to clutch housing (50).

6 - Lubricate seals (64) and fit control valve body (59).
64 59
Seals: Gearbox oil
50
F0007810
7 - Fit thrust plate (63) and circlip (62).

63 62
F0007820
8 - Fit O-ring (61) and complete piston assembly (60).
O-ring and piston: Gearbox oil 61

60
★ Insert the piston by tapping it evenly around the
circumference with a soft mallet.
F0007830
9 - Lubricate brake disc (58) and locate it in the control

valve body (59).
Brake disc: Gearbox oil

58
59
F0007710
30-152
FRONT PTO
10 - Fit cover (57) and secure with bolts (56).
57 56
F0007840
11 - Turn the unit over and fit O-ring (55) and the complete
piston assembly (54) in the clutch housing.
54
O-ring and piston: Gearbox oil 55
★ Insert the piston by tapping it evenly around the
circumference with a soft mallet.
F0007850
12 - Fit spring (51) and spring guide (53).

53
51
F0010230
13 - Position U-shaped adapter “ A” and, using a puller (or

press) compress spring (51) to expose the seat of cir-
clip (52).
52 A
51
52
F0007670
30-153
FRONT PTO
15 - Install the clutch plates in the clutch housing (50); start

with a smooth plate (46A) and then a friction plate
(46B). 46A 46B
16 - Complete the clutch pack finishing with the thicker

smooth plate (48).
★ Lubricate the friction plates.
Clutch plates: Gearbox oil
50 50 F0013660
17 - Locate thrust plate (49) inside hub (47).

★ Apply a little grease to the contact surfaces of the
thrust plate to hold it in position. 47 49
D0002680
18 - Fit the hub (47) in the clutch housing (50).
47
50
F0012600
19 - Fit shim (45) and circlip (44).

45
F0010270
30-154
FRONT PTO
2. Assembly of the PTO drive shaft

1 - Only if removed: lubricate and install bushing (43) us-
15
ing a suitable drift.
1 mm
★ The bushing must be positioned approx. 1mm be-
low the face of the shaft (15).
43
F0010280
2 - Heat bearing (16) to approx. 80° C and fit to shaft (15).

★ Make sure that the bearing is driven tight against 42
the shoulder.
3 - Fit O-ring (42).
16
15
F0007860
3. Assembly of the PTO shaft

18
1 - Heat the inner race of bearing (18) to approx. 80 ° C and
fit to shaft (17).
★ The shoulder of the race must be oriented towards 18
the toothed part of the shaft. 17
F0007870
4. Assembly of the input shaft

1 - Lubricate shaft (13) and the lip of seal (14). 14
Seal and shaft: Gearbox oil
13
2 - Fit seal (14) to shaft (13) driving it fully home.
14
F0007621
30-155
FRONT PTO
3 - Heat bearing (41) and fit to shaft (13) driving it up

against the shoulder.
5 - Only if removed. Fit circlip (40). 13
41 39
40
F0007880
5. Assembly of the pump unit

1 - Lubricate gears (37) and (38) and locate them in the 37
pump housing (33).
38
Gears: Gearbox oil
33
F0007600
2 - Locate the pump cover (34) aligning the positioning

marks made during the dismantling procedure.
34
3 - Fix the cover in position with bolts (35) and washers
(36).
35 36
F0007890
4 - Locate O-ring (31) in the flange and fit the suction pipe 29
(30). Secure with bolts (29). 29
30
32 31
30
F0007580
30-156
FRONT PTO
6. Assembly of PTO units

25
1 - Fit the pump unit (28) in the PTO housing (25).
28
F0007571
2 - Fit the complete clutch assembly (24) in the PTO hous-

ing (25).
25
24
F0007550
3 - Fit seal (23) to bolt (22) and screw the bolt into the PTO
housing (25), locating it in the clutch assembly shaft
(24).
Tighten bolt (22).
22
25
F0010290
4 - Insert the complete input shaft assembly (13) turning it

slightly in both directions in order to locate the hub (47)
and the internal gear of the pump (28).
★ If necessary, tap the end of the shaft with a soft
mallet.
13
F0007510
30-157
FRONT PTO
5 - Locate bolt (12) and screw it into the PTO housing so

that it locates in the shaft (13); tighten bolt (12).
13
12
F0010300
6 - Insert the roller bearing (21) in the PTO housing (25).

★ The shoulder of the inner race must be oriented to- 21 19
wards the output end of the PTO shaft.
7 - Insert the ball bearing (20) in the PTO housing (25).
8 - Insert gear (19) in the PTO housing (25).
20
21
F0012500
9 - Fit the PTO shaft (17) locating it in gear (19) and bear-
ing (21).
★ To install roller bearing (21), tap it lightly with a cop-
per mallet while turning the shaft (17).
17
F0007900
10 - Fit the outer race of bearing (18).

★ Tap the race evenly around the circumference with
a soft mallet.
18
F0007910
30-158
FRONT PTO
11 - Lubricate bushing (43) and fit the PTO drive shaft (15)
complete with outer bearing (16).
★ To seat the shaft, tap gently with a copper mallet 16
on the shaft and around the circumference of the
bearing.
F0007920
12 - With a drift, fit oil seal (11) in cover (10).

★ Check that the oil seal is installed the right way
round.
10
11
F0012510
13 - Apply sealant to the mating surface of the PTO hous-

ing (25) and fit cover (10).
Sealant: Silastic 738 8 9

10
★ Make sure that the sealant forms a continuous film
around the studs.
14 - Tighten down the cover with nuts (8) and washers (9).
★ Tighten the nuts evenly in a cross-wise pattern.
F0007930
15 - Using tool T7 (code 5.9030.858.0) seat the oil seal (14)

of input shaft (13).
14
T7
F0012520
30-159
FRONT PTO
16 - Fit the filter (27) to the pump suction pipe.

17 - Apply sealant to the threads of plug (26); fit the plug in
the PTO housing and tighten down.
26
Plug: Silastic 738 27
F0007940
18 - Insert the extensions (6) complete with O-rings (7).

19 - Apply sealant to the contact surface of the solenoid
valve (5).
Contact surface: Loctite 510 6
7
20 - Fit solenoid valve (5) and tighten down with bolts (4).
F0007950
21 - Apply sealant to the upper mating surface of the PTO

housing (25). 3
Surface: Silastic 738

around the cover fixing holes.
25
22 - Fit the complete cover assembly (3) aligning the oil de-
livery and return fittings.
F0007471
23 - Tighten down the cover (3) with bolts (1) and washers
(2). 1 2
3
24 - Install the unit on the tractor
(For details, see « INSTALLATION OF THE FRONT
PTO»).
F0007960
30-160
ANTISHOCK VALVE AND ACCUMULATORS OF THE FRONT LIFT (models 120 - 135)
REMOVAL OF THE ANTISHOCK VALVE AND ACUMULATORS OF THE

FRONT LIFT (Models 120 - 135)
1 - Remove the condenser cooling fan assembly. 2
(For details see « REMOVAL OF THE CONDENSER
COOLING FAN»). 1 3
2 - Remove the condenser.

(For details see « REMOVAL OF THE CONDENSER»).
3 - Disconnect pipes (2) and (3) from valve (1) and dis- 4
connect the eye coupling (4) of the RH accumulator
(5).
contaminants.
4 - Remove screws (6) and remove the complete valve. F0001260
5 - Disconnect pipes (8) and (9) from the LH accumulator.

contaminants.
4
6 - Unscrew and remove the accumulators (7) and (10).
6
F0001270
In the case of further dismantling only

8
7 - Disconnect and remove pipes (2) and (8).
prevent the entry of contaminants.
10
8 - Remove the guard (11) by unscrewing the two front
screws (12) and the four top screws (13).
9
7
F0001280
REFITTING THE ANTISHOCK

2
VALVE AND ACCUMULATORS OF
THE FRONT LIFT 8
der. 13
12
12
11
F0001290
30-161
BATTERY SUPPORT
REMOVAL OF THE BATTERY SUPPORT

Sequence for models with normal front axle
1 - Remove screw (1) and remove cover (2).
2
1
F0001310
Sequence for models with front suspension

2 - Disconnect the leads from the battery terminals (3).
1
First disconnect the negative lead (--) and then the
positive lead (+).
3
3 - Remove screws (4), the battery retaining bracket (5)
and the battery (6).
4 5
F0001320
4 - Remove the two screws (7) securing the braking mode

selector valve (8) (SB).
F0001330
5 - Remove the lower nuts (9).
F0001340
30-162
BATTERY SUPPORT
6 - Remove screw (10) and remove the battery support

(11). 11
10
F0001350
REFITTING THE BATTERY SUP-

PORT
der.
1
When reconnecting the battery, first connect the
positive lead ), and then the negative lead (--).
30-163
FUEL TANKS (Normal and supplementary)
REMOVAL OF THE FUEL TANKS (Normal and supplementary)

1 - Remove screws (1) and remove the cab access steps
(2). 1
2
1
F0000210
2 - Remove the fuel filler cap (3) and completely drain the
fuel tank by aspiration.
3
Normal tank: max 230 (60.7 US.gal.)
Normal tank+supplementary:
max 380 (100.3 US.gal.)
F0000880
3 - Supplementary tank only

Remove guard (4) and disconnect the fuel tank con-
nection hose (5).
4
5
F0000220
3a -Disconnect the breather pipe (6)

3b -Undo tie-bolt (7) and remove the strap (8) securing the
7
fuel tank (9).
9 6
F0000230
30-164
4 - Disconnect the suction pipe (10) and return pipe (11)

from the normal tank; plug the ends of the pipes to pre-
vent the ingress of contaminants. 11
5 - Disconnect the fuel level indicator connector (12) and
12
release the lead from the retaining straps.
10
F0000240
6 - Position lifting equipment under the normal tank as-

sembly (13).
7 - Remove the screws (14) securing the support frame
(15) of the fuel tank (13).
16
13
13 15
14 15
F0000260
F0000250
8 - Remove the nuts (16) and washers securing the tank

support frame (15) and remove the entire assembly.
16
13
15
F0000260
9 - For tractors with air-operated trailer braking only.

19
Discharge all residual pressure from the air reservoir
(17).
18 17
★ To discharge the air, slightly loosen off one of the
fittings.
9a -Disconnect pipes (18) and (19) from the reservoir (17).
9b -Remove nuts (20) and washers and remove the air res-
ervoir assembly (17).
20
17
F0000270
30-165
9c -Withdraw the tank (21) from the lower restraints “A”

and remove it.
21
A F0013670
REFITTING THE FUEL TANKS

• Refit the fuel tanks following the removal operations in
reverse order.
1 - Fill the fuel tanks and check for leaks.
Normal tank: max 230 (60.7 US.gal.)

Normal tank+supplementary:
max 380 (100.3 US.gal.)
2 - Start the engine and check the fittings of the com-
pressed air reservoir for leaks.
30-166
PROPELLER SHAFTS
REMOVAL OF THE PROPELLER SHAFTS

2
1. Shaft for 4WD and 4WD with front suspension
1 - Remove the front (1) and rear (2) covers.
2 - Open up the snap ring (3) of the rear coupling sleeve (4)
and remove the pin (5).
★ For 4WD without front suspension, carry out also
on front sleeve 1
3 - Remove the retaining bolts of the central support (6).

4 - Slide the sleeve (4) onto the propeller shaft (7) so as to F0002240
disengage the sleeve from the drive take-off shaft.

★ For models without front suspension, also disen- 7
gage the sleeve of the front axle
5
4 - Remove the propeller shaft (7).

4
2. Front shaft (for 4wd with front suspension only)

1 - Remove the rear propeller shaft (see paragraph 1.).
2 - Remove the nuts and screws (8) securing the universal
joint yoke (9). 3
3 - Remove the cardan shaft (10). 1
F0002250
4 7 4
8 9 10 4
6 D0000180
REFITTING THE PROPELLER

SHAFTS
der.
1
★ Tighten the nuts in a crosswise sequence.
30-167
RENEWAL OF THE FRONT AXLE PINION OIL SEAL
RENEWAL OF THE FRONT AXLE PINION OIL SEAL
This operation can be carried out directly on the

tractor without having to remove the axle.
1 - Remove the propeller shaft.
(For details, see « REMOVAL OF THE PROPELLER 2
SHAFT»).
1
For front suspension only
2 - Remove the central bolts (1), spring washer (2), wash-
er (3) and flange (4). 3
D0000750
3 - Remove the oil seal (5).

★ Take care not damage the sealing surfaces of the 5
differential carrier and the spacer.
D0000930
4 - Using a suitable drift install the new oil seal (5).

5
D0000760
5 - Refit flange (4) and tighten down with bolt (1), washer
(3) and spring washer (2).
6 - Refit the propeller shaft.
(For details, see « REFITTING THE PROPELLER
SHAFT»).
30-168
CLUTCH CONTROL UNIT
REMOVAL OF THE CLUTCH CONTROL UNIT
1 - Remove the stop ring (1) and remove washer (2).

1
2 - Loosen off the front nut (3) detach the outer sheath (5) 2
of the control cable from bracket (4). 5
3
4
F0005400
3 - Disconnect the power steering return line (7) from the

filter (6).
7
6
F0009440
4 - Disconnect the pipe (8) to the control valve (9).

8
F0005410
5 - Disconnect the clutch control pipe (11) and the sec-

ondary shaft lube pipe (12) from the clutch control unit 11
(10).
10
12 F0009441
30-169
CLUTCH CONTROL UNIT
6 - Remove the retaining bolts (13) of the clutch control

unit (10).
10
13
F0005420
7 - Remove the clutch control unit (10). 1
10
F0005430
REFITTING THE CLUTCH

CONTROL UNIT
• Refit following the removal operations in reverse or- 14
der.
15
1
★ Before refitting the clutch control unit, remove all
traces of the old sealant from the mating surfaces
and inspect them for dents.
Mating surfaces: Loctite 510
★ Carefully check the condition of the O-rings (14) F0013680
and the internal manifold connection pipes (15).
30-170
CLUTCH CONTROL UNIT
DISMANTLING THE CLUTCH CONTROL UNIT
1 - Remove guide bush (1) complete with O-ring (2) and

plunger (3). 2 1
★ The O-ring (2) must be renewed at each re-assem-
bly.
1 3
2 - Remove plunger (3). 2
1
F0008990
3 - Remove, in order, piston (4), spring (5), slide (6) and

piston return spring (7).
2
7
6
5
4
F0009000
4 - Remove fitting (8), slide (9) and spring (10).

1 2
10
9
8
F0009010
5 - Only of necessary
Remove the pressure sensor (11).
11
F0013690
30-171
CLUTCH CONTROL UNIT
ASSEMBLY AND REFITTING OF THE CLUTCH CONTROL UNIT
• Assemble and refit the unit following the removal and

dismantling operations in reverse order.
1 - Check the slides (6) and (9) and the plunger (3) for
signs of scoring.
2 - Check that the choke of slide (6) is free from obstruc-
tion.
3 - Check that the characteristics of the springs are as
specified and that they are not deformed.
1
Control unit: Loctite 510
around the fixing holes.
2
Bush and fitting: Loctite 270.
30-172
REAR WHEELS
REMOVAL OF THE REAR WHEELS
1 - Position under the rear transmission casing a trolley

jack “ A” with a minimum lifting capacity of 15 tons and
a minimum lift height of 15 cm (6 in.).
★ Position lift “ A” near the wheel to be removed.
2 - Raise the tractor sufficiently to eliminate the flexing of
the tyre walls.
A
F0000010
3 - Slacken off all the wheel nuts (1); remove the wheel
nuts, leavingone (for safety) at the top of the wheel.
1
4 - While holding the wheel perpendicular, remove the
last wheel nutand remove the wheel (2).
2 1
F0001040
5 - Position under the rear axle an axle stand “ B” with lat-

eral retaining wings for safety and lower the trolley jack
until the axle is resting on the axle stand.
★ Axle stand load capacity: 2 tons minimum.
6 - Check that the axle stand is positioned correctly and
then remove the trolley jack.
7 - Repeat the above operations to remove the other rear
wheel.
B
F0000870
FITTING THE
REAR WHEELS
• Fitting the reverse of removal.
1
Wheel nuts: 490 Nm (361 lb.ft.)
★ Tighten the wheel nuts gradually in a crosswise se-
quence.
30-173
COMPLETE PUMP ASSEMBLY
REMOVAL OF THE COMPLETE PUMP ASSEMBLY

★ The photos show the LS version.
★ Disconect all the inlet, delivery, drain and regulation
pipes from the pumps.
(For details, see « REMOVAL OF THE PUMPS»).
1 - Attach slings to the pump assembly (1); attach the 1
slings to a hoist and put the slings under slight tension.
F0005170
2 - Undo bolts (2) and remove the pump assembly (1).

★ To separate the assembly from the transmission
casing, insert a lever between the casing and the
piston pump (3). 1 2
F0005180
REFITTING THE COMPLETE

PUMP ASSEMBLY
der.
1
30-174
TESTING THE AUXILIARY SERVICES PUMP
TESTING THE AUXILIARY SERVICES PUMP
★ Test conditions:
• Engine: at normal operating temperature To free drain
• Hydraulic oil: 60 - 70 ° C (140 - 158 ° F)

• Handbrake on
• Gearbox in neutral
1. Connection of the flow meter (LS version)

1 - Connect the flow meter delivery pipes (2) to two yellow
couplers on the auxiliary service control valve block
(1).
From control valve
2 - Connect the flow meter drain pipe (5) to the free drain (4). F0013851
2. Connection of the flow meter (OC version)

1 - Connect the flow meter delivery pipe (2) to a red cou-
pler on the auxiliary service control valve block (1).
1
2 - Connect the flow meter drain pipe to the free drain (4).
3. Measuring the flow rate

1 - Start the engine and bring it up to a speed of 1000 rpm.
3
2 - Operate the levers of the control valves that are con-
nected to the flow meter.
3 - Adjust the delivery pressure to 50 bar (725 psi) and F0013860
check the pump flow rate.

4 - Release the levers and repeat the operation a number
of times.
5 - Repeat steps 2, 3 and 4 with a delivery pressure of 100
1
bar (1450.3 psi) and 150 bar (2175.5 psi).
2
6 - Bring the engine speed up to 2350 rpm and repeat
steps 2, 3, 4 and 5 in this condition.
4
7 - Check the readings against the values given in the ta-
bles below.
OC CIRCUIT
5
Flow rate at Flow rate at
Pressure F0013870
1000 rpm 2350 rpm

bar (psi)
/min (US.gpm) /min (US.gpm)
50 (725) 29,5 (7.79) 69,5 (18.36)
100 (1450.3) 28,0 (7.39) 68,5 (18.09)
150 (2175.5) 27,5 (7.26) 66,5 (17.57)
LS CIRCUIT
Flow rate at Flow rate at
Pressure
1000 rpm 2350 rpm
bar (psi)
/min (US.gpm) /min (US.gpm)
50 (725) 43,0 (11.36) 107,0 (28.27)
100 (1450.3) 41,0 (10.83) 104,5 (27.61)
150 (2175.5) 38,0 (10.04) 101,9 (26.92)
30-175
PUMPS (Version LS)
REMOVAL OF THE PUMPS (Version LS)
★ Remove the fuel tank.

(For details, see « REMOVAL OF THE FUEL TANKS»). 4
1. Charge pump
1 - Loosen clamps (1) and (2); disconnect and remove the
3
inlet pipe (3).
★ Recover the O-ring from the flange.
2
2 - Remove the delivery pipe (4) to the resonators.
★ Plug the end of the pipe that remains connected to
the power steering pump (5). 1 5
F0005020
3 - Disconnect pipe (8) from the filter (6) and the pump (7).
8
★ Recover the flange O-ring seal.
contaminants.
6
F0005030
4 - Loosen and undo as far as possible the pump retain-

ing nuts (9); tap the pump (1) gently with soft mallet to 10
release it.
F0005040
5 - Remove nuts (9) and remove the pump (10).

1 10
F0005050
30-176
PUMPS (Version LS)
2. Power steering pump

4
1 - Loosen clamps (1) and (2); disconnect and remove the
inlet pipe (3).
2 - Remove the delivery line (4) to the resonators.
1 3
F0005021
3 - Undo and remove the retaining bolts (5) and remove

the pump (6).
★ Recover the pump mounting gasket.
★ Inspect the gasket carefully and renew it if neces- 5 6
sary.
F0005060
3. Transfer pump
1 - Loosen clamps (1) and (2); disconnect the inlet pipe (3)
3
of the power steering pump and withdraw the inlet
hose (4).
★ Plug the ends of the pipes to prevent the entry of con-
taminants.
1
2
4
F0005070
2 - Remove bolts (5) and remove the inlet flange (6).

6 8
F0005080
30-177
PUMPS (Version LS)
3 - Remove pump retaining bolts (7) and nuts (8).

4 - Remove the pump (9) complete with O-ring (10). 10
9
F0005090
4. Piston pump
1 - Disconnect and remove the pump housing drain pipe
1
(1) from the piston pump (1). 2
2 - Disconnect the pump delivery line (3) from the filter
and remove it.
2
F0005100
Only where present

5 - Disconnect the connection pipe (5) to the suspended
front axle from valve (4). 4
5
F0005110
6 - Disconnect the pump regulation pipe (7) from valve

(6).
7
6
F0005120
30-178
PUMPS (Version LS)
Only where present

3 - Disconnect the delivery line (8) to the suspended front
axle (8). 8
4 - Disconnect the delivery pipe (10) to the oil transfer 9
unloader from valve (9).
10
F0005130
7 - Remove the flange and the delivery pipe (11) to the

auxiliary service control valves and the hydraulic trail-
er braking valve (where present).
★ Recover the O-ring.
11
F0005101
8 - Disconnect the sleeve (13) of the power steering pump

inlet line from inlet flange (12).
13
9 - Remove the lube pipe (14) for the secondary shaft and
range gear.
12
14
F0005071
10 - Remove retaining bolts (15) of the inlet flange (12).

12
15
F0005140
30-179
PUMPS (Version LS)
11 - Undo the screws and remove the filter unit (16).

★ Recover the O-ring from the inlet flange. 16
F0005150
12 - Undo the two bolts and remove the piston pump (1).
3 1
★ If necessary, use a soft mallet to detach the pump.
F0005160
REFITTING THE PUMPS

• Refit the pumps following the removal operations in
reverse order.
1 - Start the engine and run it at idle speed for a few min-
utes, then check the system for leaks.
1
Mating surfaces: Silastic 738
2
★ Before connecting the drain-off pipe, fill the pump
housing with oil.
Oil: approx. 0.6 litres (0.16 US gal.)
3
Mating surfaces: Silastic 738
30-180
REMOVAL OF THE FILTERS (OC Version)

(For details, see « REMOVAL OF THE FUEL TANKS») 3
4
1. Power Shift control valve filter

1 - Undo pipes (1) and (2) and plug the ends to prevent en-
try of impurities.
2
2 - Disconnect the sensor lead (3).
1
3 - Undo and remove screw (4).
5
4 - Undo the screws and remove the complete filter (5). F0013880
2. Power steering pump filter

1
1 - Undo screws (1) and remove bracket (2).
2 - Disconnect pipe (3). 1
3 - Undo screw (4) and remove the complete filter (5).
2 4
1
3 5
F0013890
3. Auxiliary services pump filters

5
1 - Disconnect the lead and remove sensor (1). 1
2 - Undo the screws (2) securing the pipe (3). Loosen
hose clamp (4) and remove pipe (3). 2
3 - Disconnect the suction pipe (5) from the pump and the
filter.
2
★ Recover the O-ring from the pump flange.
2
3
F0013900
4 - Undo the retaining screws and remove the filter group

(6).
3 4
F0013910
30-181
4. Lubrication pump filter

1 - Loosen hose clamps (10) and move the hoses (2) to 1
one side.
2 - Remove the filter (3)
2
2 3 1
F0013920
REFITTING THE FILTERS

• Refitting is the reverse of removal.
1
Flange: Loctite 510
2
Flange: Silastic 738
30-182
PUMPS (OC Version)
REMOVAL OF THE PUMPS (OC Version)

1. Auxiliary services pumps 2

1 - Disconnect the suction pipe (3) from the pump (1) and
3
the filters (2). 1
★ Recover the O-rings from the flanges.
F0014010
2 - Remove the delivery pipes (4).

★ Plug the ends of all the pipes to prevent entry of im-
purities.
3 - Undo the screws and remove the pump (5).
★ Carefully inspect the condition of the gasket and 4
renew it if necessary.
5
2
F0013930
2. Power steering pump

1 - Loosen the hose clamps (1) and remove the suction
pipe (2).
3
2
1
F0014011
2 - Disconnect and remove the suction pipe (3).

4
F0013891
30-183
PUMPS (OC Version)
3 - Remove the delivery pipe (4).

★ Recover the O-rings from the flanges. 4
purities.
4 - Undo screws (5) and remove the pump (6).
★ Carefully inspect the condition of the gasket and
renew it if necessary. 5
F0013940
3. Transfer pump
4
1 - Loosen the hose clamps (1) and remove the suction
hose (2).
2 - Remove pipe (3). 5 3 5
3 - Undo screws (4) and nut (5).
4 - Remove the pump (6) complete with O-ring. 6
1
2
F0013950
4. Lubrication pump
1
1 - Remove the delivery pipe (1).
purities.
2 - Disconnect and remove the suction pipe (2). 4
★ Recover the O-ring from the flange.
3
3 - Undo screws (3) and remove the pump (4).
★ Carefully inspect the condition of the gasket and
renew it if necessary. 2
F0013960
30-184
PUMPS (OC Version)
REFITTING THE PUMPS
Auxiliary services pumps

1
Flange on filter: Silastic 738
1 - Carefully clean the mating surfaces between the

pump and the support.
2 - Apply sealant to the pump ensuring a continuous film

around the holes for the tie-bolts connecting the
pump stages.
D0002970
2
Pump tie-rods area: Silastic 738
3
4
Flange on filter: Loctite 510
Transfer pump
5
30-185
PUMP DRIVE
DISMANTLING THE PUMP DRIVE
13
4
OPEN CENTER
5
6 11 1
7 12
10
5 6 12
3
11
1
9
1 12
10
12
13
OPEN CENTER
D0001030
30-186
PUMP DRIVE
1 - Remove the complete pump assembly from the trac-

tors.
(For details, see « REMOVAL OF THE COMPLETE 1
PUMP ASSEMBLY»).
2 - Remove all the pumps from the transmission.
★ For removal procedure, see « REMOVAL OF THE
PUMPS»).
1 F0005190
3 - Remove the drive couplings (1) of the gear pumps.
F0005200
4 - Remove the spring pin (2) and remove shaft (3) and
gear (4).
3
F0005210
5 - Withdraw the shims (5) and the bearings (6) from gear
(4).
Only if necessary: remove the inner circlip (7) of gear
(4).
7
5
F0005220
30-187
PUMP DRIVE
6 - Remove from the support (8) the distance piece (9)

and the driven gear (10) of the following pumps: 8
• transfer pump (both versions)
10
• lubrication pump (OC Version) 9
• power steering pump (LS Version)
F0005230
LS Version
7 - Remove the circlips (11).
OC Version
7a -Remove the distance pieces (13) (see exploded dia-
gram).
11
F0005240
8 - Remove the driven gear (10).

★ If necessary, use a drift and tap evenly around the
circumference of the outer bearing race.
10
F0005250
9 - Using a puller, separate bearings (12) from driven

gears (10).
ASSEMBLY OF THE PUMP DRIVE

• Assemble the pump drive following the dismantling
12
10
F0005260
30-188
REMOVAL OF THE POWER SHIFT CONTROL VALVE
1 - Remove the fuel tanks.

2 - Unplug the connectors (1) from the solenoid valves (1). 1

★ Check that the connectors are labelled with iden-
tification tags.
If necessary, label the connectors and the solenoid
valves.
★ Connectors AV and IN refer to the symbols on the cor-
responding solenoid valves.
F0004830
3 - Disconnect all the pipes (3) and (4) from the control
6 6
valve unit.
★ Before disconnecting pipe (4), remove the pres- 3
sure outlet (5); replace it immediately after discon-
necting the pipe.
contaminants.
4 - Remove the bolts (6) securing the control valve unit (2).
5 4
F0004840
5 - Remove the control valve unit (2) from the left-hand

side.
★ Recover the O-rings from the ports.
1
F0004850
REFITTING THE CONTROL VALVE

verse order.
1
★ Apply grease to the port O-rings to hold them in po-
sition during assembly.
30-189
DISMANTLING THE POWER SHIFT CONTROL VALVE
24
25
27
26
13
28 16
14
29 15
1 31
30
3 7 8
11 6
5
4
19
18
17
22
23
21
20
12
10
9
42
44
43
2 33
34
32
37 36
35
40
41
39
38 D0002530
1 - Separate the two blocks (1) and (2) by removing

screws (3). 2
★ Recover the O-rings from the ports. 1
3
F0004860
30-190
1. Dismantling the shuttle control block (1)

1 - Remove nut (4) and remove in order the forward gear
plate (5), the forward solenoid (6), the reverse gear
plate (7) and the reverse solenoid (8). 1
6 8
5 7
4
F0004870
2 - Undo nut (9) and remove solenoid (10) from the pro-
portional solenoid valve. 1
10
F0004880
3 - Remove solenoid valve spools (11) and (12).

2 3
12
11
F0004890
4 - Remove plug (13) and remove spool (14), spring (15)

and plunger (16).
16
15
14
13
F0004900
30-191
5 - Remove plug (17) and withdraw spring (18) and detent

ball (19).
19
18
17
F0004910
6 - Remove plug (20) and remove spool (21), spring (22)

and plunger (23).
23
20 22
21
F0004920
7 - Remove the pressure fitting (24) and withdraw the

slide (25) and the spring (26).
★ Renew the O-ring (27) at each re-assembly.
24
26
25 27
F0013700
8 - Remove fitting (28) and withdraw the slide (29) and the
spring (30).
28
30
29 31
F0013710
30-192
2. Dismantling the gear selection block (2)

1 - Undo nuts (32) and remove solenoids (33)
1
32 33
F0004930
2 - Remove the solenoid valve spools (34).

2 3
34 34
F0004940
3 - Remove the upper plugs (35) and remove the springs

(36) and the detent balls (37).
37
36
35
F0004950
4 - Remove the lower plugs (38) and remove the spools

(39), springs (40) and plungers (41).
★ Mark the positions of the valves to avoid confusion
on re-assembly.
41
40
39
38
F0004960
30-193
5 - Remove the plug (42) and withdraw the spool (43) and
spring (44).
44
42
43
F0013720
ASSEMBLY OF THE TRANSMIS-

A A A
SION CONTROL VALVE
• Assemble the unit following the removal operations in
reverse order.
1
Nut: Max. 6 Nm (4.4 lb.ft.)
11
2
Spools: Max. 50 Nm (37 lb.ft.)
F0004970
3
★ Check the condition and installation position of the
backup rings “ A” .
A A
Lubricate prior to assembly.
Gearbox oil
26
F0004980
30-194
SHUTTLE ASSEMBLY
REMOVAL AND DISMANTLING OF THE SHUTTLE ASSEMBLY
This operation refers only to the inspection of the

shuttle and possible renewal of the internal me-
chanical components.
For overhaul and adjustment of the control cylin-
ders, see « DISMANTLING AND ADJUSTMENT OF
THE SHUTTLE CONTROL»).
1 - Remove the right rear wheel and, where present, the
supplementary fuel tank. 1
(For details, see « REMOVAL OF HE REAR WHEELS -
REMOVAL OF THE FUEL TANKS»).
2 - Disconnect connector (1) and remove the radar (2).
2
★ Recover the spacers. F0005270
3 - Disconnect the front diff. lock pipe (4) from fitting (3).
1
4 - Disconnect the right and left brake pipes (6) and (7)
from valve (5). 2 4 3 6
5
F0005280
5 - Remove fitting (8) from the flow divider valve (9).

6 - Disconnect pipe (10) from the right brake and pipe (11) 11
from fitting (12).
12 13
7 - Remove the pipe support bracket by removing the
screw (13).
10
8
F0005290
8 - Remove the connection pipes (14) and (15) to the gear

selector control valve.
15
14
F0005300
30-195
SHUTTLE ASSEMBLY
9 - Remove fittings (16) and (17) and pipes (18) and (19).
★ Take care as the balls may drop out.
★ Plug the ends of the pipes and open fittings to pre- 18 19
16
17
F0005311
10 - Remove screws (20) and remove the complete as-

sembly (21).
★ Use a lever to detach the assembly.
3 20 21
F0006440
11 - Remove circlip (22) and remove the complete selector

fork (23). 22
23
F0006450
12 - Remove circlip (24) and withdraw the ball joint (25).
22
25
24
F0006460
30-196
SHUTTLE ASSEMBLY
13 - Remove circlips (26) and remove shoes (27).

4
27 26
F0006470
ASSEMBLY AND REFITTING OF

THE SHUTTLE CONTROL
★ Assemble the unit following the dismantling and ad-
justment operations in reverse order.
1 - Start the engine and check the system for leaks.
1
★ Engage and disengage the front differential lock a
few times in order to expel air from the system.
2
(For details, see « BLEEDING THE BARKING SYS-
TEM»).
3
Mating surface: Loctite 510
around the fixing holes and locating dowels.
4
★ On re-assembly, ensure that the synchronizer ring is in
the neutral position to facilitate engagement of the
shoes.
30-197
SHUTTLE ASSEMBLY
REMOVAL AND ADJUSTMENT OF THE SHUTTLE CONTROL
19
20
25
16
18
22 24
14
15
20
19
25 23
21
17
24
25
27
26
30
28
29
D0001040
30-198
SHUTTLE ASSEMBLY
1. Preparation
1 - Remove the right rear wheel and, where present, the
supplementary fuel tank.
(For details, see « REMOVAL OF THE REAR WHEELS
REMOVAL OF THE FUEL TANKS»).
2 - Unplug connector (1) and remove the radar (2).
★ Recover the spacers. 1
2 F0005270
3 - Disconnect the front diff. lock pipe (4) from fitting (3).
1
4 - Disconnect the right and left brake pipes (6) and (7)
from valve (5). 2 4 3 6
5
F0005280
5 - Remove fitting (8) from the solenoid valve block (9).

6 - Disconnect pipe (10) from the right brake and pipe (11) 11
from fitting (12).
12 13
7 - Remove the pipe support by removing screw (13).
10
8
F0005290
8 - Remove the front pipes (14), (15).
15
14
F0005300
30-199
SHUTTLE ASSEMBLY
9 - Remove fittings (16) and (17) and pipes (18) and (19).
★ Take care as the pressure retaining balls may be
unseated. 18 19
16 22
21 17
F0005310
10 - Using a magnetic rod “ A” , recover the balls (20).

21
11 - Label the front (21) and rear (22) cover plates of the cyl- 20
inder housing (23). 3 A
23
24
F0005320
12 - Remove bolts (24); remove the front and rear cover

plates, any shims present, and withdraw the pistons
(25) as a complete unit. 25
25
F0005330
2. Adjustment of the shuttle control

1 - Place piston (25) under a press; compress the spring
seat (26) and remove circlip (27).
NOTA. The circlips must be renewed at each re-as-
sembly
. 4
2 - Release the pressure and remove the spring seat (26). 27
26
26
25
F0005340
30-200
SHUTTLE ASSEMBLY
3 - Withdraw rod (28) and spring (29) from the piston (25).
4 - Withdraw the main spring (30).
28
29 30
F0005350
5 - Refit the spring seat (26) and circlip (27) in the piston.
6 - Repeat the above operations on the second piston.
26 27
F0005360
7 - Fit the two pistons (25) in the housing (23).
25
25
23
F0005331
8 - Using a drift, push both pistons (25) in the direction of

7,1÷7,8mm
arrow “ K” until the synchronizer is fully engaged.
★ Full engagement of the synchronizer is obtained
with a piston travel of 7.1 -- 7.8 mm (0.280 -- 0.307 25 25
K
in.) measured from the neutral position to the en-
gaged position.
D0000440
30-201
SHUTTLE ASSEMBLY
9 - While maintaining the pressure in the direction “ K”

and using a depth gauge, measure the distance “ X3”
between the end face of the cylinder housing and the
piston.
Example: X3 = 8.63 mm (0.340 in.)
X2
X3
F0012350
10 - Measure distance “ X2” on the cover plate of the side in

question.
Example: X2 = 11.5 mm (0.453 in.) X2
F0005380
11 - Calculate the distance “ S” with the formula S= X2 -- X3

-- 0.5 and round down the value obtained to the nearest
5 hundredths of millimetre (0.002 in.).
NOTE. The value 0.5 mm (0.002 in.) is constant and
takes into account of the play necessary in the
mechanism.
Example (mm): S = 11.5 -- 8.63 -- 0.5 = 2.30
(in.): S = 0.453 --0.340 -- 0.02= 0,090
S
D0000430
12 - Form a shim pack “ S” (31) to be installed under the

cover plate of the side in question. 31
13 - Repeat steps 8-12 for the other side of the housing.
F0005390
30-202
SHUTTLE ASSEMBLY
14 - Withdraw pistons (25) from the cylinder housing (23)

and complete the re-assembly of the pistons following
steps 1 to 4 of the calibration procedure in reverse or- 25
der.
25
23
F0005331
15 - Refit the shuttle control following the removal opera-

D0000450
ASSEMBLY OF THE SHUTTLE

CONTROL
★ Assemble the unit following the removal and calibra-

tion operations in reverse order.
1 - Start the engine and check the system for leaks.
1
★ Engage and release the front diff. lock repeatedly
to expel any air from the system.
2
TEM»).
3
★ Take care to refit the cover plates and shims in the
right positions.
4
★ On re-assembly of the pistons, renew the circlips
(27) securing the spring seat (30).
30-203
RANGE GEARBOX CONTROL UNIT
REMOVAL OF THE RANGE GEARBOX CONTROL UNIT
1 - Remove the rear right wheel.

(For details, see « REMOVAL OF THE REAR 1
WHEELS»).
2 - Remove the PTO clutch lube pipe (1).
4
3
F0004660
3 - Disconnect the solenoid valve connectors (2).

4 5
1
4 - Disconnect the delivery line (3) to the range change
pistons.
5 - Remove bolts (4) and remove the unit (5) and the lower
plate (6). 2
2
2 6
3
F0004670
REFITTING THE RANGE GEAR-

BOX CONTROL UNIT
verse order.
1
★ Connect the connector marked RM to the rear so-
lenoid valve and the connector marked RH to the
front solenoid valve.
2
★ Connect the connector marked RM to the rear so-
lenoid valve and the connector marked RH to the
front solenoid valve.
30-204
DISMANTLING THE RANGE GEARBOX CONTROL UNIT
13
13
14
14
16
16
17
17
1
5
4
6
2
8
10
7
11
6 9 9
12
4
12
10
8
5
1
D0001010
30-205
1 - Remove the circlips (1).
F0004680
2 - Remove the screw (2) securing the hub (3).

2
F0004690
3 - With a drift, fully drive out the cover plates (4) complete
with O-rings (5) and guide bushes (6). 4 5
★ Take care not to damage the surface of the piston.
F0004700
4 - Withdraw the centre piston (7) and hub (3).

5 - Remove the internal O-rings (8).
7
F0004710
30-206
6 - Position piston (7) under a press and, with a drift, com-

press the spring in order to release and remove circlip
(9).
7 - Withdraw the piston (10) complete with O-ring (11). 9 11
7 10
F0004720
8 - Withdraw the spring (12).

9
9 - Turn the piston (7) over and with the second circlip (9)
and the second piston (10) complete with its O-ring
(11).
12
11
7
10
F0004730
10 - Undo the nuts (13) and remove the solenoids (14).

★ Recover the O-rings (15). 13
1
14
14
15
F0004740
11 - Remove the spools (16) complete with O-rings (17)

and seals. 2 3
16
F0004750
30-207
ASSEMBLY OF THE RANGE GEARBOX CONTROL UNIT

tions in reverse order. A A
1
Nuts: max. 5 Nm (3.7 lb.ft.)
17
2 16
★ Check the condition and installation position of the
backup rings “ A” .
Lubricate before assembly.
Gearbox oil
F0004760
3
Spools: 30 Nm (22 lb.ft.)
30-208
AUXILIARY CONTROL VALVE ASSEMBLY (LS Version)
REMOVAL OF THE AUXILIARY HYDRAULIC CONTROL VALVE

ASSEMBLY (LS Version)
WARNING! 3 - Carefully inspect the condition of the O-ring seals
and, were present, the dust rings; * if there is any
1- Immediately after disconnecting or removing hy-
doubt about their condition, these should be re-
draulic system pipes, plug the ends of the pipes
newed.
and any open fittings to prevent the entry of con-
taminants. 4 - Before reassembling or refitting assemblies, re-
move all traces of sealant residue from the mat-
2 - In the case of pipe fittings with copper seals, the
ing surfaces and check that these surfaces are
seals should be renewed after each disconnec-
free from dents.
tion.
1 - Put the control levers in neutral position and discon-

nect the control cables (3) from control valves (1) and
(2).
2 3
1
F0000020
2 - Disconnect pipes (3) from the compressed air outlets

(4) for the trailer braking. 4 6
★ Label the pipes clearly to avoid confusion on re-
connection.
3
3 - Remove bolts (5) and remove the complete support
bracket (6). 3
F0004150
4 - Disconnect connectors (D upper and U lower) from

7
solenoids (7) and (8) of the lift control valve (9). 9
1
5 -Disconnect the oil recovery pipes (10) of the quick-ac-
tion couplers.
Remove the complete recovered oil collection tank
(11).
10
11
8
10
F0004160
30-209
6 - Disconnect pipe (12) from the control valve (12).

7 - Close the front lift (13) shut-off cocks and disconnect
pipes (14). 12
8 - Remove the retaining strap (15).
14
13
15
F0004170
9 - Disconnect the lift delivery line (16) from the control

valve (9).
18
16
F0004180
10 - Disconnect the delivery line (17) from the pump to the

control valve assembly (18). 18
17
F0006430
11 - Only where present.

Disconnect the front suspension delivery pipe (19).
20
12 - Remove the bolts securing the flange (20) of the de-
livery line to the control valves (18). 2
19
F0004200
30-210
13 - Remove nuts (21) and the relative washers and then

18
remove the complete control valve assembly (18).
★ Recover the O-ring seal (22).
2
21 22 F0004190
REFITTING THE AUXILIARY

HYDRAULIC CONTROL VALVE
ASSEMBLY
(LS Version)
• Refit the assembly following the removal operations in
reverse order.
1
★ Positions of the lift solenoid connectors:
D = upper solenoid
U = lower solenoid
2
★ Check the condition of the O-ring (22) and coat it
with grease to hold it in position.
1 - Start the engine and operate the lift repeatedly to ex-
pel any air from the circuit and to check the fittings
for leaks.
30-211
AUXILIARY CONTROL VALVE ASSEMBLY (OC Version)
REMOVAL OF THE AUXILIARY CONTROL VALVE ASSEMBLY (OC Version)
WARNING! 3 - Carefully inspect the condition of O-ring seals

and the amount of wear on the dust wipers; if in
1- When disconnecting or removing hydraulic
any doubt about their condition, renew them.
pipes, plug the ends of the pipes and any open fit-
tings immediately to prevent entry of impurities. 4 - Before refitting assemblies, remove all traces of
old sealant from the contact faces and check that
2 - Copper seals in pipe fittings must be renewed at
the surfaces are free of nicks or dents.
each re-assembly.
1 - Remove all the ancillary parts from the control valve

block (support for the trailer braking air compressor,
coupler oil collection tray, number plate bracket, etc.)
2 - Put the control levers in neutral position and discon-
nect the control cables from the control valves.
3 - Disconnect the delivery pipe (1).

3
4 - Disconnect the lift control pipe (2).
Only where fitted
5 - Disconnect the front lift control pipes.
1
4
2
F0013980
6 - Unplug the connectors (U upper and D lower) from the

upper (3) and lower (4) solenoids of the lift control
valve.
1 6
7 - Remove the nuts (5) with the relative washers and re-
move the complete control valve assembly (6). 5
★ Recover the O-ring. 2
F0013970
30-212
AUXILIARY CONTROL VALVE ASSEMBLY (OC Version)
REFITTING THE AUXILIARY CONTROL VALVE ASSEMBLY (OC Version)
1
★ Position the lift solenoid connectors as follows:
D = lower solenoid
U = upper solenoid
2
★ Check the condition of the O-ring (22) and coat it
with grease to hold it in place.
1 - Start the engine and operate the lift repeatedly to ex-
pel any air from the system. Check seals for leaks.
30-213
AUXILIARY CONTROL VALVES
REMOVAL OF THE AUXILIARY HYDRAULIC CONTROL VALVES
LS VERSION
OC VERSION
D0002910
30-214
NOTE. The procedure described refers to the auxiliary control valve assembly on the LS version.
The same procedure applies to the OC Version.
1 - Remove the upper bolts (1) and remove the retaining

springs (2) of the identification plates (3). 2 1
★ Record the position and colour of the identification
plates of the quick-action couplers.
1 2
F0004210
2 - Remove lower bolts (4) and (5) and remove covers (6).
2 4
4
F0004220
3 - Remove circlips (7), spacers (8) and O-rings (9).
9
7
F0004230
4 - Remove the bases (10).

10
F0004240
30-215
5 - Undo and remove the quick-action couplers (11).

★ On tractors equipped with a front lift, remove also
pipes (12) and (13).
11 11
6 - Undo and remove the quick-action couplers (11) and
distance pieces (14) with the relative seals (15).
14 12
15 13
F0004250
7 - Remove the drain pipe (16) (where fitted).

16
F0004260
LS Version only
8 - Remove pressure relief valve plug (17) and the O-ring 17
(18).
★ Recove all the adjustment shims (19).
★ Check the condition of the O-ring. 19
3
18
F0004270
LS Version only
9 - Withdraw spring (20) and poppet valve (21).
21
20
F0004280
30-216
10 - Loosen and remove the nuts (22) securing the valve

sections and the relative Belleville washers.
4
★ Loosen the nuts in stages and remove them only after
the Belleville washers have fully expanded. 22
F0004290
11 - Remove in order the end section (23), the 1st section

(24), spacer (25), the 2nd section (26) and the
electrohydraulic valve section of the lift (27).
★ Recover the O-ring seals. 23
★ Carefully inspect the condition of the O-ring seals.
5
26
24
F0004300
12 - Repeat the above operations for the left side, bearing

in mind that this contains only manually-operated sec-
tions.
27 25 23
26 24
F0004310
30-217
REFITTING THE AUXILIARY HYDRAULIC VALVES
• Assemble the valve block following the dismantling

1
★ Assembly order of the quick-action coupler iden-
tification plates.
LOAD SENSING OPEN CENTER

8 VIE (8 PORTS) 8 VIE (8 PORTS)
1 2 3 4
Giallo Rosso
(Yellow) (Red)
1 2 3 4
Giallo
Rosso (Yellow)
Lato sx (Red) Lato dx Lato sx Lato dx
L.H. side R.H. side L.H. side R.H. side
6 VIE (6 PORTS) 6 VIE (6 PORTS)
1 2 3
Giallo Rosso
Nero (Yellow) (Red)
(Black)
Nero
(Black)
1 2 3
Giallo
Rosso (Yellow)
Lato sx (Red) Lato dx Lato sx Lato dx
L.H. side R.H. side L.H. side R.H. side
D0000390 D0000400
2
Spring retaining and cover bolts:
3 Nm (2.2 lb.ft.)
3
★ Coat the adjustment shims in grease before fitting
in order to hold them in position.
4
Nut tightening torque 3 3
0 0
30 + 3 Nm (22 + 2.2 lb.ft.)
2 2
★ Obligatory tightening sequence: 1-2-3 (see illus-
tration on left) 1
1
5
★ Before connecting the valve sections, make sure
that the O-rings are positioned correctly.
D0000420
30-218
SUPPLEMENTARY LIFT CYLINDERS
DISMANTLING AND ASSEMBLY OF THE SUPPLEMENTARY

LIFT CYLINDERS
1. Dismantling
1 - Position the piston (1) so that spring clip (2) is visible
through the delivery pipe connection hole.
2
2 - Turn the piston rod until the gap in the spring clip (2) is
visible.
F0009200
3 - Using a screwing inserted through the delivery pipe

connection hole, push one end of the of the spring clip
(2) towards the groove "A" in the piston (1) and simul-
taneously rotate the piston in order to disengage the
spring clip (2). 2
4 - Withdraw the complete piston (1).
1
D0000821
5 - Remove in order the rod wiper (4), the guide shoe (5),
the seal (6) and the second guide shoe (7).
1 2
★ Make a note of which way round the seal is in-
stalled.
7 6 5 4
D0000830
2. Assembly
• Assembly is the reverse of dismantling.
1
Seal and guide shoes: Gearbox oil
2
★ Before inserting the piston, check that the guide
shoes are positioned correctly in their seats in the
cylinder.
30-219
LIFT DRAFT SENSOR
REMOVAL OF THE LIFT DRAFT SENSOR
1 Disconnect lead (1) of sensor (2) and remove the three

retaining straps.
2 - Remove screws (3) and washers (4).
1
3 4
F0009210
3 - Remove bracket (5) complete with spacers (6).

1
6
F0009220
4 - Support arm (7) and withdraw the draft sensor (2).
7
2
F0009230
REFITTING THE LIFT DRAFT

SENSOR
• Refit the sensor following the removal operations in
reverse order.
1
★ Take care to fit the sensor the right way round.
D0000840
30-220
LIFT
REMOVAL OF THE LIFT UNIT
1 - Remove the left rear wheel.

(For details see «REMOVAL OF THE REAR
WHEELS»).
2 - Remove the auxiliary hydraulic valve assembly. 3
(For details see «REMOVAL OF THE AUXILIARY HY-
DRAULIC VALVE ASSEMBLY»).
3 - Remove bolts (1) and disconnect the lift rods (2) by
withdrawing pins (3).
1
2 F0004320
4 - Disconnect the delivery lines (5) from the cylinders (4).

5 - Remove the cotterpins (6) and disconnect cylinders
(4) from lift arms (7) by removing pins (8). 6 7
1
8
5
4
F0004330
6 - Remove the cotter pin (9) and remove the top link rod
(10).
10
F0004340
7 - Remove bolts (11) and remove the top link mounting

flange (12).
12
11
F0004350
30-221
LIFT
8 - Remove bolts (13) and remove the drawbar mounting

(14).
2 12
13 13
14
F0004370
9 - Removal the central lift retaining bolt (15).

10 - Disconnect the PTO bearing lubrication line (16) and
position it to one side.
15
16
F0004360
11 - Remove the first two lift retaining nuts and remove

PTO speed selector lever (17), complete with support
bracket (18). 17
12 - Remove bracket (19) complete with microswitch (20).
18
19
20
F0004380
13 - Remove the lift arm position sensor (21) and spacers

(22).
3
22
21
F0004390
30-222
LIFT
14 - Remove the nuts (23) securing the lift (24) and move
the unit clear using a lever under the front flange. 24
23
F0004400
15 - Attach a hoist to the lift unit (24) as shown and re-

move it from the tractor. 4 5 6
24
F0004410
30-223
LIFT
REFITTING THE LIFT UNIT
• Refit the lift unit following the removal operations in re-

verse order.
1
1
★ Renew all the cotter pins at each refitting.
2 2
Support bolts: 245 Nm (181 lb.ft.)
3 3
★ Check the position of the sensor as follows:
1 - Loosen the sensor retaining nuts (1); disconnect con-
nector (3) from the sensor (2). F0012610
2 - Connect the test lead T9 (code 5.9030.860.0) to the

connector (4) and the sensor (2). T9
2
F0013730
3 - Connect a multimeter to the lead and start the engine

running at idle speed.
4 - Raise the lift arms so that the notch on cam (5) is
aligned with the tip of sensor (2).
5 - Adjust the sensor output voltage (2) by positioning the
sensor closer to or further away from the cam (5). 5
★ Output voltage: 2.6V
A
6 - Lock the sensor (1) in position with nuts (1) and nut (6).
Nut: 30±6 Nm (22.1±4.4 lb.ft.)
4 F0013740
★ Remove all traces of old sealant from the mating

surfaces.
5
★ Apply new sealant to the mating surfaces.
6
★ Tighten the bolts evenly in a cross-wise pattern.
30-224
LIFT
DISMATLING THE LIFT UNIT
20
21
17
14 16
19
24
27
28
9
15
18
23
11 22
10
13
12
26
19 17
28
25
15 16
14
D0001020
30-225
LIFT
1 - Remove fitting (1) and pipes (2), (3) and (4).

3
1
F0004420
2 - Remove the breather pipe (5) and the bolts (6) securing
cylinder (7). 5
7
6 F0004430
3 - Remove the free discharge pipe (8) and the relative

bracket.
★ Recover the shims installed under the bracket.
F0004440
4 - Withdraw the cylinder (7) from the lift casing (9).

★ Recover and carefully inspect the O-rings (10) and 9
(11).
7
11
10
F0004450
30-226
LIFT
5 - Using compressed air at low pressure (max. 2.5 bar),

expel the piston (12) from the cylinder (7).
★ The piston (12) could be expelled at high speed
and therefore must be restrained it to protect it
from damage. 12 7
F0004460
6 - Remove seal (13) from piston (12).

13
★ Take care not to damage the surface of the piston.
★ Record the installation direction of the seal for sub- 12
sequent re-assembly.
★ Renew the seal at each re-assembly.
13
1
F0004470
7 - Remove the circlips (14) securing arms (15).
15
14
F0004480
8 - Remove the arms (15) complete with bushes (16) and

(17) and, on the RH arm, cam (18).
15
18
17 16
F0004490
30-227
LIFT
9 - Remove spacers (19).
19
F0004500
Loosen nut (20), unscrew grubscrew (21) and remove
cam (18). 2
★ Note that the thinner side of the cam faces the top 18
21
of the lever.
20
F0004510
11 - Position the lift casing (9) vertically. Loosen nut (22)

and remove the grubscrew (23) of lever (24). 9 24
3
22
23
F0004520
12 - Remove the LH oil seal (25).

★ Record the direction of installation.
25
25
F0004530
30-228
LIFT
13 - Withdraw the shaft (26) from the left-hand side.

★ Use a plastic or copper mallet.
4
26
F0004540
14 - Remove the RH oil seal (27).

★ Record the direction of installation. 27
27
F0004550
15 - Check that the inside diameters of the bushings and

the diameter of the shaft are within the specified tol-
erance limits.
A B
D0001190
30-229
LIFT
ASSEMBLY OF THE LIFT UNIT

★ Check the direction of installation carefully.
1
Seal and piston: Grease
2
★ Check that the thinnest side is oriented towards
the upper part of the lever.
3
Grubscrew: Loctite 242
★ Screw fully home into the shaft seating then unscrew
by a half a turn.
Secure the grubscrew in this position with the nut.
4
Shaft and bushings: Grease
30-230
ARM-REST CONTROLS
REMOVAL OF ARM-REST CONTROL PANEL AND SEAT

1 - Open the electronic control unit compartment and
disconnect connectors (1) and (2).
2 - Remove the single-pole sockets (3) for rear equipment
2
and laterally withdraw the fitting (4) of the arm-rest ca- 1
ble.
3
4
F0000280
3 - Remove screws (5) with the relative washers and re-

move the arm-rest (6).
F0000290
4 - Raise the rear of the floor mat and withdraw the seat
compressor cable.
5 - Undo nuts (7) and remove the complete seat.
7
F0000300
REFITTING THE ARM-REST CON-

TROL PANEL AND SEAT
• Refit the seat and arm-rest by following the removal
30-231
STEERING WHEEL, STEERING COLUMN SWITCH UNIT, INSTRUMENT PANEL
REMOVAL OF THE STEERING WHEEL, STEERING COLUMN SWITCH

UNIT AND INSTRUMENT PANEL
1 - Remove the steering wheel hub cover (1) and remove
nut (2) with the relative washer. 3
1 2
2 - Remove the telescopic adjustment lock plate (3).
F0000310
3 - Remove nut (4), toothed washer (5) and steering wheel

(6). 1 6
4
5
F0000320
4 - Remove circlip (7); withdraw the steering column

switch unit (8) from the steering column and place it to
one side.
7 F0000330
9 11
5 - Remove the screws (9) securing the instrument panel
(10).
6 - Release the retaining spring (11) of shroud (12). 10
2
12
F0000340
30-232
STEERING WHEEL, STEERING COLUMN SWITCH UNIT, INSTRUMENT PANEL
7 - Pull the instrument panel towards you (10) and mark

one of the two connectors (13) and (14) of the steering 10 8
column switch unit (8) to facilitate identification during
refitting.
8 - Simultaneously remove the steering column switch
unit (8), the instrument panel (10) and the shroud (12). 13
14
12
F0000350
REFITTING OF THE STEERING

WHEEL, STEERING COLUMN
SWITCH UNIT AND INSTRUMENT
PANEL
• Refit the components following the removal opera-
1
Steering wheel retaining nut:
117.6 Nm (86.7 lb.ft.)
Steering shaft: Loctite 242
2
★ The shroud retaining spring must be inserted in the
slots in the shroud (12).
30-233
INSTRUMENT PANEL SHROUD
REMOVAL OF THE INSTRUMENT PANEL SHROUD

1 - Remove the arm-rest control panel and seat. (for de- 1
tails, see « REMOVAL OF THE ARM-REST CONTROL
PANEL AND SEAT»).
2 - Remove the steering wheel, steering column switch
unit and the instrument panel. (For details, see « RE-
MOVAL OF THE STEERING WHEEL, STEERING
COLUMN SWITCH UNIT, INSTRUMENT PANEL»).
3 - Remove the accelerator pedal (1) and creeper selector
knob (2). F0000370
4 - Remove mat (3).
F0000380
5 - Remove air pipe retaining straps (4).

1
5
6
5 5
F0000390
6 - Remove the four nuts (5) and turn the instrument panel
shroud (6) towards the rear of the tractor to disengage 6
it from the pedals.
F0000400
30-234
MOBILE PORTACRUSCOTTO
7 - Disconnect the connectors of the windscreen wiper

(7), the clutch potentiometer (8) the brake pedal mi- 8
croswitches (9), the clutch pedal microswitch (10) and 7
the front lights (11). If present, also disconnect the 11
connector (12) of the trailer air braking pressure indi-
cator.
10
12 9
F0000751
REFITTING THE INSTRUMENT

PANEL SHROUD
• Refit the shroud following the removal operations in
reverse order.
1
★ Check the condition of the fascia gasket; if dam-
aged, the gasket must be replaced.
30-235
RIGHT-HAND CONSOLE
REMOVAL OF THE RIGHT-HAND CONSOLE

1 - Remove the arm-rest control panel and the seat. (For
details, see « REMOVAL OF THE ARM-REST CON- 1
TROL PANEL AND SEAT»).
2 - For removal of console complete with wiring only.
Remove the instrument panel shroud in order to ac-
cess the wiring connectors. (For details, see « REMO-
VAL OF THE INSTRUMENT PANEL SHROUD»).
1
3 - Disconnect the control cables (1) from the auxiliary
control valves. 1 F0000021
4 - Remove the pushbutton panel. (For details, see « RE-

MOVAL OF PUSHBUTTON PANEL AND CONTROL
LEVERS FOR AUXILIARY SERVICE VALVES»).
5
5 - At the bulkhead connector plate (3), disconnect the
connectors of the engine leads (4 yellow), the lift (5 4
white), the gearbox (6 red), the feed cable (7) and the 5 8
earth lead (8).
4
6 7
F0000030
6 - Disconnect the electronic control units (9).
F0000700
7 - For tractors with trailer air braking only.

Remove the connector (34) of the trailer air braking
pressure indicator.
34
F0013751
30-236
RIGHT-HAND CONSOLE
8 - Remove the grille (10) and filter (11) from the right-
hand cab pillar.
10 11
F0000710
9 - Mark and disconnect the connectors (12) of the cab

roof wiring.
10 - Disconnect the gas spring of the right-hand door and
remove the mounting pin (13).
12 13
F0000720
11 - Remove the knob (14) of the PTO speed selector lever

and remove the rear floor mat (15).
14 15
F0000730
12 - For suspended front axle versions only.

Remove the front insulation panel (16) and unplug
connector (17) of the front axle control unit. 16
12a -Remove the bulkhead connector (18).

18
17
F0000740
30-237
RIGHT-HAND CONSOLE
13 - Unplug the connectors of the windscreen wiper (19),

the clutch potentiometer (20), the brake pedal micro- 20
switches (21), the clutch pedal microswitch (22) and 19
the front lights (23). If present, also unplug the con- 23
nector (24) of the trailer braking air pressure indicator.
22
24 21
F0000750
14 - Remove the air recirculation outlet (25) in the right-

hand cab pillar and remove cover trim (26).
25
26
26
F0000760
15 - Remove the bolts and raise the seat support (27).

16 - Cut the retaining strap and disconnect hose (28). 27
17 - Unplug the connectors (29) of the air conditioning and 29

heating systems and, where present, unplug the con-
nector of the trailer braking air pressure indicator. 28
Remove screw (30) and replace the seat support (27)).
30
F0000770
18 - Open the panel in the rear right cable way (31) to ac-
cess screw (32).
19 - Remove the retaining screws and pull the right-hand 33
console (33) away from the side of the cab. 32
31
31
F0000780
30-238
RIGHT-HAND CONSOLE
20 - Remove the right-hand console (33).

★ Support the electrical leads and control cables
33
while removing the console.
F0000790
REFITTING THE RIGHT-HAND

CONSOLE
• Refit the console following the removal operations in
reverse order.
1
★ Connect the control cables following the opera-
tions indicated in the paragraph « INSTALLATION
OF THE CONTROL CABLES OF THE AUXILIARY
SERVICE VALVES».
30-239
LEFT-HAND CONSOLE
REMOVAL OF THE LEFT-HAND CONSOLE

1 - Remove the arm-rest control panel and the seat. (For 1
details, see « REMOVAL OF THE ARM-REST CON-
2 - Remove the accelerator pedal (1) and the knob of the
creeper selector lever (2).
F0000370
3 - Remove the front floor mat (3).

4 - Where present, 4
remove the passenger seat (4).
F0000860
5 - Remove the knob of the PTO speed selector lever.

6 - Remove the rear floor mat (6). 5 6
8
F0000731
7 - Remove the handbrake cover (7).

7
8 - Remove the seat support (8) and remove the retaining
strap (9) to release hose (10). 12
Remove screw (11) and remove trim panel (12).
Remove screw (13).
11
10 13
9
F0000800
30-240
LEFT-HAND CONSOLE
9 - Remove the air recirculation vent (14) from the left-

hand cab pillar and remove trim panel (15).
10 - Disconnect the left door gas spring and remove the
mounting pin (16). 14
16
15
15
F0000810
11 - Remove the retaining screws and pull the left-hand

console (17) away from the side of the cab. 17
F0000820
12 - Unplug the four connectors (18).

13 - Disconnect the heater valve control cable (19).
18
14 - Remove the left-hand console (17). 1 19
18
REFITTING THE LEFT-HAND

CONSOLE F0000830
• Refit the console following the removal operations in

reverse order. MAX.
1
★ Connect the heater valve control cable as follows: 20
1 - Turn the heating control knob fully counter-clock- 23 21
wise (blue zone) and then clockwise two notches
(towards the red zone).
2 - Turn the lever (20) of the heater valve (21) up to the
stop pin (22) marked with the letter “ C” . +2
24 22
3- Secure the outer cable with the spring clip (23) and the
inner cable with screw (24).
F0000851
30-241
ELECTRONIC CONTROL UNITS
REMOVAL OF THE ELECTRONIC CONTROL UNITS

1
1. Gearbox - engine - lift control units
3
1 - Remove panel (1).
2
2 - Unplug the connector (2) of the control unit to be re-
moved.
★ Lift knob (3) to release the connector.
F0000580
3 - Remove the two screws (4).

★ Take care not to drop the retaining screws into the 4 5
compartment.
4 - Withdraw the control unit. 1
2. Front suspension ECU

1 - Remove the gearbox control unit (5). F0000590
2 - Unplug connectors (6) & (7).

3 - Remove the two screws (8) and withdraw the control
8
unit (9).
★ Take care not to drop the retaining screws into the
6
compartment.
REFITTING THE ELECTRONIC 7

9
CONTROL UNITS
• Refit the controls units following the removal opera-
1 F0000600
★ Take care to insert the control units in the correct po-

sition and not to mix up the connectors.
★ Control unit positions: C B
A - Lift control unit D A
B - Engine control unit
C - Gearbox control unit
D - Front suspension ECU
The control units must be inserted with their data
plates facing upwards.
After renewal of a control unit, check its calibration us-
ing the All Round Tester (ART® ).
(For details, see « 20. TESTER MANUAL»). F0009430
30-242
FUSE BLOCK
REMOVAL OF THE FUSE BLOCK

1 - Open the door of the fuse box and remove the four
screws (1) securing the fuse block (2). 1
2
F0000670
2 - Withdraw the fuse block (2) while supporting the at-

tached wires (3).
3
F0000680
3 - Push the retaining clip outwards (4) and unplug the

connectors (5).
5
4
F0000690
REFITTING THE FUSE BLOCK

• Refit the fuse block following the removal operations
in reverse order.
★ Guide the wires into the recess and position them so
that they do not interfere with the fitting of the fuse
block.
30-243
ACCELERATOR POTENTIOMETER
RENEWAL OF THE ACCELERATOR POTENTIOMETER

1 - Remove the accelerator pedal (1) and the handgrip (2) 1
of the creeper selector lever.
F0000370
2 - Remove the front floor mat (3).
F0000380
3 - Remove the screws (4) securing the potentiometer (5).

4 - Remove the potentiometer (5) and disconnect it from
connector (6).
5
F0000570
REFITTING THE ACCELERATOR

POTENTIOMETER
• Refit the potentiometer following the removal opera-
1 - After renewal of the potentiometer, check the engine
speed calibration values using the programming and
diagnostics tester.
30-244
CLUTCH PEDAL AND CONNECTED DEVICES
1. Removal of the potentiometer

1 - Lower and fully withdraw the steering wheel. Remove
the instrument panel, disconnecting the rear connec-
tor.
2 - Disconnect connector (2) from the potentiometer (1). 1
3
3 - Undo screws (3) and remove the potentiometer.
1.1 Refitting the potentiometer. 2

• Refit the potentiometer following the removal opera-
tions in reverse order. F0000500
After renewal of the potentiometer, check the calibra-

tion values using the programming and diagnostics
tester.
2. Adjustment of the clutch pedal position

5
SHROUD»). 6
2 - Remove the rubber cover from the pedal and the floor
mat. 4
212 mm
3 - Check that the pedal (4) is fully raised and that the low-
er edge is at the specified distance from the cab floor. D0000040
★ Height of lower edge of pedal: 212 mm (8.353 in.)

4 - If the pedal height is not as specified, loosen locknut
(5), adjust screw (6) to obtain the correct height and re-
tighten locknut (5).
5 - Check the adjustment of the clutch cable. (For details,
see next paragraph).
4
F0000510
After adjusting the position of the clutch pedal, check

that the travel of lever (7) which operates the poten-
tiometer (1), is centred relative to the slot in support (8). 7 11
To centre the travel, disconnect the control rod (9)
from the clutch pedal, loosen locknuts (10) and screw 8
the fittings (11) in or out to alter the length and thus the
travel of the lever; tighten locknuts (10). 10
9
F0000520
30-245
3. Removal of the clutch cable

13 12
1 - Detach clevis (12) from the clutch pedal (4).
2 - Loosen locknut (13) and remove the clevis (12) and the
locknut.
3 - Remove screws (14). 14 4
F0000530
4 - Remove circlip (15) and washer (16).

15
5 - Loosen and unscrew nut (17); withdraw the cable (19) 16
from bracket (18).
17
19
18
F0000111
3.1 Refitting the clutch cable

13 12
• Refit the clutch cable following the removal operations
in reverse order.
1 - Screw in clevis (12) to a distance of 90 mm (3.546 in.).
Tighten the locknut (13) to secure in position.
4
90 mm
F0000531
3.2 Adjustment of the clutch cable 22

1 - Fully depress the clutch pedal and adjust the outer ca-
ble (19) using adjuster nuts (17) to obtain a clearance 19
between the lever (20) and pushrod (21) of 0.1 mm 17
(0.004 in.). 20
2 - Tighten nuts (17) and replace the rubber shroud (22). 0,1 mm
21
F0000201
20
30-246
CONTROL CABLES OF THE AUXILIARY SERVICE VALVES
RENEWAL OF THE CONTROL CABLES OF THE AUXILIARY SERVICE

VALVES
1 - Remove the arm-rest control panel and the seat. (For
2 - Remove the auxiliary service valve control levers. (For
details, see « REMOVAL OF PUSHBUTTON PANEL
AND CONTROL LEVERS FOR AUXILIARY SERVICE
VALVES»).
3 - Detach the right-hand console (1) from the side of the

cab without unplugging the connectors of the front
wiring harness and the air conditioning system. 1
(For details, see « REMOVAL OF THE RIGHT-HAND
CONSOLE»).
★ Do not remove the instrument panel shroud.
F0000791
4 - Disconnect the outer sheath/s (2) of the control cables

to be renewed from the control valve/s.
F0000022
5 - Unscrew wingnut (3) and turn over the control cable

bulkhead plate (4).
With draw the control cables (5). 5
5 3
4
F0001050
30-247
CONTROL CABLES OF THE AUXILIARY SERVICE VALVES
REFITTING THE CONTROL CABLES OF THE AUXILIARY SERVICE

VALVES
1 - Pull the lever (6) of the control cable to obtain a dis- 7
tance between the lever and the protective covering
(7) of 5 mm (0.197 in.). 6
F0009450
2 - Manually move the spool of the control valve to the

bottom position.
3 - Lift the lock ring (8) and, while keeping the cable under 8
slight tension, insert the cable end fitting in the at-
tachment (9).
4 - Lower the lock ring (8); check that the control valve
spool travels through its full stroke and that the lever 9
maintains the correct distance from the protective
covering.
5 - Check also that the lever moves to its maximum "float"
position and that it does not foul the protective cov- F0009460
ering (7) in this position.
30-248
PUSHBUTTON PANEL AND CONTROL LEVERS FOR AUXILIARY SERVICE VALVES
REMOVAL OF PUSHBUTTON PANEL AND CONTROL LEVERS FOR

AUXILIARY SERVICE VALVES
1 - Undo the screws (1) and remove cover (2).
1
2
F0000610
2 - Remove the four screws (3) and raise the pushbutton

panel (4).
3 4
F0000620
3 - Unplug connectors (5) and remove the pushbutton

panel (4).
★ The connectors are marked with the same symbol
4
as the corresponding pushbutton.
5
F0000630
4 - Remove the four screws (6) securing the control lever

panel (7).
F0000640
30-249
PUSHBUTTON PANEL AND CONTROL LEVERS FOR AUXILIARY SERVICE VALVES
5 - Remove the self-locking nuts (8), the screws (9) se-

curing the lever pivot mountings (10) and the relative
washers.
9
10
8
F0000650
6 - Remove the outer cable retaining clamps (11) and dis-

connect the control valve cables (12).
12
11
F0000660
REFITTING THE PUSHBUTTON

PANEL AND CONTROL LEVERS
FOR AUXILIARY SERVICE VALVES
• Refit the component following the removal operations
in reverse order.
30-250
HEATER VALVE
REMOVAL OF THE HEATER VALVE

1 - Remove the left-hand console and place it on one
side. 1
(For details, see « REMOVAL OF THE LEFT-HAND 5
CONSOLE»).
2 - Drain the coolant from the cooling system.
Coolant: approx. 18 (5 US gal.) 2
3 - Disconnect the inner cable (1) and the outer cable (2).
1 3 4
F0000840
4 - Mark pipes (3) and (4) disconnect them from the valve
(5).
★ Plug the ends of the pipes to prevent the ingress of 9 6
contaminants.
5 - Remove locknuts (6) and remove the complete valve 10 7
(5).
6 - Remove nuts (7) and bolts (8) with the relative washers 8
and then remove pipe (9).
★ Dispose of the old gasket (10)
5
REFITTING OF THE HEATER F0000841
VALVE
• Refit the valve following the removal operations in re-
MAX.
verse order.
1
11
★ Connect the heater valve control cable as follows: 13
1 - Turn the heating control knob fully counter-clock- 12
wise (blue zone) and then clockwise two notches
(towards the red zone).
2 - Turn the lever (20) of the heater valve (21) up to the +2
stop pin (22) marked with the letter “ C” . 14
3 - Secure the outer cable with the spring clip (13) and
the outer cable with screw (14).
F0000850
1 - Fill the cooling system with coolant.

Coolant: approx. 18 (5 US gal.)
2 - Fully open the heater valve.
3 - Start the engine to circulate the coolant. Check for
leaks.
4 - Stop the engine and top up the coolant level.
30-251
HEATER MATRIX
REMOVAL OF THE HEATER MATRIX

2 - Remove the accelerator pedal (1) and the creeper se-
lector knob (2); remove the front floor mat.
F0000370
3 - Remove the PTO speed selector knob (3) and the rear
floor mat (4). 4
3
F0000732
4 - Remove retaining strap (5) and air duct (6).
6
5
F0000391
5 - Remove the screws and raise the seat support (7).

6 - Undo the screws and remove the air conditioning sys- 7
tem cover (8).
F0000920
30-252
HEATER MATRIX
7 - Drain the coolant from the engine and from the heater
matrix by disconnecting pipe (9).
Engine coolant: approx.18 (5 US gal.)
★ After draining the coolant, reconnect pipe (9).
8 - Remove the evaporator of the air conditioning system.
(For details, see « REMOVAL OF THE AIR CONDI- 9
TIONING EVAPORATOR»).
F0000950
9 - Remove the retaining strap and disconnect the verti-

cal return pipe (11) from the matrix (10).
11
F0000960
10 - Remove the retaining strap and disconnect the hori-

zontal delivery pipe (12) from the matrix (10).
10
12
F0000970
11 - Remove the matrix (10) by lifting the right end vertically

and then rotating towards the rear of the tractor.
10
F0000980
30-253
HEATER MATRIX
REFITTING THE HEATER MATRIX
• Refit the heater matrix by following the removal op-

1 - Refill the cooling circuit.
Coolant: approx. 18 (5 US gal.)
2 - Fully open the heater valve.
3 - Start the engine to circulate the coolant. Check for
leaks.
4 - Stop the engine and top up the coolant level.
30-254
AIR CONDITIONING EVAPORATOR
REMOVAL OF THE AIR CONDITIONING EVAPORATOR

2 - Remove the accelerator pedal (1) and the creeper se-
lector knob (2); remove the front floor mat.
F0000370
3 - Remove the PTO speed selector knob (3) and the rear
floor mat (4).
3 4
F0000732
4 - Connect the quick-fit couplers of the high and low

pressure pipes (R and S) to the refrigerant (R134A)
charging, testing and recovery machine.
Set the machine for recovery operation and start it; al- R S
low the machine to run until all the refrigerant has been
recovered, then disconnect the machine. 1
★ Check the quantity of oil recovered and the quan-

tity to be reintroduced into the system.
F0000910
5 - Remove the retaining strap (5) and air hose (6).
6
5
F0000391
30-255
AIR CONDITIONING EVAPORATOR
6 - Remove the screws and raise the seat support (7).

7 - Remove the screws and remove the cover (8) of the air 7
conditioning system.
F0000920
8 - Disconnect the inlet (10) and outlet (11) pipes from the
evaporator (9). 2
10 12
Immediately seal the ends of the pipes (10), (11) to
prevent atmospheric moisture from getting into the
air conditioning system.
11
9 - Release the rubber diaphragm (12).
F0000930
10 - Lift up the evaporator (9); remove the temperature

sensor (13) and place it on one side. 3
11 - Remove the evaporator (9).
12
REFITTING THE EVAPORATOR

• Refit the evaporator following the removal operations
in reverse order.
1
★ Quantity of R134a: 1600 g
★ After recharging the system, the seals of pipes (R F0001060
and S) and the air conditioning system in general

using a specific leak detector.
9
2
High pressure fitting (5/8’ - 18UNF):
13.6 -- 20.3 Nm (10 -- 15 lb.ft.)
Low pressure fitting (7/8’ - 14UNF):
35.3 -- 42 Nm (26 -- 31 lb.ft.) 13
3
★ Carefully check the fixing of the temperature sen-
sor.
1 - Carefully check the seal around the cover (8).
F0000940
30-256
RIGHT-HAND BLOWER OF THE AIR CONDITIONING SYSTEM
REMOVAL OF RIGHT-HAND BLOWER OF THE AIR CONDITIONING

SYSTEM
1
1 - Remove the arm-rest control panel and the seat.
(For details, see « REMOVAL OF THE ARM-REST
CONTROL PANEL AND SEAT»). 2
SHROUD»).
3 - Remove the retaining screws of the right-hand con-
sole.
(For details, see « REMOVAL OF THE RIGHT-HAND F0000990
CONSOLE»).
4 - Remove the seat support (1) and the cover (2) of the air
conditioning system. 3
4
5 - Remove the evaporator. (For details, see « REMOVAL
OF THE AIR CONDITIONING EVAPORATOR»)
6 - Remove the four screws (3) securing the blower (4).
7 - Remove the blower (4) and turn it upside down.
F0001000
8 - Unplug connectors (5) and (6). 1

If a new blower is to be fitted, support plate (7) must
7
also be renewed. 4
5
6
F0001010
REFITTING THE RIGHT-HAND

BLOWER OF THE AIR CONDI-
TIONING SYSTEM
• Refit the blower following the removal operations in
reverse order.
1
★ Glue the support plate to the blower impeller be-
fore replacing the blower.
Support plate: Loctite 401

1 - Carefully check the seal around the cover.
30-257
LEFT-HAND BLOWER OF THE AIR CONDITIONING SYSTEM
REMOVAL OF LEFT-HAND BLOWER OF THE AIR CONDITIONING SYS-

TEM
1
1 - Remove the arm-rest control panel and the seat.
(For details, see « REMOVAL OF THE ARM-REST
CONTROL PANEL AND SEAT»). 2
2 - Remove the left-hand console without disconnecting
the heater valve control cable. (For details, see « RE-
MOVAL OF THE LEFT-HAND CONSOLE»).
3 - Remove the seat support (1) and the cover (2) of the air
conditioning system.
F0000990
4 - Remove the evaporator. (For details, see « REMOVAL
OF THE AIR CONDITIONING EVAPORATOR»).
5 - Remove the four screws (3) securing the blower (4).
3 4
6 - Remove the blower (4) and turn it upside down.
F0001020
7 - Unplug connectors (5) and (6). 1

7
If a new blower is to be fitted, support plate (7) must
also be renewed. 4
6
F0001030
REFITTING THE LEFT-HAND

BLOWER OF THE AIR CONDI-
TIONING SYSTEM
• Refit the blower following the removal operations in
reverse order.
1
★ Glue the support plate to the blower impeller be-
fore replacing the blower.
Support plate: Loctite 401
1 - Carefully check the seal around the cover.
30-258
WINDSCREEN WIPERS
REMOVAL OF THE SCREEN WIPERS

Windscreen wiper
1 - Lower and fully withdraw the steering wheel and re- 1
move the instrument panel, disconnecting the rear
connector.
2 - Disconnect the windscreen wiper connector (1).
F0000360
Rear wiper
1 - Remove the cover (2) complete with its gasket. 2
3
2 - Disconnect connector (3).
F0000890
3 - Remove nut (4), wiper arm (5) and rubber cover (6).
5
6
F0000900
4 - Remove nut (7) securing the wiper motor (8), washer

(9), gasket (10) and seal (11). 7
9
5 - Remove the complete wiper assembly.
10
REFITTING THE SCREEN WIPERS 11
• Refit the wipers following the removal operations in re-

verse order.
8
D0000010
30-259
CONTENTS
SECTION 40
CONTENTS
CAB H-M-L UNIT

• Removal ...................................................................... 1 • Removal .................................................................. 115
• Refitting....................................................................... 6 • Refitting................................................................... 116
ENGINE • Dismantling ............................................................. 117
• Technical data............................................................. 7 • Assembly................................................................. 133
• Main components ....................................................... 8 FRONT TRANSMISSION CASING
• Dismantling ................................................................. 9 • Removal .................................................................. 146
• Tests - Technical data and dimensions .................... 41 • Refitting................................................................... 148
• Assembly ................................................................. 69 • Dismantling ............................................................. 149
REAR CAB MOUNTINGS • Assembly................................................................. 167
• Removal .................................................................. 105 REAR TRANSMISSION
POWER SHIFT COVER • Refitting................................................................... 184
• Removal .................................................................. 106 • Dismantling ............................................................. 185
• Refitting................................................................... 107 • Assembly................................................................. 225
REAR TRANSMISSION CASING COVER PTO CLUTCH
• Removal .................................................................. 108 • Overhaul.................................................................. 276
• Refitting................................................................... 109 REAR AXLE - BRAKES
ENGINE-TRANSMISSION • Dismantling and assembly ..................................... 281
• Separation............................................................... 110
• Reconnection.......................................................... 114
40-i
CAB
REMOVAL OF THE CAB

Eliminate all residual pressure from all hydraulic cir-
cuits. 2 3
1
1 - Remove the engine hood. (For details, see «REMO-
VAL OF ENGINE HOOD»).
2 - Remove the rear wheels. (For details, see «REMOVAL
OF THE REAR WHEELS»).
3
3 - Remove the fuel tanks. (For details, see «REMOVAL
OF THE FUEL TANKS»).
F0000020
4 - Put the hydraulic control valve control levers in neutral

position and disconnect the control cables (3) from
control valves (1) and (2).
5 - Disconnect from the bulkhead connector assembly 5
the electrical leads of the engine (4 yellow), the lift
(5 white), the gearbox (6 red) and the feed wire (7). 4
Disconnect the earth lead (8) from the rear axle. 5 8
4
6 7
F0000030
5a -For trailer air braking only.

Disconnect the connector (52) of the trailer air braking
pressure indicator.
52
F0013750
6 - Disconnect the connection fittings (9) and (10) of the

delivery and return pipes (11) and (12) from the evap-
orator of the climate control system. 12 10
1
★ Cover the fittings to protect against the ingress of
contaminants.
11
9
F0000040
40-1
CAB
7 - Remove the insulation panel (13), the diaphragm (14)

14
for air conditioning pipes (9) and (10) and the engine
hood gasket (15).
13
9 10
15 F0000050
8 - For front suspension only.

Disconnect the connector (16) of the front suspension
adjustment unit.
16
F0000060
9 - Disconnect the steering cylinder connection pipes “L”

and “R” from the power steering unit (17).
★ Mark the pipes to allow identification for subse- R
quent re-assembly.
★ Plug the pipes and holes to prevent ingress of con-
taminants.
L
17
F0000070
10 - Cut the retaining straps and then disconnect the pow-

er steering return pipe (19) from the filter (18).
★ Plug the end of the pipe and the filter to prevent the
ingress of contaminants.
19
18
F0000080
40-2
CAB
11 - Disconnect the power steering delivery pipe (21) from

the resonators (20).
★ Plug the ends of the pipes and the holes to prevent 21
the ingress of contaminants.
22
12 - Disconnect the creeper control rod (22) from the con-
trol lever in the cab.
20
F0000090
13 - Drain the engine coolant; disconnect the cab heating

delivery and return pipes (23) and (24).
★ Plug the ends of the pipes and holes to prevent the
ingress of contaminants.
Engine coolant: approx. 18 (5 US.gal.)

23
24
F0000100
14 - Remove lock ring (25) andwasher (26). 2

25
15 - Loosen the front nut (27) and detach the clutch cable 26
27
cover (29) from support bracket (28).
29
28
F0000110
16 - Disconnect the fork of the parking brake control cable

(31) from the parking brake lever (30). Compress the 33
spring and detach the outer sheath (32) from the sup-
port (33).
31
32
30
F0000120
40-3
CAB
17 - For cabs with air suspension only.

Remove the cotter pin (54) and disconnect the tie-rod
(35) from the cab levelling valve control lever (34).
3 35
★ Fit a new cotter pin at each re-assembly.
34
54
F0014110
18 - For models with air operated trailer braking only.

Disconnect control cable (36). 4 38 36
18a -Disconnect the air pressure indicator (38) from pres-
sure switch (37).
37
F0000140
19 - Disconnect the PTO speed selection lever (39).

20 - Remove (40) the number plate light and disconnect
the leads. 40
39
F0000150
21 - Remove (41) the screenwash liquid reservoir and se-

cure it to the cab.
41
F0000160
40-4
CAB
22 - Remove the front rearview mirrors and attach the lift-

ing brackets to the cab.
23 - Attach lifting brackets to the rear cab supports.
F0000170
24 - Rotate the flashing light (42) so that it is positioned

horizontally.
25 - Connect lifting equipment to a hoist; attach the lifting
brackets and operate the hoist to put the lifting chains
under slight tension.
42
52
F0000180
26 - Version with pneumatic suspension

Remove the central front screws (43) securing the cab
to the vibration dampers (44). 46
26a -Remove the screws (45) and washers of the rear sup-
ports (46).
44
43 45
F0000190
27 - Version without suspension

Remove nuts (47), spring washers (48) and remove the
front screws(49) and rear screws (50) complete with 49 50
their spring washers (51).
47 48
47 48
50 51
F0012620
40-5
CAB
28 - Raise the cab (53) just a few centimetres and check

that it is completely detached from the underlying
frame; check that all pipesand cables are released
from their retaining straps.
29 - Slowly lift the cab clear of the frame while supporting
all the connected pipes and cables.
30 - Lower the cab onto suitably positioned wooden sup-
port blocks.
The support blocks must be of sufficient thick-
ness to ensure that the fenders are kept off the
ground.
F0000181
REFITTING THE CAB 53

• To refit the cab, follow the steps of the removal op-
eration in reverse order.
1 0,1 mm
Air conditioning pipe fittings:
delivery (5/8’-18UNF) 13.6 --20.3 Nm (10--15 lb.ft.)
return (7/8’-14UNF) 35.3 --42 Nm (26-- 31 lb.ft.) 54
2
★ Check that, when the clutch pedal is fully depressed,
F0000200
the clearance between lever (56) and pin (57) is as
specified in the paragraph «CLUTCH PEDAL AND
CONNECTED DEVICES»
3
★ Replace the cotter pin.
4
★ 36
,5mm
Check the adjustment of the control cable (36).

20,5±0
1 - Top up the engine coolant level.

Engine coolant: approx. 18 (5 US. gal.)
2 - Turn the cab heating fully on; start the engine to check
the hydraulic and pneumatic connections for leak-
sand to circulate the coolant. D0000020
3 - Turn the steering wheel repeatedly in both directions

in order to expel air from the power steering system.
4 - Stop the engine; check the engine coolant level and
top up if necessary.
40-6
ENGINE
ENGINE TECHNICAL DATA
CHAMPION
TRACTOR MODEL
120 135 150
ENGINE TYPE 1000.6 WT 3V 1000.6 WT 3V 1000.6 WTI 3V
Configuration and type 4-stroke diesel, in-line, liquid-cooled
Cylinders N° 6 6 6
Valves per cylinder N° 2 inlet / 1 exhaust
Aspiration Turbo Turbo Turbo and Intercooler
1.15 (16.7)
Boost pressure (2100 rpm) bar (psi) 1.03 (15) 1.15 (16.7) (before intercooler)
1.10 (16)
(after intercooler)
Bore mm (in.) 105 (4.137) 105 (4.137) 105 (4.137)
Stroke mm (in.) 115.5 (4.551) 115.5 (4.551) 115.5 (4.551)
Stroke-bore ratio 1.1 1.1 1.1
Total displacement cm³ ( ᐉ) 6000 (6) 6000 (6) 6000 (6)
Cylinder swept volume cm³ ( ᐉ) 1000 (1) 1000 (1) 1000 (1)
Compression ratio 17.2:1 17.2:1 17.2:1
Inlet valve opens / closes 24° ppms / 30° dpmi 24° ppms / 30° dpmi 24° ppms / 30° dpmi
Exhaust valve opens / closes 40° ppmi / 20° dpms 40° ppmi / 20° dpms 40° ppmi / 20° dpms
Maximum power kW / rpm 94/2100 104,5/2100 117/2100
Power at max. rpm kW / rpm 87.7/2350 100/2350 110/2350
Maximum torque Nm / rpm 524/1400 586/1400 653/1400
Minimum specific fuel con-
sumption g/kWh / rpm 215/1533 219/1533 219/1533
Specific fuel consumption /

max. power g/kWh / rpm 228/2100 222/2100 226/2100
Idle speed rpm 650 - 700 650 - 700 650 - 700

Maximum permitted engine
speed rpm 2520 - 2550 2520 - 2550 2520 - 2550
Firing order 1-5-3-6-2-4

Direction of rotation Counter-clockwise (viewed from flywheel end)
Fuel injection system Direct injection - BOSCH unit injection pumps type PFR 1K
Injector type and configuration 5-hole Minisac
Engine governor Electronic
Injection pressure bar (psi) 700 (10152) 700 (10152) 700 (10152)
Static advance 16° ppms 16° ppms 16° ppms
Lubrication Forced with gear pump
Cold-starting system Glowplug thermostarter
Starter motor 12 V - 3 kW 12 V - 3 kW 12 V - 3 kW
Alternator 12 V - 150 A 12 V - 150 A 12 V - 150 A
VALVE TIMING DIAGRAM

INLET OPENS 24° 20° EXHAUST CLOSES
INLET CLOSES EXHAUST OPENS

30° 40°
D0002982
40-7
ENGINE
MAIN COMPONENTS
3 4 5 6 15
16 17
2
7
8
14 18
1
19
9
13
20
35
10
12
11 21
22
34
23
27
26
36
33 31 25
32 24
28
21
25 30 29 D0002830
1 - Cooling fan 9 - Oil vapour collector 17 - Turbocharger 25 - Crankshaft 33 - Crankshaft pulley
2 - Coolant pump 10 - Flywheel housing 18 - Intake manifold 26 - Oil cooler 34 - Timing gear (camshaft)
3 - Exhaust valve 11 - Camshaft 19 - Exhaust manifold 27 - Oil filter 35 - Pulley
4 - Inlet valve 12 - Injection pump 20 - Piston 28 - Flywheel 36 - Intermediate timing gear
5 - Exhaust valve pushrod 13 - Governor 21 - Connecting rod 29 - Oil pump
6 - Inlet valve pushrod 14 - Intake manifold 22 - Starter motor 30 - Main bearing
7 - Cross-head 15 - Plenum chamber 23 - Engine block 31 - Timing gear (crankshaft)
8 - Inlet valve 16 - Injector 24 - Sump pan 32 - Torsional vibration damper
40-8
ENGINE
DISMANTLING THE ENGINE
1- The dismantling, assembly and inspection oper- 2 - Note that some of these repair and inspection op-
ations described in this section refer to an engine erations may also be carried out on the engine
that has been removed from the tractor and while it is installed in the tractor, following the
mounted on an engine stand. same criteria and the same procedures used for
complete overhaul.
1. PRELIMINARY OPERATIONS
1 - Remove the following components from the engine:
• the injection pump cover;
• the starter motor;
• the engine cooling fan and relative drivebelt;
• the alternator;
• the compressor of the air conditioning system and
the relative drivebelt;
• the compressor of the trailer air braking system (if
fitted);
For detailed instructions, refer to the corresponding
sections in this manual.
2 - Remove the spring coupling (2) from the flywheel (1).

★ Inspect the spring coupling carefully; if the central 1
hub has excessive radial play or if the springs are
deformed or have radial play, the coupling must be
renewed.
2
F0010320
3 - Screw dowel "A" fully into the central hole in the end of
the crankshaft. 1
4 - Remove the bolts (3) and remove the flywheel (1).
★ To separate the flywheel from the crankshaft, use a
lever on both sides.
Flywheel: 26 kg (57.3 lb.)
1
A
3
F0010330
40-9
ENGINE
5 - Attach the lifting sling or chain of an engine hoist to the

flywheel housing flange (4) and take up the slack in the
chain or sling. 4
6 - Remove bolts (5) and remove the flywheel housing

flange (4).
5
F0010340
7 - Remove the bolts and remove rear oil seal cover (6)
complete with gasket (7). 7
★ Renew the gasket at each re-assembly. 6
F0011830
8 - Attach a hoist to the lifting brackets on the engine and

mount the engine on a rotating engine stand.
F0012340
40-10
ENGINE
2. REMOVAL OF THE CYLINDER HEADS
15
14
17
18
16
1
6 19
4
9
7
11
13
28
29
33
35
12 34
32
30
31 27
25
24 26
22
2
3
23 20
21
D0002750
40-11
ENGINE
1 - Remove the retaining plate (1), disconnectthe hose (2)

from the turbocharger (3) and remove the intake pipe 3
1
(4).
4 2
F0010350
2 - Undo the bolts and remove the plenum (6) with the rel-
ative gaskets. 6
F0010360
3 - Remove the bolts (7) and nuts (8) securing the intake
manifolds (9) on the injection pump side. 9
9 7
F0010370
4 - Remove the bolts and remove the support brackets

(10) of the injection pump cover.
10 10 10
F0010380
40-12
ENGINE
5 - Remove the manifolds (9) with their respective gas-

kets (11) and (12). 9 11
12
F0010390
6 - Remove the high-pressure fuel pipes (13) .

★ Hold the pump fitting firm while loosening the pipe 13
fitting. 13
13
F0010400
7 - Disconnect the breather pipe (15) from the rear rocker

cover (14). 14 16
15
8 - Remove the nuts and washers securing rocker covers
(14) and (16).
14
F0010410
9 - Lift the two rocker covers (14) and (16) simultaneously

and remove them from the cylinder head. 17
★ Carefully check the condition of O-rings (17) and
(18).
★ Discard the old rocker cover gaskets (19). 18
14
19
16
F0010420
40-13
ENGINE
10 - Disconnect the lube oil delivery (20) and return (21) pi-
pes from the turbocharger (3); loosen clamp (22), dis- 20 3 22
connect the pipes from their fittings on the crankcase
and remove them.
★ Always renew the seals on the turbocharger fit-
tings. 21
20
21
F0010430
11 - Remove the retaining nuts and washers and remove

the turbocharger (3) along with its gasket (23). 3 23
F0010440
12 - Remove the retaining nuts and spring washers and

then remove both exhaust manifolds (24) and (25) si- 26
multaneously.
★ Check the condition of the seal (26) at the joint be- 25
tween the two manifolds. 24
★ Renew the seals (27) on the cylinder head.
27
F0011691
13 - Remove the retaining nuts and washers and then re-

move the intake manifolds (28) with their gaskets (29).
28
29
F0010460
40-14
ENGINE
14 - Loosen the clamp (30) securing the hose of the coo-

lant pump (31).
15 - Remove the 12 retaining bolts and washers of collect-
ing pipes (32) and (33). 30
32
31
F0010470
16 - Removing collecting pipes (32) and (33) complete with

the thermostatic valves. 34 35
★ Always renew the O-rings (34) at the connecting 33
hose (35). 32
★ To check the thermostatic valves, see «Sect. 30 -
REMOVAL AND INSPECTION OF THE THERMO-
STATIC VALVES».
F0010480
17 - Remove the nuts, washers and tapered washers.

18 - Remove the injector mounting brackets (36) and in- 37
36
jectors (37).
36
37
F0010490
19 - Loosen the nuts (38) of the tappets (39) and unscrew

the tappets sufficiently to release the rocker arms.
41
★ Loosen nuts (40) and unscrew the tappets (41) of
42
the cross-heads (42) of the inlet valves. 40
39
38
F0010500
40-15
ENGINE
20 - Remove nuts (43) and remove the complete rocker

arm support assemblies (44) and (45).
43 44
45
F0010510
21 - Remove the cross-heads (42) and the push-rods (46).

42
46
46
F0010520
22 - Mark the positions of the cylinder heads (47) relative to

the engine block.
★ Number the cylinder heads starting from cylinder 47
N° 1 (opposite end to the flywheel).
23 - Loosen and remove the cylinder head bolts (48) 48
F0010530
24 - Lift up the cylinder heads (47) and remove the push-

rod guides (49) complete with springs (50), seals (51) 47
and thrust washers (52).
★ Make a note of the position of the thrust washers
and which way round the seals are installed. 51
25 - Remove the complete cylinder heads (47). 49

49
50
52
50
51 F0010540
40-16
ENGINE
26 - Remove the head gaskets (53).

53 53
★ If the cylinder heads are to be refitted without renew-
ing the cylinder liners, make a note of the type of gas-
ket used for each cylinder head.
The thicknesses of the head gaskets can be deter-
mined by the presence or absence of identification
holes punched in the tab with central oil hole.
(For details see «ENGINE ASSEMBLY - Fitting the
cylinder heads»).
F0010550
2.1 Dismantling the cylinder heads
38
13 43
63 44
36 39
38 62
39 40
64 37
42
62
43 61 41
45 56
46
56
61 59 53
46 54
55
51 60
60
49
47
50 48
52 53
58
51
58
57 D0002740
40-17
ENGINE
1 - Before dismantling, carefully clean the surfaces of the

cylinder heads and the valves.
Using tool T11 (code 5.9030.433.0) and a dial gauge,
check that the stand-in of the inlet and exhaust valves T11
is within the permissible limits. (See «TESTS AND TE-
CHNICAL DATA»).
F0010560
2 - If the valve stand-in is within the prescribed limits, be-

fore removing the valves, mark their positions relative
to the cylinder head so that, if not damaged, they may
be refitted in their original positions. S1
A1 S1
Example: Cylinder head 1 - A1 - A 2 - S 1 A1
2 - A3 -A4 - S2 A2
A2
F0010570
3 - Using tool T12 (code 5.9030.012.0), compress the

springs (54) and (55) and remove the split collets (56)
59 55
of valves (57) and (58).
4 - Release the pressure and remove the springs and (55) T12
and spring plates (59).
56 55
54
54
F0010580
5 - Withdraw valves (57) and (58).
57
58
F0010590
40-18
ENGINE
6 - Using a screwdriver or lever, remove the valve seals

(60).
60
F0010600
2.2 Dismantling the rocker arm supports

1 - Remove circlips (61). 62
2 - Remove thrust washers (62) and remove rocker arms 61

(63) and (64).
63
64
F0010610
40-19
ENGINE
3. REMOVAL OF THE COOLANT PUMP
D0002760
1 - Loosen the hose clamps and detach hoses (1) and (2).
2
F0010620
2 - Remove the retaining bolts and then remove the co- 3

olant pump (3) with its gasket.
★ Renew the gasket (4) at each re-assembly.
4
F0010630
40-20
ENGINE
4. REMOVAL OF THE UNIT INJECTION PUMPS, THE GOVERNOR AND THE FUEL LIFT PUMP
9
4
1
3
7 10
8
11
12
13
5 6
7
D0002810
1 - Undo fittings (1) and remove the fuel delivery pipe (2)
to the injection pumps.
F0010640
40-21
ENGINE
2 - Undo fittings (3) and the fuel return pipe (4).
F0010650
3 - Remove the bolts (5) and remove the inspection cover

(6) complete with its gasket.
6
5
5
F0012630
4 - Record the positions of the injection pumps (7) and the

relative shims (8) to avoid confusion during re-assembly.
5 - Manually move the control rod to the mid-stroke posi-
tion, remove the retaining nuts and washers and then re- 7
move the injection pump (7) along with the shim pack (8).
★ Note that if the shims and the pumps are mixed up
and not refitted in their original positions, then it will 8
be necessary to carry out the timing procedure on
all the pumps
8
F0010660
6 - Remove the bolts and washers and then remove the

governor (9) and its gasket (10).
9
10
F0010670
40-22
ENGINE
7 - Remove the screws and remove the governor support

(11) and gasket (12).
11
12
F0010680
8 - Remove the nuts and the toothed washers and then

remove the fuel lift pump (13).
13
F0010690
40-23
ENGINE
5. REMOVAL OF THE INJECTION PUMP CONTROL ROD
1
2
4
6 5
7
6 3
D0002800
1 - Loosen and remove the retaining plug (1).

★ Renew the O-ring (2) if deformed.
1 2
F0010700
40-24
ENGINE
2 - Withdraw the control rod (3), the spring guide (4) and
spring (5).
5
4
3
F0010710
3 - Remove the retaining screws and remove the control

rod guide assemblies (6) and (7).
★ Note that the central control rod guide assembly
(7) does not have a guide wheel. 6 7
★ Renew the O-rings (8) and remove all traces of the
old sealant.
F0011810
40-25
ENGINE
6. REMOVAL AND DISMANTLING OF ANCILLARY COMPONENTS
2 5
7
3 6
1
5
8
4
D0002730
1 - Remove the engine oil filters (1).

2
2 - Remove pipes (2) and (3) and remove the complete
heat exchanger assembly.
★ Check the condition of the O-rings.
3 - Remove the engine oil filler pipe (4). 1
3
F0010720
40-26
ENGINE
4 - Dismantle the heat exchanger by removing the oil

cooler assembly (5).
5
F0010730
5 - Remove the screws and remove the oil cooler (6).

★ Renew the gaskets at each re-assembly.
F0010740
6 - Remove the oil vapour collector (7).

7 - Remove the alternator mounting bracket (8).
7 8
F0010750
40-27
ENGINE
7. DISMANTLING THE VALVE TIMING DRIVE
12
10
11
3
15
15
14 16
13
5 6
7
D0002780
40-28
ENGINE
1 - Remove the bolts and remove the crankshaft pulley (1)

and the torsional vibration damper (2).
2
1
F0010760
2 - Remove the engine speed pick-up unit (3).

3
3 - Remove the cover plate (4).
★ This operation only applies to tractors equipped
with an air compressor for trailer air braking.
4
F0010770
4 - Remove the retaining screw (5) of the pulse wheel (6).
F0010780
5 - Remove the pulse wheel (6).

★ If necessary, use a lever on opposite sides of the 6
wheel to remove it.
6 - Remove the cover plate (7).
F0010790
40-29
ENGINE
7 - Remove the screws and remove the timing cover (8).

★ The gasket (9) will remain in position, but must in 8
any case be renewed at each re-assembly.
★ If the crankshaft oil seal is to be renewed see
«RENEWAL OF THE FRONT CRANKSHAFT OIL
SEAL».
F0010800
8 - Remove the retaining bolts and remove the camshaft

timing gear (10).
10
F0010810
9 - Position a dial gauge with magnetic stand so that the

contact point rests on the end face of the camshaft 11
and preload the gauge by about 3 mm (0.118 in.).
Push the camshaft along its axis in either direction; ze-
roset the dial gauge and then push the camshaft in the
opposite direction to measure the endfloat. Check
that the measured endfloat is within the prescribed
limits (see «TESTS AND TECHNICAL DATA»).
If not, replace the camshaft thrust plate (11).
F0011840
10 - Remove the retaining screws (11) and washers and re-

move the camshaft thrust plate (12).
11 11
12
12
F0010820
40-30
ENGINE
11 - Remove the circlip (13) and shim (14) and remove the
bronze thrust washer (15) of the intermediate timing
gear (16). 16 15
13
14
16
F0010830
12 - Remove the intermediate timing gear (16) and the

thrust washer (15).
15
16
F0010840
13 - Turn the engine upside down and withdraw the cam-

shaft (12).
★ Exert a constant pull in the direction of the cam-
shaft axis while rotating the shaft in both direc-
tions.
★ Take great care not to damage the bearings with 12
the cam lobes.
F0010850
40-31
ENGINE
8. DISMANTLING THE CRANKSHAFT
19
20
21
18
15
17
16 15
13 14
11
10
8
9 3
7
12
4
6
D0002790
40-32
ENGINE
1 - Loosen and remove the sump pan (2) bolts (1).

1 2
★ As there are two types of sump pan, make a note of the
positions of the washers and spacers (where fitted).
1
1
F0010860
2 - Attach the lifting slings of a hoist to the sump pan (2)

and lift it clear of the engine block.
★ To break the seal between the sump pan and
2
block, tap the pan gently with a soft mallet.
★ Always renew the gasket (3).
F0010870
3 - Remove oil vapour recovery pipe (4) by loosening fit-

ting (5) and the bracket (6) retaining nut.
6
4
4 5
F0010880
4 - Remove the bolts and washers and remove the oil

pump (7) complete with pick-up pipe.
★ Recover shims (8) and (9). 7
9
8
F0011890
40-33
ENGINE
5 - Position a dial gauge with magnetic stand “A” so that

the contact point rests on the end face of the crank- B
shaft and preload the gauge by about 3 mm (0.118 in.).
Using a lever “B”, push the crankshaft along its axis in
either direction; zeroset the dial gauge and then push
the crankshaft in the opposite direction and check that 16
the endfloat is within the prescribed limits.
If the endfloat exceeds the limit, change the thrust
washers for oversize ones (see «TESTS AND TECH- A
NICAL DATA».
F0012640
6 - Remove the cap bolts and remove the big-end bearing

caps (10) complete with the shell bearings.
★ Mark the bearing shells with their respective con- 10
necting rods for subsequent dimensional checks.
★ Note that the numbers stamped on the big-end
caps and their relative connecting rods are posi-
tioned towards the injection pump side of the en-
gine.
★ Mark the installation positions of the individual
connecting rods. If the engine is not to undergo
major overhaul, ensure that the connecting rods
and caps are refitted in their original positions.
F0010900
7 - Remove the bolts and the central main bearing caps

2
(11) complete with the half shells.
2
★ Mark the half shells with the relative main bearing
caps for subsequent dimensional checks.
★ Note that the central main bearing caps and their
1
relative crankcase positions are stamped with the
1
same number. The symbol "A" points towards the
11
injection pump side of the engine.
A
F0010910
8 - Remove the cap bolts and remove the front main bear-
ing cap (12) complete with the half shell (13).
12
★ Mark the front bearing half shell and the corre-
sponding main bearing cap for subsequent dimen-
sional checks.
★ Along with the main bearing are also removed the
triangular seals that must be renewed at each re-
assembly.
13
F0010920
40-34
ENGINE
9 - Remove the bolts and the rear main bearing cap (14)
complete with the half shell and thrust washers (15). 14
★ Mark the half shell and the rear main bearing cap
for subsequent .dimensional checks 15
★ Note which way round the thrust washers are in-
stalled. The oil grooves are oriented towards the
crankshaft.
★ Along with the main bearing are also removed the 16
triangular seals that must be renewed at each re-
assembly.
F0010930
10 - Attach the slings of hoist to the crankshaft (16) and lift

it clear of the crankcase.
16
F0010940
11 - Remove the lower halves of the thrust washers (15)

and the main shell bearings (17). 15
★ Mark the positions of the half shells for subsequent
dimensional checks.
17
F0010950
12 - Remove the cam followers (18) from the engine block.

★ Examine the bearing surfaces of the cam followers
which are in contact with the cams.
The surfaces should be completely smooth, and
the cam followers must be renewed if the bearing 18 18
surface shows any roughness or indentation.
F0010960
40-35
ENGINE
13 - Undo nuts (19) and remove the oil jets (20) with their
seals. 21
14 - Only if necessary: remove fitting (21).
19
20
F0010970
8.1 Dismantling the oil pump
9
30
8
27
5
29
22 4
28 23
26
4 6 25
24 D0002820
★ The only reason for dismantling the oil pump is to carry

out a visual inspection of the internal components; if
any undue wear is found, the entire pump assembly
must be renewed.
The pressure relief valve should be dismantled if, on
testing the pump delivery pressure, the pressure is be-
low the value indicated in the section «TECHNICAL
DATA ».
40-36
ENGINE
1 - Remove the pressure relief valve (22).
22
F0010980
2 - Remove the spring pin (23) and dismantle the valve as-
sembly by removing end cap (24), spring (25) and pi-
ston (26).
25 26
3 - Clean carefully and re-assemble the valve, checking
that the piston (26) slides freely.
24
Valve: 90±5 Nm (66.3±3.7 lb.ft.)
★ Valve calibration: 5±0.5 bar (72.5±7.25 psi)
23
F0010990
4 - Remove the oil pick-up pipe (27), screws (28) and re-
move the pump body (29) in order to inspect the gears 29
(30) and pump body for wearand to decide whether
the pump requires renewal.
★ On re-assembly, liberally lubricate the gears and the
drive shaft with oil.
Gears: Gear oil
Screws: 20.4 Nm (15 lb.ft.)

★ Capacity: 97ᐉ at 2400 rpm 30
(25.6 US.gall. a t 2400 rpm)
F0011000
40-37
ENGINE
9. REMOVAL OF THE PISTONS AND CYLINDER LINERS
4
9
5
10
6
5 7
1
1 2
D0002770
1 - Use a mallet and a plastic drift to loosen and withdraw

the cylinder liners (1) along with the pistons and con-
necting rods.
F0011010
40-38
ENGINE
2 - Withdraw the piston-connecting rod assembly (2)

from the bottom end of the liner (1).
3 - Remove the O-ring seals (3) from the cylinder liner (1).
★ The O-rings must be renewed at each re-assem- 1
2
bly.
3
F0011020
9.1 Separating the piston-connecting rod assembly

1 - Remove the circlip (5) from the piston (4).
2 - Withdraw the gudgeon pin (6) and remove the con- 7
necting rod (7).
★ Note that the arrow stamped on the piston crown 5 4 6
points in the opposite direction to the number on
the connecting rod.
F0011030
3 - Using piston ring pliers, remove the top and second

rings (8) and (9) from the piston (4). 8
8
9
9
F0011850
4 - Remove the oil scraper ring (10).
10
F0011860
40-39
ENGINE
5 - Remove the spring expander (11) of the oil scraper

ring (10).
11
F0011040
10. RENEWAL OF THE REAR CRANKSHAFT

OIL SEAL
1 - Using a punch, remove the oil seal (2) from the cover
(1).
★ Make a note of which way round the seal is in- 2
stalled and its position.
F0012650
On first assembly, the oil seal (2) is fully inserted in its

seating in the carrier. A B C
At each subsequent renewal, the oil seal (2) must be
moved a distance of 2.5 mm (0.098 in.) towards the
outside of the engine.
ORIGINAL 1st OVERHAUL 2nd OVERHAUL

A B C
X= 0 mm X= 2,5 mm X= 5 mm
(0 in.) (0.098 in.) (0.197 in.)
X X X
D0002040
2 - Using a press and a suitable drift, install the new oil

seal (2) in the carrier (1) in the correct position as per
the indications above.
F0011820
40-40
ENGINE
TESTS - TECHNICAL DATA AND DIMENSIONS
1. CYLINDER HEADS - VALVES -

ROCKER ASSEMBLIES
1.1 Inspection and renewal of valve guides T13
1 - Examine the valve guides for signs of scuffing or

damage.
Check the inside diameter using a plug gauge T13
(code 5.9030.877.0); if the NP end of the plug gauges
enters the guides, they must be renewed.
F0011870
1.2 Renewal of the valve guides

1 - Position the cylinder head on a perforated plate under
a press; using drift T14 (code 5.9030.850.0) withdraw
T14
the valve guides.
F0011050
2 - Carefully clean the valve guide seatings, lubricate the

external surfaces of the guides and insert them using
tool T15 (code 5.9030.851.0). T15
Valve guides: engine oil
★ The correct insertion depth is determined by the
full stroke of the insertion tool. (See «TECHNICAL
DATA AND DIMENSIONS)
F0011060
1.3 Inspecting the valve seats

1 - Using tool T11 (code 5.9030.433.0) and a dial gauge,
check the valve stand-in relative to the cylinder head T11
surface.
2 - If the stand-in of even a single valve is not within the
tolerance limits indicated in «TECHNICAL DATA AND
DIMENSIONS», all the valve seats will have to be re-
newed by a specialised engineering shop.
F0010560
40-41
ENGINE
3 - Inspect the valve seats and valve faces for signs of pit-
ting or deformation.
4 - If the defects are such that they cannot be removed
simply by grinding, new valve seats will have to be in-
stalled by a specialised machine shop.
★ New valve seats are supplied pre-finished; no fur-
ther grinding is required after fitting. Before fitting,
the valve seats must be cooled in liquid nitro-
gen.
★ For valve-stand-in, seat and face angles see «TE-
CHNICAL DATA AND DIMENSIONS».
1.4 Inspecting the valves

1 - Measure the diameter of the valve stem using a mi-
crometer.
★ Measure diameter of the stem at various points
along its length and at 90° intervals.
★ If the stem diameter is not within the specified tol-
erance limits, the valves must be renewed.
For tolerance limits, see «TECHNICAL DATA AND
DIMENSIONS».
F0011880
1.5 Inspecting the valve springs

1 - Stand each valve spring (1) on a flat surface and check
it for squareness. 1
F0011890
2 - Check the length of each valve spring (1).

3 - If either of these two parameters is found to be outside
the tolerance limits specified in «TECHNICAL DATA
AND DIMENSIONS», the springs must be renewed.
★ Springs with signs of corrosion on the coils must
also be renewed.
F0011900
40-42
ENGINE
1.6 Testing the valve seals

1 - After cleaning the cylinder head thoroughly, lubricate
the valve stems and fit the valves, springs and retainers.
2 - Check the valve seal by pouring a few drops of solvent
into the inlet and exhaust ports; reground valves
should not leak, while for new valves and seats, a
slight leakage is permissible.
NOTE - The valve seats automatically bed in after a
very short time of operation with the engine running.
F0010591
1.7 Checking injector protrusion

1 - Fit the injector (1) in the cylinder head and secure it
with bracket (2), tapered washer (3) and nut (4).
Nut: 39 Nm (28.8 lb.ft.) 2 1

4
3
F0011910
2 - Use a caliper to measure the protrusion "A" of the in-

jector from the cylinder head surface (5).
A
5
F0011920
3 - If the protrusion is not within the value range indicated

in "TECHNICAL DATA AND DIMENSIONS", it will be 6 B
necessary to restore the seating face "B" of the injec-
tor (1) by regrinding the copper bush (6) as shown in
the figure and interposing a 1 mm (0.0394 in) thick 1 cod. 2.1499.201.0
copper washer (code 2.1499.201.0).
★ If the copper bush has already been reground, it
will have to be renewed in the manner described in
the next paragraph.
A
18,4 + 00,1mm
D0001050
40-43
ENGINE
1.8 Renewal of the copper bushes

★ These operations should be carried out by a specia-
lised machine shop.
Ø 17,7±0,1 mm
A=31 mm
0,1 A
1 - Ream out the old bush mechanically using a system
with swarf extraction; remove enough material from
3,2
the inside diameter so that the bush can be easily de-
formed and thus withdrawn.
2 - Remove all traces of old sealant and metal particles
from the groove "C" .
★ Take care not to damage the bush seating bore.
93 mm
3 - Thoroughly degrease the bush seating bore and the
C
new bush.
4 - Apply silicone sealant to groove "C". 0,05 A
0,05
Sealant: DIRKO TRANSPARENT 3,2
★ Once the sealant has been applied, the new bush
must be inserted within 10-15 minutes; if this time D
period elapses without inserting the bush, the
sealant must be removed and fresh silicone ap-
mm
A
plied.
+0,1
+0,1
Ø 7,5 mm
0
0
5 - Insert the bush in the bore in the cylinder head and
19,4
press it fully home against seat "D".
3,2
6 - While maintaining the pressure, widen the bush to im- D0002690
prove the axial seal to a depth "A" of 31 mm (1.22 in.)

from the face.
7 - Calibrate the nozzle seat using a ball calibration tool
Ø 7.5 mm (0.295 in.).
8 - Finish the seat and the injector contact surface to the
dimensions indicated.
40-44
ENGINE
1.9 Inspecting the rocker arms and pivot posts

1 - Measure the inside diameters of the rocker bushes
and the diameters of the pivot posts.
Use a dial bore gauge and a micrometer.
If the wear exceeds the tolerance limits indicated in
«TECHNICAL DATA AND DIMENSIONS», renew the
rocker bushes and the pivot posts.
★ When renewing rocker bushes, take great care that oil
holes and grooves are correctly oriented (see «TECH-
NICAL DATA AND DIMENSIONS»).
F0011930
2 - Using the bore gauge T16 (code 5.9030.853.0) check

the inside diameter of the guide bores "A" in the cross-
heads (1), and, with a micrometer, check the outside T16
diameter of the guide post (2).
If the wear exceeds the tolerance limits indicated in
«TECHNICAL DATA AND DIMENSIONS», renew the A
cross-head and the guide post.
2
1
F0011940
40-45
ENGINE
TECHNICAL DATA AND DIMENSIONS
CYLINDER HEADS - VALVE GUIDES - VALVE SEATS

4
8
6 1
9 2
7
D0001090
Unit of measurement: mm (in.)

Normal Tolerance
Pos. Dimensions measurement limit NOTES
Inlet 0.65 0.55 -- 0.95

(0.026) (0.022 -- 0.037)
1 Valves stand-in
0.60 0.50 -- 0.90
Exhaust
(0.024) (0.020 -- 0.035)
Inlet 120° --150 ‘ --
2 Valve seat angle --15 ‘
Exhaust 90° 0 --
Inlet 3.59
Contact band (0.141)
3 (valve to seat) 3.39
Exhaust
(0.133)
Renew when the clearance be-
4 Inside diameter of valve guide 8.025 (0.316) tween the guide and the valve
8.040 (0.317)
exceeds 0.1 mm (0.004 in.).
9.0±0.2
Inlet (0.354±0.008)
Protrusion of valve guide
5
above spring seat 13.5±0.2
Exhaust --
(0.532±0.008)
19.4+0 0,1 18.4+0 0,1 W it h 18 , 4 m m (0 . 72 5 i n. )

6 Length of injector nozzle holder nozzle holder add a 1 mm
(0.764+0 0.004) (0.725+0 0.004) (0.04 in.) thick copper shim
7.5 -- 7.6
7 Injector nozzle holder bore --
(0.295 -- 0.299)
17.7 -- 17.8
8 Copper bushing bore (0.697 -- 0.701) --
9 Injector protrusion 3.01 -- 2.4 --

(0.118 -- 0.094)
40-46
ENGINE
VALVES - VALVE SPRINGS
2
3 D0001100

Normal Tolerance
Pos. Dimensions NOTES
measurement limit
7.987 (0.315)
Inlet
7.972 (0.314) Renew when the clearance be-
1 Valve stem diameter tween the guide and the valve
7.987 (0.315) exceeds 0.1 mm (0.004 in.).
Exhaust
7.972 (0.314)
35.9 -- 36.1
Inlet
(1.414 -- 1.422)
2 Valve head diameter
42.3 -- 42.5
Exhaust
(1.666 -- 1.674)
Inlet 120°
3 Valve face angle
Exhaust 90°
Inlet 41.54 (1.637)

Valve spring free length
Exhaust 48.57 (1.914)
4
Inlet --- ---
Angle No deviation from
perpendicular permitted
Exhaust --- ---
40-47
ENGINE
ROCKER ARMS - ROCKER PIVOT POSTS - TAPPETS
3
2C
1
2B
7
4 2A
6
5
D0001110

Normal Tolerance
measurement limit
Renew when the clear-

19.015 (0.749) ance between the rock-
1 Inside diameter of rocker-arm bush er-arm bush and pivot
19.025 (0.746) post exceeds 0.08 mm
(0.0031 in.).
Between cross-head
A and valve stem
0.05 (0.002)
Inlet valve clearances
2 B Between cross-head
and rocker arm
0.15 (0.006)
0.25 (0.001)
Exhaust valve clearance C Between rocker arm

and valve stem
0.15 (0.006)
0.25 (0.001)
19 -- 18.987
3 Diameter of rocker arm pivot posts
(0.749 --0.748)
10 -- 10.015 Renew when the clear-
4 Diameter of cross-head guide post bore
(0.394 --0.395) ance between the guide
post bore and the guide
9.987 (0.3934) post exceeds 0.08 mm
5 Diameter of cross-head guide post
9.972 (0.3928) (0.0031 in.).
15.984 (0.630)
6 Outside diameter of cam follower stem
15.966 (0.629)
Max. 0.3
7 Push-rod flexure ---
(Max. 0.012)
40-48
ENGINE
2. INJECTORS - INJECTION PUMPS
2.1 Testing the injectors

★ The injectors are to be tested for spray formation
and opening pressure.
1 - Unscrew the nozzle holder (1), remove the complete
nozzle assembly (2) and the direction control plate (3) 2
and empty the injector any remaining fuel. 1
★ The injector must be emptied of all residual fuel be-
fore testing.
F0011070
2 - Re-assemble the injector and connect it to the injector

test unit.
Operate the hand lever to pump air out of the circuit
and fill the injector with fuel.
Operate the pump slowly while observing the pres-
sure gauge to check the opening pressure.
Repeat the test a number of times to check that the
opening pressure remains constant.
★ This method is also used to test the uniformity of
the spray pattern; the number of fuel jets should
correspond to the number of holes in the nozzle
and these jets should be both finely atomised and
uniform.
If the opening pressure does not correspond to
that indicated in «TECHNICAL DATA AND DIMEN-
SIONS», the injector will have to be calibrated by a
specialised repair shop.
F0011080
3 - Also test the seal between the nozzle seat (2) and the
needle valve. To do this, operate the pump to build up
the pressure that is approx. 10% lower than the open-
ing pressure.
Maintain the pressure and check that no fuel leaks
from the nozzle.
If leakage occurs, the entire injector assembly must be
renewed.
F0011090
40-49
ENGINE
INJECTOR TECHNICAL DATA

Injector type:: D17 code 2.4719.420.0
Calibration pressure: 180 +0 8 bar (2610.5 +0 116 psi)
Max. injection pressure: 1200 bar (17403.6 psi)
Nozzle type D.17 5-hole Dis. 2.4729.210.0
Nozzle holder: type D.17 Dis. 2.4719.430.0
120° 2 A
30°
1 3
2,5
Ø14
5 4
B
145°
A = Injector axis
275
B = Combustion chamber axis

Ø 0,
1,21
Ø 6,25
D0002070
2.2 Testing the injection pumps

Injection pump testing and calibration must be carried out
by a specialised service centre equipped with a pump test
bench and the necessary test and calibration equipment.
The service centre must be given the technical specifica-
tions indicated in this section.
40-50
ENGINE
PUMP CHARACTERISTICS
ENGINE POWER kW (CV) 88,2 (120) 100 (135) 110 (150)
Injection pump type BOSCH PFR 1K 90A 555 BOSCH PFR 1K 90A 555 BOSCH PFR 1K 90A 535
Pumping element code (BOSCH) D411702017 D411702017 D401702025
Identification plate colour Red Red Black
Control rod stop position at point X mid-stroke mid-stroke mid-stroke
Full stroke mm (in.) 19 --20.5 (0.749 --0.808) 19 --20.5 (0.749 --0.808) 19 --20.5 (0.749 --0.808)
Nominal pre-lift for mm (in.) 2.4 -- 2.5 (0.095 -- 0.098) 2.4 -- 2.5 (0.095 -- 0.098) 2.4 -- 2.5 (0.095 --0.098)
delivery start at X+3
Constant pressure reflux valve
calibrated to bar (psi) 70+10 +145
0 (1015.2 0 ) 70+10 +145
0 (1015.2 0 ) 70+10 +145
0 (1015.2 0 )
Depth of start
mm (in.) 0.5 (0.02) 0.5 (0.02) 0.5 (0.02)
retard notch
Retard notch intervention mm (in.) X+7 (X+0.276) X+7 (X+0.276) X+7 (X+0.276)
starting point
TEST METHOD
• Engine injector: Dis. 2.4719.200.0/11
• High-pressure fuel pipe: Ø 6x1,5x267 mm (0.236x0.059x10.512 in.)
• Test oil: ISO4113 at a temperature of 40°±2°C (104°±35.6°F)
• Supply pressure: 0.4±0.05 bar (5.8±0.73 psi)
• Cam: BOSCH Dis. 1586.101.021 - lift 7 mm (0.276 in.)
• Calibrated outlet hole: 1 mm (0.04 in.)
INJECTION PUMP CALIBRATION FOR 88.2 - 100 kW (120 - 135 CV)
Rotation speed Control rack- Delivery (mm³/shot)

stroke
rpm mm Calibration Test
Calibration 300 X--1.9 (X-- 0.075) 12.5 -- 13.5 8.0 -- 18
1st test 750 X 53.5 -- 59.5 52.5 -- 160.5
2nd test 1300 X 50.5 -- 55.5 49.5 -- 56.5
3rd test 100 X+9 (X+0.355) 91.0 -- 109.0 90.0 -- 10.0
INJECTION PUMP CALIBRATION FOR 110 kW (150 CV)
Rotation speed Control rack- Delivery (mm³/shot)

stroke
rpm mm Calibration Test
Calibration 300 X--3.9 (X-- 0.154) 13.0 -- 14.0 8.5 -- 18.5
1st test 750 X+3 (X+0.118) 102.0 -- 108.0 101.0 -- 109.0
2nd test 1250 X+3 (X+0.118) 86.0 -- 92.0 85.0 -- 93.0
3rd test 100 X+9 (X+0.355) 94.0 -- 112.0 93.0 -- 113.0
40-51
ENGINE
3. PISTONS - CONNECTING RODS
3.1 Inspection of the pistons and piston rings

1 - After removing all carbon deposits and cleaning the
pistons thoroughly, measure the outside diameters of
the pistons using a micrometer.
Measure the diameter at 17 (0.670 in.) and 58.5 mm 58,5 mm
(2.305 in.) from the bottom of the skirt and at 90° to the 17 mm
gudgeon pin axis.
If the measurements are not within the tolerance limits
specified in «TECHNICAL DATA AND DIMENSIONS»,
renew the pistons.
F0011950
2 -Check the groove clearances of the second piston

ring and the oil scraper ring.
Use a feeler gauge and a new ring as shown in the fig-
ure.
★ The top piston ring has a tapered section and
therefore it is not possible to check its groove
clearance.
If the groove clearance of the second piston ring or the
oil scraper ring exceeds the values specified in «TE-
CHNICAL DATA AND DIMENSIONS», renew the pi-
ston.
F0011960
3 - Clean the carbon deposits from the upper parts of the

cylinder liners; insert the compression rings and oil
scraper rings one at a time into the bottom end of the
cylinder liner and check the end gap using a feeler
gauge.
★ Push the rings in by about 20 mm (0.788 in.) while
20 mm
keeping them square to the cylinder head.
If the end gaps are not within the tolerance limits in-
dicated in «TECHNICAL DATA AND DIMEN-
SIONS», renew the compression and oil scraper
rings.
F0011970
4 - Check the inside diameter of the bore for the gudgeon

pin using a bore gauge.
F0014100
40-52
ENGINE
3.2 Inspecting the connecting rods - gudgeon pins

1 - Check the parallelism between the small-end and big-
end axes of the connecting rod using tool T17 (code
5.9030.651.4) and a dial gauge with the contact point T17
resting on the gudgeon pin.
The procedure is as follows:
1 - Fit the gudgeon pin and the big-end cap to the
connecting rod.
2 - Position the connecting rod on the tool, and rotate
it in both directions; preload and zeroset the dial F0011980
gauge at the point of .maximum radius.

3 - Turn the connecting rod over and take the reading
again.
The difference between the two readings is the
parallelism error. If the error is greater than the tol-
erance limit specified in «TECHNICAL DATA AND T17
DIMENSIONS», the connecting rod must be re-
newed.
If one or more connecting rods are re-
newed, the weight of the new rods must be
compared with that of the original rods that
are reutilised; the maximum permissible
weight difference between the lightest F0011990
connecting rod and the heaviest is 20 g.

2 - Using a bore gauge, measure the inside diameter of
the big-end shell bearing. If the bearing wear exceeds
the tolerance limit specified in «TECHNICAL DATA
AND DIMENSIONS»), renew the shell bearing.
F0012000

the small-end bush; if the bush wear exceeds the tol-
erance limit specified in «TECHNICAL DATA AND
DIMENSIONS», renew the bush.
When inserting new small-end bushes, make sure
that oil grooves and the splits in the bushes are
positioned correctly.
F0012010
40-53
ENGINE
4 - Using a dial gauge, measure the outside diameters

of the gudgeon pins; if the diameter of a gudgeon
pin is not within the tolerance limits specified in
«TECHNICAL DATA AND DIMENSIONS», renew
the gudgeon pin.
F0012020
4. INSPECTION OF THE BIG-END CAP

BOLTS
1 - Using a dial gauge or micrometer, measure the diam-
eter of the bolts along the central reduced diameter
section; the difference between the maximum and
minimum dia-meter gives an indication of the stress to
which the bolt has been subjected during previous
tightenings.
If the difference between the minimum and maximum
diameter exceeds that indicated in the table «TECH-
NICAL DATA AND DIMENSIONS», renew the bolts.
F0012030
40-54
ENGINE
PISTONS - PISTON RINGS

TOP
1 2
TOP
5
3
A1 4
4 B 2-3-4
39,5
60°
26,5
20
2 60°
3
D0001120
Pos. Dimensions Normal Tolerance NOTES

measurement limit
Piston diameter 104.9 (4.133) 104.680

A = 104.89 (4.1326) (4.1244)
1 (Distance from bottom of skirt:
A= 17 mm (0.670 in.) 104.83 (4.1303) 104.600
A1= 58.5 mm (2.305 in.) A1=
104.81 (4.1295) (4.1212)
Top --- --- Chromium-plated

wedge section
0.070 (0.0027) 0.150 Chromium-plated
Piston-ring side clearance Second 0.105 (0.0041) (0.006) asymmetric torsional
2 0.030 (0.0012) 0.150
Oil scraper Chromium plated
0.065 (0.0026) (0.006)
3
Top 0.40 -- 0.65 1.5
4 (0.016 -- 0.026) (0.06)
0.30 -- 0.50 1.5
Piston-ring end gap "B" Second (0.012 -- 0.020) (0.06)
0.30 -- 0.60 1.5
Oil scraper
(0.012 -- 0.024) (0.06)
Outside diameter of gudgeon pin 34.99 -- 34.984 34.960

(1.3786 -- 1.3784) (1.3774)
5
35.012 (1.3795) 35.020
Inside diameter of gudgeon pin bores 35.006 (1.3792) (1.3798)
40-55
ENGINE
CONNECTING RODS
49
1
3
30°
2
B A
B=Assembly reference
D0001130

Normal Tolerance
Pos. Dimensions measurement limit NOTES
35.015 (1.3796) 35.060

1 Inside diameter of small-end bush
35.025 (1.3800) (1.3814)
Inside diameter of big-end bearing 63.535 (2.5033) 63.620

65.575 (2.5836) (2.5066)
63.285 (2.49349 63.370
2 1st undersize (regrinding) 63.325 (2.4950) (2.4968)
63.035 (2.4836) 63.120
2nd undersize (regrinding)
63.075 (2.4851) (2.4870)
3 Parallelism of connecting rod axes -- Max. 0.08

(measured at 49 mm from the longitudinal axis) (Max. 0.0032)
Max. 0.1
4 Difference in diameter in section A of bolt -- (Max. 0.004)
5 Difference in weight between connecting rods -- Max. 20 g
40-56
ENGINE
5. CRANKSHAFT
1 - Using a micrometer, measure the diameters of the

main bearing journals and the crankpins.
★ Measure the diameter of each journal at several
points around the entire circumference to detect
taper and out-of-round errors.
F0012040
2 - If the dimensional errors of even just one journal ex-

ceed the tolerance limits specified in the «TECHNICAL
DATA AND DIMENSIONS» the entire crankshaft will
have to be reground, and the diameters of the journals
reduced to one of the specified undersizes.
★ If the crankshaft is reground, it will be necessary to
fit new big-end and main shell bearings.
F0012050
Only if necessary
3 - Using puller T18 (code 5.9030.008.4/10) remove the
timing gear (1) from the crankshaft 1 T18
4 - Heat the new timing gear on a hot plate and fit it on the
crankshaft, ensuring that it is positioned up against
the shoulder.
★ Check the condition of the key.
F0012060
Only if necessary
5 - Using puller T18 (code 5.9030.008.4/10), remove the
oil pump drive gear (2). 2 T18
★ Remove all traces of old sealant from the crank-
shaft.
F0012330
40-57
ENGINE
6 - Heat the new gear on a thermostatic hotplate to a tem-

A 2
perature 100°C greater than that of the crankshaft. 3
3
7 - Apply sealant to the gear contact surfaces of the
crankshaft.
2
Crankshaft: Loctite 648
8 - Fit the gear (2) onto the crankshaft (3) so that it is a dis-
tance "A" from the crankshaft shoulder (3).
★ A = 0.2 -- 0.5 mm (0.079--0.197 in.).
F0012070
9 - When the gear has cooled, remove the excess sealant

and check that the side play of the gear does not ex-
ceed 0.1 mm (0.004 in.) when measured in correspon-
dence with the Ø116 mm (4.56 in.).
★ If the side play exceeds 0.1 mm (0.004 in.), using a
soft metal punch (copper, aluminium, brass),
move the gear to within the tolerance limits.
F0012080
40-58
ENGINE
CRANKSHAFT
n°1 n°2 n°3 n°4 n°5 n°6
4
5 1 1 1 1 1 1 1
2 2
3
2 2 2 2
D0001140
Pos. Dimensions Normal Tolerance NOTES

measurement limit
Main bearing journal diameter 69.98 -- 69.96 (2.7572 -- 2.7564) 69.90 (2.7541)
1st undersize (regrinding) 69.73 -- 69.71 (2.7474 -- 2.7466) 69.65 (2.7442)
1 2nd undersize (regrinding) 69.48 -- 69.46 (2.7375 -- 2.7367) 69.40 (2.7344)
Permitted taper Max. 0.030 (Max. 0.0012) 0,050 (0.002)
Permitted ovality Max. 0.005 (Max. 0.0002) 0,050 (0.002)
Crankpin diameter 63.50 -- 63.48 (2.5019 -- 2.5011) 63.40 (2.4980)
1st undersize (regrinding) 63.25 -- 63.23 (2.4920 -- 2.4913) 63.15 (2.4881)
2 2nd undersize (regrinding) 63.00 -- 62.98 (2.4822 -- 2.4814) 62.90 (2.4783)
Permitted taper Max. 0.030 (Max. 0.0012) 0.050 (0.002)
Permitted ovality Max. 0.005 (Max. 0.0002) 0.050 (0.002)
Crankshaft endfloat 0.105 -- 0.300 (0.0041 -- 0.0118) 0.500 (0.020)
1st assembly --
3
Thrust washers 1st oversize +0.250 (+0.01) --
2nd oversize +0.500 (+0.02) --
Max. 0.1 Max. 0.1
4 Side play of pump drive gear (Max. 0.004) (Max. 0.004)
5 Crankshaft pulley tightening torque See «ENGINE ASSEMBLY»
NOTES FOR REGRINDING

1 - Before regrinding the crankshaft, check for cracks using a penetrating liquid .
If even the smallest crack is detected the crankshaft must be discarded.
2 - If the crankshaft is reground to one of the specified undersizes, it will not be necessary to restore the journal fillets.
★ Do not cut into the existing fillet radii.
3 - During regrinding, the crankshaft should preferably be rotated in the opposite direction to its normal rotation in ser-
vice; however, it is still acceptable for the crankshaft to be rotated in its normal operating direction.
4 - During polishing, the crankshaft must be rotated only in the same direction as its normal rotation in service.
5 - The surfaces of the crankshaft journals must be totally smooth (Ra=0.25 mµ)
40-59
ENGINE
6. ENGINE BLOCK - CYLINDER LINERS
6.1 Engine block

1 - Fit the main bearing caps complete with their half
shells to the engine block.
★ Position the caps and half shells in accordance
with their identification numbers and the position-
ing marks made during dismantling.
2 - Tighten down the bearing cap bolts.
3 - Using a telescopic bore gauge with dial, measure the

inside diameters of the main bearings and check for
ovality.
★ Note down the measurements taken for each
bearing, and if the diameters exceed the tolerance
limit specified in «TECHNICAL DATA AND DIMEN-
SIONS», they must be renewed.
★ Undersize main shell bearings must be fitted each
time the crankshaft is reground.
F0012090
4 - Using a bore gauge with dial, measure the diameters

of the camshaft shell bearings.
★ If the diameters of the shell exceed the tolerance
limit specified in «TECHNICAL DATA AND DIMEN-
SIONS» the bearings must be renewed and the
new bearings must be reamed after fitting.
★ To facilitate removal of the old bearings and ream-
ing of the new ones, remove the plug on the fly-
wheel side of the engine block.
On completion of the operations, fit a new plug co-
ated with sealant.
Plug: Loctite 554 F0012100
6.2 Inspection of the cylinder liners

70 mm
1 - After carefully removing all carbon deposits, measure
the inside diameters of the cylinder liners using a bore
gauge with dial.
The measurements should be taken at a depth of 70
mm (2.758 in. ) from the top of the cylinder liner and at
90° intervals around the circumference.
★ If the diameter of a cylinder liner exceeds the tol-
erance limit specified in «TECHNICAL DATA AND
DIMENSIONS», the liner must be renewed.
F0012110
40-60
ENGINE
2 - If new compression and scraper rings are to be fitted,

check that crosshatch honing pattern is still visible on
the internal surfaces of cylinder liners; if the pattern is
not present (even partially worn), then the liners will
have be honed by a specialised machine shop to rec-
reate the correct surface finish with the specified
crosshatch angle using tool T19 (code 5.9030.349.0).
F0012120
3 - Before final assembly of new cylinder liners in the en-

gine block, remove all traces of old sealant, insert the
liners without the O-rings and fix in position with
blocks T29 (code 5.9030.631.4/10).
Using tool T11 (code 5.9030.433.0) check that the nip T11
clearance is as specified in «TECHNICAL DATA AND
DIMENSIONS».
To assemble the liners in the engine block, follow the
instructions given in the section «ENGINE ASSEM-
BLY».
T29
F0011100
40-61
ENGINE
ENGINE BLOCK - CYLINDER LINERS
2
3 1 3
4 D0001150

Normal Maximum
measurement tolerance limit
Cylinder liner diameter

105.000 (4.1370) 105.100
distance from liner top: A= 70 mm 105.022 (4.1379) (4.1410)
(2.758 in.))
1
Cylinder liner ovality 0.020 (0.0008) Max. 0.080
(Max. 0.0032)
2 Nip clearance 0.020 -- 0.090 --

(0.0008 -- 0.0035)
3 Cross-hatch angle of honed internal finish (α°) 40 -- 50° 40 -- 50° Roughness index
Ra 0.2-- 0.6 µm
Main bearing shell diameter 70.018 -- 70.068 70.130

(2.7587 -- 2.7607) (2.7631)
1st undersize (regrinding) 69.768 -- 69.818 69,880
4
(2.7488 -- 2.7508) (2.7139)
2nd undersize (regrinding) 69.518 -- 69.568 69.650
(2.7390 -- 2.7410) (2.7442)
55.060 -- 55.090 55.180

Camshaft bearing diameter
5 (2.1694 -- 2.1705) (2.1741)
Clearance between bearing and camshaft 0.060 -- 0.120 (0.0024 -- 0.0047)
40-62
ENGINE
7. CAMSHAFT
1 -Carefully examine the surfaces of the cams; they should

be perfectly polished and free of scoring, pitting and
scuff marks .
Any defects will necessitate renewal of the camshaft.
2 - Using a micrometer, measure the diameters of the

camshaft journals and check for out-of-round .
If any of the camshaft journals is out of the tolerance
limits specified in «TECHNICAL DATA AND DIMEN-
SIONS», the camshaft must be renewed.
F0012130
40-63
ENGINE
CAMSHAFT
2 1 1 1 1 1 1 1
n°1 n°2 n°3 n°4 n°5 n°6
D0001160
Pos. Dimensions Normal Maximum NOTES

measurement tolerance limit
1 Camshaft journal 54.970 -- 55.000 55.950

(2.1658 -- 2.1670) (2.2044)
2 Endfloat 0.08 -- 0.206 Max. 0.25

(0.0032 --0.0081) (Max. 0.001)
40-64
ENGINE
8. TIMING GEARS

the bush of the intermediate timing gear (1).
If the wear exceeds the tolerance limit specified in
«TECHNICAL DATA AND DIMENSIONS», renew the
bush.
F0012140
2 - Using a micrometer, measure the diameter of the

shaft (2) for the intermediate timing gear.
2
If the diameter is less than that specified in «TECH-
NICAL DATA AND DIMENSIONS», renew the shaft.
★ The shaft must certainly be renewed if it shows any
sign of seizure.
★ For removal and refitting, see «TECHNICAL DATA
AND DIMENSIONS».
F0012150
3 - Before timing the valves, check the backlash between

the timing gears in order to prevent excessive noise in
service. Measured Gear NOTES
backlash to fit
★ Permitted backlash:
0.06 -- 0.1 mm (0.0024 -- 0.0004 in.) 0.06 -- 0.10
(0.0024 --0.004) Red label Standard gear
The correct backlash can be restored by choosing
the appropriate size intermediate timing gear from 0.11 -- 0.13 Yellow/white
(0.0043 --0.005) label 1st oversize ✽
the three available. The gears are identified by co-
loured labels: over 0.13
(over 0.005) Green label 2nd oversize ✽
For the checking procedure, see «ENGINE ASSEMBLY
- Valve timing». ✽ Oversizes have increased tooth thickness on the
8.1 Removal of the gear shaft pitch diameter.
1 - To remove the shaft, use a bolt with a long nut be-

tween the shaft and inner bulkhead.
2 - Before fitting the new gear shaft, carefully clean the oil
hole; after fitting shaft to the engine block, close the oil
hole with the plug coated with sealant.
Plug: Loctite 242

3 - The gear shaft must only be fitted to the engine block
using the liquid nitrogen cooling method.
★ DO NOT use a hammer, mallet or hydraulic install-
er.
F0011110
40-65
ENGINE
TIMING GEARS
5 6
Loctite 542
2
4
D0001170

Normal Tolerance
measurement limit
Inside diameter of intermediate timing 40.025 (1.5770) 40.125

1
gear bush 40.064 (1.5785) (1.581)
Outside diameter of intermediate timing 39.975 (1.5750) 39.950
2
gear shaft 40.000 (1.5760) (1.574)
0.13 -- 0.53 Max. 0.80
3 Intermediate timing gear endfloat
(0.0051 -- 0.0208) (Max. 0.0315)
Backlash between 0.06 -- 0.10 Max. 0.10
4
crankshaft timing gear - intermediate timing gear (0.0024 -- 0.004) (Max. 0.004)
Backlash between intermediate timing gear 0.06 -- 0.10 Max. 0.10
5
and camshaft timing gear (0.0024 -- 0.004) (Max. 0.004)
for backlash 0.06 -- 0.10
Standard Red label
(0.0024 -- 0.0004 in.)
for backlash 0.11 -- 0.13

6 Intermediate timing gear 1st oversize White/yellow label
(0.0043 -- 0.005 in.)
pfor backlash greater

2nd oversize Green label
than 0.13 (0.005 in.)
40-66
ENGINE
9. FLYWHEEL
The flywheel is to be checked as follows:

a- Check the condition of the ring gear (visual examination).
b- Check radial runout (after fitting).
c- Check flywheel face runout (after fitting)
1 - If the ring gear is damaged, it must be removed using

a drift.
★ Tap the ring gear evenly around the circumference
until it comes free of the flywheel.
★ Note which way round it is fitted; the chamfered
side of the teeth should be oriented away from the
engine block.
F0012160
2 - Clean the ring gear carefully; heat the new ring gear on
a thermostatic hotplate to approx. 100°C and then fit it
to the flywheel; make sure that it is fully inserted on its
seat.
F0012170
3 - After having fitted the flywheel to the crankshaft and

tightened down the retaining bolts, use a dial gauge to
check the radial and face runout.
★ The maximum permissible runout is 0.10 mm
(0,004 in.).
★ For the tightening torque, see «ENGINE AS-
SEMBLY».
F0012180
40-67
ENGINE
ENGINE ASSEMBLY
1- All engine assembly operations must be carried out This rule does not apply to the cylinder liners and
on a clean bench in a clean environment. the relative O-rings and seal seats; the cylinder
liners are to be inserted into the block dry and in
2- Before proceeding with assembly, remove all carbon
accordance with the specific assembly instruc-
deposits, old sealant, etc.. from the parts to be re-
tions.
used; clean out the oil ways with compressed air.
4- When positioning the bearing shells of the main
3- Lightly lubricate all parts with engine oil prior to as-
bearings, big-end bearings and camshaft bearings
sembly, except for the bolts unless otherwise indi-
make sure that oil holes are correctly oriented.
cated.
5- Always remove excess sealant.
1. FITTING THE PISTON COOLING NOZZLES

1 - Only if the sprayer nozzles have been removed. Ap-
ply sealant to the root of threaded fitting (1), screw into 1
the block and tighten.
Fittings: Loctite 242
Fittings: 30 +0 5 Nm (22.1 +0 3.7 lb.ft.)
F0010971
2 - Turn over the engine block and fit tool T20 (code
5.9030.732.4) to Cylinder No. 1; fit the following parts
in the order given: copper gasket (2), sprayer nozzle
(3), second gasket (4) and finally nut (5). 5
With the sprayer nozzle inserted in tool T20 (code 4
5.9030.732.4) tighten nut (5). T20
0 0
Nut: 25 + 4 Nm (18.4 + 2.9 lb.ft.)
2
3 - Repeat the operation for the remaining cylinders. 3
5
F0011120
40-68
ENGINE
2. FITTING THE CYLINDER LINERS, PISTONS AND CONNECTING RODS
1 - Position the O-rings (2) on the cylinder liner (1).

The O-rings must be perfectly clean and free of grease.
The O-rings have been specially treated and
1
once removed from their packaging, they must
not be exposed to the air for more than 48 hours.
★ Do not lubricate the O-rings (2).
F0011130
2 - Using piston ring pliers, fit the piston rings (4) and (5) to
the piston (3). 3 4
The second piston ring (5) must be fitted so that
the marking TOP is facing the piston crown.
4
5
5 F0011851
3 - Turn over the piston (3) and fit the expander (6) and the
oil scraper ring (7).
★ The gap in the oil scraper must positioned at 180° 3 3
relative to the gap in the expander .
7
6
F0011140
4 - Turn over the cylinder liner (1), lightly oil the bore and
partially insert the piston (3).
5 - Position the piston ring end gaps as indicated in «TE-
CHNICAL DATA AND DIMENSIONS» and, using a pi-
3
ston ring compressor T25 (code 5.9030.654.0/10) and
a drift made of soft material, fully insert the piston (3) in
the liner (1).
T25
1
F0011150
40-69
ENGINE
6 - Slide the piston (3) out of the liner so that the bore of
gudgeon pin (8) is exposed.
9
7 - Lubricate the gudgeon pin seat (8) and fit the con-
10
necting rod (9) and circlips (10). 8
3 3
The connecting rod must be fitted so that the
number marking (referring to the big-end cap) is
one the opposite side to the arrow marking on
the piston.
1 1
F0011160
8 - Apply a continuous film of sealant around the flange of

the liner (1) and fit the assembly in the corresponding
bore of the block.
Cylinder liner: Loctite 986 AVX

1
★ Ensure that sealant film is continuous and avoid
contact with the O-rings.
F0011170
9 - Apply constant strong hand pressure to ensure that

the O-rings engage the sealing surfaces of the
block bore.
★ Do not use a mallet at this stage.
10 - Once the second O-ring has seated in the sealing sur-
face of the bore, drive the liner (1) home using a soft-
faced mallet.
11 - Fit the diagonally opposed clamping blocks T29
(code 5.9030.631.4/10) and leave them in position un-
til the sealant has fully cured (approx. 4 hours). 1
T29 F0011180
40-70
ENGINE
3. FITTING THE CAMSHAFT-CRANKSHAFT AND CONNECTING ROD BIG-ENDS
1 - Lubricate the seats and fit the cam followers (1).

Cam follower seats: Engine oil
1 1
F0010961
2 - Lubricate the bearing shells (2) and install the cam-

shaft (3).
Camshaft bearing shells: Engine oil 2
★ Take great care not to damage the bearings with

the cam lobes.
F0011190
3 - Fit the thrust plate (4) and secure it with bolts (5) and
washers. 5 4
4 - Lubricate the camshaft groove that engages the
thrust plate and try turning the camshaft. The cam-
shaft should rotate freely without high spots.
★ Check the end float, which must be within the tol-
erance limits specified in «TECHNICAL DATA AND
DIMENSIONS».
F0011200
5 - Position the main bearing half shells (6) with the oil
holes in their seats in the block. 8
★ Make sure that the tabs of the half shells (7) are lo-
cated in their notches.
6 - Position the two lower semi-circular thrust washers
(8). 6
★ The oil grooves must face outwards. 7
★ To hold the thrust washers in place, coat them in
grease.
F0010951
40-71
ENGINE
7 - Liberally oil the main bearing shells (7) and the thrust
washers (8) and lower the crankshaft (9) into position.
Bearing shells and thrust washers: Engine oil 9
F0010941
8 - Liberally oil the crankshaft (9) and fit the main bearing
half shells and caps (10).
Crankshaft: Engine oil 10

★ Make sure that the caps (10) are fitted the right way 1
round; the smaller diameter spot face "A" should 1
be on the injection pump side of the block.

9
The main bearing caps are numbered and must be A
fitted in the correct sequence in accordance with
the numbers marked on the block.
F0011210
9 - Fit the upper semi-circular thrust washers (8) and the

triangular seals (12) to the rear main bearing cap (11). 11
★ Apply grease to the thrust washers and seals to
12
stick them in position; also apply grease to the
outer surfaces of the seals.
10 - Position two guide sheets in soft material "A"
(thickness 0.3 mm (0.012 in.)) and fit the rear main
bearing cap. 8 A
F0011220
11 - Insert the cap bolts and hand tighten to hold the bear-
ing cap (11) in position; withdraw the guide sheets "A" 11
by pulling them in a crosswise direction relative to the
seal.
A
F0012190
40-72
ENGINE
12 - Fit the front main bearing cap (13) with the same pro-
cedure used for the rear main bearing cap. 12
A 13
F0011230
13 - With a torque wrench, tighten the five cap bolts (14) to

the Stage 1 torque setting.
Bolts: Stage 1 = 10 Nm (7.4 lb.ft.)

14 - Still with the torque wrench, tighten the main bearing 15 14
cap bolts to the Stage 2 torque setting.
Bolts - Stage 2: 40 Nm (29.5 lb.ft.) 15

Before proceeding, check that the crankshaft end-
float is within the tolerance limit specified in «TE-
CHNICAL DATA AND DIMENSIONS»
(For endfloat checking procedure, see «REMOVAL
F0011240
OF THE CRANKSHAFT»).
15 - Using the same torque wrench and a protractor for an-

gle-tightening T26 (code 5.9030.640.0), tighten the
main bearing cap bolts (11) and (13).
Bolts: Angle-tighten an additional 55°±1° T26

16 - Check that the crankshaft rotates freely without high
spots.
11
F0011250
17 - Trim off the protruding parts of the triangular seals

(12). 12
Make sure that the seal protrusion does not exceed
0.2 mm (0.008 in.). 12
F0011260
40-73
ENGINE
18 - Fit the half shells (17) in the big-ends of the connecting

rods (16).
★ Make sure that the tabs on the half shells (17) lo-
cate in the notches in the big-ends.
19 - Liberally oil the half shells and position the big-ends on
17
the crankshaft.
Half shells: Engine oil.
★ Check that the connecting rods are installed the
right way round; the number markings should be 16
towards the injection pump side of the engine.
F0012200
20 - Oil the crankshaft, and fit the big-end caps (18) com-
plete with their half shells.
21 - Hand tighten the big-end cap bolts (18). 18
18
F0011270
22 - Using a torque wrench, tighten the big-end cap bolts

(19) to the stage 1 torque.

23 - Still using the torque wrench, tighten the cap bolts (19)
to the specified stage 2 torque.
18
19
Bolts stage 2 torque: 30 Nm (22.1 lb.ft.)
19
F0011280
24 - Using the same torque wrench and a protractor, finally

tighten cap bolts (19).
T26
Bolts: Angle-tightening 90±1°
25 - Check that the crankshaft rotates smoothly and freely.
★ While rotating the crankshaft, check that the oil
spray is perfectly aligned with the centre of the pi- 19
19
ston chamber.
F0011290
40-74
ENGINE
4. REFITTING THE OIL PUMP - SUMP PAN
1 - Connect the pick-up pipe (2) complete with O-ring to

the oil pump (1) and secure with bolts and washers. 1
Bolts: 24 +0 2 Nm (17.7 +0 1.5 lb.ft) 2

2 - Position the shims (3) and (4) that were removed with
the pump (1).
4
3
F0011891
3 - Secure the pump with the bolts (5) and washers; using
a dial gauge with magnetic stand, check the backlash
between the drive gears.
Bolts: 49 --0 5 Nm (36.1 +0 3.7 lb.ft.)

★ Permitted backlash:
0.12 -- 0.27 mm (0.0047 -- 0.0106 in.)
5
★ If necessary, add or remove shims (3) and (4) on
both sides.
F0011300
4 - Connect the pump to the return pipe (6) from the oil va-
pour collector and attach the return pipe to the pick-
up pipe (2) with bracket (7) and nut and washer (8).
Tighten the connection fitting on the pump. 7
9
5 - Liberally oil the shaft of the pump drive gear (9). 6 2
6 - Apply sealant to the surfaces in contact with the sump F0011310
pan in correspondence with the seals of the front and

rear main bearing caps.
Seal area: Silastic 738 11

7 - Position the gasket (1) and fit the sump pan (11) taking
care to align the rear face of the sump pan with the rear
face of the engine block (shown by the arrows); tighten
down the bolts.
★ Replace the washers and spacers under the bolt 10
heads in their original positions as noted during
dismantling.
Bolts: 30 --0 5 Nm (22.1 --0 3.7 lb.ft.)

F0010871
40-75
ENGINE
5. CALCULATING THE THICKNESSES OF THE HEAD GASKETS AND REFITTING

THE CYLINDER HEADS
This operation must be repeated for each cylinder.
1 - After the 4 hours required to allow the sealant to cure,
remove the clamping blocks T29 (code 5.9030.631.4/ T29
10)fitted during installation of the cylinder liner.
2 - Carefully clean all excess sealant from the surfaces.
3 - Move the piston (1) of the cylinder in question to TDC,

checking the position with tool T11 (code F0012270
5.9030.433.0) and a dial gauge on the piston, applying

preload of approximately 4 mm; zeroset the dial gauge
at TDC.
The tool must be positioned at the centre of the piston
parallel to the gudgeon pin.
4 - Move the tool and measure the distance "X" between
the piston crown (1) and the gasket contact surface on
the liner (2).
5 - In accordance with the measurement "X" , select the

correct gasket thickness from the three available.
A
Distance Gasket 4
"X" thickness Gasket N° of
mm (in.) mm (in.)
colour holes 3
0.15 -- 0.40
(0.0059 -- 0.0157)
1.2 (0.0472) Red --
0.41 -- 0.60
(0.0161 -- 0.0236)
1.4 (0.0551) Black 2
0.61 -- 0.80
(0.0240 -- 0.0315)
1.6 (0.0630) Green 1
F0011320
★ The different gaskets can be identified by the pres-

ence or absence of small holes as shown in the figure.
★ Position each cylinder gasket, checking that the
O-rings (3) are (4) present.
The gaskets must be fitted the correct way round:
check that the gasket code markings "A" and the
flame guard ring "B" are facing upwards.
The gaskets must not be degreased.
40-76
ENGINE
6. REFITTING THE CYLINDER HEADS
1 - Fit the cylinder heads complete with valves on their re-

spective cylinders.
★ Refitting is the reverse of removal.
★ Make sure that each head is fitted to the right cylin-
der.
1
F0011330
2 - Oil the cylinder head bolts (2) and screw them in fully
by hand.
Bolts: Engine oil

3 - Check that the mating surfaces are clean and tempo-
rarily fit the exhaust manifolds (3); tighten the manifold
retaining nuts to a torque of approx.15 Nm ( 11 lb.ft.).
★ This operation serves to align the head mating sur-
faces with the manifolds.
2 3
F0011340
4 - Using a torque wrench, tighten the bolts (2) to the

specified Stage 1 torque setting.
1 3
Bolts Stage 1 torque: 50 Nm (37 lb.ft.)
4 2
★ Tighten the bolts in the sequence indicated.
F0011350
5 - Using the same torque wrench and a protractor, per-

form the final angle-tightening of the head bolts (2). 1 3
Bolts: Angle-tightening 100 ±3°
4 2
★ Tighten the bolts in the sequence indicated.
F0011360
40-77
ENGINE
6 - Remove the exhaust manifolds (3).

3
F0011341
7 - Using tool T22 (code 5.9030.635.0), fit the push-rod

guides (4) complete with thrust washers, springs and
seals.
5
8 - Fit the push-rods (5).
4
T22
F0011370
40-78
ENGINE
7. FITTING THE INJECTION PUMP CONTROL ROD
1 - Fit O-rings (3) to control rod guides (1) and (2).

2 - Apply sealant to the cylindrical part below the flange
and fit control rod guides (1) and (2), aligning the re- 1 2
taining bolt holes.
Control rod guide: Loctite 510

★ The control rod guide without the guide wheel
must be fitted in the central position.
3
F0011811
3 - Partially screw in the retaining bolts and fit the control

rod (4) complete with spring guide, spring and (4) and
linkage plate (5).
★ To stick the linkage plate (5) in place, apply grease
to the surface in contact with the control rod (4).
4
★ Fix supports (1) and (2) and check that the control
rod slides freely.
5
F0010711
4 - Screw in the control rod retaining plug (6) complete

with O-ring (7) and tighten down.
6 7
F0010701
40-79
ENGINE
8. FINAL ENGINE ASSEMBLY - REAR END
1 - Apply sealant to the contact surfaces of the block

around the threaded plugs and the camshaft hole.
Loctite 510
Surfaces: Loctite 510
Loctite 510
D0002050
2 - Attach the flywheel housing flange (1) to a hoist and of-

fer it up to the engine block (2).
Fix it in place with the bolts (3). 1
Bolts: 120 Nm (88.4 lb.ft.) 2

★ Tighten the bolts gradually in a cross-wise sequence.
3
F0010341
3 - Fit a new gasket (5) to the rear oil seal carrier (4).
4 - Lubricate the lips of the oil seal and fit the carrier using
bolts (6).
4
Bolts: 24.5 Nm (18 lb.ft.) 5
★ Tighten the bolts progressively in a cross-wise se-
quence.
6
F0011380
5 - Screw dowel "A" into the central hole of the crank-

shaft.
6 - Lubricate the bolt threads. 9
8 7
Bolts: Engine oil
7 - Fit the flywheel (8) so that it locates on the dowel (9).
F0011390
40-80
ENGINE
8 - Tighten down the flywheel retaining bolts (11).

10
11
F0011400
9 - Fit the spring coupling (12), centering it on the locating

dowels of the flywheel. 10
12
F0010321
10 - Insert the spring coupling retaining bolts (13) and

toothed washers and tighten down.
Bolts: 50 Nm (36.8 lb.ft.) 12
13
F0011410
40-81
ENGINE
9. ADJUSTMENT OF THE TIMING GEARS
★ Valve timing operations are to be performed on cylin-

der N° 1.
1 - Temporarily fit the intermediate timing gear (1) com-
2 1 2
plete with thrust plates (2), shim (3) and circlip (4).
F0011420
2 - Position a dial gauge "B" with magnetic stand so that

the contact point is perpendicular to a tooth on the in- 1
termediate timing gear; preload the dial gauge by 4
about 2 mm (0.079 in.).
3 - Turn the intermediate timing gear (1) in both directions
to measure the tooth backlash.
★ Make a note of the backlash before proceeding to B
the next stage.
F0011430
4- Temporarily fit the camshaft gear (5) , the flange (6) and
6
the bolts (7). 5
★ Tighten the bolts to a low torque 10 Nm (7.4 lb.ft.) o 7
ensure that the gear is forced up against the end
face of the camshaft.
5 - Screw the pulse wheel retaining bolt (8) fully into the
crankshaft.
★ The bolt will serve as a purchase for the wrench
during the subsequent precision checks.
8
F0011440
6 - Position the dial gauge "B" so that the contact point is

perpendicular to a tooth on the camshaft gear.
B
7 - Mesh the intermediate gear (1) turn the camshaft gear
(5) in both directions to measure the backlash.
★ Make a note of the backlash
F0012210
40-82
ENGINE
8 - Check the two measured backlash values against the

tolerance limits indicated in «TECHNICAL DATA AND
DIMENSIONS» . If the values are not within the toler-
ance limits, replace the original intermediate timing
gear with the appropriate oversize gear to restore op-
timum backlash.
★ The oversize gears available are indicated in «TE-
CHNICAL DATA AND DIMENSIONS».
9 - Remove the intermediate timing gear (1) used for

backlash testing, but leave the thrust washer (2) in
place.
★ Check that the thrust washer is fitted with the oil 2
grooves facing the gear.
10 - Loosen, but do not remove, the camshaft gear retai-
ning bolts.
1
F0010841
40-83
ENGINE
10. VALVE TIMING
1 - Move cylinder N° 1 to TDC.

2 - Remove the spring of the rear inlet valve and the seal. A B
★ After removing the spring, fit an O-ring to the end of
the valve stem to prevent the valve from falling into
the cylinder.
3 - On the two studs for inlet valve rocker support, fit tool
T21 (code 5.903.735.0), complete with dial gauges 1
"A" and "B".
★ The dial gauge "B" for the inlet valve must have a T21
stroke of 25 mm (0.985 in.), while the dial gauge "A"
used for the push-rod (1) must have a stroke of 10
F0011450
mm (0.394 in.).
4 - Preload the inlet valve dial gauge by about 20 mm

(0.788 in.), find TDC and then zeroset the dial gauge.
A B
5 - Turn the camshaft clockwise to bring the inlet valve
cam to the valve closed period ; in this position, pre-
load the dial gauge by about 3 mm and zeroset it.
★ The valve closed period refers to that part of the cam
profile for which the valve remains closed. PMS
D0002010
6 -Turn the crankshaft clockwise until the piston has

performed a downstroke of exactly 17,273 mm
(0.6806 in.)
B
The specified stroke position must be obtained 17,273 mm
through clockwise rotation only.
If the downstroke continues past this position, re-
turn the piston to TDC and repeat the entire op- 17,273 mm
eration.
D0002020
4,726 mm
7 - Turn the camshaft clockwise until the push-rod has
performed an upstroke of 4.726±0.05 mm A
(0.1862±0.002 in).
This push-rod position must be obtained through
clockwise rotation only.
If the push-rod upstroke extends beyond this
position, return the piston to TDC and repeat the
entire operation.
4,726 mm
D0002030
40-84
ENGINE
8 - Being careful not to cause any rotation of the camshaft

or the crankshaft, fit the intermediate timing gear (3) to 3
shaft (2).
2
F0011460
9 - Fit the bronze thrust washer (4), the shim (5) and the
circlip (6).
★ Check that oil grooves on the thrust washer (4) are 5
facing the intermediate timing gear. 6
F0011470
10 - Remove the retaining bolts (7) of the camshaft timing

gear one at a time, coat them with sealant, and then re- 8
place them. 7
11 - Without moving the camshaft, apply a light tangen-

tial force in a counter-clockwise direction to gear
(8) to take up the play; tighten the bolts (7) gradually in
a number of stages.
12 - Finally tighten the bolts in a cross-wise sequence.
Bolts: 50 +0 4.5 Nm (36.8 +0 3.3 lb.ft.)
F0011441
10.1 Checking the camshaft timing

B
1 - Rotate the crankshaft clockwise through two turns so
that cylinder N°6 is at TDC at the beginning of its pow-
er stroke and the valves over cylinder N° 1 are on the
rock.
2 - Continue with the clockwise rotation of the crankshaft
until the piston has performed a downstroke of 17.23 1
mm (0.6789 in.) as shown on the dial gauge “B”.
F0011451
40-85
ENGINE
3 - In this condition, zeroset the dial gauge “A” on the pu-

shrod (1).
A
4 - Rotate the crankshaft counter-clockwise and check
on the dial gauge “A” that the pushrod performs a
downstroke of 4.726±0.05 mm (0.1862±0.002 in.) to
arrive at the valve closed period of the cam.
F0011452
40-86
ENGINE
11. TIMING THE INJECTION PUMPS
1 - The operations described below refer to cylinder

N° 1, but they must be repeated for all the cylin-
ders.
2 - These operations must be carried out each time a T23
new camshaft is fitted and whenever the valve
timing is adjusted.
1 - Fit a dial gauge on tool T23 (code 5.9030.617.4/10) ze-
roset the dial gauge with preload of about 3 mm, push-
ing the tool against a flat surface so the wheel is fully
retracted.
F0012220
2 - Bring the piston in cylinder N° 1 to TDC at the begin-

ning of its power stroke and zeroset the dial gauge
B
“B”.
3 - Turn the crankshaft counter-clockwise so that the pi-
ston moves down by about 5 - 6 mm.
4 - Slowly turn the crankshaft clockwise to take up the
play and bring the piston to 2.92 mm (0.115 in.) BTDC,
corresponding to an injection advance angle of 16°.
F0011453
5 - Fit tool T23 (code 5.9030.617.4/10) sui prigionieri del-

la pompa d’iniezione e bloccarlo con i dadi.
6 - on the studs of the injection pump and secure it with
the nuts.
6 - Read off the distance "X" relative to the zero position
established in step 1 (Example X=0.58 mm (0.0228
in.)).
★ Take the readings for all the pumps.
T23
F0011480
7 - To the measured reading, add the value "Y" (in tenths

of a millimetre) stamped on the body of the injection
pump (1) to be fitted.
The value thus obtained "S" is the thickness of the Y
shims to be inserted under the pump (1). 1
★ Round off the value "S" to the nearest tenth of a
millimetre.
Example mm (in):
X=0.58; Y=0.2; S= 0.58+0.20= 0.78 → 0.80
(X=0.0228; Y=0.0079; S= 0.0228+0.0079= 0.0307
→ 0,315)
F0011490
40-87
ENGINE
8 - Form a shim pack (2) of the thickness calculated.
F0012230
9 - Fit tool T23 (code 5.9030.617.4/10) with the shim pack

(2); tighten down nuts (5).
T23
Nuts: 25÷28 Nm (18.4 -- 20.6 lb.ft.)
10 - Check that the reading on the dial gauge is within
±0,04 mm (±0.0016 in.) of the “zero” position estab-
lished in Step 1.
5
F0012320
11 - Remove the rubber plug (3) from the injection pump (1)
and insert locking pin T32 (code 5.9030.876.0). T32
F0011500
12 - Fit the rod centering tool T33 (code 5.9030.875.0) e

and bolt down.
T33
F0012290
40-88
ENGINE
13 - Apply a film of sealant between the shims (2), and to

the mounting surfaces on the injection pump and en-
gine block.
Sealant: Silastic 738
2
14 - Fit the shim pack (2).
F0012280
15 - Fit the injection pump (1), apply clockwise rotation

and, while holding the pump in position, secure with
washers and nuts (5).
4
★ Repeat the above steps for all the pumps.
1
Nuts: 25÷28 Nm (18.4 -- 20.6 lb.ft.)
5
F0012300
16 - Remove the locking pins T32 (code 5.9030.876.0) and

tool T33 (code 5.9030.875.0); check that the pump 5
control rod slides freely. 3
17 - Insert the rubber plugs (3) in the holes on the pumps.
F0011520
18 - Return piston N° 1 to TDC, remove tool T21 (code

5.9030.735.0) complete with the dial gauges and refit
the inlet valve spring that was previously removed for
the timing operation.
T21
F0011454
40-89
ENGINE
11.1 Removal and refitting an injection pump for

testing T32
★ This procedure only applies in cases where no
components are renewed and the calibration is not
adjusted.
1 - Remove the rubber plugs and lock all the injection
pumps in position with the locking pins (1).
★ To locate the locking pins, move the control rod by
hand. 1
2 - Remove the pump (1), but leave the shim pack in
place.
F0011530
3 - After testing, apply sealant to the underside of the

pump flange (1), fit the pump and tighten down with
the retaining nuts
Pompa: Silastic 738

Dadi: 25 -- 28 Nm (18.4 -- 20.6 lb.ft.)
1
F0012240
11.2 Renewal of an injection pump

1 - Proceed as indicated in point 11.1 except that it will be
necessary to adjust the thickness of the shim pack if
the value "Y" stamped on the new pump is different
from that on the old pump.
In this case, remove shims equal to the old value "Y"
from the shim pack and add a shim thickness corre-
sponding to the new value "Y".
F0012231
11.3 Removal and refitting of an injection pump

after overhaul
1 - An injection pump that has been overhauled and test-
ed on the test unit will have a new value "Y" stamped
on the body.
2 - Fit the pump and adjust the shim pack thickness fol-
lowing the procedure indicated in point 11.2.
40-90
ENGINE
12. REFITTING THE ROCKER ASSEMBLIES
1 - Re-assemble the rockers by fitting the rocker arms (3),

thrust washers (4) and circlips (5) to the support pivots 4
(1) and (2).
2 - Loosen off completely the valve clearance adjuster 3 5
screws (6).
1 2 6
F0011540
3 - Oil the cross-heads (7) and fit them on their respective

guide posts (8).
7
Cross-heads: Engine oil
★ The adjuster screw should be positioned towards
the rear inlet valve.
8
F0011550
4 - Oil the pivot posts and fit the rocker supports (1) and
(2) of the exhaust and inlet valves.
5 - Tighten down the rocker with the nuts (9). 2
Nuts: 25 -- 28 Nm (18.4 -- 20.6 lb.ft.)
6 - Adjust the valve clearances following the procedure
described below. 9
F0011560
40-91
ENGINE
13. ADJUSTMENT OF VALVE CLEARANCES
The procedure described below refers to cylin-

der N° 1; however the same procedure is to be
repeated on all the cylinders in the sequence of
the firing order 1-5-3-6-2-4.
Cylinder Cylinder
1 - Turn the crankshaft clockwise to bring the piston of at start of power stroke on the rock
cylinder N° 1 to TDC at the beginning of its power 1 6
stroke (inlet and exhaust valves closed).
5 2
★ To check that cylinder N° 1 is at the beginning of its
power stroke, check that the valves over cylinder 3 4
N° 6 are on the rock (inlet and exhaust valves
open).
2 - Apply slight pressure on the cross-head (2) and, using

a feeler gauge, turn the adjuster screw (1) to obtain the
specified clearance between the tip of the inlet valve
stem and the adjuster screw. 1
3
★ Clearance: 0.05 mm (0.002 in.) 2
3 - After adjusting the clearance, tighten lock nut (3) while

holding the adjuster screw (1) in position.
Lock nut: 21 Nm (15.5 lb.ft.)
F0011580
1
0,05 mm
3
D0002710
4 - Using a feeler gauge, turn the adjuster screw (4) for the
inlet valves rocker arm (5) to obtain the specified clear-
ance between the cross-head (2) and rocker arm (5). 6 4
★ Clearance: 0.20±0.05 mm (0.008±0.002 in.) 5
F0011590
40-92
ENGINE
5 - After adjusting the clearance, tighten lock nut (6) while

4 5
holding adjuster screw (4) in position. 6
0,20±0,05 mm
D0002700
6 - Repeat steps (4) and (5) for the exhaust valve.

7 - Repeat the valve clearance adjustment operations on
the other cylindersi
6 4
F0011600
4
6
D0002720
13.1 Fitting the injectors

4
1 - Fit the injector (1), the retaining bracket (2), the tapered
washer (3) and the nut (4). 1
3
★ The "G" symbol stamped on the injector should be G
facing the injection pump.
Nut: 21 Nm (15.5 lb.ft.)
F0011570
40-93
ENGINE
14. FINAL ENGINE ASSEMBLY OPERATIONS
1 - Fit the rocker cover gaskets (1).
F0011610
2 - Fit the rocker covers (2) and fit the retaining nuts and
washers and tighten down. 2
0 0
Nuts: 10 + 1,5 Nm (7.4 + 1.1 lb.ft.)
★ Check the condition of the O-ring at the joint be-
tween the rocker covers.
★ Tighten the nuts gradually in a cross-wise se-
quence.
F0011620
3 - Fit the fuel lines (3) to the injectors complete with the
vibration damping bracket. 3 3
★ Hold the fitting on the pump stationary while turn-
ing the fitting on the pipe.
Nuts: 25 +0 5 Nm (18.4 +0 3.7 lb.ft.)
F0011630
4 - Fit the gasket (4) and fit the governor support (5) com-
plete with the O-ring (6). 5
6
4
F0011640
40-94
ENGINE
5 - Apply sealant to the contact surfaces of the gasket (7).

Position the gasket and fit the governor (8). 8
Gasket: Silastic 738
9
Using screwdriver through the inspection win-
dow "A", move the control rod so that the con-
trol shaft engages the linkage plate (9).
A
7 F0011650
6 - Tighten down the governor (8) bolts progressively in

an alternate sequence.
F0011660
7 - Install the connection hose complete with O-rings (11)

between the cooling system collecting pipes (10). 11
8 - Position the new gaskets, fit the collecting pipes and 10

tighten down the retaining bolts.
Nuts: 30 +0 5 Nm (22.1 +0 3.7 lb.ft.)
10
F0011670
9 - Position the new gaskets (12), fit the intake manifolds

13
(13) on the exhaust side and secure with the nuts and
washers. 13
12
F0011680
40-95
ENGINE
10 - Fit the new gaskets (14); join together the exhaust

16
manifolds (15), fit them and secure with the nuts and
spring washers.
★ Carefully inspect the seal (16) at the joint between the 15 15
two exhaust manifolds.
14
F0011690
11 - Position the new gasket and install the coolant pump

(17).
Pump retaining bolts: 49 -- 54 Nm (36-- 40 lb.ft.)

★ If a new pump is fitted, check the alignment be-
17
tween the crankshaft pulley and the pump pulley.
(For details, se «Section 30 - TENSIONING AND
RENEWAL OF THE ALTERNATOR DRIVEBELT»).
A
F0012660
12 - Fit the O-rings to the oil cooler and fit the heat ex-
changer (18). 18
Tighten the retaining bolts.
Bolts: 30 +0 5 Nm (22.1 +0 3.7 lb.ft.)

13 - Connect the pipes to the coolant pump and tighten the
fittings and hose clamps .
19
14 - Fit the O-ring to the oil filler pipe (19); fit the oil filler pipe
using the bolts (20) and washers. 20
F0010721
15 - Position the gasket (21) and fit the turbocharger (22),

securing it with the washers and nuts (23).
21 22
23
F0011700
40-96
ENGINE
16 - Position the new gasket and connect the lower oil

drain pipe (23) to the turbocharger (22); connect the
22
pipe to the fitting on the engine block
23
23
F0010431
17 - Pour approximately 50 cc of engine oil into the turbo-

charger through the oil delivery port.
★ This oil is to ensure that the turbocharger is ade-
quately lubricated when the engine is first started. 24
18 - Fit a new gasket and connect the lube oil delivery pipe
(24).
19 - Connect pipe (24) to the fitting on the engine block and
tighten clamp (25). 25
F0011710
20 - Fit the fuel return pipe (26) and secure it with fitting (27)
and the relative seals.
27
26
F0010651
21 - Fit the fuel delivery pipe (28) , securing it with fittings

(29) and the relative seals.
29
28
F0010641
40-97
ENGINE
22 - Fit the support brackets (30) for the injection pump

cover.
30 30 30
F0010381
23 - Fit new gaskets and fit the intake manifolds (31) on the
injection pump side.
Secure the manifolds with the washers and nuts (32).
★ Fix the fuel pipe vibration damper bracket under
the upper nut.
31
32
F0011720
24 - Fit the gaskets and fit the plenum (33).

33
F0010361
25 - Fit the intake pipe (34) complete with O-rings, con-

necting the hose (35) to the turbocharger (22). 22
34
35
F0011730
40-98
ENGINE
26 - Fit the oil vapour collector (37) and secure with the rel-
ative washers and bolts
38
27 - Connect pipe (38) to the rear rocker cover.
28 - Fit the alternator mounting bracket (39) 39
37
F0011740
29 - Apply sealing to the contact surfaces “H” of the timing

cover.
H
Surfaces: Silastic 738
F0012310
30 - Fit a new gasket (40) and fit the timing cover (41),
securing it with the relative bolts and washers. H
★ Do not tighten the bolts at this stage.
40
42 41
F0011750
31 - Lubricate the lips of the seal (42); temporarily fit the

pulse wheel (43) and secure it with bolts (44) and 41
washer (45) tightened to a torque of approximately 30
Nm (22.1 lb.ft.).
T24
32 - Fit tool T24 (code 5.9030.634.0) between the timing
cover (41) and the engine block; tighten the tool bolts
to align the surface.
45
44
43 F0011760
40-99
ENGINE
33 - Tighten the bolts in the following sequence A-B-C.

A
Bolts: 24.5 Nm (18 lb.ft)
34 - Tighten the other bolts in a triangular sequence to the T24
same torque.
35 - Remove tool T24 (code 5.9030.634.0) and trim off the
excess gasket through the gear housing.
C B
D0000131
36 - Remove the pulse wheel (43) and fit the cover plate
(46).
46
42
F0012250
37 - Refit the pulse wheel (43) and secure with bolt (44) and
washer (45).
45
★ Oil bolt (44), washer (45) and the hole in the crank- 43
shaft 44
Bolt: Olio motore
★ Tighten the bolt in two stages.
Stage 1: 60 -- 70 Nm (44.2 - 51.6 lb.ft.)
Stage 2: 320 -- 360 Nm (236 - 258 lb.ft.)
F0012260
38 - Fit the cover (47) of the auxiliary power take-off com-

plete with its gaskets.
If the tractor is equipped with a compressor for 47
trailer air braking, this cover is to be left off to allow
installation of the compressor.
(See Section «30. REFITTING THE AIR COM-
PRESSOR»).
F0011770
40-100
ENGINE
39 - Fit the pick-up unit (48) and secure it with bolt (49) and
the relative spring washer and flat washer. 48 49
Bolt: Loctite 242
Bolt: 6 Nm (4.4 lb.ft.)

★ Check that the distance between the pick-up unit
and pulse wheel is 0.35 -- 0.75 mm (0.014 -- 0.029
in.).
If the distance between the pick-up and the pulse
wheel is not as specified, refer to «FITTING THE
PICK-UP UNIT».
F0011780
40 - Fit the two shims, the vibration damper (50), the crank-
shaft pulley (51) and secure with the bolts (52) and
toothed washers.
★ Before fitting the vibration damper, check that it is
50 51
not dented or deformed.
52
F0011790
40-101
ENGINE
15. ENGINE TESTS
★ These tests are necessary for the final setup of the fuel
injection system and to check the efficiency of the en-
gine lubrication system.
The tests are to be carried out after the engine has
been installed on the tractor and after all the liquid lev-
els have been restored (engine oil, coolant, fuel and re-
charging of the air conditioning system).
1 - Initial start-up and oil pressure check

1- Check that the battery is fully charged and then con-
nect the terminals. +
★ First connect the positive terminal (+) and then the --
negative (--).
1
F0012670
2 - Disconnect and remove the engine oil pressure sen-

sor and connect a 10 bar pressure gauge "A" to a
pressure test fitting "B". A
★ Note that in this condition, the oil pressure warning
light will not illuminate when the electrical circuits
are powered on.
B
F0012680
3 - Loosen the drain plug (2) on the fuel filter (3) and op-
erate the fuel lift pump (4) until the fuel flowing out of 2
the drain hole is free of air bubbles.
Tighten the plug (2).
★ If no resistance is encountered when operating the
4
lever of the fuel lift pump and no fuel flow is ob-
tained, turn the starter key briefly back and forth
until the fuel starts to flow.
4 - Run the engine at idle speed and check that pressure 3
gauge (fitted in step 2) shows a reading of 0.5 -- 1.5 bar
(7.25 -- 21.75 psi).
F0012690
40-102
ENGINE
5 - Leave the engine idling for about 5 minutes, and then,

using the hand throttle, set an engine speed of about
1200 rpm to bring the engine up to its normal oper-
ating temperature (engine oil temperature above
50°C).
6 - Return the engine to idle speed and check that the oil
pressure indicated on the pressure gauge is greater
than 0.5 bar.
7 - Stop the engine, remove the pressure gauge and carry
out the procedure to synchronize the injection pumps.
2. Synchronizing the injection pumps.

★ This procedure must be carried out:
a - After the removal of one or more pumps for test-
ing, overhaul or renewal.
b -When the engine runs unevenly and the engine pa-
rameters have already been checked using the All
Round Tester.
The following tests are to be carried out in a well-ven-
tilated environment and with the exhaust pipe con-
nected to a fume extraction system
2.1 - Test
1 - Bring the engine to normal operating temperature and
then leave it running at idle speed.
2 - Remove the plugs (1) from the lower part of the ex-
haust manifold (2).
3 - Insert the digital temperature probe T28 (code 2
1
5.9030.667.4) in the manifold hole corresponding to 1
cylinder n°1; allow the temperature reading to stabi-
lise, then note down the value.
T28
4 - Repeat the operation for all the cylinders.
5 - Check the temperature difference between all the cyl-
inders; if the temperature difference is not within the
F0012700
optimum range of 15°C (59°F), t will be necessary to
adjust the angular position of the injection pumps.
2.2 Angular adjustment of the injection pumps

1 - Remove the injection pump cover .
2 - With the engine running at idle speed, slightly loosen
the three retaining nuts (1) of the injection pump (2) to
be adjusted.
★ The nuts should be loosened sufficiently to eliminate
the tightening torque but so that the pump is still held
firmly. 2
1
F0012710
40-103
ENGINE
3 - Using a suitable drift on the side of the pump (2) and a

mallet, rotate the pump.
★ Rotate the pump CLOCKWISE to INCREASE the
temperature of the exhaust gases. 2
Rotate the pump COUNTER-CLOCKWISE to RE-
DUCE the temperature of the exhaust gases.
NOTE -After adjusting the angular position of one
pump, it will be necessary to re-check the exhaust
gas temperature for all the cylinders.
F0012720
4- Tighten the retaining nuts (1) of the pump (2) to the

specified torque.
Nuts: 25 -- 28 Nm (18.4 -- 20.6 lb.ft.)
2
1
F0012710
40-104
REAR CAB MOUNTINGS
REMOVAL OF THE REAR CAB MOUNTINGS
1 - Remove the cab.

(For details see «REMOVAL OF THE CAB»).
1. Cab without suspension

1 - Remove bolts (1) and remove mountings (2). 2
1 1
F0012730
2. Cab with air suspension

1 - For EXPORT D versions with trailer air braking only.
Remove the parking brake valve (3).
(For details see «REMOVAL OF THE TRAILER AIR
BRAKING UNITS»). 3
F0004621
2 - Remove the bolts (4) and remove the tie-rod (5).

3 - Remove the bolts and remove the mountings (6). 6 5
F0004640
REFITTING THE REAR CAB

MOUNTINGS
• Refit the mountings following the removal operations
in reverse order.
6
4
F0004650
40-105
POWER SHIFT COVER
REMOVAL OF THE POWER SHIFT COVER
1 - Remove the cab.

(For details, see «REMOVAL OF THE CAB»). 2
2 - Disconnect connectors (1) from the solenoid valves. 1

★ Check that the connectors are labelled with iden-
tification tags.
If necessary, label the connectors and the solenoid
valves.
★ Connectors AV and IN refer to the symbols on the cor-
responding solenoid.
F0004830
3 - Disconnect all pipes (3) and (4) from the control valve
unit (2).
★ Before disconnecting pipe (4), remove pressure 3
outlet (5); replace it immediately after disconnect-
ing the pipe.
contaminants.
5 4
F0004841
4 - Remove the solenoid of solenoid valve L (6).

6
5 - Partially unscrew the screw (7) under solenoid valve L.
8
6 - Remove the cover fixing bolts (8) and, using a lever “A”
in the slots provided, release the cover
7
A F0004990
7 - Remove the left-hand screw of the control valve unit

(2) and screw a long-stem eye-bolt “B” into the cover. 2 B
F0005000
40-106
POWER SHIFT COVER
8 - Attach a hoist to the eye-bolts and lift the cover (8) until
screw (7) can be released. Remove the cover by lifting
it straight up (8).
★ Reccover O-ring (9) and check its condition.
9
1 8
7
F0005010
★ Check the condition of the O-rings of the 1st-3rd-

HML oil fittings (10) and renew them if necessary.
10
10
F0012480
REFITTING OF THE POWER SHIFT

COVER
★ Before fitting the cover, remove all traces of old
sealant from the mating surfaces and check the
surfaces for dents and nicks.
1
★ Coat the O-ring (9) with grease to hold it in its seat.
★ Lightly oil the O-rings of the fittings (10).
Surfaces: Loctite 510
1 - Start the engine, leave it running at idle speed for a few
minutes and then check the seals for leaks.
40-107
REAR TRANSMISSION CASING COVER
REMOVAL OF THE REAR TRANSMISSION CASING COVER
1 - Remove the cab.

(For details, see «REMOVAL OF THE CAB»).
1
As the removal operation progresses, plug the ends
of all disconnected pipes and open fittings to pre-
2 - Remove pipes (1) and (2) and the fitting (3) for bearing
lubrication and the PTO clutch. 3
1 2
F0004770
3 - Disconnect connectors (4) and (5) from the range se-

lector solenoid valve.
4 - Disconnect the delivery line (6) to the range selector.
4 5
6
F0004780
5 - Remove the delivery line (7) to the power steering.

6 - Remove the piston pump drain pipe (8).
8
F0004790
7 - Disconnect pipes (10), (11) and (12) from valve (9).

10
8 - Remove valve (9). 11
9
9 - Disconnect the wiring connectors that pass over the
cover;removetheretainingstrapsandcleartheworkarea.
12
2
F0004800
40-108
REAR TRANSMISSION CASING COVER
10 - Undo the bolts and remove the cover (13).

3
★ To facilitate removal, tap the centre of the cover 13
using a copper mallet.
F0004810
IREFITTING THE REAR TRANS-

MISSION CASING COVER
der. 14 B
1
★ Check that hole “B” is perfectly clean.
★ Check the condition of the O-ring OR (14) of the
clutch fitting.
Lubricate prior to assembly.
O-ring: gearbox oil

F0004820
2
★ Plug in the connectors and secure the cables with
retaining straps, checking that the wiring is not too
tightly curved.
3
★ Before repositioning the cover, remove all traces
of old sealant from the mating surfaces and check
for dents.
Apply fresh sealant to the surfaces.
Silastic 738
40-109
ENGINE-TRANSMISSION
ENGINE - TRANSMISSION SEPARATION
★ For this operation it is not necessary to remove the cab

from the tractor.
1 - Remove the battery support.
(For details, see «REMOVAL OF THE BATTERY»).
2 - Remove the fuel tanks.
(For details, see «REMOVAL OF THE FUEL TANKS»).
3 - Remove the propeller shaft.
(For details, see «REMOVAL OF THE PROPELLER
SHAFT»)
4 - Disconnect the flexible hoses (2) from the braking

mode selector valve (1) 1
5 - Remove rear brake pipes (3) and the front diff. lock 2 3
pipes (4).
1 F0005440
6 - Disconnect the pipes (6) to the braking mode selector

valve (1) from fittings (5).
7 - Undo nuts (7) and remove the pipe union bracket (8) 7
and valve (1). 8
4 5
6
F0005450
8 - Remove strap (9) and wiring (10).

9
10
F0005460
40-110
ENGINE-TRANSMISSION
9 - Disconnect power steering pipe (12) and oil cooler

pipe (13) from the front side of the bulkhead connector
plate; also disconnect the front lift pipes (where 11 16 15
present).
10 - Remove the wiring and pipe duct (14); disconnect rod
(16) from the hood support (15.
12
14
13
F0005470
11 - Disconnect the bulkhead connector plate (17) from

the hood support (15).
15
17
F0005480
For models with trailer air braking only

12 - Disconnect the compressor delivery pipe (18).
13 - Disconnect the heater hoses (19).
19
18
F0005490
14 - Disconnect the fuel suction and return pipes (20).
20
F0001932
40-111
ENGINE-TRANSMISSION
15 - Undo bolts (21) and remove the earth lead (22) to re-
move the hood support (15).
22
21
15
F0005500
For models with suspended front axle only

First discharge all residual pressure in the accumula-
tors.
(For details, see «REMOVAL OF THE FRONT SUS-
PENSION SOLENOID VALVES»). 24
23
16 - Disconnect the pipes (23) for the axle suspension cyl-
inders.
17 - Disconnect the pump connection pipes (24).
F0002131
18 - Remove the rear bolts (25) of the right and left coun-
terframes and remove the solenoid valve block (26)
. 2
26
25
F0005510
19 - Remove the front bolts (27) and remove the counter-

frames (28
2
★ Recover and record the positions of the shims;
keep the left and right shims separate. 3
27
28
F0005520
40-112
ENGINE-TRANSMISSION
20 - Remove nuts (29) and bolt (30) and remove the fuel
tank frame mountings (31) and (32).
32
30 29
31
F0005530
21 - Position a non-slip beam “A” and a screw jack “B” un-

der the intermediate transmission casing.
22 - Position a non-slip beam “C” and wheel-mounted
screw jack “D” under the engine sump.
C A
B
D
F0005540
23 - Drive two wedges “E” between the front carrier (33)

and the axle (34) to prevent the engine from swinging E E
when it is separated from the transmission.
33 33
34 34
F0005550
24 - Remove the six bolts (35) and the fourteen nuts (36)
from the left and right sides.
36
35
F0005560
40-113
ENGINE-TRANSMISSION
25 - Push both front wheels to separate the engine-front

38
axle assembly (37) from the central transmission cas-
ing (38).
ENGINE - TRANSMISSION 37 F0005570
RECONNECTION
1
(For details, see «BLEEDING THE BRAKING SYS-
TEM»).
2
Bolts: 228 -- 252 Nm (168 -- 185.7 lb.ft.)
3
★ If the shims have been lost or mixed up, proceed as
follows:
1 - Fit the counterframes and bolt them at the rear.
2 - Measure the distances between the right and left
counterframes and the front carrier.
3 - Insert shims to obtain a clearance of less than 0.2
mm (0.008 in.).
4 - Bolt down the counterframes
Bolts: 228 -- 252 Nm (168 -- 185.7 lb.ft.)
4
★ Adjust the height of the screw jacks to bring the
mating surfaces parallel.
★ Lightly oil the dowels and the mating surfaces.
Mating surfaces and dowels: Oil

• Reconnect the engine to the transmission following
the steps of the separation procedure in reverse order.
1 - Start the engine and run for a few minutes to allow the
coolant to circulate and then check the system for
leaks.
2 - Stop the engine, check the liquid levels and top up if
necessary.
40-114
H-M-L UNIT
REMOVAL OF H-M-L UNIT
★ It is not necessary to remove the cab for this operation.

1 - Separate the engine from the transmission.
(For details, see «ENGINE - TRANSMISSION SEPA-
RATION»).
2
2 - Remove the clutch control unit.
(For details, see «REMOVAL OF THE CLUTCH CON-
TROL UNIT»). 1
3 - Remove the fitting (1) from the shuttle pipe (2).
contaminants.
F0005580
4 - Remove nuts (3) and the rear centre bolts.
F0012360
5 - Remove the retaining bolts (4) of the control valve (5).

★ Carefully inspect the control valve gasket; renew
the gasket if in any doubt about its condition. 5
1 4
F0012370
6 - Screw the two bolts (6) in the relative holes.

Tighten the bolts alternately to detach the H-M-L unit (7).
2 3 6
F0012380
40-115
H-M-L UNIT
7 - Fit a suitable lifting bracket and attach it to a hoist.

Put the slings under tension and lift the HML unit (7)
clear.
★ Support shaft (8) to prevent it from falling and being
damaged.
8
7
F0005620
REFITTING THE H-M-L UNIT

verse order.
1
★ Before fitting a new gasket, remove all traces of the
old sealant from the control valve (5) and apply new
A
sealant.
Gasket: Loctite 510

A
★ The gasket must be fitted with the larger diameter
hole "A" at the bottom. F0012390
★ All the holes must be unobstructed.

★ To make the gasket adhere properly, apply a
weight with a flat surface and wait for the sealant to
polymerize (approx. 45 minutes).
2
★ Before refitting the H-M-L unit, remove all traces of
the old sealant from the mating surfaces and check
that the surfaces are free of dents.
3
Check that the hub of the main clutch engages all the
clutch plates.
★ To facilitate engagement of the clutch plates, ro-
tate the input shaft using wrench T34 (code
5.9030.870.0).
40-116
H-M-L UNIT
DISMANTLING THE H-M-L UNIT
37
39
22
41
35
36
38
1 40
20 19
21
65
84
2 70
28 69
27
30
34
67
68
66
29
26
24
7
31
13 5
15 3 7
32 9
33
14
10
18
23
4
6
16 11
12
17
17
16
D0000880
40-117
H-M-L UNIT
72
73
3 76
78
77
75
74
75
80 79
83 82
81
71
58
55
57 56
59
61
64 63
39 60
62
48
41
54 49 40
53
44
42 47 45
51
50
52
43 46
D0000890
40-118
H-M-L UNIT
1. Dismantling
1 - Remove the oil seal (1) from the drive input end.
★ Take great care not to damage the shaft. 2
★ Make a note of which way round the oil seal is in-
stalled.
1
★ The oil seal must be renewed at each re-assembly.
2 - Remove the circlip (2).
F0005630
3 - Remove hub (4) from the main clutch (3).
F0005640
4 - Relieve the staking on the ring nut (5).
F0005650
5 - Hold the shaft with wrench T34 (code 5.9030.870.0

and, using wrench T35 (code 5.9030.692.0), loosen
ring nut (5) by a few turns.
★ After these operations (which must be carried out
with the unit vertical), rest the unit horizontally on
two blocks.
T34
T35 F0005660
40-119
H-M-L UNIT
6 - Attach tool T36 (code 5.9030.691.0) to compress

spring guide (6) and spring (7).
T36
F0005670
7 - With wrench T35 (code 5.9030.692.0), fully unscrew

and remove ring nut (5). 5
★ Ring nut (5) must be renewed at each re-assembly.
F0005680
8 - Relieve the pressure on the spring by unscrewing the

handles of tool T36 (code 5.9030.691.0).
6
9 - Remove spring guide (6) and spring (7).
F0005690
10 - Lift the complete clutch unit (3).

★ Lift the unit straight upwards to avoid damaging
the seals.
3
F0005700
40-120
H-M-L UNIT
11 - Remove pipes (8) and (9).

★ Plug the ends of the pipes to prevent the entry of con- 10
taminants.
9
8
F0005710
12 - Withdraw spring (13) and spool (14) complete with

15
nozzle (15) from the manifold (10).
10
★ Blow compressed air through the nozzle to re-
move any contaminants.
14
13
F0005720
13 - Withdraw pipes (16) from manifold (10).

★ Check the condition of the O-rings (17) and renew 10
them if necessary.
17
16
11 12
17 F0005730
14 - Remove bolts (11), washers (12) and remove manifold

(1) and thrust washer (18) with oil hole.
10
18
F0005740
40-121
H-M-L UNIT
15 - Screw special bolts T37 (code 5.9030.704.4) into the

holes of the spring guides and thrust plates and tight-
en them fully.
★ This operation serves to keep the thrust plates of
the M and L clutches packed together.
T37
F0005750
16 - Undo and remove the bolts (19) and washers (20) se-
curing flange (21) 4 21
19 20
F0005760
17 - Remove flange (21).

★ Recover O-ring (22) and inspect it carefully; if it
21
shows any sign of deformation it must be renewed
22
F0005770
18 - Using a puller, remove bearing (23) from flange (21).
21
23
F0005780
40-122
H-M-L UNIT
19 - Position tool T39 (code 5.9030.872.0); secure it by

screwing two bolts “B” (M10x80) with washers fully
T37 T37
into the fixing holes of disc (24). T39
B
20 - Remove special bolts T37 (code 5.9030.704.4).
B
21 - Gradually and evenly loosen off bolts “B” until the 24
force of the springs is relieved.
22 - Remove tool T39 (code 5.9030.872.0).
T37
F0005790
23 - Remove spring guide plate and M - L thrust plate (26).
26
F0005800
24 - Remove L speed clutch plate (27).
27
F0005810
25 - Remove the short (28) and long (29) springs.

NOTE.Note that the short springs (28) are inserted in
the stopped holes and that the long springs 28
(29) are inserted in the through holes.
29
F0005820
40-123
H-M-L UNIT
26 - Remove the intermediate disc (24) between the M and

L clutches.
24
F0005830
27 - Remove the M speed clutch plate.

★ Make a note of the positioning of the oil discharge
slots, which are oriented towards the planet car-
rier.
30
F0005840
28 - Remove guide ring (31), bushes (32) and springs (33.

31
32
33
F0005850
29 - Remove the thrust plate (34).

★ Note the position of the chamfer, which is oriented
towards the planet carrier.
34
F0005860
40-124
H-M-L UNIT
30 - Remove the bearing thrust plate (35), the hub thrust

plate (36) and the L speed clutch plate hub (37). 35
36
37
F0005870
31 - Remove the sun wheel (38).

38
F0012850
32 - Remove the complete planet carrier assembly (39).
39
F0005890
33 - Remove the roller cage (40.
40
F0005900
40-125
H-M-L UNIT
34 - Remove the clutch unit (41) complete with the H speed

unit.
★ Lift the assembly straight upwards to avoid dam-
aging the seals.
41
F0005910
35 - Remove seals (42) and inner bearing (43)

★ The outer bearing (84), as it is not fixed, may remain
in the H-M-L casing or fall out.
42 43
F0005920
36 - Remove bolts (44) and remove cylinder (46) from the

annulus (45).
46
44
45 F0005930
37 - Remove the clutch pack (47) and shims (48).

★ If the clutch pack is to be renewed, it will be nec-
essary to calculate the required shim thickness to
limit the clutch travel.
47
48
F0005940
40-126
H-M-L UNIT
38 - Position the cylinder (46) under a press, and using U-

shaped tool, press disc (49) to compress Belleville
spring (50). 51
46
F0005950
40 - Relieve the pressure gradually and withdraw disc (49)

and Belleville spring (50). 49 49
★ Make a note of which way round the disc (49) is in-
stalled. 50
46
F0005960
41 - Using a puller, remove the inner race of the roller cage

(40).
40
F0005970
42 - Fit tool T38 (code 5.9030.871.0) to cylinder (46) and

use a compressed air jet to expel the piston (52).
T38
46 52
F0005980
40-127
H-M-L UNIT
43 - Remove O-rings (53) and (54) from the piston.

★ The O-rings must be renewed at each re-assembly.
53
52
54 F0005990
44 - Remove the circlips (55) of the planet pins (56).

55
56
F0006000
45 - Partially withdraw the planet pins (56) and recover the

ball (57).
56
57
F0006010
46 - Fully withdraw the planet pins (56) and recover planet

pinions (58), rollers (59) and the intermediate ring (60).
58
56 60
59
F0006020
40-128
H-M-L UNIT
47 - Remove the second sun wheel (61).
61
F0006030

49 - Remove the shaft (63) from the planet carrier (64). 63
62
64
F0006040
50 - Blow compressed air at low pressure into the holes in

66
flange (21) in order to expel the pistons. 21
★ Be careful. The pistons may be ejected at high
65
speed and be damaged
F0006050
51 - Remove O-rings (67), (68), (69) and (70) from pistons

(65) and (66).
★ The O-rings must be renewed at each re-assem-
bly. 69
65 66
67 68 70 F0006060
40-129
H-M-L UNIT
2. Dismantling the main clutch

1 - Remove the seals (71). 1
71
F0006070
2 - Remove the circlip (72) securing the clutch pack.

2
72
F0006080
3 - Remove the clutch pack cover plate (73).

★ Make a note of which way round it is fitted; the
blind holes are inserted on the spring guide rods 73
(78).
78
F0006090
4 - Remove the clutch friction plate (74) and the smooth

steel plate (75).
★ Note that plate (75) is not located on the spring 74
guide rods (78).
5 - Remove the second friction plate (74. 75
3
74
F0006100
40-130
H-M-L UNIT
6 - Remove springs (76) and smooth plate (75).

★ Note that this plate is located on the spring guide
rods (78). 78
76
75
F0006110
7 - Proceed with the removal of the friction plates (74) and

smooth steel plates (75).
★ Note that the last smooth steel plate is thicker, that
it rests on the spacers (77) and that it is located on
the spring guide rods (78).
8 - Remove the spring guide rods (78) and spacers (77.
78
77
F0006120
9 - Remove the spring guide plate (79).
79
F0006130
10 - Screw the two service bolts “A” (M6x80) into the pi-
ston (80). A
80
11 - Tightening the screws evenly, withdraw the piston
(80).
F0006140
40-131
H-M-L UNIT
12 - Remove the O-rings (82) and (83) from the clutch

housing (81) and the piston (80). 4
★ The O-rings must be renewed at each re-assem- 83
82
bly. 80
81
F0006270
40-132
H-M-L UNIT
ASSEMBLY OF THE H-M-L UNIT
1. Assembly of the main clutch

• Assemble the clutch following the dismantling oper-
ations in reverse order.
1
Seals: Gearbox oil
2
★ Avoid positioning the open side of the circlip in cor-
respondence with the notches on the smooth steel
plates.
3
★ Lubricate the clutch friction plates.
Friction plates: gearbox oil
4
69 66
O-rings: Grease 65
2. Assembly of the flange

1 - Fit O-rings OR (67), (68), (69) and (70) to pistons (65)
and (66).
★ Stretch the internal O-rings (68) (69) evenly so that
they stay in their grooves. 67 68 70 F0006060
O-rings: Grease
2 - Fit pistons (65) and (66) in flange (21).

★ Lubricate the surfaces of the piston chambers.
66
Mating surfaces: Grease
65
★ To insert the pistons, keep them level and tap them
evenly around the circumference with a soft mallet.
21
F0006150
3. Assembly of the planet carrier 63

62
1 - Fit shaft (63) in planet carrier (64) and fit the circlip (62).
64
F0006160
40-133
H-M-L UNIT
2 - Fit the second sun wheel (61) in the planet carrier.
61
64
F0006031
3 - Apply grease to one side of the bores of the planet pin-

ions (58) and position the 32 rollers (59).
4 - Turn over gear (58), insert the intermediate thrust plate
(60) and then repeat the operations in step 3 for the
59
second set of rollers. 60
★ Check that the rollers are tight against the sides of
the bore.
58
F0006170
5 - Fit the complete planet pinions (58) in planet carrier

(64) and partially insert the planet pins (56).
58
64
56
57
F0006180
The planet pinions (58) must be positioned with the

timing marks facing outwards and in line with the axes
passing through the centres of the pins and the planet
carrier.
★ When fitting the planet pinions, hold the sun wheel (61)
still.
6 - Apply grease to the seats of the balls and insert balls
(57).
7 - Ensure that the pins (56) are correctly oriented and in-
sert them fully.
D0002510
40-134
H-M-L UNIT
8 - Secure pins (56) in position with circlips (55).

55
56
F0006000
4. Assembly of the H speed clutch

53
O-rings: Grease
52
54 F0005990
2 - Fit the complete piston (52) in the cylinder (46).

★ Lubricate the surfaces of the piston chamber.
Surfaces: gearbox oil

52
★ To insert the piston, keep it level while tapping
evenly around the circumference with a soft mallet.
46
F0006190
3 - Using a press and a drive, fit the inner race of the roller
cage (40).
40
46
F0006200
40-135
H-M-L UNIT
4 - Position cylinder (46) under a press; position the Bel-

leville spring (50) and disc (49). 49 49
NOTE. The oil discharge groove of disc (49) must be
facing upwards. 50
46
F0005960
5 - Press disc (49) using a U-shaped tool and fit the circlip
(51).
51
46
F0005950
4.1. Adjusting the stroke of the H clutch piston

6 - Position the clutch pack (47) in the annulus (45). 47
★ Do not install shims (48).
45
F0006280
7 - Fit cylinder (46) and secure it with six bolts (44) posi-
tioned at intervals of 60°.
46
44
F0006210
40-136
H-M-L UNIT
8 - Fit tool T38 (code 5.9030.871.0) to the cylinder (46).

46
T38
F0006220
9 - Position a dial gauge “C” with its contact point resting

on the piston (52) in correspondence with one of the C
annulus retaining bolts; preload the gauge by approx.
3 mm (0.118 in.) and zeroset it.
10 - Direct compressed air at 5 -- 6 bar (72.5 -- 87 psi) into
52
tool T38 (code 5.9030.871.0) and measure and record
the stroke of piston (52).
★ Repeat the measurement a number of times.
F0010050
11 -Select the shims (48) to be added under the clutch

plates to obtain a stroke of 1.2±0.1 mm (0.047±0.004
in.). 48
12 - Remove bolts (44), remove the annulus (45) and install

a shim pack of calculated thickness (48).
F0010060
13 - Assemble the clutch (41) and bolt down with bolts (44).
41
44
F0006230
40-137
H-M-L UNIT
14 - Fit bearing (43) and seals (42) to clutch unit (41).

★ If necessary, use a suitable drift to drive the bear-
ing home.
43
42
F0006240
5. Assembly of the H-M-L unit

1 - Insert the complete H speed clutch in the H-M-L cas-
ing (25).
Seals: gearbox oil 41

★ Keep the unit vertical during insertion to avoid
damaging the seals.
25
F0005911
2 - Fit roller cage (405) to the clutch unit (41).
Roller cage: gearbox oil
40
F0005900
3 - Fit the sun wheel (38) in the planet carrier assembly

39
(39). 38
F0006250
40-138
H-M-L UNIT
4 - Fit the planet carrier (39) simultaneously with the hub

(37).
★ Rotate the unit slightly in both directions to mesh
37
the teeth of the planet pinions with the annulus.
39
F0006260
5 - Position springs (33) and bushes (32) on the reaction

plate (34). T37 31
★ The springs and the bushes must rest on the op-
posite side to the chamfer.
6 - Fit the guide plate (31) for bushes (32). T37
7 - Center the guide plate using the special boltsT37 32
(code 5.9030.704.4) (with long shank).
T37
34
33
F0006290
8 - Screw bolts “D” M8x40, complete with washers, into

the adjacent holes. T37
9 - Tighten bolts “D” alternately in order to obtain a clear-
ance of approx. 5 mm between the two plates.
T37
10 - Remove the special bolts T37 (code 5.9030.704.4)
(with long shanks) and replace them with special bolts D
T37 (code 5.9030.704.4) (with short shanks).
11 - Further tighten bolts “D” in order to fully lock special
bolts T37 (code 5.9030.704.4).
5 mm F0006300
12 - Remove bolts “D” along with the washers.

13 - Install the unit assembled in the previous steps in the
H-M-L housing (25). 38
25
F0006310
40-139
H-M-L UNIT
14 - Fit the M friction plate (30) and centre it on the sun

wheel (38).
WARNING! The oil discharge slots must be ori- 30
ented towards the planet carrier.
F0006320
15 - Fit the intermediate plate (24) so that oil ways “P” are
aligned with those on the H-M-L housing (25).
24
25
F0005831
16 - Fit hub (37), rotating it slightly to ensure it is fully in-

serted.
17 - Fit the L friction plate (27) centre it on hub (37). 27
37
F0005811
18 - Fit the short springs (28) in the stopped holes and the
long springs (29) in the through holes.
29
28
F0006330
40-140
H-M-L UNIT
19 - Fit the upper spring guide/thrust plate (26)
26
F0006340
20 - Fit L friction plate thrust washer (36) and bearing thrust

washer (35) on the shaft.
35
36
F0006350
21 - Install tool T39 (code 5.9030.872.0) and secure it with

two screws “B” (M10x80) with washers screwed into
the fixing holes of flange (21). T39
B
22 - Tighten screws “B” alternately one turn at a time to B
compress the springs, until bushes (32) protrude 4
mm (0.158 in.) relative to upper plate (26). 32
23 - Fully screw in the long special bolts T37 (code
5.9030.704.4) and remove tool T39 (code
5.9030.872.0).
26
F0005791
24 - Position O-ring seal (22) between the oil ways of the H

clutch.
O-ring: Grease
21
25 - Locate flange (21), positioning it in accordance with
the oil hole, and secure with bolts (19) and washers
(20).
19 20
22
F0006360
40-141
H-M-L UNIT
26 - Remove the long and short special bolts T37 (code

5.9030.704.4).
T37
T37
F0006370
27 - Fit bearing (23) in flange (21).

NOTE. If necessary, using a soft mallet, tap evenly 23
around the circumference of the bearing.
21
F0006380
28 - Fit the bearing thrust washer (18) and manifold (10).
18 10
F0006390
29 - Insert pipes (16) complete with O-rings (17) flush with

the flange face and fit the bolts (11) and washers (12) 10
that secure the manifold (10).
★ Do no tighten the bolts (11) at this stage. 17
16
11 12
17 F0005730
40-142
H-M-L UNIT
30 - Fit the spool (14) and spring (13) in manifold (10).

15
Spool and spring: gearbox oil 10
★ Check that the hole of the nozzle (15) is free from

obstruction.
14
13
F0005720
31 - Fit pipes (8) and (9).

10
9
8
F0005710
32 - Fit the main clutch assembly (3) to the manifold (10).
Manifold: gearbox oil

★ Keep the clutch assembly vertical during assem- 3
bly so as not to damage the seals.
33 - Tighten the bolts (11) to secure the manifold (10).
10
11
F0005701
34 - Fit spring (7) and spring guide (6) to the clutch assem-
bly. 6
F0005690
40-143
H-M-L UNIT
35 - Install tool T36 (code 5.9030.691.0) and turn the han-

dles to compress spring (7).
T36
F0006400
36 - Screw a new ring nut (5) onto the shaft with special
wrench T35 (code 5.9030.692.0). 5
37 - Remove tool T36 (code 5.9030.691.0).
F0005680
38 - Attach a hoist to the lifting bracket fixed to the H-M-L

unit. Lift the unit to the vertical position.
39 - Hold the shaft with wrench T34 (code 5.9030.870.0)
and, using wrench T35 (code 5.9030.692.0) tighten
ring nut (5). T35
Ring nut: 500 Nm (368 lb.ft) T34
F0006410
40 - Stake ring nut (5) on two sides.
F0005650
40-144
H-M-L UNIT
41 - Fit bearing (23) on the drive takeoff side.

42 - Fit circlip (2) to secure the bearing.
84
43 - Using a suitable drift, fit the oil seal (1).
2 1
F0006420
44 - Fit hub (4) to the main clutch (3).

★ Rotate the hub slightly in both directions to align
the splines with the clutch friction plates. 4
F0005640
40-145
FRONT TRANSMISSION CASING
REMOVAL OF THE FRONT TRANSMISSION CASING
1 - Remove the cab.

2 - Separate the engine from the transmission.
(For details, see «ENGINE-TRANSMISSION SEPA- 1
RATION»).
3 - Remove the H-M-L unit. A
(For details, see «REMOVAL OF THE H-M-L UNIT»).
4 - For LS Version only
Remove the hydraulic pump to access the retaining
nuts.
4a -For OC Version only F0006480
Remove the filters, the power steering pump and the

suction pipes in order to able to remove the front
transmission casing.
(For details, see «REMOVAL OF THE FILTERS» and
«REMOVAL OF THE PUMPS»).
5 - Remove the cover of the power shift transmission
casing. 2
(For details, see «REMOVAL OF THE POWER SHIFT
COVER»). B
6 - Position an anti-tip stand “A” under the drawbar (1).
7 - Position a stand “B” and non-slip blocks under the
rear gearbox (2). F0006490
8 - Screw two eyebolts “C” into the threaded holes in the

transmission casing (3) as shown; attach the eyebolts C
3
to slings and hoist and put the slings under slight ten-
sion.
F0006500
9 - Loosen the nuts (4) securing the transmission (3).

10 - Remove all nuts (4) except the two internal nuts and
the two lower side nuts. 1 3
F0006510
40-146
11 - Fit long tool T43 (code 5.9030.856.0) on the top left in-
ternal stud and unscrew the nut (4) to force the trans- 2 4 T43 3
mission (3) apart from the rear gearbox (2).
F0006520
12 - Apply the two short struts T43 (code 5.9030.856.0) to

the lower side studs and unscrew nuts (4) to help sep-
arate the two casings.
4
T43
F0012740
13 - Unscrew the nuts gradually and evenly until the trans-

mission (3) is separated from the rear gearbox (2). 2
3
2 3
F0006530
40-147
REFITTING THE FRONT TRANSMISSION CASING
• Refit the transmission following the removal opera-

1
★ Tighten the nuts gradually and alternately starting
with lower centre nuts.
2
Rear gearbox mating surface: Loctite 510
around the studs.
★ While attaching the transmission to the rear gear-
box, slowly rotate the lower shaft of the shuttle in
both directions in order to align it with the sleeve
coupling of the creeper unit.
3
★ Rotate the rear PTO input shaft to facilitate en- NO
gagement of the splines. NO
Make sure that the shuttle neutral gear is perfectly

positioned to allow connection of the transmission
casings.
F0012750
OK
F0012760
40-148
DISMANTLING THE FRONT TRANSMISSION CASING
Main shaft and shuttle 55 14

53
28 16 17
18
26 11
30
27
30 15
54
29 26
70
22
20 24
19
102 21
23
100
31
33
101
32
35
34
57
58 56
36 57
2nd gear clutch 28 84

80
73 77
79
76 75
75
72
67 83 81
66 69 82
78
74
74
68
70 71 D0000850
40-149
Secondary shaft
52
50
51
47
91
46
86
49
4
98
99
12 97
59
61
62
94
95
37
96
10 9
60 13
38
63
43
65
45 40
42
41
44
44
48
D0000870
40-150
Shuttle synchronizer
41 64
111
106 110
107
105
104
103
109
108
39
49
50
1st and 3rd gear clutch
92 90
50
85 88
87
89
D0000860
40-151
1. Dismantling
1 - Remove nipples (1) complete with O-ring seals (2).
★ Check the condition of the O-rings.
F0006540
2 - Disconnect pipes (3) from manifold (4) and remove

them.
3 - Disconnect fitting (5).
3 5
F0006550
4 - Remove the control valve (7) complete with its gasket

(8). 7
8
★ Check the condition of the control valve gasket; if
there is any doubt about its condition, the gasket
must be renewed in the way described in the as-
sembly procedure.
F0012420
5 - Remove the complete creeper unit (9).

6 - Remove the shim (10).
9 10
F0006570
40-152
7 - Relieve the staking on ring nut (11).
11
F0006580
8 - Apply a wrench “A” to the flats provided on the main

shaft. A
Rotate the shaft until the wrench is brought to bear
against the side of the transmission casing; using
wrench T40 (code 5.9030.708.0) undo and remove 11
ring nut (11).
T40
★ This ring nut must be renewed at each re-assembly.
F0006590
9 - Remove bolts (12) and remove the ring gear carrier

(13).
3
13
12
F0006600
10 - Remove bolts (14) and their washers and remove the

complete manifold (15).
15
14
F0006610
40-153
11 - Remove bearing (16) complete with inner bush (17).

★ If the bearing is to be renewed, recover the inner
bush.
16
12 - Remove shims (18). 17
18
F0006620
13 - Remove complete shuttle assembly (25).

(For details, see «REMOVAL AND DISMANTLING OF
THE COMPLETE SHUTTLE CONTROL»).
25
F0006640
14 - Apply clamp "Z" to gears (20) and (29) to prevent the

shims (23), the thrust plate (22) and the bearing (21)
from falling. 2
21 22 23
20
29
F0012770
15 - Using tool T47 (code 5.9030.873.0), move the main

shaft (19).
★ Do not use a mallet, even if made of soft material. T47
16 - Push the shaft (19) until it is clear of the bearing on the 19
side connected to the H-M-L unit.
F0013760
40-154
17 - Remove the clamp "Z", remove the needle roller bear-

ing (21), thrust washer (22), shim pack (23), bearing
(24) and gear (20).
20
★ Make a note of which way round the thrust washer 29
24
(22) is installed.
23 22 21 D0000680
18 - Withdraw the main shaft (19) complete with bearing

(102).
19
102
F0006630
19 - Move the circlip (26) towards the rear of the gearbox.
26 26
F0006650
20 - Withdraw hub (27) towards the front of the casing until

it completely disengages the clutch unit (28).
28
27
F0006660
40-155
21 - Withdraw the complete 2nd gear clutch assembly

(28).
28
F0006670
22 - Withdraw hub (27) complete with gear (29).
29 27
F0006680
23 - Remove the roller cages (30) from the hub (27).

27
30 30
F0006690
24 - With a mallet, free and partially withdraw shuttle shaft

(31).
31
F0006700
40-156
25 - Remove the circlip (32) securing gear (33) and move it

towards the front of the gearbox.
33
32
31
F0006710
26 - Further withdraw shaft (31) in order to be able to re-

move the circlip (34) securing bush (35).
35
34
F0006720
27 - Withdraw bush (35), circlip (32), thrust plate (36) and

gear (33).
28 - Fully withdraw the shaft (31).
33 31 36
32
35
F0006730
29 - Using a mallet and a suitable drift against the shoulder

of the shaft (37), partially withdraw the shaft until it is
released from the rear support bearing (38).
★ Take care not to disassemble the synchronizer
(39).
38
37 39
F0006740
40-157
30 - Remove the circlip (40) securing the synchronizer (39).
39
40
F0006750
31 - Remove gear (41) and the outer parts of the synchro-

nizer (39), while simultaneously withdrawing the com-
plete shaft (37).
37
41 39
F0006760
32 - Remove the roller cage (43) from the secondary shaft

(42).
33 - Remove the front part of synchronizer (39).
42
43
39
F0012440

45 44 44
35 - Remove the gear (45) and the second circlip (44).
F0012450
40-158
36 - Remove the nuts with washers (46) and remove the

manifold (4).
★ Recover the shims (47). 46 47
4
F0006790
48
F0006800
49
F0006810
39 - Apply special wrench T45 (code 5.9030.857.0) to the

secondary shaft (42).
★ Insert the wrench through the side access window. 42
T45
F0006820
40-159
40 - Using wrench T40 (code 5.9030.708.0) and a exten-

sion “A”, undo and remove ring nut (49). 49
★ Position a block under the extension arm to sup- T40
port it.
A
F0006830
41 - Attach a hoist sling to clutch assembly (50) and place

the sling under slight tension.
★ Use a sling of reduced thickness. 50
F0006840
42 - Using tool T47 (code 5.9030.873.0) drive the second-

ary shaft (42) to disengage it from the front bearing (51) 42 51
and rear bearing (52).
T47
F0013770
43 - Withdraw and remove the secondary shaft (42).
42
F0006850
40-160
44 - Withdraw the complete clutch assembly (50).

45 - Recover the front (51) and rear (52) bearings. 50
F0006860
46 - Using a puller and drifts made of a soft material (alu-

minium, brass or copper), drive out of their housings in
the casing the outer races of the tapered roller bear-
ings for the main and second shafts.
F0006870
2. Dismantling the manifold (15)

54
1 - Remove spacer (53) and remove seals (54).
55
15
53
15
F0006880
3. Dismantling the shuttle gear (33)

1 - With a drift, remove bearings (57) from gear (56).
Only if necessary
57
58
56
F0006890
40-161
4. Removal of the shuttle output shaft (37)

59 61
2 - Remove thrust plate (60) and shims (61).
60
F0006900
3 - Remove bearing (38) and plate (62).

4 - Remove shims (63).
63 62 38
F0006910
5. Dismantling the gear-synchronizer (41)

1 - Remove the rear synchronizer assembly (39) from
gear (64).
★ Take care not to disassemble the synchronizer as-
sembly (39).
64
39
F0006920
2 - Withdraw the roller cages (65).
64 65
F0006930
40-162
6. Removal of the 2nd gear drive

1 - Withdraw gear (66) from the clutch assembly.
66
28
F0006940
2 - Remove circlip (67) and thrust washer (68) from gear

(66).
★ Note which way round the thrust washer (68) is in-
stalled. 68
1 68 67
67
F0006950
3 - Remove roller cage (69) and thrust washer (70).
70 69
F0006960
7. Clutches
★ The 1st and 3rd gear clutch unit and the 2nd gear
clutch unit must be replaced with new units avail-
able as replacement parts that have been pre-as-
sembled, calibrated and certified.
Under no circumstances are the clutch units to
be dismantled or overhauled.
40-163
8. Removal of the hubs and roller cages from the

1st and 3rd gear clutch (50).
85
1 - Remove the gear (85) from the 1st gear side of the clu-
tch assembly.
50
F0007130
2 - Remove the thrust plate (86) from gear (85). 4
85
86
F0007140
3 - Withdraw the complete bush assembly (87) from gear

(85).
85
4
87
F0007150
4 - Withdraw the roller cages (88) and spacer (89) from

bush (87).
88
87
88
89
F0007160
40-164
5 - Repeat steps 1 to 4 for the 3rd gear side; note that roll-
er cage (93) is fitted to the bush without spacers.
93
93
F0012460
9. Dismantling the creeper unit (9)

1 - Remove thrust plate (94), shim (10) and withdraw the
complete planet carrier assembly (96) from the annu- 96
lus (95). 10
94
95
F0007170
2 - Withdraw planet pins (97) and planet pinions (98) com-

plete with the rollers (99). 98 97
F0007180
3 - Remove the needle rollers (99) from the planet pinions

(98).
98 99
F0012470
40-165
9. Dismantling the main shaft (19)

1 - Remove circlip (100) and thrust plate (101).
101
100
F0007100
2- With the aid of a puller, remove bearing (102).
102
F0007190
40-166
ASSEMBLY OF THE FRONT TRANSMISSION CASING
1. Assembly of the transmission

1 - Fit the outer races of taper roller bearings (24) and (52)
in the housings in the intermediate wall of the trans- 24
mission casing.
★ Use a drift made of soft metal (aluminium, copper,
brass), and tap the races evenly around their cir-
cumference.
52
D0000690
2 - Fit the inner race of bearing (52) and insert the com-
plete 1st - 3rd gear clutch assembly (50).
★ To hold the bearing in position, apply a magnet to 50
the shuttle compartment side. 52
F0007200
3 - Insert the secondary shaft (42) and, using tool T47

(code 5.9030.873.0), engage it in bearing (52).
T47 42
F0013780
4 - Heat the inner race of bearing (51) to about 80°C and fit
it to shaft (42); insert the outer race of bearing (51) and
gently drive it home against the inner race.
51
5 - Screw the old ring nut “G” on to the shaft. G
49
F0007220
40-167

secondary shaft (42).
★ Insert the wrench through the side access window.
42
T45
F0006820
7 - Using wrench T40 (code 5.9030.708.0) and an exten-

sion, tighten ring nut "G" with the torque wrench.
T40
8 - Loosen and remove old ring nut “G”; apply threadloc-
ker to the threads of the shaft.
Threads: Loctite 270

9 - Fit and tighten the definitive ring nut (49).
F0007230
10 - Stake the ring nut on both sides.

51
G 49
D0002540
11 - Fit manifold (4) with a provisional shim pack (47) 2.5

mm (0.099 in.) thick to drive home the outer race of
47 46
bearing (51). 4
★ Tighten nuts (46) gradually in a cross-wise se- 4
quence until the clutch unit is forced to rotate.
Remove manifold (4)
F0010070
40-168
12 - With a depth gauge, measure the amount X by which

the outer race of bearing (51) protrudes. X
51
F0007240
13 - Measure the depth Y of the shoulder of manifold (4).

Y
14 - Calculate the difference between Y and X to obtain the
thickness S of the shim to be installed in manifold (4).
Example (mm): Y = 6.03, X = 5.45
S = Y -- X = 6.03 -- 5.45 = 0,58
Example (in.): Y = 0.238, X = 0.215
S = Y -- X = 0.238 -- 0.215 = 0.023
★ Round the value S down to the nearest 0.05 mm
(0.002 in.).
Example (mm): S = 0,58 rounds down to = 0.55 4
(in.): S = 0.023 rounds down to = 0.021
F0007250
15 - Compose a shim pack (47) of thickness S, selecting

shims from those available.
47
F0007260
16 - Install the shims (47) in manifold (4).

★ Apply a thin coating of grease to the housing to
hold the shims in place. 47
4
F0007270
40-169
17 - Fit the three seals (48) to shaft (42).

Seals: gearbox oil.
48 42
F0006801
18 - Install the complete manifold assembly (4) and bolt

down with nuts (46) and washers.
4 46
F0007280
19 - Fit the first circlip (44) to shaft (42).
44
42
F0009240
20 - Apply the end fitting “A” of tool T44 (code

5.9030.736.0) and the 2nd circlip (44) to the shaft (42).
Lubricate the bearings. A
44
Bearings: Gearbox oil T44
F0009250
40-170
21 - Install tool T44 (code 5.9030.736.0) on the transmis-

sion casing and secure it with studs “C” as shown in
the previous figure.
22 - Screw the central rod into end fitting “A”. C
23 - Screw in inner nut “D” to drive home the thrust bearing
D
of tool T44 (code 5.9030.736.0 and the end fitting “A”
T44
against the circlip (44). C
F0009260
24 - While holding the locknut “D” behind the thrust bear-

ing against rotation, screw the outer nut tight up
against the locknut.
★ Apply a measured force of 200 kg with this ope-
ation.
25 - Now rotate shaft (42) repeatedly in both directions to
help seat the taper roller bearing (52).
T44
26 - Remove tool T44 (code 5.9030.736.0) and end fitting
"A" after removing the circlip (44).
F0009270
27 - Fit gear (45) to the shaft (42).
42
45
F0009280
28 - Fit the second circlip (44) to the shaft (42).
29 - Lubricate roller cage (43) and fit it to the shaft (42).
44 42
42
43
F0007300
40-171
Only if dismantled
105 106
30 - Assemble the synchronizer unit by inserting springs 104
(104), plungers (105) and blacker pins (106) and fitting 105 104
sliding sleeve (107).
★ Use a drift compress the three spring assemblies
so that they locate in the sliding sleeve.
106
104
103
105
106 107
F0003691
31 - Position front gear (108) and synchronizer ring (109)

on shaft (42).
108 109
F0007320
32 - To gear (64), fit the rear part of synchronizer (39) com-

plete with synchronizer ring (110) and gear (111).
64
110
111
F0006921
33 - Position the complete gear assembly (41) in the trans-

mission casing. 41
34 - Fit shaft (37) and locate it in gear (41).
37
F0007330
40-172
35 - Block gear assembly (41) and the synchronizer in po-

sition with circlip (41).
36 - Insert the shaft far enough to locate it in roller cage
(43); slightly rotate shaft (37) to locate the synchronizer 41
ring and push it in up to the secondary shaft (42).
37
40
F0006751
37 - With a depth gauge, measure distance A between the

casing wall and the shoulder on the shaft (37). A
Example: A = 17.55 mm (0.691 in.)
F0007340
38 - Position plate (62) on bearing (38).

B
39 - With the depth gauge, measure distance B between
the plate (62) and the anchoring ring.
Example: B = 14.25 mm (0.561 in.)
62
38
F0007350
40 - Calculate the shim thickness S to be installed between

the shoulder of shaft (37) and plate (62) as follows:
S = A -- (B+0.3) where 0.3 mm (0.012 in.) is the pre-
determined play.
Example (mm): S = 17.55 -- (14.25+0.3) = 3 63
(in.): S = 0.691 -- (0.561+0.012) = 0.118
41 - Form a shim pack (63) of thickness S selecting shims
from those available.
F0007261
40-173
42 - Fit in order to shaft (37), spacers (63) plate (62) and

bearing (38). X
43 - Fit the thrust plate (60) and circlip (59). 38
44 - With a feeler gauge, measure the clearance X between
circlip (59) and bearing (38).
59
60
F0007070
45 - Form a shim pack (61) of thickness X selecting shims

from those available.
46 - Remove the circlip (59) and the thrust plate (60) from
the shaft (37).
61
47 - Fit the following to the shaft in order: shim pack (61), 60
thrust plate (60) and circlip (59). 59
D0000700
48 - Only if removed. Fit circlip (58) in gear (56).

49 - Using a drift, fit bearings (57) in gear (56).
56
57
58
56
F0007080
50 - Insert the shuttle shaft (31) in the transmission casing

and, in order, fit the gear assembly (33), thrust plate
(36), circlip (32) and bush (35).
34
51 - Secure bush (35) in position with circlip (34). 32
31
36
35
33
F0006721
40-174
52 - Locate gear (33) and thrust plate (36) and secure in po-
sition with circlip (32).
53 - Install the complete shaft assembly (31) in the trans- 33
mission casing.
32
31
F0006710
54 - Install the shuttle control (25).

(For details, see «ASSEMBLY AND REFITTING OF
THE SHUTTLE CONTROL»).
2. Preparation of the main shaft on the bench

55 - To main shaft (19), fit gear (20), the inner race of bear-
ing (24), a 3 mm shim pack (23), thrust washer (22), 11 T41
thrust bearing (21), hub (27) complete with gears (29)
and (66), roller bearings (30), thrust washers (70),
28
thrust bearing (69) and thrust washer (68); fit the clutch
assembly (28) complete with the 2nd gear clutch.
★ During assembly of the 2nd gear unit, check that
the stop ring on the main shaft is present inside the
bore of the clutch unit (28).
56 - Fit spacer T41 (code 5.9030.854.0) and secure with
ring nut (11). 68
70
★ Make sure that the clutch housing is tight against 69
the shoulder on the main shaft.
66 30
27
29 70
21
24
20
22
23
19
D0000710
40-175
57 - Position a dial gauge and preload it by 3-4 mm with the

contact point resting on gear (29).
58 - Force the gear (29) upwards to measure the end float.
★ Normal end play: 0.05 --0.15 mm (0.002 --0.006 in.)
59 - If the end play is not within the normal range, adjust the
thickness of the shim pack accordingly.
29
F0007090
60 - Remove from the main shaft (19) all the parts fitted in
order to check the end play and fit bearing (102), thrust
plate (101) and circlip (100). 102
101
100
19
F0007101
61 - Refit the complete assembly in the transmission cas-

ing following the removal operations in reverse order.
★ To prevent the shims (23) of the thrust bearing (21)
and thrust plate (22) from falling, insert the PTO
shaft to act as a guide.
★ Rotate the main shaft (19) in both directions in or-
der to locate the broachings and insert the shaft
sufficiently so that bearing (102) is flush with the
19
102
F0006631
62 - Install tool T47 (code 5.9030.873.0) on the two studs

and secure it in position with two spacers, washers T47
and nuts.
63 - Screw in slowly to locate the centre of bearing (102)
and continue to slightly compress the thrust washer.
102
F0013790
40-176
64 - To the main shaft, fit service spacer T42 (code

5.9030.855.0) thickness 4 mm (0.158 in.), bearing (16)
complete with bush (17) and spacer (53).
53 B
T42 17 16
D0000900
65 - Screw end fitting “B” of tool T44 (code 5.9030.736.0)

onto the shaft, and, while holding the shaft against ro-
tation with a wrench on the flats provided, tighten the
end fitting to 300 Nm (221 lb.ft.).
B
F0009290
66 - Fit studs “C” and tool T44 (code 5.9030.736.0) to the

C
67 - Screw the central rod into end fitting “B”.
B
68 - Screw in inner nut “E” to drive home the thrust bearing
of the tool.
E
C
F0009300
69 - While holding the locknut next to the thrust bearing

against rotation, screw nut “E” up against the locknut.
★ Apply a force of 200 kg during this operation.
70 - Now rotate the main shaft (19) repeatedly in both di-
rections in order to seat the tapered bearing (16).
F0009310
40-177
71 - Loosen nut “E” and repeat the above operations for

nut “D” in order to seat bearing (24).
72 - Remove tool T24 (code 5.9030.736.0), leaving end fit-
ting "B" in position.
E
B
T44 D
F0009320
73 - Position a dial gauge "C" with magnetic stand so that

the contact point rests on end fitting "B".
Preload the dial gauge by approximately 3 mm (0.118
in.).
B
C
F0013800
74 - With a lever, force the shaft along its axis in both di-
rections; measure the end float.
Example: 0.87 mm (0.034 in.)
75 - Calculate the final shim thickness by subtracting the
measure end float from the thickness of the service
spacer T44 (code 5.9030.855.0).
Example: 4--0.87 = 3.13 mm (0.158 --0.034 = 0.124 in.)
76 - Round the value thus obtained down to the nearest
5/100.
Example: 3.13 → 3.10 mm (0.124 → 0.122 in.)
F0013810
77 - Remove end fitting "B", spacer (53), bearing (16) com-

plete with bushing (17) and service spacer T42 (code
5.9030.855.0).
18 16
78 - Position the shim pack of the calculated thickness (18)
and refit bearing (16) complete with bush (17).
F0009330
40-178
79 - Fit the seals (54) to spacer (53).

54
80 - Lubricate the seals (54) and fit the complete spacer in
manifold (15).
Seals: Gearbox oil 55

15
81 - Install O-ring (55) in the manifold. 53
15
F0006880
82 - Lubricate the main shaft (19) and fit the complete man-
ifold assembly (15).
Shaft: Gearbox oil 15
83 - Secure manifold (15) with bolts (14).
19
14
F0009340
84 - Apply sealant to the threads of ring nut (11) and screw

it onto shaft (19) using wrench T40 (code
5.9030.708.0).
Ring nut: Loctite 270 11

85 - Tighten down the ring nut (11).
T40
F0009350
86 - Stake the ring nut (11) in correspondence with the

slots in the shaft.
11
F0006580
40-179
87 - Fit annulus carrier (13) and bolt down with bolts (12).
★ Orientate the shuttle shaft.
13
12
F0009360
88 - Assemble the creeper unit following the dismantling

operations in reverse order (see paragraph «8. DIS-
MANTLING THE CREEPER UNIT»).
★ Apply grease to the bore to hold the planet rollers in
place. 10 9
89 - Locate shim (10) and fit the complete creeper unit (9).
F0009370
90 - Only if it is to be renewed. Apply sealant to control

valve (7) and fit gasket (8). 7 8
Control valve: Loctite 510

★ The gasket must be fitted with the larger diameter
hole "A" at the bottom.
★ All the holes must be unobstructed.
A
★ After locating the gasket, apply a weight with flat
surface and wait for the sealant to cure (about 45
minutes).
A
91 - Fit the control valve (7).
F0012391
92 - Fit pipes (3) and (5) and screw the fittings by hand onto
the manifold (4).
3 5
F0006550
40-180
93 - Apply sealant to the threads of fittings (1) and screw

them on to the pipes of the control valve (7) and pipes
(3) and (5) tight up against the elastic ring.
Fittings: Loctite 243
94 - Tighten the fittings of pipes (3) and (5). 1
F0006540
40-181
REAR TRANSMISSION
REMOVAL OF THE REAR TRANSMISSION
1 - Remove the cab.

2 - Remove the pumps assembly.
(For details, see «REMOVAL OF THE COMPLETE
PUMP ASSEMBLY»).
3 - Remove the lift.
(For details, see «REMOVAL OF THE LIFT»).
4 - Remove the cover of the rear transmission casing.
(For details, see «REMOVAL OF THE REAR TRANS-
MISSION CASING COVER»).
5 - Remove the cover of the front transmission.
(For details, see «REMOVAL OF THE FRONT TRANS-
MISSION CASING»).
6 - Remove the rear wheel supports and the brake as-
semblies.
(For details, see «REMOVAL OF THE REAR AXLE -
BRAKES»).
7 - Remove the flow divider valve (1) and all the connec-
tion pipes.
F0005291
8 - Position a stand "A" and non-slip blocks under the

front gearbox (2).
For safety, position two stands "A" under the
front axle and drive wedges between the front
axle and the carrier.
2
F0012780
40-182
REAR TRANSMISSION
9 - Bolt a suitable lifting bracket "B" to the holes of the

rear transmission (3) as shown; attach the sling of a
hoist to the bracket and put the sling under slight ten- B 3
sion.
F0012790
10 - Loosen the nuts (4) securing the front transmission (2)

and the rear transmission (3). 2 3
11 - Remove all the nuts (3) except for the inside nut at the
top left and the two lower lateral nuts.
4
1
F0012860
12 - Apply tool T43 (code 5.9030.856.0) to the inside top

left stud and unscrew the nut (4) to separate the rear 2 4 T43 3
transmission (3) from the front transmission (2).
F0012870
13 - Apply two tools T34 (code 5.9030.856.0) to the lower

lateral studs and unscrew the nut (4) to further sepa-
rate the two transmission casings.
3
14 - Unscrew the two nuts evenly and alternately until the
rear transmission (3) is separated from the front trans-
mission (2).
4
T43
F0012741
40-183
REAR TRANSMISSION
REFITTING THE REAR TRANSMISSION
1
★ Tighten the nuts alternately starting with the lower
central nuts.
2
Rear transmission casing face: Loctite 510.
★ Make sure that sealant forms a continuous film
around the studs.
★ When bolting the two units together, slowly turn
the lower shaft of the shuttle to centre the sleeve of
the creeper unit.
3
★ Rotate the rear PTO input shaft to help engage the
splines.
Carefully check that the shaft of the shuttle neu-
tral gear is perfectly positioned when connecting NO
NO
the two transmission casings.
F0012750
OK
F0012760
40-184
REAR TRANSMISSION CASING
DISMANTLING THE REAR TRANSMISSION CASING
1. DISMANTLING THE PTO SHAFT
6
3 4
2
1 14
15
8 5 13
11 9
12
11
7 D0000380
1 - Remove the screws (14), washers (15) and the cover

(13).
10
13
14 15
F0003380
2 - Remove the circlip (9), and using a punch, disengage

the outer race of the bearing (7) from its seat in the cas-
ing.
7
9
F0012800
40-185
3 - Using a punch made of soft material and a mallet,

drive the PTO shaft (1) towards the rear until you can
remove the circlip (11); remove the bearing (12) and
the second circlip (11).
1 12
11
F0012810
10
12
11 11
D0000190
4 - Remove the circlip (9), the thrust washer (8) and the
roller bearing (7) from the shaft (1).
★ Make a note of which way round the bearing (7) and 8
the thrust washer (8) are installed. 7
5 - Withdraw the complete shaft (1).
10
F0003360
10
7
8
D0000200
40-186
6 - Remove the circlip (6) and the bearing (5) from the
shaft (1).
1
6
5
F0012820
7 - Remove the spacer (4), gear (3) and spacer (2) and, us-
ing a soft punch and a mallet, remove the inner race of
the roller bearing (7). 3 2
★ Tap the race evenly all around its circumference.
4
F0012830
8 - Remove the speed sensor and its copper gasket.
F0012840
40-187
2. DISMANTLING THE PTO CLUTCH AND THE PUMP DRIVE GEAR
12
8 10
1
2 11
9
5
6
3
4 D0000290
1 - Remove the lubrication plug (8) and the toothed

washer (9).
9 8
F0002380
2 - Using a soft drift, drive out the complete gear assem-

bly (1).
★ Note the position of the lubrication hole "A". A 7
F0002370
40-188
3 - Remove the clutch unit (12) and the shaft (10) simul-
taneously.
★ For overhaul of the clutch unit, see «OVERHAUL
OF THE PTO CLUTCH».
12
10
F0002390
4 - Remove the circlip (6) from the gear assembly (1).

5 - Remove the bearing (5) from the gear assembly (1). 6
1
F0014090
6 - Remove the spacer (4) and the outer race of the bear-
ing (3).
4
F0003130
7 - Remove the inner race of the bearing (3).

2 3
8 - Only if necessary. Remove the circlip (2) from inside
the gear (1).
3
1
1
F0003120
40-189
9 - Remove roller pack (11) from the power take-off shaft.

11
D0002930
40-190
3. DISMANTLING THE CREEPER SELECTOR FORK ASSEMBLY
35 22 21
23
12
11
10
29 20
28 19
27 24
13
26 25
8 18
5
17
4
16
14
15
6 7
3
1 2 D0000330
1 - Remove the plug (33) complete with its copper gasket

(34).
2 - Remove the plunger (32), spring (31) and ball (30) from
33 34
the transmission casing. 30
31
32
F0013190
3 - Remove the screw (29) and the spring washer (35); re-
move the sprung lock plate (28).
27 28
29
35 F0003310
40-191
4 - Remove the potentiometer (27) from the lever (23).

23
27
24
F0010170
5 - Undo nut (26) and grub screw (25) and remove the le-
ver (23). 23
26
25
F0013140
6 - Remove the circlip (22) and remove the spacer (21).
21
22
F0013150
7 - Withdraw the lever (19) from the transmission casing

(9).
9
19
F0003270
40-192
8 - Remove the O-ring (20) from lever (19).
20 19
F0003260
9 - Remove the plug (18), spring (17) and ball (16) from the
17
18 16
F0013160
10 - Undo nut (15) and remove the grub screw (14).
15 14
F0013170
11 - Remove the control rod (13).
13
F0013180
40-193
12 - Remove the O-ring (12) and withdraw the spindle (11)

from the transmission casing.
11
12 11
F0013130
13 - Using a suitable drift, remove the roller cage (10) from

the spindle (11).
14 - Using a magnetic rod, remove the pin (8).
8
9
10
11
F0013200
15 - Push the fork (5) so that it disengages the selector (6)

on the gear (7).
5 7
6
F0003200
16 - Remove the fork (4).
2
F0003190
40-194
17 - Remove the sleeve (1) complete with tab ring (2) from
the gear (3).
1
3
F0003180
18 - Rotate the tab ring (2) and separate if from the sleeve
(1). 2
2 1
F0013210
40-195
4. DISMANTLING THE RANGE SELECTOR FORK
4
3
2
D0000370
1 - While holding firm the selector fork (1), withdraw the

rod (2) from the casing.
2 1
F0003150
40-196
5. DISMANTLING THE PARKING BRAKE AND 4WD UNIT
26
25 24 16
27 1
28 29
30
20
18 22 21
6 17
3 5
10 7 4
8
11
12 15 9
14 13
23
23
35
35
37
36 38 33
34
33
43
42
31 41 40 39
48
49
46
47 45
32
44
D0000320
40-197
1 - Remove the fitting (44) complete with O-ring (45) and

pipe (49).
49
44 45
F0003110
2 - Undo and remove bolts (46) and nuts (47); remove the
nuts, bolts and washers (48).
31
47 48
46 48
F0003100
3 - Screw two bolts "F" (M10x70) into opposite bolt holes

of the lower cover (31) to secure the cover and prevent
it from falling.
F 31
F0013220
4 - Remove the complete cover (31) using a lever in the re-

cesses provided.
31
F0012880
40-198
5 - Using hoist, turn the casing (19) over so that it is po-

sitioned vertically; position a wooden block "A" to 19
avoid damage to the studs.
★ Check that the casing is stable before detaching
the hoist.
A
F0012890
6 - Remove the oil seal (30).

30
F0013820
7 - Using the low profile wrench "B" (7 mm (0.276 in.)) and

special wrench T54 (code 5.9030.869.0), loosen and
fully unscrew the ring nut (24). T54
24 F0010140
8 - Remove the circlip (28) and recover the shims (29).
29
28
F0002960
40-199
9 - Fit a puller "B" with an M10 threaded rod screwed into

the centre hole of the shaft (26) and locked in position
with a nut "C".
B
10 - Turn the top nut to withdraw the shaft complete with
the bearing.
★ To facilitate shaft removal, tap the upper gear as-
sembly gently with a copper mallet.
30 mm
M10x200 mm
B
155 mm
30x3 mm (tubo) 125 mm 30 mm

D0002900
F0012900
11 - Withdraw the shaft (26) complete with bearing (25).

B
25
26
F0012910
12 - Remove the gear (2) complete with bearings (1) and

ring nut (24). 1
24
F0003020
40-200
13 - Remove the braking discs (23).
23
F0002860
14 - Remove the complete clutch unit (6).
F0002840
15 - Remove the inner race, and using a puller, remove the

outer race of bearing (22).
22
22
F0012920
16 - Remove the spacer (21) and circlip (21).
20
21
F0013230
40-201
17 - Remove the clutch unit (6), the manifold (18) and the
seals (17).
★ Not which way round the manifold is installed. 17
18
6 6
F0013240
18 - Remove the hub (16).
16
F0002790
19 - Remove the guide spacer (15).

★ Note which direction the oil discharge grooves
face. 14
20 - Remove the circlip (14) securing the clutch pack (10). 15
F0013250
21 - Remove the spacer (13) and the first friction plate (12).
13 12
F0013260
40-202
22 - Proceed with removal of the clutch pack down to the

last plain steel plate (11).
10 11
F0002760
23 - Using tool T52 (code 5.9030.866.0) and a press, com-

press the spring in order to disengage the circlip (9)
from the clutch housing (6).
T52
F0002750
24 - Remove the circlip (9), the spring guide ring (8) and the
spring (7).
9
7
8
6
F0013270
25 - Remove the complete piston (3).

★ To expel the piston, use a compressed air jet at low
pressure; hold the piston to prevent it from being 3
damaged.
F0002730
40-203
26 - Remove the piston (3) and the O-rings (4) and (5).
★ Renew the O-rings at each re-assembly.
5
4
3 3
F0002720
27 - Using a drift, remove the outer races of the bearings (1)

from the gear (2). 2 2
1
F0012930
28 - Remove the bearing (25) from the shaft.
25
F0012940
29 - Remove the circlip (43) from the lower cover (31).
43
F0003060
40-204
30 - Partially withdraw the lever (39) and remove the cam

(42).
★ Note the position of the cam.
39
42
F0003050
42
31 - Withdraw the control lever (39) and recover the O-ring

(41) and the spacer (40).
★ Renew the O-ring on re-assembly.
41 40
39
F0003040
32 - Remove the cotter pin (38).

★ Renew the cotter pin on re-assembly.
38
F0003030
33 - Remove the first guide pin (34) and remove the pres-
sure plate (37).
37
34
F0003010
40-205
34 - Remove the brake shoes (35) and (36) and the second
guide pin (34).
36
F0003000
35 - Remove the central (32) and lateral (33) drain plugs

with their gaskets from the cover (31).
32
31
33 F0002980
40-206
6. REMOVAL OF THE DIFFERENTIAL
21
17 15
19 1
41
19
15
39
14
40 13
12
16 18
20
3 4
6
2
11
8
5 7
9
10
28
37
35
37
24
36 27
26
38
23 22 25
34
D0000340
★ The first two operations in this procedure serve to hold

the pinion against rotation.
1 - Relieve the staking on the pinion lock nut.
40-207
2 - While holding the pinion (4), loosen and remove the

ring nut (38).
38
F0012950
41
F0010130
4 - Remove the upper centre stud (19) from the crown

wheel side of the casing.
★ Use the nut and lock nut method.
19
F0003840
5 - Remove the two retaining bolts (14) of the flange (17).

17
6 - Screw two M12x70 bolts "A" into the holes provided in
14
the crown wheel side of the flange (17).
7 - Tighten the two bolts evenly to separate the flange
(17).
A A
14
F0012960
40-208
8 - Loosen and remove the crown wheel retaining bolts

(40).
40
F0012970
9 - Insert the lifting device and raise the differential (20) to

a horizontal position.
10 - Using a copper punch and a mallet, separate the
crown wheel (39) from the differential unit (20).
39
20
F0012980
11 - Withdraw the differential unit (20).
39
20
F0003770
12 - Withdraw the crown wheel (39) from the transmission

casing (1). 1
39
F0003760
40-209
13 - Remove the outer race of bearing (13) from the flange

(11) and recover the shims (12).
13
12
14 - Using the same method as that used for flange (17), re-
move flange (11). 11
★ Do not remove the upper central stud.
F0003510
15 - Remove the outer race of bearing (18) from the flange

(17) and recover the shims (16).
18
17 16
F0003530
40-210
7. DISMANTLING THE DIFFERENTIAL
13
14
16
17
10
9 4
2
1
3
20
18 15
19
5
4 2
7 6
8
11
11
11
11
12
12
12
12
10
D0000280
1 - Remove screws (18) and washers (19); remove the

cylinder assembly (13) from the differential (1).
18 19 13
18 19
1
F0002350
40-211
2 - Remove the piston (17) from the cylinder (13).
17
F0002340
3 - Remove the O-rings (15) and (16) from the cylinder

(13).
★ Renew the O-rings on re-assembly.
15
16
13
F0002330
4 - Remove bearing (14) from the cylinder.

★ Use a bearing separator.
14
F0013830
5 - Remove the clutch plate pack (10) from the differential

(1).
11
11 12
10
1
F0002310
40-212
6- Remove the shim (2) from the sun gear (9).
F0002300
7 - Remove the sun gear (9).

9
F0002290
F0002280
9 - Remove the thrust washers (7) from the grooves in the

crosspins (5).
7
5
F0002270
40-213
10 - Remove the spacers (6) from the differential cage (1).
F0002260
11 - Remove the crosspins (5) and the planet pinions (4).

4
F0010110
12 - Remove the planet pinion (3).

13 - Remove the shim (2). 3
14 - Remove bearing (20) from the differential cage.
★ Move the bearing using a very thin punch and then
use a bearing separator.
F0010090
40-214
8. REMOVAL OF THE BEVEL PINION
21
17 15
19 1
41
19
15
39
14
40 13
12
16 18
20
3 4
6
2
11
8
5 7
9
10
28
37
35
37
24
36 27
26
38
23 22 25
34
D0000340
1 - Remove gear (35) complete with bearing (34).

★ If necessary, use a soft drift and a mallet.
34
35
F0012990
40-215
2 - Remove the synchronizer ring (22).
22
F0013000
3 - Remove the bearing (37) and the thrust washer (22).

★ Note which way round the thrust washer is in-
stalled.
37 23
F0013110
4 - Remove the synchro unit (22).

22
10
F0013010
6 - Apply special wrench T49 (code 5.9030.719.0) on ring

nut (10) and special box wrench T50 (code
5.9030.720.0) to the pinion shaft.
T49 T50
7 - Loosen the ring nut (10) and disengage it from the
thread on the pinion shaft (4).
F0003680
40-216
8 - Position wooden blocks in the transmission casing (1)

to support the pinion (4). 1
F0003610
9 - Using drift made of soft material, drive the pinion (4)

complete with bearing (3) towards the inside of the
casing in order to be able remove the gears.
F0003620
10 - Remove in order the gear (25), the thrust plate (27), the
pin (28) and the ring nut (10).
25 28 10
27
F0003670
11 - Remove gear (9) and the inner race of bearing (5).
25 9
10 5
F0003660
40-217
12 - Remove the complete pinion (4).
F0003450
13 - Remove the outer race of bearing (3) from the casing

and recover shims (6).
6
1
F0003430
14 - Remove the outer race of bearing (5).
5 1
F0003420
15 - Only if necessary. Remove the circlips (2) securing

the bearing races (3) and (5). 2
F0003400
40-218
16 - Remove the thrust washers (7) and (8) and the bearing
(3) from the pinion shaft (4). 4
F0003440
17 - Remove the circlip (36) from gear (35) and remove the
bearing (34).
★ To remove the bearing use a bearing separator and
a press.
36
34
35
F0013990
18 - Remove the outer races of bearings (37) from gear

(35).
★ Tap with a punch all round the circumference. 35 37
37
D0002960
40-219
9. REMOVAL AND DISMANTLING OF THE 540/1000 - 750/1000 PTO GEARS
15
18
22
23
21
16
20 19
13 17
24
31
27 26
11
12
9
14
10
28 1
29
30
6
7
8
5
4
3
2 D0000300
1 - Relieve the staking on the ring nut (30).
30
5 F0002540
40-220
2 - Using special tool T56 (code 5.9030.494.0) and hold-

ing the PTO shaft with a suitable wrench, unscrew and 30
remove the ring nut (30).
T56
F0013020
3 - Remove the thrust plate of bearing (29).

29
★ Note which way round the thrust plate is installed.
29
F0013030
4 - Remove the circlip (21) and release the thrust washer

(20) and spring (19).
5 - Withdraw the spring pin (24) and remove the selector
lever (23).
★ Recover the disc (22). 22 23
20
19
24
21
F0013120
6 - Withdraw the control rod (16) and simultaneously the

selector fork (15).
7 - Remove the thrust washer (20) and spring (19).
19
20
15
16
F0013040
40-221
8 - Remove the nuts (26) and (27) and loosen the rear
flange assembly (1).
26 27
1
F0014000
9 - Slowly withdraw the PTO shaft while simultaneously

removing the gears (11) and (14). 14
★ Note that the concave side of the flange (1) faces
upwards.
11
1
F0013050
10 - Remove the hub (10), sleeve (9) and bushes (12) and
(28) from the gears. 11
9
12
10
11
F0002440
11 - Remove the shaft (5) complete with output shaft (6)

from the flange (1).
5 6
F0013060
40-222
12 - Remove the oil seal (4) from the flange (1).

★ Note which way round the oils seal is installed. 4 1
D0002940
F0013070
14 - Using a suitable drift and a press, remove the bearing

(2).
F0013080
15 - Using a suitable punch and a mallet, remove the bear-

ing (29) from the transmission casing.
29
F0013090
40-223
16 - Remove the key (18) and the O-ring (17) from the con-
trol rod.
17
16
18
F0002480
40-224
ASSEMBLY OF THE REAR GEARBOX

1. GEAR ASSEMBLY PTO 540/1000 - 750/1000
15
18
22
23
21
16
20 19
13 17
24
31
27 26
11
12
9
14
10
28 1
29
30
6
7
8
5
4
3
2 D0000300
1 - Using a press and a suitable drift install bearing (1) in

support (2).
2 - Install the circlip (3).
2 3
1 1
F0002410
40-225
3 - Using tool T48 (code 5.9030.865.0) fit the seal (4).

★ Check that the seal is fitted the correct way round.
T48
4
F0002420
4 - Using the press, fit shaft (5) complete with output shaft
(6).
6
5 - Secure the output shaft (6) with nuts (7) and washers
(8).
5
F0002430
6 - Insert hub (10) in sleeve (9) and fit the assembly to gear
(11). 11
7 - Insert bush (12) in gear (11). 9
12
★ Lubricate the assembled components with gear-
box oil.
10
11
F0002440
8 - Apply sealant to the contact surface on the transmis-

sion casing (13).
Loctite 510 13
★ Ensure that the sealant forms a continuous film
around the studs. A
11
9 - Simultaneously install gear (11) and bearing support
assembly (1).
★ The bearing support (1) must be installed with the
concave side “A” facing upwards and the sleeve
(9) of gear (11) must be oriented towards the ge- 1
arbox (13). F0002450
40-226
10 - Install gear (14) without inserting the internal bush.

★ The meshing side of the gear must be oriented to- 14
wards bearing support (1).
13
F0002460
11 - Insert selector fork (15) complete with shoes between

gears (11) and (14).
★ Ensure that the selector fork shoes engage the
groove in sleeve (9).
15
11
14
9 F0002470
12 - Fit O-ring (17) and key (18) control rod (16).

★ Lubricate the O-ring (17) with grease.
17
16
18
F0002480
13 - Insert control rod (16) in the hole in the transmission

casing and fit, in order, the spring (19), thrust washer
(20) and circlip (21).
14 - Insert the control in the selector fork (15), securing it 19
with key (18). 20
15
21
16
F0002490
40-227
15 - Fit key (22) on control rod; fit selector lever (23) and se-
cure in position with spring pin (24)
16 - Compress spring (19) and install circlip (21).
22 23
19
24
21
F0002500
17 - Only if removed.
Using a suitable drift, fit the plug (25).
Plug: Silastic 738 25

26 27
18 - Fix bearing support (1) with nuts (26) and toothed
washers (27).
★ Tighten nuts in a crosswise sequence.
1
F0002510
19 - Lubricate and insert bush (28) in gear (14).

20 - Fit roller bearing (29) to shaft (5).
★ The edge of the inner bearing race must be orient-
29
ed towards the shoulder of the shaft. 28
F0002520
21 - Drive bearing (29) home using a drift.

★ Tap evenly around the entire circumference of the
bearing.
29
F0002530
40-228
22 - Fit thrust washer of bearing (29).

★ The chamfered edge of the washer should be up
against the locknut and the washer must be posi- 30
tioned centrally relative to shaft (5).
29
D0002950
23 - Fit the locknut (23) and apply special wrench T56

(code 5.9030.494.0); using a torque wrench and a
suitable wrench on the output shaft, tighten to the
specified torque.
T56
Locknut: Loctite 270
Locknut: 137 Nm (101 lb.ft.)
6
F0013840
24 - Stake the locknut (30) on two sides.
30
5 F0002540
40-229
2. ASSEMBLY OF THE BEVEL PINION - REAR DIFFERENTIAL -

RANGE GEARS
WARNING!
1- The assembly operations described below refer 2- In the following assembly and inspection opera-
to the overhaul of a rear gearbox. For this reason, tions, it is presumed that all the bearings and the
some of the procedures make reference to the relative thrust washers/shims have been re-
original adjustment shims that have been removed, even if these parts are not to be renewed.
moved or recovered.
Any additional shims or alterations in shim thick-
nesses will instead require the use of new parts
that can be found in the parts catalogue.
2.1 Assembly of the rear differential
13
14
16
17
10
9 4
2
1
3
20
18 15
19
5
4 2
7 6
8
11
11
11
11
12
12
12
12
10
D0000280
40-230
1 - Install shim (2) in differential cage (1).

Shim: Grease 2
★ The lubrication grooves must be oriented so that
they face upwards.
1
F0010080
2 -Fit the first sun gear (3).

3
F0010090
3 -Insert the first planet pinion (4), the cross pin (5) and
the second planet pinion (4). 4
F0010100
4 -Repeat step 3 to install the second cross pin (5).

4
F0010110
40-231
5 - Fit spacers (6).
F0002260
6 - Fit the thrust washers (7), ensuring that they engage

the groovesin the cross pins (5).
7
5
F0002270
7 - Secure the thrust washers in position with circlips (8).

★ The openings in the circlips (8) must be positioned
at 90° to the joints between the two halves of the
thrust washers (7).
F0002280
8 - Fit the second sun gear (9).

9
F0002290
40-232
9 - Fit shim (2) to sun gear (9).

Shim: Grease
2
★ The lubrication grooves must be oriented towards
the sun gear.
F0002300
10 - Install the clutch pack (10) (8 + 8).

★ Start with a friction plate (11) followed by a plain
steel plate (12). 11
Alternate the plates until they are all installed, fin-
ishing the pack with a plain steel plate (12).
11 12
10
1
F0002310
11 - Using a press and a suitable drift, fit the inner race of

bearing (14) onto the cylinder (13).
14
13
F0002320
12 - Turn the cylinder over and fit the O-rings (15) and (16).
★ Stretch O-ring (16) to make it stay in its seating.
15
O-rings: Grease
16
13
F0002330
40-233
13 - Fit the piston (17) and press fully home.

★ Take care not to damage the O-rings (15) and (16). 17
F0002340
14 - Fit cylinder (13) on to the differential cage (1) and se-

cure with the two bolts (18) and toothed washers (19).
Bolts: Loctite 242

★ Using a mallet, tap gently and evenly around the
18 19 13
circumference of the cylinder. 18 19
1
F0002350
15 - Using a press and a suitable drift, install the inner race

of bearing (20) on the diff. cage (1).
20
F0002360
40-234
21
17 15
19 1
41
19
15
39
14
40 13
12
16 18
20
3 4
6
2
11
8
5 7
9
10
28
37
35
37
24
36 27
26
38
23 22 25
34
D0000340
2.2 Preparation of the gearbox

1 - With a caliper measure the width of the slot “A” in the
central wall of the transmission casing (1).
A
F0003390
40-235
2 - From the available circlips (2) (thickness 3.25-3.30-

3.35), select three circlips to obtain a total thickness 2
equal to the width of the slot, rounded up to the near-
est 5 hundredths of millimetre.
3 - Fit the circlips (2) in the slot one at a time.
★ Position the circlips so that the openings are stag-
gered at intervals of approx. 120°.
★ Ensure that the circlips are properly seated in the
slot.
F0003400
2.3 Preparation of the bevel pinion

1 - Heat the inner race of bearing (3) to approx. 100°C
(212°F) and fit it on the pinion shaft (4).
★ To heat the bearing, use an electric hotplate or a 3
hot air blower.
3
4
F0003410
2.4 Assembly of the bevel pinion

1 - Install the outer race of the bearing (5) in the housing in
the transmission casing (1) and drive it fully home.
5 1
F0003420
2 - Determine the thickness “S” to be added to or sub-

tracted from the shim pack removed and to be re-in- PINI0N REMOVED PINION TO BE INSTALLED
stalled under the outer race of the pinion bearing (3). +0
,20 -- 0
The thickness “S” is obtained by subtracting the value ,20
stamped on the teeth of new pinion to be installed

from that of the pinion removed.
Example 1: S=+ 0.20 --(--0.20 )=+0.40 mm
S=+ 0.008 --(--0.008 )=+0.016 in.
--0
,10 +
0,3
0
Example 2: S=--0.10 --(+0.30 )= -- 0.40

S=--0.004 --(+ 0.008 )=--0.016 in. D0000220
40-236
3 - In the case of a positive result (Example 1), a thickness

of 0.40 mm (0.016 in.) must be added to the original 5 6
3
shim pack; in the case of a negative result (Example 2),
8
a thickness of 0.40 mm (0.016 in.) must be subtracted 7
from the original shim pack to obtain the correct thick-
ness of shim pack (6).
D0000210
4 - The same thickness “S” must be added to or sub-

tracted from the two thrust washers (7) and (8) inter-
posed between the inner races of the two bearings (3) Shims (mm) Shims (mm)
and (5).
9.80 10.25
Select two thrust washers (7) and (8) to obtain the cor- 9.85 C 10.50
rect combined thickness from those available (see 9.90 10.025
parts catalogue). 9.95 10.275
10.0 10.525
★ The two thrust washers must aligned with the in-
ternal oil outlet slots“B” and the oil grooves “C”.
7 8
B
D0000230
5 - Install the shim pack (6) and the outer race of the pinion
bearing (3) in the transmission casing (1); drive the as-
sembly home.
6
1
F0003430
6 - Install thrust washers (7) and (8) on the pinion shaft (4).
★ Ensure that the oil outlet channels and the oil 4
grooves are correctly positioned.
F0003440
40-237
7 - Install the complete pinion assembly (4) in the casing

(1).
F0003450

(212°F).
9 - Install bearing (5) and gear (9) on the pinion shaft.
4 5 9
10 - Drive the assembly home and lock in position with ring
nut (10).
10
F0003460
11 - Fit special wrench T49 (code 5.9030.719.0) to the ring

nut (10) so that it rests against the side of the casing
(1).
T49
10
F0003470
12 - Fit the special socket wrench T50 (code 5.9030.720.0)

to the end of the pinion shaft (4).
13 - Tighten ring nut (10) using a torque wrench.
T50
Ring nut: 785 -- 880 Nm (578 -- 648 lb.ft)
F0003480
40-238
14 - 14 -Lubricate bearings (3) and (5) and rotate them in

both directions in order to seat the rollers; while ro-
tating the bearings, tap lightly on the head of the pinion
(4) to help seat the bearing rollers.
4
Bearings: gearbox oil
F0003490
15 - Check the bearing preloading by measuring the ro-

tating friction torque of the pinion. Wrap a length of
soft wire around the pinion shaft (4) where its diameter
is Ø 52 mm (2.049 in.) and pull the wire tangentially T51
with a spring balance T51 (code 5.9030.529.0).
★ Rotation torque: 11.5 -- 15.4 kg (25.3 -- 34 lb.) with
continuous rolling.
F0003500
16 - If the rotation torque is greater than the maximum

permissible value, it will be necessary to remove
bearing (5) and increase the thickness of one of the Shims (mm) Shims (mm)
two thrust washers (7) and (8).
9.80 10.25
If the rotation torque is less than the lowest per- 9.85 C 10.50
9.90 10.025
missible value, the thickness of the thrust washers 9.95 10.275
must be reduced. 10.0 10.525
★ Alter the thickness by 0.025 mm (0.001 in.) at a
time.
7 8
B
D0000230
2.5 Checking the pinion mounting distance

1 - Install the previously removed shims (12) and the outer 13
12
race of the lh bearing (13) in the lh flange (11).
11
★ To install the outer bearing race, tap gently and
evenly with a mallet around the entire circumfer-
ence.
F0003510
40-239
2 - Apply sealant to the mating surface of the flange (11)

14
and install the flange on the transmission casing (1).
Flange: Loctite 510
E
★ Check that the sealant forms a continuous film 15
around the studs.
3 - Bolt the flange (11) with bolts (14), with service spa-
cers "E" and nuts (15). E
15
14
F0003520
4 - Remove one shim from the shim pack (16) that was
previously removed from the rh flange (17) and install
the remaining shims; install also the outer race of the 18
rh bearing (18).
17 16
F0003530
5 - Remove the uppermost central stud (19) from the cas-

ing (1).
19 1
6 - Fit the flange (17) to the differential unit (20).
7 - Raise the differential unit and install it in the transmis- 20
sion casing (1).
F0003540
8 - Bolt the flange (17) to the casing with bolts (14), spa-
cers “E” and nuts (15). 14
E
15
E
15
F0003550
40-240
9 - Position a dial gauge “F” with magnetic base and ze-

roset it to the head of the differential of the unit (20).
20
F0003560
10 - Using a lever, push the differential unit (20) along its

axis in both directions.
★ Measure and record the end play.
11 - To the measured end play value, add 0.1 mm (0.004
in.) to determine the thickness of the shim pack to be
installed in the rh flange (17). 20
20
F0003570
12 - Remove the rh flange (17), leaving the differential unit

(20) in position.
18
13 - Remove the outer race of the rh bearing (18) install the
shim thickness determined in step 10 between two 17 16
thicker shims.
Re-install the shims (16) and the outer bearing race
(18) in the flange (17); fit the flange to the transmission
casing (1).
F0003530
14 - Check the bearing preload by measuring the rolling

drag torque of the differential unit (20). To do this, wrap T51
a length of soft wire around the Ø 90 mm (3.546 in.) of
the differential and pull the wire tangentially with a
spring balance T51 (code 5.9030.529.0).
★ Continuous rolling torque:
4.5 -- 8.8 kg (10 -- 19.4 lb.).
20
F0003590
40-241
15 - Check the value stamped on the tooth of the installed

pinion (4) and add it (if positive) or subtract it (if neg-
ative) to the nominal dimension of 23 mm (0.906 in.)to
obtain the dimension “X”. +0 -- 0
,20 ,20
Example 1: Example 2:
(mm) 23+0.20=23.20=X (mm) 23 --0.20=22.80=X
(in.) 0.906+0.008=0.914=X (in.) 0.906--0.008=0.898=X
D0000240
16 - Using a feeler gauge, measure the distance between

the end face of the pinion (4) and the ground surface of
the differential unit (20) (dimension “Z”).
F0003580
17 - If the measured dimension “Z” differs from the calcu-

lated dimension X, calculate the difference between 6
the two.
The result “Y” is the thickness to be added to or sub-
tracted from the shim pack (6) installed under the pin-
ion bearing and the preloading adjustment shims (7)
and (8).
7 8 X
On fitting the pinion, check the rolling torque as
described in step 14.
Measured Calculated Variation of
dimension “Z” dimension “X” thickness “Y”
Example 1 23.30 (0.918 in.) 23.20 (0.914 in.) +0.1 (0.004 in.)
Example 2 22.70 (0.894 in.) 22.80 (0.898 in.) -- 0.1 (0.004 in.)
D0000250
2.6 Final assembly of the bevel pinion

1 - Remove the rh flange (17) and the differential unit (20).
17
20
F0003541
40-242
2 - Fit the splash plate (21) in the casing (1) and fix in po-
sition by bending the tabs “G”.
G 21 G
F0003600
3 - Position blocks in the casing (1) to support the pinion

(4). 1
F0003610
4 - Remove the ring nut (10) and using a drift made of soft
material, drive out the pinion(4) complete with bearing
(3).
Only of necessary
Insert the previously calculated shim thickness under 4
the outer race of bearing (3) and alter the thickness of
the shims (7) and (8).
F0003620
5 - Fit synchro unit (22) and thrust washer (23) to pinion 23

shaft (4).
★ The oil discharge groove on the thrust washer (23) 4
must oriented towards the synchro unit (22).
23
22
F0003630
40-243
6 - Using a feeler gauge, check that there is a clearance of

0.2 -- 0.3 mm (0.008 -- 0.012 in.) between the synchro
unit (22) and the thrust washer (23).
4
★ Choose from the two thrust washers available that
which ensures the correct clearance (see parts
catalogue).
23
22
F0003640
7 - Fit the circlip (24) to the pinion shaft and fit the roller
cages (26) to gear (25). 4
25
24
26
F0003650
8 - Insert the pinion (4) and fit to the pinion shaft the bear-
ing (5), gear (9), ring nut (10) (apply sealant), thrust ring
(27) and gear (25) complete with roller cages (26). 25 9
Ring nut: Loctite 242 10 5
★ The stop groove of the thrust plate must be ori-
ented towards the pinion.
F0003660
9 - Hand-tighten the ring nut (10).

10 - Fit pin (28) to the shaft, engage the thrust plate (27) and
position gear (25).
25 28 10
27
F0003670
40-244

ring nut (10) and apply special socket wrench T50
(code 5.9030.720.0) to the pinion shaft.
Tighten ring nut (10). T49 T50
Ring nut: 785 -- 880 Nm (578 -- 648 lb.ft.)

12 - Stake the ring nut (10) into the slot on the shaft end.
F0003680
Only if dismantled
31 32
13 - Assembly the synchro unit by inserting springs (30), 30
locker pins (31), and stop plates (32) in the central hub 31 30
(29), then fit the sliding ring (33).
★ Use a compressing tool to compress the three
sprung assemblies, which are to engage the slid-
ing ring.
32
30
29
31
32 33
F0003690
14 - Install the synchro unit (22).

★ The thicker ring “H” must be oriented towards the 22 25
gear (25).
H
F0003700
15 - Heat the ball bearing (34) to approx. 80 °C (176°F) and

key it onto the gear (35).
16 - Secure the bearing (34) in position with circlip (36).
36
34
35
F0003710
40-245
17 - Using a press and suitable drifts, fit the outer races of

the tapered roller bearings (37) to gear (35).
★ Check that the bearing races are installed the right
way round.
37
35
35
F0003720
18 - Fit thrust washer (23) to the pinion shaft.

★ The oil discharge groove of the thrust washer must
be oriented towards the synchro unit (22).
19 - Fit the inner race of the first bearing (37).
23 37
F0003730
20 - Fit the gear (35).

★ Ensure that the teeth of the gear mesh with the syn-
chro ring (22).
21 - Fit the inner race of the second bearing (37) and ring 35
nut (38).
38
Ring nut: Loctite 270
37
F0003740
22 - While holding the pinion against rotation, tighten ring

nut (38) in a number of stages, rotating gear (35) in both
directions in between each stage.
★ This operation helps to ensure the bearings (37)
are correctly seated. 35
Ring nut: 14.7 Nm (10.8 lb.ft.)
F0003750
40-246
23 - Slacken off ring nut (38) and rotate gear (35) in both di-
rections; perform final tightening of ring nut (38).
Ring nut: 4.9 -- 6.8 Nm (3.6 -- 5 lb.ft.)
★ Be careful not to exceed the specified tighten- 38
ing torque.
24 - Stake the ring nut in correspondence with the slots.
35
F0010120
2.7 Assembly of the differential unit

1
25 - Insert crown wheel (39) in the transmission casing (1).
39
F0003760
26 - Screw the two guide studs “L” into the crown wheel
(39).
Fit the differential unit (20) to the crown wheel (39).
39
20
F0003770
27 - Ensure the crown wheel (39) is correctly seated on the

differential cage (20) by turning the diff. cage while
tapping it gently and evenly with a copper mallet.
★ Seat the crown wheel.
39
20
F0003780
40-247
28 - Insert the crown wheel bolts (40) and remove guide

studs “L”.
20
Tighten bolts (40) with an ordinary wrench until the
crown wheel (39) is seated against the diff. cage (20). 40
L
40
F0003790
29 - Insert a bar “M” in a side aperture of the diff. cage (20)

and turn the cage clockwise until locking occurs.
20
F0003800
30 - Using a torque wrench, tighten bolts (40).
Crown wheel bolts: 122 Nm (90 lb.ft.)

31 - Remove the lifting equipment.
40
F0003810
32 - Fit the rh flange (17) on the studs; insert lifting toolin

the diff. cage; centre the bearings in the housings and 14
fix rh flange (17) with bolts (14), spacers “E” and nuts 17
(15).
E
15
E
15
14 F0003820
40-248
33 - Position a dial gauge with magnetic stand “F” and po-

sition the contact point perpendicular to the side of the
crown wheel tooth, on the external diameter. F
Preload the dial gauge by approximately 4 mm (0.158
in.) and check backlash “Z" between the pinion and
crown wheel by moving the differential cage (20) in
both directions.
★ Normal backlash “Z": 0.24 --0.33 mm (0.009--0.013 in.) 20
★ Take the average of four readings measured at 90°
intervals.
F0003830
34 - If the backlash “Z” is less than 0.24 mm (0.010 in.), re-

move one of the shims (16) installed under the outer
race of the rh bearing (18) and reposition it under the
outer race of the lh bearing (13).
If the backlash “Z” is greater than 0.33 mm (0.013 in.),
remove one of the shims (12) from under the outer race 17
of the lh bearing (13) and reposition it under the outer
race of the rh bearing (18).
★ Repositioning of 0.1 mm (0.04 in.) shim will alter
the backlash “Z” by approximately 0.07 mm
(0.003 in.).
13 18
35 - To transfer the shims, remove the rh flange (17) and

move the diff. cage (20) outwards in order to remove
the outer race of the lh bearing (13).
★ Position the thinnest shims towards the flange.
D0000360
36 - Refit the rh flange (17) and check backlash “Z”.

★ If necessary, repeat the shim transfer procedure
until the backlash is within the permissible limits.
20
F0003831
40-249
37 - Remove the rh flange (17) and fit the seal segments

(41) to the differential cage.
Segments: Grease
41
F0010130
38 - Fit the previously removed stud (19).

Use the nut and locknut method.
Stud: 80 Nm (59 lb.ft.)
19
F0003840
39 - Apply sealant to the mating surfaces of the flange (17).

14
Flange: Loctite 510 17
★ Ensure that the sealant forms an unbroken film
around the studs and bolts.
E
40 - Fit the flange, checking that the seals are inserted cor-
15
rectly. Tighten down with bolts (14), spacers "E" and
nuts (15). E
★ After about 15 minutes, remove spacers "E".
15
14 F0003820
40-250
4WD UNIT AND PARKING BRAKE
26
25 24 16
27 1
28 29
30
20
18 22 21
6 17
3 5
10 7 4
8
11
12 15 9
14 13
23
23
35
35
37
36 38 33
34
33
43
42
31 41 40 39
48
49
46
47 45
32
44
D0000320
40-251
1 - Using a press and a suitable drift, fit the outer races of

bearings (1) in gear (2).
2 1
1
2
F0002710

O-rings: Grease
5
4
3 3
F0002720
3 - Insert the complete piston (3) in the clutch housing (6)

and drive it home.
★ The discharge side must be facing upwards. 3
★ If necessary, tap evenly around the circumference
of the piston with a mallet.
F0002730
4 - Position spring (7), spring guide ring (8) and circlip (9)
in piston (3). 9
7 8
6
F0002740
40-252
5 - Using tool T52 (code 5.9030.866.0) and a press, com-

press the spring (7) and insert the circlip (9) in the hub
of the clutch housing (6).
T52
F0002750
6 - Fit the clutch pack (10) (6 + 6 plates) in the housing (6),

starting with a plain steel plate (11) followed by a fric-
tion plate (12).
10 11
F0002760
7 - Continue to alternate the plates up to the final friction

plate (12).
12 13
8 - Fit the spacer (13).
F0002770
9 - Fit the circlip (14) to retain the clutch pack (10).

10 - Fit the guide spacer (15). 14
★ The oil discharge grooves of the spacer must face
upwards. 15
F0002780
40-253
11 - Instal the hub (16) and rotate it in both directions until it

is fully seated.
★ Rotate it in alternate directions so as to engage all 16
the friction plates.
F0002790
12 - Turn the clutch unit over and fit the seals (17) and man-
ifold (18) to the clutch housing hub (6).
★ The manifold must be fitted with the inlet hole "F" 17
facing to the right.
18
6 6
F0002800
13 - Using a hoist, turn the transmission casing (18) over to

the vertical position, placing a wooden block “A” to
prevent damage to the studs.
★ Ensure the casing is stable before detaching the
hoist.
19
F0002810
40-254
14 - Fit circlip (20) and spacer (21) in the casing (19).
20
21
19 F0002820
15 - Fit the outer race and insert the bearing (22).

★ Check that the outer race is installed the right way
round.
★ To seat the outer race of the bearing, tap it gently
and evenly all around the circumference using a
copper mallet.
22 22
F0002830
16 - Fit the complete clutch unit (6).
F0002840
17 - Insert tool T53 (code 5.9030.867.0) to support the

braking discs (23).
T53
F0002850
40-255
18 - Fit the four braking discs (23) (n° 4).
23
F0002860
19 - Position ring nut (24).

★ The collar of the ring nut must be facing down-
wards. 24
24
23
F0002870
20 - Fit the inner races of bearings (1) to gear (2).

21 - Position the complete gear assembly (2). 1
24
F0003020
22 - Heat the inner race of bearing (25) and fit it to shaft (26).
★ Bearing temperature: approx. 90 °C (194°F).
26
25
F0002880
40-256
23 - Insert shaft (26), centring the splines of the previously

fitted clutch hub (16); only release the shaft when the
threads are resting on ring nut (24).
★ Support the shaft so as not to damage the threads. 26
F0002890
24 - Apply the lock wrench “B” to the ring nut and apply the
special wrench T54 (code 5.9030.869.0) to the splines
of shaft (26). T54
Slowly turn the ring nut (24) until fully tightened.
F0002900
25 - Fit the outer race of bearing (25) in the transmission

casing (19).
★ Use a suitable drift; tap gently with a hammer to
avoid damaging the bearing housing.
19
25
F0002910
26 - Fit the initial shim pack (27).

★ Shim pack composition:
n° 2 sp.0.15 mm (0.006 in.) 27
n° 2 sp. 0.5 mm (0.02 in.)
n° 1 sp. 2.0 mm (0.08 in.)
★ The thinnest shims should be installed up against
the outer race of the bearing. 28
27 - Fit the circlip (28).
F0002920
40-257
28 - Position a dial gauge with magnetic stand “C” and po-

sition the contact point on the end face of the shaft
(26). C
★ Preload the dial gauge by approximately 3 -- 4 mm
(0.118-- 0.158 in.).
F0002930
29 - Using a lever against the casing (19) and gear (2), ap-
ply downward force on the assembly. C
30 - Zeroset the dial gauge “C”.
19
F0002940
31 - Apply force on a lever inserted between the casing (19)

and the manifold (18).
Read off the movement obtained on the dial gauge.
Repeat the operation a number of times to determine 19
the shim thickness to be added to the shim pack in-
stalled in step 26, in order to obtain a final play of 0.05
mm (0.002 in.).
Ex.Play measured = 0.20 mm (0.008 in.)
Shim thickness to be added: 0.20--0.05=0.15 mm
(0.008-- 0.002=0.006 in.)
18
F0002950
32 - Remove the circlip (28) and add a shim (29) of the cal-
culated thickness to the shim pack.
★ The thinner shims should be positioned up against 29
the outer race of the bearing (25).
33 - Refit circlip (28) and check the play.
★ Final play: 0.05 mm (0.002 in.) 28
F0002960
40-258
34 - Using a 7 mm (0.276 in.) low profile wrench "B" to hold

ringnut (24) and special wrench T54 (code
5.9030.869.0), tighten ring nut (24). T54
Check that the synchroniser is in neutral position
(not engaging any gears).
Ring nut: 40 Nm (29.5 lb.ft.)

B
★ Check that inner race of bearing (25) is tight up
against the shaft (26).
35 - Back off the ring nut (24) by one full turn.
24 F0010140
36 - Gradually tighten the ring nut (24) until a rolling torque

of 1.9 to 2.8 kg (4.2 to 6.2 lb) can be measured on the D
strain gauge.
★ Rolling torque: 1.9 to 2.8 kg (4.2 to 6.2 lb)
50
F0010150
37 - Stake the ring nut (24) in correspondence with the

splines on shaft (26).
24
F0010160
38 - Using a suitable drift, install the seal (30).

★ Make sure that seal is installed the right way round.
30
30
F0002970
40-259
39 - Fit the central drain plug with the relative gasket and
the lateral plugs (33) with their copper gaskets to the
lower cover (31).
32
31
33 F0002980
40 - Fit the first brake shoe guide pin (34) to the cover (31).
41 - Fit the brake shoe (35) with the friction lining facing the 35
centre of the cover.
34
31
F0002990
42 - Fit the three inner brake shoes (36) with double-faced

friction linings.
36
F0003000
43 - Fit the second brake shoe (35) with the friction lining
facing towards the other brake shoes (36).
44 - Fit the pressure plate (37) and insert the second guide 37
pin (34). 34
★ Position the pressure plate as shown.
F0003010
40-260
45- Secure the guide pins (34) in position with cotter pins
(38).
38
F0003030
46 - Fit spacer (40) and O-ring (41) to the control lever (39).
O-ring: Grease
While holding lever (39) vertical, insert it in the cover
(31).
41 40
39
F0003040
47 - Fit la the cam (42) and, while holding both the control
lever (39) and the cam (42) vertical, couple the two le-
vers together.
★ Check that the marks on the end face of the control
39
lever (39) and of the cam (42) clash.
42
F0003050
42
48 - Fix the levers in position with the circlip (43).
43
F0003060
40-261
49 - Return the transmission casing (19) to a horizontal po-

sition and remove tool T53 (code 5.9030.867.0).
19
T53
F0003070
50 - Apply sealant to the mating surfaces of the lower cov-

er (31).
Cover: Loctite 510 23

★ Check that the sealant forms a continuous film
51 - Fit the lower cover (31) with two temporary opposing
bolts "F" (M10x70) and, using a screwdriver, position
35 36
the brake shoes (35) and (36) and plates (23).
F 31
F0003080
52 - Tighten the bolts “F” alternately to engage the plates

(23).
53 - Provisionally tighten fitting (44) to centre the manifold 18
fitting (18).
★ Remove fitting (44).
44
F0003090
54 - Fit bolts (46) and nuts (47) complete with washers (48);
tighten the bolts and nuts evenly in a crosswise pat-
tern to close the cover (31).
31
55 - Tighten down the cover (31).
47 48
46 48
F0003100
40-262
56 - Fit O-ring (45) on fitting (44).

Position pipe (49) and the copper gaskets and tighten
down fitting (44) onto the manifold. 49
★ The fitting must be tightened are fixing pipe (49) to
the solenoid valve block.
44 45
F0003110
40-263
4. ASSEMBLY OF THE RANGE SELECTOR FORK
4
3
2
D0000370
1 - Locate selector fork (1) and insert rod (2).
2 1
F0003150
2 - Lock in position with grubscrew (3) and nut (4).
Grubscrew: 20 Nm (14.7 lb.ft.)
Nut: Loctite 270
Nut: 37 Nm (27.3 lb.ft.)
3 4
F0003160
40-264
5. ASSEMBLY OF THE CREEPER SELECTOR FORK
35 22 21
23
12
11
10
29 20
28 19
27 24
13
26 25
8 18
5
17
4
16
14
15
6 7
3
1 2 D0000330
1 - Fit tab ring (2) to sleeve (10), engaging the tabs in the
slots. 2
★ Tab ring (2) may only be fitted one way round.
2 1
2 - Rotate the ring (2) through 90°.
F0003170
3 - Fit the sleeve assembly (1) in gear (3).

★ Maintain the position of the tab ring (2) relative to
the sleeve (1). 1
★ The side with internal teeth must be facing the out- 3
side of the transmission casing.
F0003180
40-265
4 - Fit the selector fork (4), centring the outer edge of the
ring (2).
2
F0003190
5 - Push the fork (5) so that it fully engages the selector (6)
on the gear (7).
5 7
6
F0003200
6 - Insert pin (8) in the casing (9).

7 - Using a suitable drift, insert the roller cage (10) in spin-
dle (11).
8
9
10
11
F0003210
8 - Fit spindle (11) in the casing (9) and push it outwards.

9 - Fit O-ring (12) to the spindle.
11
11 12
F0003220
40-266
10 - Insert rod (13) in the casing (9) and ensure that the
nose of the spindle (11) engages slot “A".
Push rod (13) to align the niche for the fork grubscrew 11
(14).
4 13
A
F0003230
11 - Insert and fully tighten grubscrew (14).
Grubscrew 20 Nm (14.7 lb.ft.)

12 - Lock the grubscrew in position with nut (15). 15
14
Nut: Loctite 270
Nut: 37 Nm (27.3 lb.ft.)
F0003240
13 - Fit detent ball (16) spring (17) and plug (18) in the trans-
mission casing (9).
Plug: Loctite 270

14 - Fully tighten plug (18). 17
16 18
F0003250
15 - Fit O-ring (20) to lever (19).

★ Lubricate the O-ring with gearbox oil.
20 19
F0003260
40-267
16 - Insert lever (19) from the inside of the casing (9) and
engage fork (5).
9
19
F0003270
17 - Fit spacer (21) and lock in position with circlip (22).
21
22
F0003280
18 - Insert spring pin (24) in lever (23) so that it protrudes

3±0.1 mm (0.1181±0.0039 in.).
★ Check the amount of protrusion carefully.
23
24
F0003290
19 - Fit lever (23) and secure it with grubscrew (25).

23
Grubscrew: 20 Nm (14.7 lb.ft.)
20 - Lock the grubscrew with nut (26). 26
Nut: Loctite 270
Nut: 37 Nm (27.3 lb.ft.)

25
F0003300
40-268
21 - Check the integrity of the potentiometer spindle seat

to ensure the spindle locates perfectly.
23
Fit the potentiometer (27) on the front of lever (23);
align with the location in the head of the pin (19) and
turn the potentiometer counter-clockwise to locate 27
the spring pin (24) of the lever (23).
★ The spindle seat is square.
24
F0010170
22 - Apply the sprung lock plate (35), the spring washer

(28) and screw (29).
Lock the assembly in position with screw (29).
27 28
29
35 F0003310
23 - Insert the detent ball (30), spring (31) and plunger (32)
in the transmission casing (9).
24 - Fit plug (33) complete with its copper gasket (34). 34
30
31
32
33
F0003320
40-269
6. ASSEMBLY OF THE PUMP DRIVE GEAR AND PTO CLUTCH
12
8 10
1
2 11
9
5
6
3
4 D0000290
1 - Fit circlip (2) inside the gear (1).

2 3
2 - Heat the inner race of roller bearing (3) to 60°C (140°F)
and fit it to gear (1).
★ Make sure that the race is fitted the right way 3
round.
1
1
F0003120
3 - Fit the outer race of bearing (3) and spacer (4).
F0003130
40-270
4 - Heat bearing (5) to approx. 80°C (176°F) and fit it to

gear (1).
6
1
F0003140
6 - Insert the complete gear assembly (1) in transmission

casing (7) using a soft faced mallet.
★ Make sure bore “A” of the spacer is facing up- A 7
wards.
1
F0002370
7 - Fit serrated washer (9) to oil plug (8); apply threadloc-

ker to the threads and screw the oil plug fully into the
casing (7) so that engages the bore in the spacer.
Lubricator: Loctite 242

9 8
F0002380
8 - Using a suitable drift, fit the roller case (11) to shaft

(10).
11
10
F0010180
40-271
9 - Insert shaft (10) in clutch assembly (12).

★ The roller case end is to be installed inside the clu-
tch assembly (12).
12
10
F0002390
10 - Fit the clutch assembly (12), engaging the shaft in the

pump drive gear (1).
★ The fixing of the clutch assembly (holding against
rotation) is to be carried out during the connection
12
of the hydraulic pipes.
1
F0002400
40-272
7. ASSEMBLY OF THE PTO SHAFT
6
3 4
2
1 14
15
8 5 13
11 9
12
11
7 D0000380
1 - Fit spacer (2), gear (3) and spacer (4) to the shaft (1).
1
3
4
F0003330
2 - Using a press and a suitable installation tool, fit bear-

ing (5) to the shaft.
★ The bearing must be fitted with the stop ring ori- 5
ented towards the end face of the shaft. 4
5
F0003340

(176°F) and fit it onto shaft (1) up against the pinion.
★ Ensure that the bearing race is installed the right 7
way round. 7
F0003350
40-273
5 - Partially insert shaft (1) in the transmission casing and

fit in sequence the outer race of bearing (7), bearing
thrust washer (8) and circlip (9). 8
★ The chamfered edge of the thrust washer must be 7
oriented towards the gears.
10
F0003360
6 - Insert shaft (1) further into the casing and, working

through the other aperture in the casing (10), fit in se-
quence circlip (11), bearing (12) and the second circlip 12 11
(11).
11
F0003370
7 - Push the shaft (1) until it engages the clutch output

shaft.
Locate circlip (11), bearing (12) and second circlip (11).
10
★ Use a soft faced mallet to install the bearing, tap-
ping it evenly around its circumference. 12
11 11
D0000190
8 - Fit the outer race of bearing (7).

★ If necessary, tap it gently with soft-faced mallet to
10
drive it home.
9 - Fit the bearing thrust washer (8) and circlip (9). 7
8
D0000200
40-274
10 - Apply sealant to the contact surface of cover (13) and

fit it to the transmission casing (10); tighten it down
with bolts (14) and washers (15).
Cover: Loctite 510
★ Ensure that the sealant forms a continuous film 10
around the bolt holes. 13
★ Tighten the bolts in a cross-wise pattern.
14 15
F0003380
11 - Fit the speed sensor with copper gasket.

Sensor: Loctite 242
F0012840
40-275
PTO CLUTCH
OVERHAUL OF THE PTO CLUTCH
7
9
10
11
12 13
14
8 15
16
18
19
20 17
21
2
27 25
26
1 4
3
23
22
24
5
6
D0000310
1. Dismantling
1 - Using the blade of a screwdriver, turn the spring clip
(1) until the end is positioned in correspondence with a
slot in the clutch housing (2).
Raise the end of the spring clip (1).
1
2
F0002550
40-276
PTO CLUTCH
2 - Grip the end of the spring clip (1) with a pair of pliers
and tap the pliers with a hammer to withdraw the
spring clip.
1
F0002560
3 - Using the blade of a screwdriver, compress circlip (3)

and lever the cover plate (4) away from the clutch
housing (2). 3
Repeat the operation at various points to remove the
cover plate (4) and circlip (3).
2
F0002570
4 - Remove the inner clutch housing (5) without removing

the clutch pack (6).
3
6
F0002580
5 - Remove the complete clutch pack (6).

★ If the clutch plates are not to be renewed, keep
them in the original order.
★ If any of the clutch plates is worn or damaged, the 6
entire pack will have to be renewed.
1
F0002590
40-277
PTO CLUTCH
6 - Hold the clutch housing in a vice and, using a chisel,

relieve the staking on the heads of screws (7).
2
F0002600
7 - Remove screws (7) along with braking strap (8), plate

(9) and crosspiece (10). 7 9
10
8
F0002610
8 - Remove pistons (11) and (12) of the braking unit.

3
11
12
F0002620
9 - Remove plug (13), spring (14) and slide (15).
13 13
14
15
F0002630
40-278
PTO CLUTCH
10 - Remove the circlip (16) securing the outer clutch

housing (2).
2
16
F0002640
11 - Using a soft-faced mallet, remove the outer clutch

housing (2). 2 17
2
F0002650
12 - Using a suitable drift, remove bearing (18) and shim

(19) from the clutch housing (17).
17
19
18
F0002660
13 - Remove seals (20) and bearing (21) from the clutch

housing (2).
20
3
2 21
F0002670
40-279
PTO CLUTCH
14 - Using a press and tool T55 (code 5.9030.868.0), fully

compress (by approx. 2 mm - 0.0787 in.) spring guide
(22) and spring (23). 24
15 - Remove circlip (24), spring guide (22) and spring (23).

T55
22
22
23
F0002680
16 - Use compressed air at low pressure to withdraw pi-

ston (25) from clutch housing (2).
★ The piston may be ejected at high speed; restrain it 2 25
to prevent it from being damaged.
F0002690
17 - Remove O-rings (26) and (27) from piston (25).

3
27
25
2. ASSEMBLY OF THE PTO CLUTCH

26
• To assemble the clutch, follow the dismantling procedure
in reverse order. F0002700
1
★ Insert first a plain steel plate followed by a friction
plate.
Fit the remaining plates in alternate order (8 plain
plates + 7 friction plates).
Clutch plates: Gearbox oil
2
★ Stake the lockplate to secure the screws.
3
Lubricate with gearbox oil
40-280
REAR AXLE - BRAKES
DISMANTLING AND ASSEMBLY OF REAR AXLE - BRAKES
1. Preparation prior to dismantling.

1 - For tractors with front suspension only. A A
2
Completely lower the suspension and switch off the 2
engine. 1
2 - Drain the oil from the transmission.
Gearbox oil: 113 litres (30 US gall.).

3 - Insert two safety wedges "A" between the front axle
(1) and the carrier (2).
1
Discharge all residual pressure from the trailer air
braking reservoir. F0005551
4 - Using a jack under the tow hook, raise the tractor until
the rear wheels are clear of the ground and then po-
sition a stand "B" and non-slip block under the rear
transmission casing (3).
5 - Remove the rear wheels. 3
(For details, see «REMOVAL OF THE REAR
WHEELS»).
B
6 - Remove the cab.
7 - For EXPORT D version only
Remove the trailer air braking units attached to the F0013280
rear axle and the reservoir.

(For details, see «REMOVAL OF THE TRAILER AIR
BRAKING UNITS»). 6
8 - Remove the rear cab mountings.
(For details, see «REMOVAL OF THE REAR CAB 4
MOUNTINGS»).
5
9 - Disconnect pipes (4) and remove bracket (5) and valve
(6).
F0013290
10 - Disconnect pipes (7) and remove the supplementary

lift cylinders (8).
★ Plug the ends of the pipes and the open fittings on
the cylinders to prevent entry of impurities.
8
7
F0013300
40-281
REAR AXLE - BRAKES
11 - Disconnect the brake pipes (9), the differential lock

pipe (10) and remove the clamps (11) securing the
draft sensors.
11
★ Plug the ends of the pipes and the open fittings to 10
prevent entry of impurities.
F0013310
12 - Remove the draft sensors (12) and the lower link arm
assemblies complete lateral tie-rods (13) and lift rails
(14). (For details regarding removal of the draft sen-
sors, see «REMOVAL OF THE LIFT DRAFT SEN-
SORS»).
Weight of lower link arm assembly:

58 kg (110 lb)
14
12
13
F0013320
13 - Remove the supports (15).
15
F0013330
40-282
REAR AXLE - BRAKES
36
25
29
23
34
33
26
27
26
30
28
24
34
33
35
7
2 1
3
8 2 7
5
22 4
31
20 19
21
10
9 16 11
15 18 14
13
12 D0000350
40-283
REAR AXLE - BRAKES
2. Removal and dismantling of the axle casings

A
1 - Attach a hoist to the axle casing (15) and put the lifting 33 34
sling under slight tension.
2 - Remove nuts (33) and washers (34).
15
F0013340
3 - Screw the two separator bolts "B" into the holes pro-
vided and tighten them evenly and alternately to dis-
15
lodge the axle casing (15).
4 - Remove the axle casing (15).
★ Support the halfshaft to prevent it from falling. B
Axle casing: 188 kg (414 lb).
5 - Withdraw the halfshaft (31).
F0013350
6 - Position a distance piece "C" between the teeth of the

annulus (35) and one of the retaining nuts (33) of the
brake housing (23). Unscrew the nut (33) to separate 23
the annulus from the housing.
C
33
35
F0013360
7 - Attach the annulus (35) to a hoist and remove it.
35
F0013370
40-284
REAR AXLE - BRAKES
8 - Using a slide hammer puller, remove the thrust plate

(22) of the halfshaft (31). 22
F0013380
9 - Unscrew the bolts and remove the flange (19) and the
spacers (21). 19
21
F0013390
10 - Attach the planet carrier assembly (6) to a hoist and lift

it clear.
Planet carrier: approx. 75 kg (165 lb).

6
F0013400
11 - Remove the outer race of bearing (9).

★ If necessary, use a puller with the legs inserted in
the slots provided.
F0013410
40-285
REAR AXLE - BRAKES
12 -Attach a hoist to the axle casing and lift the casing (15)
clear of the hub (11); rest the axle casing on a work
bench.
Axle casing: approx. 112 kg (247 lb).
15
11
F0003950
13 - Using a lever, remove the oil seal (16) and the dust seal
(18) on the wheel side of the casing.
16 18
F0013420
14 - Remove the outer race of the bearing (14).
14
F0013430
15 - Using a punch and a mallet, remove the inner race of

bearing (14) from the hub (11).
16 - Only if necessary. Remove the spacer (13) and the
cover (12) from the hub (11). 14
13
11
12
F0013440
40-286
REAR AXLE - BRAKES
17 - Using a pin punch, drive out the spring pins (8).
F0013450
18 - Remove the planet pins (5), the planet pinions (1) and
the shims (7). 5
1
F0013460
19 - Remove the roller cages (2) and the spacers (3) from
the planet pinions (1).
3
2
F0010190
20 - Remove the O-ring (10) from the planet carrier (6).

21 - Using a puller in the slots provided, remove the inner 6
race of bearing (9).
10
F0003880
40-287
REAR AXLE - BRAKES
3. Assembly of the axle casing

1 - Fit the roller cages (2), spacers (3) and second roller
cages (2) in the planet pinions (1).
3
2
F0010190
2 - Fit the planet pinion assemblies (1) in the planet carrier

(6). 1 7
3 - Insert the shims (7) on each side and insert the planet 7
pin (5). 6
A
★ The hole "A" must be facing the opposite side to
the planet carrier hub "B".
B F0003850
4 - Secure the pins (5) by inserting the spring pins (8).

★ Drive the pins flush with the edge of the planet car-
rier.
F0003860
5 - Heat the inner race of bearing (9) to about 100 °C (212

°F) and fit it to the planet carrier (6).
9
F0003870
40-288
REAR AXLE - BRAKES
6 - Fit the O-ring (10) in the planet carrier (6).

★ Ensure that the O-ring is correctly seated in its slot
6
and apply grease.
O-ring: Grease.
10
F0003880
2. Preparation of the halfshafts

1 - Fit the cover (12) on the hub (11) and push it fully home.
★ Take care not to deform the cover.
11
2 - Heat the spacer (13) and fit it on the hub (11). 11
★ The threaded holes must be facing downwards. 13
12
12
F0003890
3 - Heat the inner race of bearing (14) to about 100 °C (212

°F) and fit it to the hub (11).
11
14
F0003900
3. Assembly of the axle casing

1 - Using a suitable drift, fit the oil seal (16) in the axle cas-
ing (15). 16
★ Check that the seal is installed the right way round. 15
F0003910
40-289
REAR AXLE - BRAKES
2 - Using a suitable drift, fit the outer race of bearing (9) in

the axle casing (15).
★ Check that the race is installed the right way round. 9
16
15
F0003920
3 - Turn the axle casing (15) over and, using a suitable

drift, fit the outer race of bearing (14).
★ Check that the race is installed the right way round. 14
15
F0003930
4 - Using a suitable drift, fit the felt seal (18) in the axle
casing (15).
18
18
F0003940
5 - Attach a hoist to the axle casing (15) and lower it slowly

onto the hub (11).
★ During assembly, check that the seals and bear-
ings are correctly aligned with the hub shaft.
15
11
F0003950
40-290
REAR AXLE - BRAKES
6 - Attach a hoist to the planet carrier (6) and lower it onto

the hub (11).
★ Take great care that the planet pinions (11) are cor- 1
rectly oriented relative to the holes in the halfshaft. A
A 1
D0000010
F0003960
7 - Fit the triangular flange (19) and bolts (20).

19
Bolts: Loctite 242
★ New bolts are supplied already treated. 20
Bolts: 29.4 Nm (21.7 lb.ft.)

8 - Rotate the casing through at least ten turns in order to
seat the bearings.
9 - Re-check the tightening torque and then rotate the
casing a further ten times.
F0003970
10 - Remove the flange (19) and, with a depth gauge,

measure the distance "X" between the end face of the 19
halfshaft and the flange contact surface on the planet X
carrier.
D0000270
11 - Form a shim pack (21) of thickness "X" ±0.02 mm

(0.0008 in.) 19
12 - Position the shims (21) under the flange (19).
Tighten down with bolts (20). 20 21
Bolts: 112±6 Nm (82.5±4.4 lb.ft.)

Bolts: Loctite 270
F0003980
40-291
REAR AXLE - BRAKES
13 - Position the halfshaft thrust plate (22) to retain bolts

(20) and, using a suitable drift, drive it up against the
flange (19). 22
★ Take care not to damage the threads of the ex- 22
tractor hole.
F0003990
4. Removal and dismantling of the brake units

1 - Remove the retaining nuts (33) and washers (34) of the
brake housing (23).
33 34
23
F0013470
2 - Apply a puller "C" in the supplementary lift cylinder

mounting hole and tighten to put the brake housing 23
(23) under tension.
3 - Insert a lever in the slot provided on the opposite side 23
and prise the brake housing (23) away from the trans-
mission casing.
F0013480
4 - Screw an eyebolt "D" into the threaded hole used for

connection of the brake pipe and, using a hoist, lift the D
brake housing (23) clear.
23
F0013490
40-292
REAR AXLE - BRAKES
5 - Remove the halfshafts (31), the brake discs (26) and

the intermediate disc (27).
27
31
26
F0013500
6 - Remove the dipstick (36) from the brake housing (23).
36
F0013510
7 - Using a punch made of soft material and a mallet, re-

move the complete piston assembly (25).
25
F0013540
8 - Remove the shims (28) and the seal ring (30) from the
brake housing (23).
23
28
30
F0013520
40-293
REAR AXLE - BRAKES
9 - Remove the seal (29) from the piston (25).
29
25
F0013530
5. Assembly and adjustment of the brake units

1 - Fit three anti-rotation pins (24) in the brake housing
(23) to hold the piston (25) against rotation. B
★ The pins must be inserted chamfered end "A" first
and with the flat "B" facing the centre of the brake 23
24
housing.
B A
F0004000
2 - Fit the piston (25) in the brake housing (23) without the
seal rings, locating the anti-rotation pins.
25
23
F0004010
3 - Fit the first friction disc (26) and the pressure plate (27)
in the brake housing (23).
26
27
F0004020
40-294
REAR AXLE - BRAKES
4 - Fit the second friction disc (26).
26
F0004030
5 - With a feeler gauge, measure the clearance "Y" be-

tween the face of the brake housing and the face of the
second friction disc (26). 26
★ Measure the clearance at various points.
C
F0004040
6 - If the clearance "Y" is greater than 0.30 - 0.35 mm

(0.0118 -0.0138 in.) calculate the thickness of shims 26 23
"S" to be installed using the formula: Y
S (mm)=Y--(0.30 -- 0.35)
S (in.)=Y--(0.0118 -- 0.0138)
27
26 25 24
D0000260
7 - Remove the brake disc (26), pressure plate (27) and pi-
ston (25).
8 - Position shims (28) of the calculated thickness on the 28
pins (24).
24
F0004050
40-295
REAR AXLE - BRAKES
9 - Fit the O-ring (29) on piston (25) and lubricate it.

O-ring: grease
25
29
F0004060
10 - Fit the O-ring (30) in the brake housing (23) and lubri-
cate it.
O-ring: grease
★ Stretch the O-ring evenly to make it easier to seat 30
in its groove.
F0004070
11 - Fit piston (25) in brake housing (23), locating the anti-

rotation pins correctly (24). 23
★ To install the piston, tap it evenly around the cir-
cumference with a soft-faced mallet. 25
Drive the piston fully home.
F0004080
12 - Refit the friction discs (26) separated by the pressure

plate (27) and fit shaft (31).
13 - Apply sealant to the contact surface on the rear trans-
27 26
mission casing.
31
Surface: Loctite 510
F0004090
40-296
REAR AXLE - BRAKES
6. Assembly of the axle casings - brake units

1 - Attach the housing (23) to a hoist and offer it up to the 32
transmission casing (32). 23
★ Turn shaft (31) by hand to engage it in the planet
carrier.
31
F0004100
2 - Bolt down the brake housing (23) with nuts (33) and
spring washers (34).
Nuts: 125 -139 Nm (99.2-102.5 lb.ft.)

33 34
★ Tighten the nuts evenly in a crosswise pattern.
F0004110
3 - Apply sealant to one surface of the annulus (35).
Annulus: Loctite 510

35
★ Check that the sealant forms a continuous film
around the stud holes.
4 - Attach the axle casing assembly (15) to a hoist; as-
semble the annulus (35) on the planet pinions, with the
sealant surface oriented towards the casing (15).
15
F0004120
5 - Apply sealant to the other face of annulus (35) and fit

the assembly to the transmission casing (32). 32
15
35 F0004130
40-297
REAR AXLE - BRAKES
6 - Bolt down the axle casing assembly (15) with nuts (36)
and spring washers (37).). 36 37
Nuts: 125-139 Nm (99.2 -102.5 lb.ft.) 15

★ Tighten the nuts evenly in a crosswise pattern.
F0004140
7. Completion of the assembly and starting

★ Assemble the removed parts and the wheels fol-
lowing the removal procedure indicated in para-
graph 1in reverse order.
1 - Fill the transmission with oil.
Gearbox oil: 113 litres (30 US gall.)
(For details see «BLEEDING THE BRAKING SYS-
TEM»).
3 - Start the engine and repeatedly engage and disen-
gage the differential lock to bleed the system.
4 - If the tractor is equipped with trailer air braking, check
the pneumatic system for leaks and check operation
of the pressure gauge.
5 - Raise and lower the lift repeatedly in order to ex-
pel all air from the supplementary lift cylinders.
40-298

Champion 120-135-150

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WORKSHOP MANUAL

GENERAL SAFETY RULES

HOW THE MANUAL IS STRUCTURED

Section 10 Contains technical descriptions and information regarding the mechan-

Section 20 Contains information and diagrams regarding the machine's electrical

HOW TO CONSULT THE MANUAL

1. Removal and refitting of assembled units

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

3. List of special tools

HOW TO USE AND UPDATE THE MANUAL

1. UPDATING THE MANUAL

Consecutive page number

20-5-2 Existing page

3. SYMBOLS USED IN THE MANUAL

Symbol Meaning Notes Symbol Meaning Notes

Weight of main assemblies.

SAFETY PRECAUTIONS FOR REMOVAL AND REFITTING OPERATIONS

1. Precautions for removal operations

2. Precautions for refitting operations

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

WIRE ROPES - SLINGS

WIRE ROPES POLYESTER SLINGS

8 650 620 500 25 500 400 860 700

NOTE. Lifting capacities are calculated with a safety coefficient.

30° 60° 90° 120° 150°

STANDARD TIGHTENING TORQUES FOR NUTS AND

BOLT SIZE 8.8 10.9 12.9

THREADLOCKERS, ADHESIVES, SEALANTS AND

FUNCTION DESIGNATION DESCRIPTION

ucts; after drying, promotes uniform curing of threadlockers.

FUNCTION DESIGNATION DESCRIPTION

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

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

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

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

SYMBOL CODE DESCRIPTION NOTES

T2 5.9030.864.0 Tool for positioning steering sensor plate

T3 5.9030.861.0 Special wrench for 4WD pinion retaining nut

T4 5.9030.862.0 Installer for 4WD pinion seal

T5 5.9030.863.0 Service shim thickness 2±0.1 mm for pinion adjustment

T6 5.9030.618.4/10 Slide hammer puller

T7 5.9030.858.0 Installer for input side oil seal

T8 5.9030.859.0 Special wrench for removal/refit of brake damper

T9 5.9030.860.0 Tool for lift and sensor position check

T10 5.9030.730.0 All Round Tester

T10A 011.5445.4 Control unit wiring

T10B 011.6178.4 Armrest wiring

T11 5.9030.433.0 Gauge for measuring valve stand-in, etc.

T12 5.9030.012.0 Valve spring remover

T13 5.9030.877.0 Bore gauge for valve guides

T14 5.9030.850.0 Valve guide removal tool

T15 5.9030.851.0 3V valve guide installer

T16 5.9030.853.0 Bore gauge for cross-head rocker arms

T17 5.9030.651.4 Square for connecting rods

T18 5.9030.008.4/10 Crankshaft gear puller

T19 5.9030.349.0 Cylinder hone

T20 5.9030.732.4 Installer for oil jets on 3V

T21 5.9030.735.0 Dial gauge stand for 3V engine

T22 5.9030.635.0 Push-rod guide pliers