Cs 150

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Disassembly and assembly ......................................................................................2005 Don 7-70670
Workshop Manual (from DBD0075001) ...................................................................2007 7-98510
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How it works - Injection System (from DBD0075001) ..............................................3A 7-99110
Removing and Fitting the Fuel Injection Pump (up to DBD0015192).......................3001 7-96660
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How it works and troubleshooting - Combi Instrument .............................................4 7-97221
Electrical Schematics (GE/EN).................................................................................4001 Don 7-70640

Electrical Schematics (post Power-Shuttle)..............................................................4003 7-95830
Circuit diagram .........................................................................................................4004 6-50950
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How it works, troubelshooting and settings
Front Axle with Independent Suspension 20.25S.....................................................5 7-97101
Workshop manual - Front axle 20.20 and 20.25 (GE/EN) .......................................5001 7-71500
Independently Suspended Front Axle 20.25S ..........................................................5002 7-98580
75$160,66,21
How it works - Transmission T 7200 ........................................................................6 7-95450
How it works - Power-Shuttle (supplement to section 6) ..........................................6A 7-95490
How it works and troubleshooting-
transmissioncontrol electric and electronic (up to Power-Shuttle)............................6B 7-97230
Electronicbox forward / reverse (up to Power - Shuttle) ...........................................6C 7-97240
How it works - ECCU (Electronic Central Control Unit) ............................................6D 7-97110
How it works and troubleshooting - PTO control and PTO management.................6E 7-97250
Troubleshooting transmissioncontrol - electric and electronic (post Power-Shuttle) ...6002 7-97180

Troubleshooting 4-Wheel Drive and Differential lock management
(post Power Shuttle versions)...................................................................................6003 7-97130
Disassembly and assembly Transmission T 7200 ...................................................6006 Don 7-71450
Disassembly and assembly Power-Shuttle clutch
(Supplement to Chapter 6006) .................................................................................6008 7-97320
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How it works - OC/LS hydraulic system (Open Center-Load Sensing) ....................8 7-95430
OC hydraulic system (Open Center) ........................................................................8A 7-95310
Electronic Hitch Control EHR-D................................................................................8B 7-97260
How it works - CC/LS hydraulik system (Closed Center-Load Sensing) ..................8C 7-95320
Circuit diagram CC/LS hydraulics with sprung front axle 7-97700
Circuit diagram CC/LS hydraulics with sprung front axle and hydr. trailer brake 7-97710
Circuit diagram CC/LS hydraulics with 4-wheel brake 7-97720
Circuit diagram CC/LS hydraulics with hydr. trailer brake and 4-wheel brake 7-97730
Troubleshooting in the high-pressure Hydraulic Circuit
with Load Sensing Control Units ..............................................................................8001 7-96361
Hydraulic circuit diagram up to the Power-Shuttle version 7-96380
Hydraulic circuit diagram from the Power-Shuttle version onwards with sprong front axle 7-96400
Load Sensing - hydraulic valves for fixed displacement pump ................................8002 7-96960
Load-Sensing (LS) block assembly drawing 7-96980
Troubleshooting in the low-pressure hydraulic circuit (P1-18bar) ............................8003 7-97200
Troubleshooting in the high-pressure hydraulic circuit
post PFC – Reciprocating Pump versions................................................................8004 7-98540
&1+gVWHUUHLFK*PE+ Copyright © 2002 CNH Österreich GmbH

Sva 7-96902
1RYHPEHU
Sva 7-96902 November, 2002
Chapter
2007
WORKSHOP MANUAL
M968 CS68 from DBD0040007

M975 CS75 from DBD0040007
M9078 CS78 from DBD0055001

M9086 CS86 from DBD0055001
M9094 CS94 from DBD0055001
9105 CS110 from DBD0075001

9115 CS120 from DBD0075001
9125 CS130 from DBD0075001
9145 CS150 from DBD0075001
2007
CASE-STEYR Landmaschinentechnik GmbH Sva 7-98510 EN © 2000 Case Steyr Landmaschinentechnik GmbH
Technical Documentation May, 2000
A - 4300 St. Valentin, Steyrer Straße 32
2007-2
INDEX
INDEX ......................................................................................................................................2
SPECIAL TOOLS .....................................................................................................................5
FOR THE USER ......................................................................................................................7

Engine serial number ............................................................................................................7
SAFETY REGULATIONS ........................................................................................................8
ENGINE DATA .........................................................................................................................9

Lifting the engine ...................................................................................................................9
TECHNICAL DATA ................................................................................................................10

Cylinder block ......................................................................................................................10
Cylinder liners ......................................................................................................................10
Cylinder head ......................................................................................................................10
Valves, rocker arms and push rods .....................................................................................11
Camshaft .............................................................................................................................12
Crankshaft ...........................................................................................................................12
Flywheel ..............................................................................................................................13
crankshaft inertia weight (engine type 420) .........................................................................13
Camshaft drive ....................................................................................................................13
Con-rods ..............................................................................................................................14
Pistons, piston rings and piston pins ...................................................................................14
Lubrication system ..............................................................................................................15
Lubrication oil pump (320, 420) ...........................................................................................15
Lubrication oil pump (620) ...................................................................................................15
Thermostat ..........................................................................................................................15
Coolant temperature switch
Coolant temperature transmitter ..........................................................................................15
Cooling water pump (320, 420) ...........................................................................................16
Cooling water pump (620) ...................................................................................................16
Turbo charger ......................................................................................................................16
Tightening torques ...............................................................................................................17
CONSTRUCTION ..................................................................................................................18
General information .............................................................................................................18
Cylinder block ......................................................................................................................18
Flywheel casing ...................................................................................................................18
Cylinder head ......................................................................................................................19
Valve mechanism ................................................................................................................19
Crankshaft drive ..................................................................................................................19
Timing gears ........................................................................................................................20
Lubrication system ..............................................................................................................21
Cooling system ....................................................................................................................22
Intake / exhaust system .......................................................................................................23
Sva Sva 7-98510 EN Edition 05/00

2007-3
JOB INSTRUCTIONS ............................................................................................................24
1. CYLINDER BLOCK .........................................................................................................24
A. Measuring the cylinder liner wear ..................................................................................24
B. Removing the cylinder liner ...........................................................................................24
C. Checking the cylinder block ...........................................................................................24
D. Replacing the camshaft bush ........................................................................................24
E. Oversize bushes for the camshaft .................................................................................25
F. Fitting the plug at the rear camshaft end .......................................................................27
G. Fitting the plug at the rear camshaft end after inserting an oversize bush ....................27
H. Installing the oil dipstick tube .........................................................................................27
I. Fitting the cylinder liner ...................................................................................................27
2. FLYWHEEL CASING .......................................................................................................29
A. Fitting the flywheel casing .............................................................................................29
B. Replacing the rear crankshaft sealing ring ....................................................................29
3. CYLINDER HEAD ............................................................................................................30
A. Removing the cylinder head ..........................................................................................30
B. Removing the valves .....................................................................................................30
C. Checking the cylinder head ...........................................................................................30
D. Replacing the valve guides ...........................................................................................31
E. Machining the valve seat ...............................................................................................32
F. Replacing the valve seat rings .......................................................................................32
G. Grinding the valves .......................................................................................................32
H. Fitting the valves ...........................................................................................................32
I. Fitting the cylinder head ..................................................................................................33
4. VALVE MECHANISM ......................................................................................................34
A. Maintenance of the rocker arm system .........................................................................34
B. Replacing the camshaft / camshaft gear wheel .............................................................34
C. Checking and adjusting the valve clearance .................................................................35
5. CRANKSHAFT ................................................................................................................36
A. Removing the crankshaft ...............................................................................................36
B. Checking the crankshaft ................................................................................................36
C. Replacing the crankshaft gear wheels ..........................................................................36
D. Replacement of the crankshaft ring gear (engine type 420 only) ..................................37
E. Fitting the crankshaft .....................................................................................................37
F. Crankshaft hub ..............................................................................................................38
G. Replacing the crankshaft belt pulley and vibration damper ...........................................38
H. Checking the rubber element in the vibration damper (620/420) ..................................39
6. CON-RODS AND PISTONS ............................................................................................40
A. Removing the pistons together with the con-rods .........................................................40
B. Checking and replacing the con-rod bearings ...............................................................40
C. Checking the con-rod ....................................................................................................40
D. Con-rod weight groups ..................................................................................................41
E. Checking and replacing the piston rings ........................................................................42
F. Checking the pistons .....................................................................................................43
G. Fitting the piston pin ......................................................................................................43
H. Fitting the pistons and con-rods ....................................................................................43
7. BALANCING UNIT (420) .................................................................................................44
A. Removing and dismantling the balancing unit ...............................................................44
B. Balancing unit maintenance ..........................................................................................44
C. Fitting the balancing unit ...............................................................................................44

2007-4
8. FLYWHEEL .....................................................................................................................45
A. Replacing the starter ring gear on the flywheel .............................................................45
B. Fitting the flywheel .........................................................................................................45
9. TIMING MECHANISM .....................................................................................................46
A. Removing the timing gear case .....................................................................................46
B. Replacing the intermediate gear wheel bush ................................................................46
C. Fitting the timing gear case ...........................................................................................47
D. Front power take-off / auxiliary drive .............................................................................48
10. LUBRICATION SYSTEM ..............................................................................................49
A. Checking the oil pressure valve ....................................................................................49
B. Removing and checking the oil pump ...........................................................................49
C. Assembling and fitting the oil pump ..............................................................................50
D. Fitting the sump .............................................................................................................50
E. Oil cooler .......................................................................................................................50
F. Piston cooling nozzles (620) ..........................................................................................51
G. Recommended lubrication oils ......................................................................................51
11. COOLING SYSTEM ......................................................................................................52
A. Thermostat ....................................................................................................................52
B. Repairing the coolant pump ..........................................................................................52
C. Coolant quality requirements ........................................................................................53
12. INTAKE / EXHAUST SYSTEM ......................................................................................54
A. Checking the air filter .....................................................................................................54
B. Checking the intake / exhaust system ...........................................................................54
C. Checking the boost pressure ........................................................................................54
D. Checking the turbo charger ...........................................................................................55
E. Fitting the turbo charger ................................................................................................56

2007-5
SPECIAL TOOLS
Pressing tool for the front crankshaft Assembly pin for the water pump seal
dust seal
SS00B068
SS00B064 1 off 1TSW 523
1 off 1TSW 519
Universal pin
Pressing tool for the front crankshaft
shaft sealing ring
SS00B077
1 off 1TSW 18390
Pressing tool for valve guides

SS00B065
1 off 1TSW 520
Pressing tool for the rear crankshaft

shaft seal
SS00B069
1 off 1TSW 524
Valve spring tensioning lever

SS00B066
1 off 1TSW 521
Pressing tool for

cam shaft cover
SS00B071
1 off 1TSW 014
SS00B067
1 off 1TSW 522
Sva 7-98510 EN Edition 05/00
2007-6
Extractor Screw-in fitting
SS00B082
1 off 1TSW 663
Mini-measuring connection
SS00B070
1 off 1TSW 662
Cylinder liner extractor
SS98J031
1 off 1TSW 640 M10x1
Mini-measuring line
SS98J030
1 off 1TSW 635
SS00B072
1 off 1TSW 510
Pressure gauge and connection
Extraction plate
SS00B073
SS00B076
1 off 1TSW 508 1 off 1TSW 645 Connection
1 off 1TSW 5002 Pressure gauge
Dial test indicator and holder
Open-ended spanner for visco-hub
Not illustrated
SS00B075
1 off 1TSW 5610 Holder 1 off 1TSW 664
1 off 1TSW 17049-6 Dial test indicator

2007-7
FOR THE USER

The purpose of this manual is to provide basic information required to service and repair Steyr – Sisu diesel
engines.
Engine types 320, 420 and 620 are of the same design, therefore the same repair instructions can be used
for the varying engine types. Any differences affecting repair work are listed in the technical data and repair
instructions. All dimensions are specified in millimetres and apply to parts at a temperature of +20 °C, if not
specified otherwise.
Before starting repair work, make sure all necessary special tools, spare parts and accessories are
available. It is not absolutely necessary to have all the special tools mentioned in this manual. However,
having them does make it quicker and easier to carry out any repairs necessary. After a repair, the engine
must be run in just like a new engine.
If any questions arise, which cannot be clarified with the aid of this manual, please contact Case Steyr
Customer Service in St. Valentin or the respective importer.
When making any queries, please specify the following engine data:
Engine serial number
Engine type
320.80 M968 CS68
Produced for Case Steyr 320.81 M975 CS75
Important Engine Information
420.81 M9078 CS78
Type STEYR 320.80
Power 68 PS 2300 rpm 420.82 M9086 CS86
Serial No. J19111 420.83 M9094 CS94
420.85 9105 CS110
Cust.
Part No. 320.80.00.0001 620.94 9115 CS120
620.92 9125 CS130
620.93 9145 CS150
Engine number
SS99N123
(serial number)
Year code
H 1998 This adhesive label is affixed to
the right-hand side of the engine.
J 1999
K 2000
L 2001
M 2002
N 2003
320 420 620
SS99N014

2007-8
SAFETY REGULATIONS
The possibility of injury always exists •) Naked flames and smoking are not permitted in
when carrying out maintenance and the vicinity of fuel tanks or batteries. Electric
repair work. Read the following sparks should be avoided. (Particularly when
safety regulations and informa- charging the batteries. Explosion hazard!)
tion before starting work. •) Disconnect the cable at the negative battery
•) Never start repair work, which you do not fully pole before carrying out service or repair work on
understand. the electrical system.
•) Make sure that the environment is safe to work •) If the engine gets excessively hot (over 300 °C),
in. for example, if it catches fire, the viton seals (e.g.
•) Make sure the location is clean and in a good bottom O-ring on the cylinder liner or the O-ring on
state. the oil pressure valve) release highly caustic HF
acid. Never touch viton seals, which have been
•) Never use incorrect or unsuitable tools. subjected to unusually high temperatures, with
•) Remove all rings, chains and watches before bare hands. Always wear neoprene gloves or thick
commencing work. work gloves and safety goggles when removing
•) Use state of the art safety equipment. For these harmful substances. Wash the seals and
example, wear goggles when using compressed contaminated surfaces with a 10 % hydroxide
air for cleaning, grinding, hammering or similar solution or another alkaline solution. Collect the
work. material in air-tight sealed plastic bags and bring
them to an authorised collecting depot.
•) Use a lifting device for lifting or transporting
heavy parts (over 20 kg). Make sure the hooks and IMPORTANT: Viton seals may never be burned!
chains are in a good condition and sit firmly in •) When checking the injection nozzles, never
place. touch the fuel, which is ejected under high
•) Never work below an engine hanging from a pressure. The jet will penetrate the skin and cause
lifting device or raised by a jack. Always secure serious poisoning. If contact is made with the skin,
with strong support trestles before commencing consult a doctor without delay!
work. Fuel, lubrication oil and coolant can cause skin
•) Only use original Case-Steyr spare parts. irritations, if contact is made over a longer period.
•) Only start the engine from the cab, using the •) Avoid running the engine in idle unnecessarily.
ignition key. When carrying out service work, take measures to
•) Never start the engine with the protective covers prevent fuel or other fluids from entering the
removed. ground or drains.
WARNING: It is difficult to see the radiator fan •) All seals are asbestos-free.
when the engine is running! Baggy clothes and •) Be careful when washing the engine using a
long hair can get caught in rotating engine washing facility with a high water pressure. Do not
parts! wash, for example, the electrical and fuel systems
•) If the engine is started in a confined space, under high pressure as they can easily be
sufficient ventilation must be provided. damaged.
•) Never use auxiliary starting fuels on an aerosol
basis whilst the pre-glow starting facility is in
operation (explosion hazard).
•) Ear muffs must be worn when testing the engine
or working close to the engine.
•) Always switch the engine OFF before carrying
out
maintenance or repair work.
•) Avoid touching the exhaust manifold, turbo
charger and other hot engine parts.
•) When the engine is hot and the coolant is
pressurised, be careful when opening the radiator
cap. Coolant and lubrication oil out of the hot
engine can cause severe injuries if contact is made
with the skin.

2007-9
ENGINE DATA
Engine type 320.80 320.82 420.81 420.82 420.83 420.85 620.94 620.92 620.93
Number of cylinders 3 4 6
3
Capacity (dm ) 3,3 4,4 6,6
Bore (mm) 108
Stroke (mm) 120
±1
Delivery start marking of the 15 14±1 15±1 13±1
V-belt pulley (° before UDC)
Compression ratio 16,5 : 1 18,5 : 1 16,5:1 18,5 : 1 16,5:1
Method of combustion direct injection
Injection sequence 1-2-3 1-2-4-3 1-5-3-6-2-4
1
Compression pressure (bar) 24
2
Charge-air pressure (bar) 1,10 1,20 1,10 1,20 1,30 1,30 0,70 0,78 1,1
3
Weight (kg) 280 340 510
Direction of rotation of the Clockwise
crankshaft
1
) Minimum value when idling at operating temperature.
Highest permissible difference between the cylinders is 3 bar.
2
) measured at full load and nominal engine speed
3
) Without flywheel and electrical equipment.
Lifting the engine
The engine is lifted safely by means of a lifting device,

on which the lifting power acts vertically on the lifting eyes.
A = Engine lifting eyes
A A
SS99N013

2007-10
TECHNICAL DATA
Cylinder block
Guide pin bore holes ........................................................................................... 13.250 - 13.320 mm
Diameter of the crankshaft bearing base bore hole ............................................. 91.000 - 91.025 mm
Diameter of the crankshaft bearing base bore hole (bearing 162000010800) ...... 92.000 - 92.025 mm
Bore hole diameter of the cylinder liner:
- top ................................................................................................................ 124.514 - 124.554 mm
- bottom .......................................................................................................... 123.000 - 123.040 mm
Diameter of the camshaft bearing bush (if fitted) ................................................. 50.010 - 50.070 mm
Construction height of the cylinder block ......................................................... 428.170 - 428.430 mm
Cylinder liners
Liner height above the cylinder block ..................................................................... 0.030 - 0.080 mm
Highest permissible height difference between cylinder liners .............................................. 0.02 mm
Diameter of the cylinder liner bore holes in the engine block:
- top end of liner .............................................................................................. 124.475 - 124.500 mm
- bottom end of liner ........................................................................................ 122.961 - 122.986 mm
Cylinder liner bore hole ................................................................................... 108.010 - 108.032 mm
Height, cylinder liner flange ........................................................................................ 9.03 - 9.05 mm
Height, cylinder liner flange, 1st oversize SP NO 162000040713 ............................... 9.08 - 9.10 mm
Height, cylinder liner flange, 2nd oversize SP NO 162000040714 .............................. 9.13 - 9.15 mm
Height, cylinder liner flange, 3rd oversize SP NO 162000040715 ............................... 9.23 - 9.25 mm
Outer diameter of the cylinder liner flange ....................................................... 131.700 - 131.800 mm
Cylinder head
Construction height of the cylinder head ......................................................... 104.800 - 105.000 mm
Minimum height of the cylinder head after surface grinding ............................................ 104.000 mm
Inner diameter of the valve guide (when not fitted) ................................................. 9.000 - 9.015 mm
Outer diameter of the valve guide ....................................................................... 16.028 - 16.039 mm
Diameter of the bore hole for the valve guide in the cylinder head ...................... 16.000 - 16.018 mm
Projection of the valve guide over the cylinder head face ........................................................ 21 mm
Depth, valve head below cylinder head surface:
- Inlet valve ........................................................................................ 0.7 ± 0.05 mm (max. 1.70 mm)
- Outlet valve ..................................................................................... 0.6 ± 0.05 mm (max. 1.60 mm)
Valve seat angle:
- Inlet valve ............................................................................................................................. 35°+20’
- Outlet valve .......................................................................................................................... 45°+20’
Valve seat width:
- Inlet valve .................................................................................................................... 2.9 - 3.7 mm
- Outlet valve ................................................................................................................. 1.3 - 2.3 mm
Diameter, outlet valve seat insert SP NO 162000040718 .................................... 44.070 - 44.132 mm
Bore hole in cylinder head for outlet valve seat insert .......................................... 44.000 - 44.025 mm

2007-11
Valves, rocker arms and push rods
Valve control times at a valve play of 1.0 mm:
- Inlet valve opens ................................................................................................. 0° ±2° before TDC
- Inlet valve closes ................................................................................................. 16° ±2° after BDC
- Outlet valve opens ........................................................................................... 39° ±2° before BDC
- Outlet valve closes ................................................................................................ 1° ±2° after TDC
Valve play when engine is cold/hot:
- Inlet valve ........................................................................................................................... 0.35 mm
- Outlet valve ........................................................................................................................ 0.35 mm
Valve head angle:
- Inlet valve .............................................................................................................................. 35°-20’
- Outlet valve ........................................................................................................................... 45°-20’
Valve head diameter:
- Inlet valve .............................................................................................................................. 48 mm
- Outlet valve ........................................................................................................................... 41 mm
Maximum opening of the valves:
- Inlet valve ........................................................................................................................... 10.9 mm
- Outlet valve ........................................................................................................................ 12.1 mm
Diameter, inlet valve stem ...................................................................................... 8.960 - 8.975 mm
Diameter, outlet valve stem .................................................................................... 8.925 - 8.940 mm
Clearance, inlet valve stem (guide fitted in cylinder head) ...................................... 0.025 - 0.055 mm
Wear limit (inlet valve stem) .................................................................................................. 0.30 mm
Clearance, outlet valve stem (guide fitted in cylinder head) .................................... 0.060 - 0.090 mm
Wear limit (outlet valve stem) ............................................................................................... 0.35 mm
Inner diameter of the valve guide (when not fitted) ................................................. 9.000 - 9.015 mm
Outer diameter of the valve guide ....................................................................... 16.028 - 16.039 mm
Diameter of the bore hole for the valve guide in the cylinder head ...................... 16.000 - 16.018 mm
Projection of the valve guide over the cylinder head face ........................................................ 21 mm
Depth, valve head below cylinder head surface:
- Inlet valve .................................................................................................................. 0.7 ± 0.05 mm
- Outlet valve ............................................................................................................... 0.6 ± 0.05 mm
Length of the valve spring, relaxed ....................................................................................... 69.8 mm
Force of the valve spring compressed to a length of:
- 48.6 mm ............................................................................................................................ 327±17 N
- 37.4 mm ............................................................................................................................ 500±23 N
Diameter, rocker arm shaft ................................................................................. 22.970 - 22.990 mm
Diameter of rocker arm bore hole ....................................................................... 23.000 - 23.021 mm
Permissible deflection of the push rod (free) ........................................................................... 0.4 mm
Length of the rocker arm spring, relaxed ................................................................................. 80 mm
Force of the valve spring compressed to a length of 58 mm .............................................. 80 - 100 N
Outer diameter of the tappet ............................................................................... 29.939 - 29.960 mm
Diameter of the tappet bore holes in the cylinder block ....................................... 30.000 - 30.043 mm

2007-12
Camshaft
Diameter, 1st camshaft bearing journal .................................................................... 49.925 - 49.950 mm
Diameter of the other camshaft bearing journals ...................................................... 49.885 - 49.910 mm
Diameter, camshaft bearing journals 2, 3 and 4 (engine type 620) ........................... 49.865 - 49.890 mm
Diameter of the 1st camshaft bearing bore hole (bushes fitted) ................................ 50.010 - 50.070 mm
Diameter of the other camshaft bearing bore holes .................................................. 50.000 - 50.025 mm
Play, 1st camshaft bearing .......................................................................................... 0.060 - 0.145 mm
Play of the other camshaft bearings ............................................................................ 0.090 - 0.140 mm
Play of camshaft bearings 2, 3 and 4 (engine type 620) ............................................... 0.110 - 0.160 mm
Bearing tolerances in the cylinder block ...................................................................... 0.025 - 0.080 mm
Diameter of the bearing seat bore holes in the cylinder block ................................... 55.620 - 55.650 mm
Axial play of the camshaft with a 0.5 mm seal between the cylinder block and
timing case and between the timing case and timing case cover ......................................... 0.5 - 1.0 mm
Cam height (dimension between cam base circle and cam lobe):
- Inlet valve .............................................................................................................. 41.180 - 41.430 mm
- Outlet valve ........................................................................................................... 40.080 - 40.330 mm
Cam stroke:
- Inlet valve ............................................................................................................................... 7.38 mm
- Outlet valve ............................................................................................................................ 8.28 mm
Max. permissible deviation of the camshaft ............... 0.03 mm (max. deflection of the dial test indicator)
Crankshaft
Diameter of the con-rod bearing journals:
- Standard dimension ............................................................................................... 67,981 - 68000 mm
- 1st repair level 0.25 mm ........................................................................................ 67.731 - 67.750 mm
- 2nd repair level 0.50 mm ...................................................................................... 67.481 - 67.500 mm
- 3rd repair level 1.00 mm ....................................................................................... 66.981 - 67.000 mm
- 4th repair level 1.50 mm ....................................................................................... 66.481 - 66.500 mm
Width of the con-rod bearing journal ....................................................................... 40.000 - 40.160 mm
Diameter of the crankshaft journals:
- Standard dimension .............................................................................................. 84.985 - 85.020 mm
- 1st repair level 0.25 mm ........................................................................................ 84.735 - 84.770 mm
- 2nd repair level 0.50 mm ...................................................................................... 84.485 - 84.520 mm
- 3rd repair level 1.00 mm ....................................................................................... 83.985 - 84.020 mm
- 4th repair level 1.50 mm ....................................................................................... 83.485 - 83.520 mm
Diameter, crankshaft bearing casing ....................................................................... 91.000 - 91.025 mm
Thickness of the main bearing shells
- Standard dimension .................................................................................................. 2.955 - 2.965 mm
- 1st repair level 0.25 mm ............................................................................................ 3.080 - 3.090 mm
- 2nd repair level 0.50 mm .......................................................................................... 3.205 - 3.215 mm
- 3rd repair level 1.00 mm ........................................................................................... 3.455 - 3.465 mm
- 4th repair level 1.50 mm ........................................................................................... 3.705 - 3.715 mm
- Bearing ET NR 162000010800 (see Chapter 5. B) .................................................... 3.705 - 3.715 mm
Crankshaft bearing play .............................................................................................. 0.050 - 0.127 mm
Width of the journal at the thrust bearing (crankshaft bearing at flywheel):
- Standard dimension (2 standard thrust washers) .................................................. 45.000 - 45.080 mm
- 1st repair level (one standard thrust washer and one with an oversize of 0.1 mm) 45.100 - 45.180 mm
- 2nd repair level (one standard thrust washer and one with an oversize of 0.2 mm) 45.200 - 45.280 mm
- 3rd repair level (one 0.1 mm thrust washer and one with an oversize of 0.2 mm) .. 45.300 - 45.380 mm
- 4th repair level (two thrust washers with an oversize of 0.2 mm) ........................... 45.400 - 45.480 mm
Other crankshaft bearing journals must not be ground wider.
Axial play of the crankshaft ......................................................................................... 0.100 - 0.380 mm
Max. permissible out-of-true of the crankshaft or con-rod bearing journals ................................ 0.03 mm
Max. permissible imbalance of the crankshaft ................................................................... 1.0 Ncm max.
Diameter of gear wheel collar for the additional
crankshaft inertia weight (engine type 420) ......................................................... 150.220 - 150.260 mm
Inner diameter of ring gear for the additional
crankshaft inertia weight (engine type 420) ......................................................... 150.000 - 150.040 mm

2007-13
Flywheel
Overlap of the starter ring gear on the flywheel ...................................................... 0.425 - 0.600 mm
Before pressing the starter ring gear onto the flywheel, the
ring gear must be heated up to a temperature of ............................................................ 150 - 200 °C
Max. permissible imbalance at the flywheel .................................................................. 1.0 Ncm max.
Max. permissible warpage of the clutch surface measured at the inner
edge of the clutch surface .................................................................................................. 0.06:ø200
crankshaft inertia weight (engine type 420)

tooth flank play for the wheels:
- crankshaft gear wheel and flywheel .............................................................................. 0.1 - 0.3 mm
- between the flywheels ............................................................................................ 0.05 - 0.250 mm
Axial play of the flywheels .............................................................................................. 0.1 - 0.5 mm
Shaft diameter at the bearing points ................................................................... 36.000 - 36.016 mm
Inner diameter of the flywheel bush (when fitted) ................................................ 36.050 - 36.075 mm
Drilling diameter, rear wall of casing ................................................................... 36.058 - 36.083 mm
Drilling diameter, front wall of casing .................................................................. 35.958 - 35.983 mm
Thickness of a washer between casing and cylinder block ...................................................... 0.2 mm
Camshaft drive
Tooth flank play:
Intermediate gear wheel – crankshaft ......................................................................... 0.05 - 0.25 mm
Intermediate gear wheel – camshaft ........................................................................... 0.05 - 0.25 mm
Intermediate gear wheel – injection pump ................................................................... 0.05 - 0.25 mm
Max. permissible lateral runout of the wheels ....................................................................... 0.05 mm
Intermediate gear wheel SP NO 162000010708 (with friction bearing):
- Inner diameter, intermediate gear wheel shaft bush (when fitted) ..................... 55.000 - 55.030 mm
- Diameter of the intermediate gear wheel shaft .................................................. 54.951 - 54.970 mm
Inner diameter, camshaft gear wheel .................................................................. 32.000 - 32.025 mm
Diameter, end of camshaft shank ........................................................................ 32.043 - 32.059 mm
Timing marks:
The timing marks located on the gear wheels correspond to the TDC of the
piston in the 1st cylinder, between the compression stroke and firing stroke.
On the crankshaft gear wheel ............................................................................... 2 dots on the teeth
On the intermediate gear wheel:
- opposite the crankshaft gear wheel ................................................................. "0" mark on the tooth
- opposite the camshaft gear wheel ........................................................................ 1 dot on the tooth
- opposite the injection pump gear wheel .............................................................. 1 dot at the recess
On the camshaft gear wheel ................................................................................. 1 dot at the recess
On the injection pump gear wheel ........................................................................... 1 dot on the tooth

2007-14
Con-rods
Inner diameter, small end bearing bush
(bush pressed into the con-rod) .......................................................................... 40.025 - 40.040 mm
Outer diameter of the small end bearing bush ..................................................... 44.082 - 44.120 mm
Bearing bush taper in the con-rod .......................................................................... 0.057 - 0.120 mm
Bore hole, upper con-rod bearing ........................................................................ 44.000 - 44.025 mm
Bore hole, lower con-rod bearing ........................................................................ 71.730 - 71.749 mm
Thickness of the con-rod bearing shells:
- Standard .............................................................................................................. 1.835 - 1.842 mm
- 1st repair level 0.25 mm ....................................................................................... 1.960 - 1.967 mm
- 2nd repair level 0.50 mm ..................................................................................... 2.085 - 2.092 mm
- 3rd repair level 1.00 mm ...................................................................................... 2.335 - 2.342 mm
- 4th repair level 1.50 mm ...................................................................................... 2.585 - 2.592 mm
Con-rod bearing play ............................................................................................. 0.046 - 0.098 mm
Con-rod bearing axial play ..................................................................................... 0.200 - 0.410 mm
Perpendicular of the con-rod bore holes to the longitudinal axis of the con-rod .................... 0.15:100
Parallelism of the con-rod bearing bore holes ...................................................................... 0.05:100
The weight markings are punched in the bottom end of the con-rod.
Max. permissible weight difference between con-rods in the same engine .................................. 20 g
Pistons, piston rings and piston pins

Smallest gap width between the piston and cylinder head measured
through the injection nozzle orifice using lead wire ................................................. 0.900 - 1.150 mm
Piston diameter:
- 17 mm upwards from the base ...................................................................... 107.873 - 107.887 mm
Piston pin bore hole in the piston ........................................................................ 40.003 - 40.009 mm
Diameter, piston pin ............................................................................................ 39.991 - 40.000 mm
Width of the piston ring grooves:
- 1st groove (rectangular compression ring) ........................................................... 2.560 - 2.580 mm
- 2nd groove ........................................................................................................... 2.520 - 2.540 mm
- 3rd groove ........................................................................................................... 4.040 - 4.060 mm
Vertical play of the piston rings in their grooves:
- 1st groove (rectangular compression ring) ............................................................. 0.07 - 0.102 mm
- 2nd groove ............................................................................................................. 0.03 - 0.062 mm
- 3rd groove ............................................................................................................. 0.05 - 0.082 mm
- Wear limit .......................................................................................................................... 0.15 mm
Piston ring height (in direction of cylinder):
- 1st groove (rectangular compression ring) ........................................................... 2.478 - 2.490 mm
- 2nd groove ........................................................................................................... 2.478 - 2.490 mm
- 3rd groove ........................................................................................................... 3.975 - 3.990 mm
End play of piston rings (with piston fitted):
- 1st groove (wedge-type compression ring) ............................................................... 0.40 - 0.55 mm
- 1st groove (rectangular compression ring) ............................................................... 0.30 - 0.45 mm
- 2nd groove ............................................................................................................... 0.60 - 0.80 mm
- 3rd groove ............................................................................................................... 0.30 - 0.60 mm
- Wear limit, rings I and III ...................................................................................................... 1.0 mm
- Wear limit, ring II .................................................................................................................. 1.5 mm
Max. permissible weight difference between pistons in the same engine ..................................... 25 g
NOTE: When fitting the pistons, make sure the piston recess is on the same side as the injection
nozzles.

2007-15
Lubrication system
Oil pressure at normal operating temperature:
- idling ........................................................................................................................ at least 1.0 bar
- at operational speed ........................................................................................................ 2.5 - 4 bar
Length of the spring in the oil pressure valve, relaxed ............................................................. 80 mm
Force of the valve spring compressed to a length of ................................................................ 54+5 N
Oil pressure valve piston diameter ...................................................................... 19.602 - 19.635 mm
Oil pressure valve cylinder diameter ................................................................... 19.700 - 19.752 mm
Lubrication oil filter – overflow valve opens at a differential pressure of .......................... 1.5 - 2.5 bar
Oil pressure switch opens when ....................................................................................... p > 0.5 bar
Lubrication oil pump (320, 420)

Tooth flank play when the crankshaft lies firmly against the under side of the bearing
- between the crankshaft and oil pump drive gear wheels ........................................... 0.05 - 0.25 mm
- between the oil pump gear wheels ........................................................................... 0.16 - 0.26 mm
Diameter of the drive shaft in the housing and cover .......................................... 17.966 - 17.984 mm
Diameter of the drive shaft bore hole in the housing and cover ........................... 18.000 - 18.018 mm
Bore hole diameter of the gear wheel on the drive shaft ..................................... 18.060 - 18.078 mm
Diameter of drive shaft ....................................................................................... 18.028 - 18.039 mm
Depth of the drive shaft end below the housing surface .................................................. 0.5 - 1.0 mm
Thickness of the housing seal .................................................................................... 0.06 - 0.08 mm
Outer diameter of the gear wheels ...................................................................... 43.486 - 43.525 mm
Housing diameter ............................................................................................... 43.650 - 43.750 mm
Width of the gear wheels .................................................................................... 24.000 - 24.027 mm
Axial play of the gear wheels ...................................................................................... 0.03 - 0.11 mm
Housing depth .................................................................................................... 24.000 - 24.043 mm
Number of teeth on the drive gear wheel (engine type 320) ........................................................... 51
Number of teeth on the drive gear wheel (engine type 420) ........................................................... 46
Lubrication oil pump (620)

Tooth flank play when the crankshaft lies firmly against the under side of the bearing
- between the crankshaft and oil pump gear wheels ................................................. 0.05 - 0.025 mm
- between the oil pump gear wheels ........................................................................... 0.16 - 0.26 mm
Diameter of the drive shaft in the housing and cover .......................................... 17.966 - 17.984 mm
Diameter of the drive shaft bore hole in the housing and cover ........................... 18.000 - 18.018 mm
Bore hole diameter of the gear wheel on the drive shaft ..................................... 18.000 - 18.018 mm
Diameter of the drive shaft at the drive ............................................................... 17.966 - 17.984 mm
Diameter of the drive shaft in the pump housing ................................................. 20.035 - 20.048 mm
Depth of the drive shaft end below the housing surface .................................................. 0.5 - 1.0 mm
Thickness of the housing seal .................................................................................... 0.06 - 0.08 mm
Outer diameter of the gear wheels ...................................................................... 43.486 - 43.525 mm
Housing diameter ............................................................................................... 43.650 - 43.750 mm
Width of the gear wheels .................................................................................... 32.000 - 32.027 mm
Axial play of the gear wheels ...................................................................................... 0.03 - 0.11 mm
Housing depth .................................................................................................... 32.000 - 32.043 mm
Number of teeth on the drive gear wheel ....................................................................................... 46
Thermostat
Type .................................................................................................................................. ∅67/79 °C
Starts opening at ................................................................................................................... 79 °C±2
Fully open at .............................................................................................................................. 94 °C
Maximum opening ..................................................................................................................... 8 mm
Coolant temperature switch

Coolant temperature transmitter
Type of contact ............................................................................................................ Normally open
Operating temperature ........................................................................................................ 106 °C±3
2007-16
Cooling water pump (320, 420)
Bearing outer diameter ............................................................................................................ 52 mm
Bearing housing diameter ................................................................................... 51.979 - 52.009 mm
Shaft diameter at bearing .................................................................................... 20.002 - 20.015 mm
Shaft diameter at impeller ................................................................................... 15.907 - 15.920 mm
Diameter of impeller bore hole ............................................................................ 15.881 - 15.899 mm
The impeller must be pressed onto the shaft so that the remaining
clearance to the back of the housing is .......................................................................... 1.8 - 2.2 mm
Diameter of fan hub ............................................................................................... 25.00 - 25.20 mm
Permissible imbalance of the fan ..................................................................... 0.3 Ncm max (30 pcm)
Permissible eccentricity of fan ............................................................................................. ± 0.3 mm
V-belt tension, when pressed on between the two pulleys,
amount of give ................................................................................................................. 15 - 20 mm
Cooling water pump (620)

Bearing outer diameter ............................................................................................................ 52 mm
Bearing housing diameter ................................................................................... 51.979 - 52.009 mm
Shaft diameter at bearing .................................................................................... 19.980 - 19.993 mm
Shaft diameter at impeller ................................................................................... 15.907 - 15.920 mm
Diameter of impeller bore hole ............................................................................ 15.876 - 15.894 mm
The impeller must be pressed onto the shaft so that
there is the following clearance to the back of the housing ............................................. 0.8 - 1.2 mm
Diameter of the fan hub ................................................................................... 0.3 Ncm max (30 pcm)
V-belt tension, when pressed on between the two pulleys,
amount of give ................................................................................................................. 15 - 20 mm
Turbo charger
Schwitzer (320 )
Axial play of the shaft ................................................................................................... max. 0.14 mm
Radial play of the shaft1 ............................................................................................... max. 0.61 mm
Tightening torque for the turbine housing bolts ......................................................................... 22 Nm
Tightening torque for the hexagon nut on the shaft ................................................................. 6.8 Nm
Schwitzer (420 )
Tightening torque for the hexagon nut on the shaft ................................................................. 8.1 Nm
Schwitzer (620 )
Tightening torque for the hexagon nut on the shaft ............................................................... 15.6 Nm
1
) Measured at the turbine shaft nut.

2007-17
Tightening torques
Cylinder head nuts and bolts .................... 80 Nm+90°+90° (+60° after 15 - 20 min. warming up time)
Cylinder head bolts in the cylinder block .................................................................................. 30 Nm
Crankshaft bearing bolts ........................................................................................................ 200 Nm
Con-rod nuts .................................................................................................................. 40 Nm + 90°
Nut on the crankshaft (face):
- 320/420 ............................................................................................................................... 600 Nm
- 620 .................................................................................................................................... 1000 Nm
Counterweight of the crankshaft (320) ................................................................................... 160 Nm
Belt pulley bolts ....................................................................................................................... 30 Nm
Securing bolts for flywheel ..................................................................................................... 140 Nm
Securing bolts for flywheel casing:
- internal M12 bolts ................................................................................................................ 110 Nm
- external M10 bolts ................................................................................................................. 60 Nm
Retaining screws for intermediate gear wheel (with friction bearing):
- M10 ....................................................................................................................................... 60 Nm
- M14 ..................................................................................................................................... 200 Nm
Bolts for balancing unit (420) ................................................................................................... 60 Nm
Piston cooling nozzles (620.93) ............................................................................................... 30 Nm
Nut for lubrication oil pump gear wheel .................................................................................... 60 Nm
Retaining screws for lubrication oil pump ................................................................................. 60 Nm
Connecting pipe for lubrication oil cooler ................................................................................. 60 Nm
Nut for belt pulley on coolant pump ....................................................................................... 120 Nm
Fan bolts ................................................................................................................................. 30 Nm
Nuts/bolts for exhaust manifold ............................................................................................... 50 Nm
Bolts for air intake duct ............................................................................................................ 30 Nm
Nut for injection pump gear wheel ........................................................................................... 90 Nm
Retaining nuts for injection nozzles (for bolts) ......................................................................... 15 Nm
Injection nozzle union nut ........................................................................................................ 60 Nm
Injection line union nut ............................................................................................................. 25 Nm
NOTE: Use washers for aluminium parts.
If no particular tightening torques are specified,

always use the values specified in the table below.
M8 M10
±5
Cast iron 35 Nm 70±5 Nm
Aluminium 25±5 Nm 50±5 Nm
Bolts for the self-supporting oil sump

1 M8 25 Nm
3
2 M10 90 Nm
3 M14 160 Nm
4 M20 600 Nm 4 2
1 SS99N015

2007-18
CONSTRUCTION
General information
The 20 series Steyr-Sisu diesel engines are water-
cooled, four stroke, in-line engines (with 3, 4 or
6 cylinders) with direct injection. All models are
equipped with an exhaust gas turbocharger.
Cylinder block
The rib-reinforced cylinder block forms the main
engine unit, onto which other engine components
are mounted.
The wet, replaceable cylinder liners are supported
in the middle, thus reducing vibration and the
coolant flow is mainly directed to the upper section
of the cylinder liners.
The bottom part of the cylinder liner and the
cylinder block are sealed by three O-rings, which
are inserted in the grooves in the cylinder liner.
The upper part is sealed by the cylinder head
gasket.
The camshaft is located in the cylinder block. The
front camshaft bearing seat is fitted with a
separate bearing bush. The remaining bearing
seats are incorporated into the cylinder block. The
exception is the engine type 620 which is fitted
with separate bearing bushes in all camshaft
bearing seats. The bore hole for the rear end of the
camshaft is sealed by means of a plug.
Guide bearings are fitted on both sides of the rear SS99N016
crankshaft bearings (crankshaft – axial bearings).
Flywheel casing
The flywheel casing is fitted at the rear end of the
cylinder block. The seal for the rear end of the
crankshaft is fitted in a bore hole in the casing. The
flange for the starter is located in the flywheel
casing.
The underside of the flywheel casing is used as a
sealing surface for the oil sump seal. This means
that the underside of the cylinder block must be
flush with the flywheel casing. When the flywheel
casing is fitted, its position is determined by
sprung dowel pins.

2007-19
Crankshaft drive
The crankshaft is made from forged chrome alloy
special steel and the bearing and sealing surfaces
are induction tempered. The bearings can thus be
ground four times without further heat treatment
being necessary. The gear wheels are located at
the front end of the crankshaft. They are force fit
and drive the intermediate gear wheel and the oil
pump. In addition, the front end of the crankshaft
has key-ways for the V-belt pulley hub. An oil
scraper ring is used between the hub and gear
wheel and a dust seal is fitted on the hub to protect
the seal.
The crankshaft is supported in the cylinder block
by crankshaft bearings on both sides of each
cylinder. Thus, there is one crankshaft bearing
more than there are cylinders. The crankshaft axial
bearings are located in both sides of the rearmost
crankshaft bearing. A flywheel is mounted at the
rear end of the crankshaft and carries a strong,
force fit crown gear.
SS99N017
The forged con-rod has an I-shaped cross-section.
The lower con-rod bearing is split horizontally. The
Cylinder head bearing cover is secured by means of two special
bolts and nuts. The upper part has a wedge-
Engine types 320 and 420 are equipped with one shaped bearing seat in which the small end
cylinder head. Engine type 620 is equipped with bearing bush is force fitted.
two cylinder heads which are interchangeable with
each other and also with the type 320 cylinder The piston is made of an eutectic aluminium alloy.
head. Each cylinder has its own intake and outlet There is a combustion chamber in the piston head.
ducts in the cylinder head. To compensate for The shape of the combustion chamber optimises
thermal stress, a cold inlet valve is fitted between the carburetion of air and fuel.
the hot outlet valves The piston is equipped with three rings. The upper,
The cylinder head bolts are high-tensile pre- molybdenum-coated piston ring has a rectangular
tensioned bolts, which are tightened to their cross-section. Types 420.85 and 620.93 have an
elongation limit in accordance with the angular upper piston ring with a trapezoidal cross-section.
tightening principle. Due to the high degree of The middle ring is wedge-shaped and is fitted in its
elongation, the retaining power is kept constant groove. The wedge shape takes up the play.
throughout the entire service life, and the bolts do
not therefore have to be check tightened. The oil scraper ring is sprung and has a two-stage,
chrome-plated scraping edge.
The injection nozzle seats are integrated into the
cylinder head. The inlet and outlet valve guides are The pistons are ring carrier pistons (the top piston
identical and can be interchanged. Furthermore, ring has a cast iron ring carrier, which is cast into
the outlet valves are fitted with replaceable valve the piston). In addition, the piston is graphite-
seat inserts. coated to ensure trouble-free running in.
Four-cylinder engines (type 420) are equipped with
Valve mechanism a balancing unit. The eccentric weights, which
The valve mechanism is operated by the camshaft rotate at double the engine speed, compensate for
in the cylinder block. The drive power is transferred the up and down mass forces exerted by the
via valve tappets and push rods. The camshaft pistons and crankshaft drive.
gear wheel is force fitted and is secured by a
feather key. Every bearing is lubricated by the
pressure lubrication system via the drilled oil
channels.

2007-20
SS99N018
Timing gears
The timing gears are tempered, helical gear wheels.
The gear wheels are located in the timing gear case, which is fitted at the front of the engine.
The timing gears drive the camshaft, the fuel injection pump and the oil pump.
The hydraulic pump is driven by the timing gears or by a separate drive unit on the gearbox.
The intermediate gear wheel is borne on a friction bearing.
The bearing journal is fixed to the front surface of the cylinder block.

2007-21
7
6
5
Lubrication system
(engine type 620)
1. Lubrication oil pump
2. Oil pressure valve
3. Oil filter
4. Turbocharger
1 5. Main oil line
6. Piston cooling nozzles
SS99N019
7. Oil pressure switch
Lubrication system
The engine is equipped with a pressure lubrication The oil pressure valve is located below the oil filter
system, in which the oil pump (gear pump) is fixed on the left-hand side of the engine. The valve
to the lower part of the cylinder block. The pump regulates the lubrication oil pressure so that a
sucks the oil in via an intake basket. After the pump, constant value is maintained independent of the
the oil is fed through an oil line to the oil pressure engine speed. Depending upon the grade of oil, the
valve and oil filter. The oil is then fed through the engine speed and temperature, the oil pressure is
main oil line, from which other oil lines branch off. aprox. 2.5 - 4 bar.
The oil flows through the oil lines to the crankshaft The oil pressure is at least 1.0 bar at idling speed.
bearings and through the crankshaft to the con-rod
The oil filter is a one-way main stream filter, which is
bearings.
fitted on the left-hand side of the engine. An
The main oil line then feeds the oil to the turbo overflow valve, on the underside of the filter,
charger, to the balancing unit (420) and to a ensures reliable cold starting and sufficient
pneumatic compressor, if fitted. In addition, the lubrication in the event of a filter blockage. In
intermediate gear wheel bush, the camshaft bearing addition, there is a non-return valve which prevents
points and the valve mechanism are lubricated via the filter being completely drained of oil.
the main oil line. The oil pressure switch opens at a pressure of 0.5 bar.
In the 620,93 engine, the piston heads are sprayed
with oil from below and cooled as long as the
lubrication oil pressure is higher than 3 bar.

2007-22
7
6
1
4
SS99N020
Cooling system
1. Coolant pump 5. Expansion chamber
2. Thermostat 6. Oil cooler
3. Bypass channel 7. Engine temperature transmitter
4. Radiator
Cooling system
The belt-driven rotary coolant pump is located at the front end of the cylinder block.
The thermostat housing is situated above the pump.
The system operates with internal coolant circulation through the bypass channel, the circulation being
regulated by means of a two-way thermostat.
This function ensures an even temperature-rise under all conditions.

2007-23
SS99N022
Intake / exhaust system

The filter system for the engine intake air comprises exhaust turbocharger and between the turbocharger
a pre-cyclone filter (integrated into the air filter) and and the inlet manifold.
a dry air filter with safety cartridge. The intake air is
The exhaust manifold is fixed to the cylinder head by
rotated in the pre-cyclone filter. This removes most
means of anti-fatigue bolts, without a separate seal
of the dirt particles, which are then discharged via
The manifold bolts do not need to be check
the pre-cyclone filter’s dust discharge valve.
tightened.
The dirt particles in the air are collected in the main
The turbocharger is small and thus also reacts
cartridge, which can be cleaned as required. The
quickly at low engine speeds. The turbocharger is
internal safety cartridge stops dirt particles getting
lubricated and cooled by oil from the engine
into the engine in the event of the main cartridge
lubrication system.
breaking or being fitted incorrectly.
An electronic differential pressure transmitter is
located in the filter housing. This transmitter causes
an indicator lamp to light up on the instrument panel
if the air filter is blocked. The intake system also
comprises the lines between the air filter and the

2007-24
JOB INSTRUCTIONS
1. CYLINDER BLOCK
A. Measuring the cylinder liner wear
1. Set the dial test indicator to zero by means of a
micrometer screw or using a new cylinder liner
(initial dimension 108.00 mm). 1TSW 510
2. Thoroughly clean the inner surface of the
cylinder liner before the measurement.
1TSW 508
SS99N037
C. Checking the cylinder block

1. Clean the cylinder block and all oil lines.
2. Check the cooling channels and remove scale
and dirt deposits in order to ensure correct engine
cooling.
3. Check the tightness of the shell plugs and screw
plugs in the cylinder block and make sure the
cylinder block and sealing surfaces are in good
condition.
SS99N036
4. Measure the wear on the camshaft bearing
points (compare with nominal values).
3. Measure cross-wise at the top end, bottom end NOTE: If the surface of the cylinder block has to
and in the middle of the cylinder liner. be re-ground, the pistons must be shortened by
a corresponding amount. Pay attention to the
4. Check the displayed value for max. wear and valve head clearances at the top surface of the
ovality (compare with nominal values). piston.
B. Removing the cylinder liner D. Replacing the camshaft bush

1. If the cylinder liners are to be re-used, they must 1. Pull the bush out using an internal extractor.
be marked so they can be re-fitted in the same After removing the rear camshaft end support
positions. piece, the bush can be driven out using a long drift.
2. Remove the cylinder liners using the 1TSW 508 2. Clean the bush seating.
and 1TSW 510 extraction tools.
0.1 - 0.4 mm
SS99N038

2007-25
3. Press fit a new bush. Pay attention to the position of the oil bore hole. The bush does not have to be
reamed as it has the correct inner diameter if it is fitted in the correct place.
NOTE: For the engine type 620 all camshaft bearing points are fitted with a separate bearing bush.
Pay attention to the different outer diameters when removing and fitting the bushes.
5 4 3 2 1
SS99N039
The numbering starts at the front end of the engine.
Spare part number Bore hole diameter

1. 162000010716 55.62 - 55.65
2. 162000010718 55.42 - 55.45
3. 162000010719 55.22 - 55.25
4. 162000010718 55.42 - 55.45
5. 162000010720 55.64 - 55.67
E. Oversize bushes for the camshaft

If the seat of the camshaft bush (front bearing) is damaged, a bush with an oversize outer diameter of
0.4 mm can be fitted. Bushes are also available for the other camshaft bearings which are not normally
fitted with bushes. The spare part numbers and machining dimensions for the bush seatings are shown in
the figure.
WARNING: Observe the position of the bush oil bore holes.
The bushes do not have to be reamed after being fitted.
Oversized bearing bushes for engine type 320

140 mm 134 mm
Spare part Bore hole diameter
6 -7 mm
number
1. 162000010776 56.02 - 56.05
2. 162000010718 55.42 - 55.45
3. 162000010718 55.42 - 55.45
4 3 2 1
4. 162000010720 55.64 - 55.67
SS99N040

2007-26
272 mm 134 mm
6 - 7 mm
4 3 2 1
SS99N040
Oversized camshaft bearing bushes for engine type 420

1. 162000010776 56.02 - 56.05
2. 162000010718 55.42 - 55.45
3. 162000010718 55.42 - 55.45
4. 162000010720 55.64 - 55.67
266 mm
272 mm 134 mm
6 - 7 mm
5 4 3 2 1
SS99N042
Oversized camshaft bearing bushes for engine type 620
1. 162000010776 56.02 - 56.05
2. 162000010777 55.62 - 55.65
3. 162000010718 55.42 - 55.45
4. 162000010777 55.62 - 55.65
5. 162000010779 55.84 - 55.87

2007-27
F. Fitting the plug at the rear camshaft 3. Drive the guide tube into the cylinder block to
end the dimension shown in the figure.
116 mm = 320 , 420

111 mm = 620
SS99N044
1. Clean the plug seating.

SS99N045
2. Apply sealant (e.g. Loctite 572) to the contact
surface of the plug. NOTE: The position of the tube influences the
measured engine oil level.
3. Force fit the plug using the pressing tool
(1TSW 522). I. Fitting the cylinder liner
NOTE: Do not drive the plug in too far, as it
1. Clean the cylinder liner and liner recess in the
could impair the axial play of the camshaft.
cylinder block. Without the O-ring, it must be easy
to turn the liner to its installation position.
G. Fitting the plug at the rear camshaft
end after inserting an oversize bush 2. Apply a thin coat of marking paint to the
underside of the cylinder liner flange. Fit the
cylinder liner without O-rings and turn it back and
O - Ring forth. Remove the cylinder liner and check whether
there is paint over the entire contact surface.
3. Clean the contact surfaces.
Cover plate
0.03 - 0.08 mm
Plug
SS99N043
Upon completion, the rear camshaft end plug is

replaced by the plug (spare part number SS99N048
162000010797) and the O-ring (spare part number
162000010798). In engines where the flywheel 4. Fit the cylinder liners and secure each liner
casing does not cover the stopper plug, the cover using two clamps. Measure the cylinder liner
plate (spare part number 162000010799) must be height using a dial test indicator and the holder
fitted. (1TSW 5610). Set the dial test indicator to zero on
a flat surface, e.g. the cylinder block. Measure
each cylinder liner at four points. The cylinder liner
H. Installing the oil dipstick tube
should protrude from the top of the cylinder block
1. Clean the tube seating. by 0.03 - 0.08 mm.
2. Apply locking fluid (e.g. Loctite 601) to the
bottom end of the tube.

2007-28
The difference in height between the cylinder liners
within one cylinder head must not exceed
0.02 mm. In addition, a middle cylinder liner must
not be lower than one of the outer ones.
5. If the cylinder liner height is insufficient, a liner
with a higher flange must be fitted. BLACK
GREEN
SS99N050
7. Insert the O-rings in the grooves in the lower

SS99N049
cylinder section and lubricate them with liquid soap
(not with oil).
Spare part Height (H) Marking NOTE: Stretch the O-rings as little as possible
number grooves when pulling them onto the cylinder liners.
(quantity) The max. permissible elongation is 6 %.
162000040704 9.03+0,02 (standard)
162000040713 9.08+0,02 1
162000040714 9.13+0,02 2
162000040715 9.23+0,02 3
An oversize of the cylinder liner (higher flange) is

marked as follows on the outer circumference by
means of one or more marking grooves:
1. oversize, 0.05 mm = 1 marking groove
2. oversize, 0.10 mm = 2 marking grooves
3. oversize, 0.20 mm = 3 marking grooves
6. If the height of a cylinder liner is not the same
over the entire circumference, the cylinder liner
flange and recess depth must be checked.
Cylinder liners with warped flanges must be
SS99N051
replaced. If necessary, ream the liner seating in
the cylinder block.
8. Press the cylinder liners into the cylinder block.
It should be easy to press them into their initial
position. Make sure the cylinder liners do not move
upwards once they have been fitted.

2007-29
2. FLYWHEEL CASING
Spacer ring
A. Fitting the flywheel casing
The flywheel casing is centred on the cylinder
block by means of two sprung dowel pins. The
flywheel casings, which are also available as a
spare part, are supplied with the bore holes for the
pins.
1. Clean the sealing surfaces between the cylinder
block and flywheel housing.
SS99N054
NOTE: If the crankshaft is worn at the sealing

ring seat, a 2 mm spacer ring (spare part
number 162000020718 can be fitted behind the
crankshaft sealing ring.
5. Carefully press the sealing ring in down to the
bottom of the flywheel casing using the 1TSW 521
and 1TSW 662 fitting tools.
1TSW 662
SS99N052
2. Apply sealant (e.g. silicone) to the points shown

in the figure.
3. Lift the flywheel casing to the correct position
and insert all the bolts.
4. Centre the casing and fit the sprung dowel pins
using a mandrel. 1TSW 521 SS99N056
5. Tighten the inner ring bolts to a torque of 60 Nm NOTE: THE ASSEMBLY PROCEDURE MUST
and the outer ring bolts to a torque of 110 Nm. BE CARRIED OUT IN A DRY AND OIL-FREE
STATE.
B. Replacing the rear crankshaft sealing
ring
1. Separate the tractor between the engine and
power unit.
2. Remove the flywheel.
3. Remove the sealing ring without damaging the
crankshaft.
4. Clean the sealing ring seat and grind any burr.

2007-30
3. CYLINDER HEAD
A. Removing the cylinder head
1. Clean the outside of the engine.
Drain plug
SS99N057
1. Screw a nut on a grub screw for the rocker arm

mechanism. For 3 and 6 cylinder engines no grub
screw is provided on the valves for the middle
cylinders. A screw of an appropriate length should
be used instead.
SS99B056 2. Compress the valve springs by means of the
1TSW 014 lever. Remove the valve spring seat
Drain the coolant at the engine drain plug and the retainers, the spring guide and the spring. Remove
drain cock on the underside of the radiator. the valves.
Disconnect the coolant hoses from the cylinder
head and the thermostat housing.
C. Checking the cylinder head
2. Remove the intake lines between the exhaust
1. Remove carbon deposits from the outlet
turbo charger and the air filter and between the
channels, clean the sealing surfaces and wash the
exhaust turbo charger and the intake manifold.
cylinder head.
3. Remove the oil lines from the exhaust turbo
2. Check the cylinder head for cracks and any
charger.
other damage.
4. Remove the fuel hose running to the thermo-
start tank.
5. Remove the injection lines and leakage oil lines.
Remove the injection nozzles. Fit all open
connections with sealing caps.
6. Remove the intake and exhaust manifolds as
well as the thermostat housing.
NOTE: It is also possible to remove the cylinder
head even when these parts are still fitted.
7. Remove the valve cover and bleed hose.
SS99N058
8. Remove the rocker arm mechanism and the
push rods. 3. Check the evenness of the cylinder head using a
straight edge. An uneven or bent surface must
9. Loosen all cylinder head bolts by a ¼ of a undergo surface grinding. After being ground, the
revolution and then unscrew them. Remove the height of the cylinder head may not be less than
cylinder head. 104.00 mm. The valve disk depth from the surface
of the cylinder head must be 0.60 mm for outlet
B. Removing the valves valves and 0.70 mm for inlet valves.
Make sure that those valves which are to be re-
used are marked accordingly, so that they can be
re-inserted in their original seating.

2007-31
D. Replacing the valve guides
SS99N059
4. If necessary, clean the injection nozzle support

in the cylinder head using a reamer.
SS99N061
1. Press or drive the old guides out using a

mandrel. Clean the valve guide seats.
2. Fit the new guides using the 1TSW 524
pressing-in tool, thus ensuring the correct
installation height (21 mm above the end face of
the spring).
1TSW 524
SS99N060
5. Measure the clearance between the valve stem

and guide by means of a dial test indicator. Lift the
valve so that the valve disk juts out of the surface
of the cylinder head by 15 mm and measure the
clearance. In the case of inlet valves, it may not
exceed 0.30 mm and 0.35 mm for outlet valves. To
determine whether the valve guide is worn, a new 21 mm
valve must be used for the measurement.
SS99N062
3. The same guides are used for inlet and outlet

valves. Make sure the steepest chamfer on the
guide points towards the valve spring. Also make
sure the valves do not stick in the guides.

2007-32
E. Machining the valve seat
SS99N065
A B
-20’
INLET VALVE 35° 35°+20’
SS99N063 OUTLET VALVE 45°-20’ 45°+20’
A damaged valve seat must be machined using a

milling cutter. If the width of the seat exceeds 1. Grind the damaged valve disk using a valve
2.3 mm in the case of an outlet valve and 3.7 mm grinding tool. Adjust the angle to 45°-20’ for outlet
in the case of an inlet valve, then it has to be valves and 35°-20’ for inlet valves.
reduced at the outer edge, in particular.
2. If the edge of the valve disk is less than 1.5 mm
The valve seat angle is 45°+20’ for outlet valves and after grinding or the valve stem is bent, the valve
35°+20’ for inlet valves. must be replaced.
3. Grind in the valves using grinding paste and
F. Replacing the valve seat rings check the contact surface with marking dye.
The outlet valves are equipped with separate valve 4. Clean the grinding paste off the cylinder head
seat rings. If the sealing surface is so badly and valves.
damaged that it cannot be repaired, then the valve
seat rings have to be replaced.
H. Fitting the valves
1. Grind the valve disk on a disused valve so that it
1. Use a spring tester to check the straightness,
fits snugly in the valve seat. Fit the valve and weld
length and tension of the valve springs. Compare
it to the seat correctly. Cool it with water.
these values with the technical data.
2. Turn the cylinder head round and drive the valve
2. Lubricate the valve stems and insert the valves
out together with the seat.
in the cylinder in the correct order.
3. Clean the valve seat. Cool the new valve seat
3. Fit the valve springs, valve disks and valve
ring in dry ice or liquid nitrogen.
spring seat retainers in the cylinder head with the
4. Fit the valve seat ring using a suitable pressing aid of the 1TSW 014 lever.
tool. Re-work the seat.
4. After inserting the valves, tap the ends of the
valve stems, e.g. with a plastic hammer, to make
G. Grinding the valves sure the valve spring seat retainers are sitting
In order to ensure that a sufficient sealing effect is correctly.
attained around the valves, there are different
sealing surface angles. Thus, there is a particularly
narrow sealing surface, which ensures an effective
sealing effect even after prolonged operation.

2007-33
I. Fitting the cylinder head
420
1. Measure the length of the cylinder head bolts.
The length should lie within the limit values specified
in the figure. If this is not the case, the bolt must be
replaced.
max. 142 mm
max. 188.5 mm SS99N068
4. The figures show the bolt tightening sequence.

The correct sequence is also cast into the cylinder
SS99N066
heads.
2. Screw the cylinder head grub screws into the 5. Tighten the bolts in phases as follows:
cylinder head and a tighten them to a torque of 1. Pre-tension of 80 Nm
30 Nm. Insert the push rods, if they have been
removed. 2. Tighten by 90°
3. Make sure the sealing surfaces are clean and fit 3. Tighten by 90°
the cylinder head gasket. For engine type 620 use a 4. Adjust the valve clearance (see page 35).
straightedge to make sure the cylinder heads are
parallel to each other. Clean, oil and insert the bolts. 5. Fit the other engine parts, add coolant and
engine oil. Let the engine run at low load for
approx. 15 - 20 minutes.
320, 620
6. Tighten by 60°.
7. Adjust the valve clearance
NOTE: The cylinder head does not have to be
tightened again after this procedure.
SS99N067
Tighten the exhaust manifold securing bolts/nuts to a torque of 50 Nm.
SS99N069
50 Nm

2007-34
4. VALVE MECHANISM B. Replacing the camshaft / camshaft
gear wheel
A. Maintenance of the rocker arm system 1. Remove the suction pipe between the turbo
1. Check the valve tappets, particularly the guide charger and the intake manifold. Remove the cover
surface on the camshaft. Replace worn and bent for the valve mechanism and the bleed pipe.
valve tappets. Remove the rocker arm mechanism.
2. Remove the radiator, the fan, the alternator and
the V-belts.
3. Loosen the crankshaft nut. Remove the V-belt
pulley complete with hub (for engine type 620
loosen the belt pulley first).
4. Remove the gearwheel case cover.
SS99N070
2. Check the straightness of the push rod. Also

check the condition of the spherical faces at the
ends of the push rod.
3. Dismantle the rocker arm mechanism and clean
the components. Check the rocker arm shaft for
wear and the condition of the oil lines. SS99N075
4. If the pressure surface of the rocker arm is worn, 5. Lock the valve tappets so that they do not fall
grind it until it has the right shape. Do not grind off down on removing the camshaft and impair the
more than necessary as the pressure surface is installation of the camshaft. Raise two adjacent
hardened. valve push rods by tilting them towards each other.
Clamp adjacent push rods together to form a pair
(e.g. using an O-ring) so they remain in the top
position.
WARNING: Excessive tensioning of the push
rods causes deformation.
6. Turn the crankshaft, so the positioning marks on
the camshaft gear wheel and intermediate gear
SS99N072
wheel coincide. Pull the camshaft out.
7. Loosen the camshaft gear wheel using a
60° suitable mandrel.
8. If the used camshaft or camshaft gear wheel is
going to be re-fitted, clean them before assembly.
9. Push the feather key into the corresponding
groove in the camshaft. Heat the camshaft gear
wheel up to 200 °C and fit it in the corresponding
position.
SS99N073 10. Grease the bearing surfaces and press the
shaft into the cylinder block, paying attention to the
5. Fix a flange seal on one end of the rocker arm position marks on the camshaft gear wheel.
shaft. Lubricate the shaft and assemble the parts
in the correct order. Make sure the shaft and the 11. Fit the timing gear case cover and the belt
bearing retainers are in the right position. The split pulley complete with hub.
side of the retainers and the oil bore holes in the
shaft must be on the valve side, as shown in the
figure. Fix the other flange seal

2007-35
12. Release the push rods and fit the rocker arm Engine type 320
mechanism. Adjust the valves. Then screw the
Check the valve play in the injection sequence.
valve cover and air bleed hose onto the cylinder
head. Also fit the suction pipe between the turbo
charger and intake manifold.
Injection sequence: 123
13. Fit the alternator and V-belts. Tension the
V-belts accordingly. Fit the radiator. - check the valves in cylinder 1 when the cylinder 3
outlet valve is fully open (6th valve from the front of
C. Checking and adjusting the valve the engine).
clearance - check the cylinder 2 valves when the cylinder 1
outlet valve (2nd valve) is fully open.
- check the cylinder 3 valves when the cylinder 2
outlet valve (4th valve) is fully open.
0.35
Engine type 420
- turn the crankshaft in the direction of rotation until
the valves of cylinder 4 overlap. (Outlet valve
closes, inlet valve opens). Check the valves of the
first cylinder.
SS99N077 - turn the crankshaft 1/2 of a revolution in the
direction of rotation so that the valves of cylinder 3
The inlet and outlet valves have a clearance of change over. Check the valves of cylinder 2.
0.35 mm. It can be checked when the engine is hot
- continue work in the sequence of injection:
or cold. Check and adjust the valve clearances of a
cylinder whilst the piston is at top dead centre of
the compression stroke. Proceed according to the Injection sequence: 1 2 4 3
injection sequence of the engine.
Change-over of the valves in the 4 3 1 2
If the valve clearance deviates from the specified
cylinders:
value, loosen the locking nut and adjust it to the
correct value via the adjusting screw. A 0.35 mm Engine type 620
feeler gauge must fit tightly between the rocker
arm and the end of the valve stem. - turn the crankshaft in the direction of rotation until
the valves of cylinder 6 overlap. (Outlet valve
closes, inlet valve opens). Check the valves of the
I = INLET first cylinder.
O = OUTLET - turn the crankshaft 1/3 of a revolution in the
I O I O I O direction of rotation so that the valves of the 2nd
cylinder overlap. Check the valves of the 5th
cylinder.
- continue work in the sequence of injection:
320, 620
Injection sequence: 1 5 3 6 2 4
Valve overlap: 6 2 4 1 5 3
I O I O I O I O
420 SS99N077

2007-36
5. CRANKSHAFT
A. Removing the crankshaft
1. Unscrew the sump.
2. Separate the balancing unit lubrication oil line
from the cylinder block and remove the balancing
unit fixing bolts. Remove the balancing unit and the
lubrication oil line (only for engine type 420).
3. Unscrew the securing bolts for the lubrication oil SS99N079
pump pressure line in the cylinder block. Remove
the oil pump and the intake/pressure lines. 4. If the bearing play exceeds 0.18 mm for the
crankshaft bearings or 0.14 mm for con-rod
4. Remove the flywheel casing. bearings with new bearing shells, the bearing
5. Remove the belt pulley/hub from the front end of journals on the crankshaft must be ground. For the
the crankshaft (also refer to the instructions correct undersize and corresponding bearings,
concerning the timing gears page 46). refer to the technical data. Make sure the radii do
not change during the grinding process.
6. Remove the con-rod bearing covers and push
the con-rods up so they are not in the way when NOTE: In the event of the crankshaft bearing
removing the crankshaft. base bore holes being damaged or worn as a
result of bearing damage, crankshaft bearings
7. Remove the crankshaft bearing covers and lift are also available as a spare part with an
the crankshaft out. oversize of 1.0 mm (outside dimension) and an
undersize of 0.5 mm (inside dimension). The
B. Checking the crankshaft cylinder block must now be machined to a
dimension of 92.000 - 92.025 mm. The
crankshaft must be machined to a dimension of
84.485 - 84.520 mm. The bearing shell with a
groove and a hole is fitted in the cylinder block
and the bearing shell without an oil bore hole in
the bearing cap.
C. Replacing the crankshaft gear wheels
1TSW 662
SS99N078
1. Clean the crankshaft. Do not forget to clean the

oil bore holes.
2. Measure the wear on the crankshaft bearing
SS99N080
journals at different points. Ovality, conicity or
other wear must not exceed 0.03 mm. 1. Attach an extractor to the crankshaft gear
3. Insert the bearing caps with new bearing shells wheels and pull off both gear wheels.
and tighten them to the correct torque. Measure 2. Clean the seat on the crankshaft using a wire
the inner diameter with a dial test indicator, which brush, for example.
has been reset to zero according to the
dimensions measured under item 2. The indicator 3. Heat up the new gear wheels to 200 °C. Drive
thus displays the actual bearing play. If the bearing the gear wheels onto the shaft using a suitable
housing which shows signs of wear is not round, sleeve or soft mandrel. Pay attention to the
take measurements at several points. position of the feather key and make sure the
alignment marks on the front gear wheel are
visible. Allow the parts to cool down.

2007-37
D. Replacement of the crankshaft ring Make sure the bearing shell noses engage in the
gear (engine type 420 only) corresponding notches and that the shells to be
fitted in the cylinder block have an oil bore hole
which aligns with the oil bore hole in the cylinder
20° block.
3. Lubricate the bearing surfaces and fit the
crankshaft. Insert the axial bearings for the
crankshaft so that the lubrication grooves point
towards the crankshaft.
SS99N081
6 7 7
1. Mark the position of the ring gear on the shaft.
2. Heat the ring gear using a welding torch and 6 7 200 Nm
loosen it using a suitable mandrel.
3. Heat up the new gear wheels to 250 °C. Fit the
ring gear such that the contact surface faces the
crankshaft flange and the gears are aligned with
the marking or in accordance with the above
SS99N083
figure. Hammer the ring gear downward and allow
it to cool down. 4. Insert the crankshaft bearing covers according
to their numbering, with axial bearings at the rear,
NOTE: The above figure shows the back view of
the crankshaft and the con-rod foot bearing for which have got joggles. Lubricate the bolts and
cylinder 2. tighten them to a torque of 200 Nm.
E. Fitting the crankshaft

0.10 - 0.35 mm
1. Clean the oil lines, bearing shells and seats.
Make sure the crankshaft is clean.
SS99N084
5. Make sure the crankshaft turns freely and with-

out sticking. Check the axial play using a dial test
indicator. The correct axial play is approx. 0.10 -
0.35 mm. If there is excessive axial play, oversized
axial bearings must be fitted.
NOTE: The bearing shells must never be
SS99N082 reamed or machined and the sides of the
bearing covers must not be filed.
WARNING: For engine type 320 the bolt
tightening torque for the crankshaft
2. Fit a bearing shell (A) with an oil bore hole and counterweight is 160 Nm. Apply a locking fluid
(e.g. Loctite 271) to the bolt threads.
oil groove in the cylinder block and a bearing shell
(B) without an oil bore hole in the bearing cover.
2007-38
F. Crankshaft hub 3. Fix a new vibration damper or belt pulley onto
the crankshaft. Drive the dowel pins in and tighten
the securing bolts to a torque of 30 Nm.
NOTE: Vibration dampers (belt pulleys)
supplied as a spare part do not have an
injection marking. New vibration dampers must
be marked after being fitted.
4. Turn the crankshaft until the piston of the first
cylinder is at top dead centre (TDC). Let the valve
fall against the cylinder head. Mount the dial test
indicator at the top of the valve stem and set it to
zero when the piston is at top dead centre. Then
turn the crankshaft against the direction of rotation
until the dial test indicator reads approx. 15 mm
SS99N085 below TDC. Then slowly turn the crankshaft in the
direction of rotation until the dial test indicator
When fitting the hub at the front end of the shows the value which corresponds to the injection
crankshaft, make sure it is in the correct position. marking (see table below).
(engines with injection marking on the vibration
damper.) The hub has an installation marking: NOTE: Refer to setting data on page 9
-- both lines on the hub must lie adjacent to the dot 5. Inscribe the injection marking by means of an
marking • on a crankshaft tooth. electric engraving pen (do not punch it in).
G. Replacing the crankshaft belt pulley Piston stroke to top dead centre in
and vibration damper comparison to crankshaft angle
320, 420, 620
Degrees mm Degrees mm
1° 0.012 16° 2.983
2° 0.047 17° 3.363
3° 0.106 18° 3.765
4° 0.188 19° 4.188
5° 0.294 20° 4.633
6° 0.423 21° 5.100
7° 0.576 22° 5.587
8° 0.752 23° 6.095
9° 0.951 24° 6.624
10° 1.173 25° 7.173
11° 1.418 26° 7.742
12° 1.686 27° 8.331
SS99N086
13° 1.976 28° 8.939
14° 2.289 29° 9.567
NOTE: In the case of a second hydraulic circuit
the markings on the belt pulley and on the 15° 2.625 30° 10.213
casing are located lower down for reasons of
space.
1. Loosen the alternator securing bolts and remove
the V-belt.
2. Unscrew the bolts holding the belt pulley and
vibration damper and remove the parts. The belt
pulley and vibration damper are pinned together
with the crankshaft hub (injection mark on the
vibration damper).

2007-39
H. Checking the rubber element in the

vibration damper (620/420)
A OK
1.5 mm
OK
SS99N087
OK
SS99N088
1. If the lines (A) are misaligned by more than
1.5 mm, the vibration damper must be replaced. 2. Also check the condition of the rubber element. If
pieces of rubber are missing or the rubber part is
more than 3.5 mm below the surface, or if a forward
motion of the inertial component (outer ring) is
discernible, the vibration damper must be replaced.
IMPORTANT: The vibration dampers should be
replaced every 4000 operating hours!

2007-40
6. CON-RODS AND PISTONS
A. Removing the pistons together with
the con-rods 5
1. Unscrew the sump and the lubrication oil 40.025 -
pressure and suction lines.
40.040
2. Unscrew the cylinder head.
3. Scratch the carbon ridge off the cylinder liner. If
necessary, scrape off the sharp abrasion edge at
the reversal point of the piston ring.
4. Remove the con-rod bearing covers and bearing
shells. If the bearing shells are to be re-used, their
order must be marked.
SS99N091
5. Push the piston and con-rod up by using the
shaft of a hammer or some similar object.
4. Press the new bush in. The oil channel in the
6. Remove the piston pin circlips. Push the piston bush must coincide with the corresponding
pin out. channel in the con-rod. After fitting it, drill a hole
with a ∅ of 5 mm. Use a reamer to ream the bush
NOTE: If the piston pin does not move by
to the correct diameter.
applying finger pressure, the piston must be
gradually heated up to 100 °C.
C. Checking the con-rod
B. Checking and replacing the con-rod Check the con-rod by means of a special device.
bearings
1. Clean the con-rod and bearing shells. Fit the
bearing shells and tighten the bolts to a torque of
40 Nm + 90°.
208.00
40 Nm+90° SS99N092
1. Fit the con-rod covers and tighten the nuts to a

torque of 40 Nm + 90°.
2. Clamp the con-rod in the test device and insert
the piston pin into the bush.
SS99N090
2. Measure the inner diameter with a plug gauge,

which has been zeroed at the diameter of the
applicable bearing journal. If new bearing shells
have a clearance of more than 0.14 mm, the con-
rod bearing journals must be ground and the next
bearing shell undersize fitted (repair kit).
3. If the small end bearing bush is worn, it must be
driven out using a suitable mandrel.

2007-41
SS99N095
5. Also check the con-rod for S-shaped bending.

For this purpose, use a micrometer to measure the
distance between the outer face of the small end
bearing bush and the measuring surface of the test
device. Then turn the con-rod round and carry out
the same measurement. The difference between
SS99N093
the measured values must not exceed 0.6 mm.
3. Place the aligning gauge at the top of the piston
pin. Check the con-rods for distortion with the max. 86.50
alignment gauge pins in a horizontal position.
SS99N096
6. Measure the length of the con-rod bolts. This

must not exceed 86.50 mm. If the bolt is longer, it
must be replaced by a new one. It is advisable to
replace the bolts every time they are loosened.
D. Con-rod weight groups

The con-rods are split into weight groups of 20 g.
A letter designates the weight group. It is marked
on the side of the con-rod. All con-rods in an
engine must belong to the same weight group,
which means the permissible weight difference
is 20 g.
SS99N097
SS99N094
4. Check the con-rods for bending with the test

pins in a vertical position.

2007-42
The letter stands for the following weights:
Weight: Spare part number
X 2150 - 2169 g 354139A1
A 2170 - 2189 g 162000030706
B 2190 - 2209 g 162000030707
C 2210 - 2229 g 162000030708
D 2230 - 2249 g 162000030709
I 2250 - 2269 g 162000030710
H 2270 - 2289 g 162000030711
I 2290 - 2309 g 162000030712
J 2310 - 2329 g 162000030713
K 2330 - 2349 g 162000030714
SS99N099
L 2350 - 2369 g 162000030715
M 2370 - 2389 g 162000030716 3. Insert the piston ring in the cylinder and
N 2390 - 2409 g 162000030717 measure the distance between the ring ends. The
distance measured for the 1st and 3rd rings may
O 2410 - 2429 g 162000030718
not exceed 1 mm and 1.5 mm for the 2nd ring.
P 2430 - 2449 g 162000030719
4. Re-insert the piston rings with the aid of the
R 2450 - 2469 g 162000030720 piston ring pliers. Make sure the rings are fitted in
S 2470 - 2489 g 162000030721 the right place and the letters TOP or the
T 2490 - 2509 g 132000030703 manufacturer’s identification mark on the rings
point(s) upwards.
U 2510 - 2529 g 354140A1
TOP
E. Checking and replacing the piston
rings
only 420.85/620.93
1. Release the piston rings using piston ring pliers.
Do not expand the rings more than necessary. If
the same rings are to be re-used, then they should
be kept in the correct order.
TOP
TOP
SS99N100
SS99N098
2. Carefully clean the piston ring groove and then

measure the piston ring play in the groove. The
play must not exceed 0.15 mm. Check whether the
play is due to wear in the ring groove. The rings
and/or the pistons must then be replaced
accordingly.

2007-43
F. Checking the pistons H. Fitting the pistons and con-rods
Inspect the pistons and piston pins by performing a 1. Insert the bearing shells in the con-rods. Make
visual check. Pay particular attention to possible sure the contact surfaces are clean and the
cracks at the edge of the combustion chamber or bearing shells sit correctly.
at the upper part of the piston pin bore hole.
2. Lubricate the piston, piston rings and cylinder
Measure the diameter of the piston at the point
with engine oil. Turn the piston ring gaps to
indicated in the figure and compare the result with
different sides of the piston.
the specified value. Replace the piston, if
necessary.
∅107.873 -
107.887
17 mm
SS99N101
G. Fitting the piston pin

1. Insert the con-rod in the piston and push the
piston pin to its position.
SS99N103
3. Use a piston ring clamp or tapered installation

tool for fitting. Insert the piston and con-rod so that
the weight class mark is on the camshaft side
(arrow on the piston points towards the front).
4. Oil the con-rod bearing journals and bearing
shells and push the piston down. Mount the
bearing cover so that the joggles on the bearing
shells are on the same side. Then tighten the nuts
to a torque of 40 Nm+90°.
5. Check whether the lower con-rod bearing has
sufficient axial play on the crank journal.
SS99N102
WARNING: The combustion chamber in the

piston and the letter for marking the weight
class of the con-rod come on the opposite side.
2. Then fit the circlips for the piston pin. The ends
of the circlips must point upwards.

2007-44
7. BALANCING UNIT (420)
A. Removing and dismantling the
balancing unit
1. Remove the sump.
2. Loosen the lubrication oil line to the balancing
unit.
3. Loosen the balancing unit fixing bolts and
remove the balancing units including any spacer 0,1 - 0,5
washers between the balancing unit and the
cylinder head.
4. Loosen the balancing shaft clamping bolts. Slide
out the shaft in the direction of the clamping bolts. SS99N105
Remove the counterweights and the thrust
4. Check whether the counterweight tooth play is
washers.
according to specifications (0.05 - 0.25 mm) and
5. Clean all parts thoroughly. that the counterweight axial play is correct (0.1 -
0.5 mm).
B. Balancing unit maintenance
Check the shaft wear and the condition of the gear
C. Fitting the balancing unit
wheels and bearings. 1. Fix the sprung dowel pins into place on the
cylinder block.
1. If the gear wheels are worn out, the
counterweights must also be replaced. The gear
wheels are not available as a separate spare part.
2. If necessary drive the old bearing bushes out of
the counterweights using a suitable mandrel.
Before removing the bushes mark the position of
the oil groove in the bearing bush on the
counterweight. Press the new bearing bush into
the counterweight, keeping the oil groove aligned
with its original position. After fitting, machine the
bearing bushes down to their final dimension. SS99N106
2. Fit the balancing unit into place such that the

2 marking point on the gear wheel matches with the
marking point on the crankshaft gear wheel.
3. Tighten the balancing unit bolts to a torque of
60 Nm. Measure the tooth play between the
counterweight and the crankshaft. If the value
deviates from that specified (0.1 - 0.3 mm) then
the tooth play must be adjusted using 0.2 mm thick
1 spacer washers (spare part number
142080020707) to be fitted between the balancing
1. Marking lines
SS99N104 unit housing and the cylinder block. Insertion or
2. Marking dots
removal of a 0.2 mm ring, alters the tooth play by
3. Fit the counterweights into the housing. Take approx. 0.07 mm.
care that the counterweights are in the correct
4. Secure the lubrication oil pipes.
position. The gear wheel marked with a dot should
be located uppermost in the housing. The marking 5. Fit the sump.
lines on the gear wheels should be aligned with
each other. Slide the shafts into place from the
clamping bolt end. When fitting the shaft between
the gear wheel and the housing, also fit the thrust
washer.
The end of the shaft is flush with the housing.
Apply locking fluid to the clamping bolt threads,
(e.g. Loctite 279), and tighten the bolts.

2007-45
8. FLYWHEEL 3. Tighten the flywheel bolts evenly to a torque
of 140 Nm.
A. Replacing the starter ring gear on the WARNING: Flywheels for "green (low-emission)
flywheel engines" supplied as a spare part do not have
an injection register marking for the "Time
The ring gear cannot be re-finished because the Track" check. The new flywheel should be
teeth on the side of the starter are chamfered and marked when carrying out the assembly
hardened. process.
1. Free the old ring gear by hitting it with a - Turn the crankshaft until the piston of the first
mandrel. Clean the ring gear seat on the flywheel cylinder is at top dead centre (TDC). Let the
using a wire brush. cylinder 1 valve fall against the cylinder head.
Mount the dial test indicator at the top of the valve
stem and set it to zero when the piston is at top
dead centre. Then slowly turn the crankshaft in the
direction of rotation until the dial test indicator
reads 4.633 mm after TDC (320 , 420 , 620).
- Drill the hole for the injection register mark in the
flywheel using a twist drill (see figure below).
7 mm
∅ 5 mm twist drill
SS99N107
2. Heat up the ring gear to 150 - 200 °C. Mount the

ring gear. The chamfered inner edge must point ∅ 8 mm guide
towards the flywheel and the tooth chamfer SS99N041
towards the starter.
IMPORTANT: Allow the ring gear to cool down.
Do not use coolant.
B. Fitting the flywheel

1. Clean the contact surfaces on the rear
crankshaft flange and on the flywheel.
Bolt the flywheel onto the crankshaft. M12 grub
screws should be used as guide pins
(2), which fit into the in the securing holes in the
flywheel. A guide sleeve is used for one flywheel
bolt to determine the correct crankshaft position.

2007-46
9. TIMING MECHANISM 1
A. Removing the timing gear case 2
The timing gear case acts as a seal to the sump.
The casing cannot be removed without first
removing the sump.
1. Remove the sump.
2. Remove the fan, the alternator, the V-belt
pulleys and the V-belts. If the tractor is equipped
with an air-conditioning system or compressed air
system, the compressor must also be removed.
3. Loosen the crankshaft nut and remove the belt
pulley.
NOTE: In the case of 620 engines, the belt SS99N109
pulley must be taken off before unscrewing the 1. Lathe chuck
nut. 2. Roller ø = 5 mm
4. For engine types 320 and 420 (with the
After fitting, machine the inner diameter of the
exception of 420.85), remove the hydraulic pump.
intermediate gear wheel bush to the correct size.
5. Remove the timing gear casecover and remove Centre the intermediate gear wheel according to
the metal ring from the crankshaft. the above figure so the tooth play is kept even.
6. Remove the injection pump.
NOTE: If the timing gear case is not going to be
replaced, the injection pump can remain in place.
In this case, disconnect all lines and pipes from the
pump.
7. Unscrew the intermediate gear wheel bolts.
Remove the flange, gear wheel and bearing
journal.
8. Pull out the camshaft.
0.10 - 0.25
NOTE: If the cylinder head and valve
mechanism are not removed, the valve tappets
must be secured against falling down (refer to 55.00 -
instructions in page 34). 55.03
9. Unscrew the bolts on the timing gear case and 30 SS99N118
remove the timing gear case. If a wedge has to be
driven in between the engine block and timing gear
case, make sure the sealing surfaces are not
damaged.
10. Take the front crankshaft sealing ring off the
timing gear case and clean all parts which have
been removed.
B. Replacing the intermediate gear wheel

bush
If the intermediate gear wheel bush is to be
replaced, press in a new bush so that its rear edge 0.10 - 0.25
lies within the rear gear wheel edge by 0.1 -
0.25 mm (see figure). 55.00 -
55.03
50
SS99N119

2007-47
C. Fitting the timing gear case
The position of the timing gear case and the cover
is determined by two sprung dowel pins. It
therefore does not have to be centred for the
assembly process. However, the clearance
between various gear wheels must be checked.
The timing gear case and cover supplied as spares
already have bore holes for the sprung dowel pins.
1. Fit the timing gear case onto the cylinder block
using a new seal. Drive the sprung dowel pins in by SS99N113
means of a mandrel. Tighten the nuts and bolts.
6. Fit the metal ring onto the crankshaft and fit the
2. Install the injection pump together with the gear timing gear case cover, using a new seal. Drive the
wheel (if removed). sprung dowel pins in, by means of a mandrel (mate
3. Oil the camshaft bearings and fit the shaft in the the hollow pin with the grub screw). Tighten the
cylinder block. Release the push rods and valve nuts and bolts.
tappets, if they have been suspended.
90Nm
200Nm
60Nm
SS99N114
SS99N111 7. Fit the guard plate in the bearing seat and insert
the front crankshaft sealing ring by means of the
4. Fit the intermediate gear wheel with the shaft
1TSW 520 special tool.
grub screw and make sure the marks are aligned
correctly. Insert the washer and tighten the bolts to
the specified torque.
SS99N112
5. Check the tooth play.

It should be between 0.05 - 0.25 mm.

2007-48
D. Front power take-off / auxiliary drive
Engine types 320 and 420 (with the exception of
420.85) are equipped with a timing gearcase with
auxiliary drive. The auxiliary drive is driven by the
camshaft wheel and drives the hydraulic pump.
SS99N115
8. If it has been removed, re-fit the dust cap on the

V-belt pulley hub on the crankshaft. To do so, use
the 1TSW 519 pressing tool. SS99N121
Use ball bearing grease (NLGI 2) for the hydraulic

pump shaft grooves and coupling sleeve.
The auxiliary drive is fitted with an external
lubrication tube.
600 Nm (320, 420) SS99N116

1000 Nm (620)
9. Oil both the seal and the sealing surfaces and fit
the V-belt pulley together with the hub.
10. Apply a little oil to the thread on crankshaft nut.
Tighten the nuts for engine types 320 and 420 to a
torque of 600 Nm and those for engine type 620 to
a torque of 1000 Nm.
11. Re-fit the other parts which have been
removed.

2007-49
10. LUBRICATION SYSTEM Make sure the wider side of the spring is fitted
towards the cover.
A. Checking the oil pressure valve
B. Removing and checking the oil pump
Always check whether the oil pressure valve is
functioning if the engine oil pressure does not 1. Drain the engine oil and remove the sump.
increase sufficiently or fluctuates noticeably. 2. Disconnect the intake and pressure lines on the
However, first check whether there is enough oil in oil pump.
the engine.
3. Remove the oil pump and any adjusting disks
between the pump base and the cylinder block.
4. Release the pump cover and the seal. Remove
the gear wheel fitted on the axle.
5. Clamp the pump, at the pump gear wheel, in a
vice with protected jaws and unscrew the nut on
the drive gear wheel. Use a plastic hammer to
drive the pump drive shaft off the gear wheel. Pull
SS99N122 the drive shaft gear wheel out of the pump body.
6. Wash the parts and check the wear compared
1. Remove the cover on the oil pressure valve and with the dimensions specified under "Lubrication
the spring located underneath. Take care to retain oil pump". Replace worn parts and all paper
the washer between the cover and the spring. Pull gaskets.
the valve insert and cone out of the cylinder block.
Take care that the O-Ring is also removed.
Gear wheel
2. Clean the parts. Check that the valve cone
moves freely in the valve insert. If the valve cone
sticks, clean out any particles of dirt. If necessary,
grind the parts with fine abrasive wool or use new
parts. Clean the sealing surfaces between the
cylinder block and the cover.
3. Place a new O-Ring in the groove in the valve
insert. Fit the cone and the valve insert in the
cylinder head. Fit the washer, cover and spring
using a new cover seal.
4. Take note of the asymmetrical shape when 60Nm
fitting the valve cover. The side with the greater +Loctite 243
SS99N124
distance between the cover centreline and the
fixing opening should be underneath. 7. The oil pump bearing points for engine type 620
IMPORTANT: From engine number J 7595 are fitted with separate bearing bushes. On
onward, a new oil pressure valve should be replacing the bearing bushes, machine them to the
used. dimension 18.000 - 18.018 mm after fitting them.
25 Nm
SS00B054
The valve seat (X) in this oil pressure valve is

glued in using Loctite 638.

2007-50
C. Assembling and fitting the oil pump NOTE: When measuring the tooth play, the
engine must be in its operating position
1. Insert the gear wheels into the recess in the (upright) as the bearing play has an effect on
pump body. Fit a new seal between the pump body the tooth play.
and cover (as required). Tighten the securing bolts
a little. Turn the shaft and tap the cover laterally 5. Fix the pump intake and pressure lines, replace
into the position, in which it rotates most easily. the seals on the mounting flange.
Tighten the cover securing bolts and check that the 6. Fit the sump and fill it with engine oil.
shaft still rotates easily.
2. Fit the drive gear wheel onto the shaft, apply D. Fitting the sump
locking fluid to the nut threads (e.g. Loctite 243) Fit the sump seal with the silicone strips pointing
and tighten the nut to a torque of 60 Nm. towards the cylinder block.
SS99N128
E. Oil cooler
Engine types 620.92 and 620.93 are equipped with
an oil cooler, which is located between the engine
oil filter and the cylinder block.
SS99N126 1. The coolant must be drained out of the oil cooler
before removing it.
3. Clamp the pump at the mounting base in a vice
with protected jaws. Check the axial play of the
gear wheel (0.03 - 0.11 mm) with a dial test
indicator. Change the number of seals between the
cover and pump body as required.
SS99N129
2. Fit new seals. Mount the oil cooler so that the

drain connection points downwards. Secure the
coolant hoses in a regular manner.
3. Put some screw locking fluid (e.g. Loctite 243)
on the thread on the engine end of the mounting
SS99N127
pipe and tighten it to a torque of 60 Nm.
4. Secure the pump in its position below the
cylinder block and use a dial test indicator to check
the tooth play between the crankshaft and pump
gear wheels. (0.05 - 0.25mm). Change the number
of shim rings between the pump base and the
cylinder block (0.2 mm shim ring, order number
162000070716). Inserting/removing a 0.2 mm ring
changes the tooth play by approx. 0.07 mm.

2007-51
F. Piston cooling nozzles (620)

The piston cooling nozzles for engine type 620.93
can be taken out after removing the sump. The
nozzle is equipped with a ball valve. It has an
opening pressure of 3±0.25 bar.
SS99N131
2. On assembling the nozzle, fix the nozzle pipe, as

shown in the figure, at an angle of 90° to the
SS99N130 longitudinal axis of the engine. Tighten the nozzle to
a torque of 30 Nm. After assembly, check that the
1. Change the nozzles as required. Unscrew the nozzle pipe does not touch the piston or con-rod
nozzles from the engine and remove the nozzle when the engine is turned over.
pipe. Insert the new nozzles.
G. Recommended lubrication oils

- For engines with a turbo charger
API CD/ CE/ CF/ CG-4

ACEA E2-96/E3-96
Temperature °C
-30 -20 -10 0 +10 +20 +30
5W 20
5W 30
5W 40
10W
10W 20
SAE CLASS
10W 30
10W 40
15W 30
15W 40
20W 20
20W 30
20W 40
30 SS99N132

2007-52
11. COOLING SYSTEM 4. Pull the impeller off using the 1TSW 662
extractor.
A. Thermostat 5. Remove the circlip from the pump body. Use a
hydraulic press, for example, to press the shaft
The thermostat is of a two-way design with an
with the bearing out of the pump body towards the
opening temperature of 79 °C.
fan. Clamp the pump body so that the shaft
If you have doubts about the functionality of the bearing can be taken out.
thermostat, check it as follows:
6. Remove the axial and shaft seals from the pump
- place the thermostat in boiling water without it body by means of a mandrel. Clean the parts and
touching the sides of the vessel. check their condition. Replace worn or faulty parts.
- the thermostat must start to open within NOTE: If the pump bearings have to be
20 seconds. replaced, it is better to fit the pump repair kit,
which also comprises all seals required for the
- the thermostat must be fully open after no longer
repair (refer to spare parts catalogue).
than 50 seconds. Compare the measured values
with those specified in the technical data.
1TSW 18390
1TSW 523
SS99N138
SS99N135
B. Repairing the coolant pump

1. Drain the coolant. Unscrew the thermostat
housing, the fan and the V-belt.
2. Remove the coolant pump. Take the back plate
off the pump and clean the sealing surfaces.
3. Unscrew the securing nut for the V-belt pulley
and remove the belt pulley. Use the 1TSW 662
extractor, if required.
SS99N140

2007-53
7. Use the 1TSW 523 mandrel to drive the shaft
seal into the pump body. Mount the bearings and
intermediate sleeves on the shaft. Grease the
bearings with plenty of heat-resistant bearing
grease. Fit the shaft and bearings in their place so
that the forces produced by pressing do not act on
the bearing balls. Fit the bearing circlip in its place.
SS99N143
10. Fix the back plate using a new seal. To fit the
back plate, use guide pins with a diameter of
8.5 mm for the bore holes shown in the figure
(engine type 620).
C. Coolant quality requirements

-if there are no frost resistance requirements, a
mixture ratio of 30 % is enough to ensure sufficient
corrosion protection.
SS99N141
- check the coolant (anti-freeze) mixture ratio at
certain intervals. Replace the coolant every two
8. Fit the impeller whilst supporting the other end of
years.
the coolant pump shaft. The play (X) between the
pump casing and impeller for engine types 320/420 - the water used must be clean and soft, i.e. it must
is 1.8 - 2.2 mm, and for type 620 engines 0.8 - not contain any metals and their salts.
1.2 mm. Check that the coolant pump shaft rotates
WARNING: Never use only water as a coolant.
freely.
9. Fix the belt pulley on the shaft and tighten the
securing nut to a torque of 120 Nm.

2007-54
12. INTAKE / EXHAUST SYSTEM 6. Make sure no loose objects or dirt particles have
ingressed into the exhaust pipe or silencer. Such
An engine equipped with a turbo charger is far loose objects or dirt particles can increase the
more sensitive to faults and contamination in the back-pressure for the exhaust gases from the
intake/exhaust system than conventional engines. turbine wheel.
Particular attention must therefore be paid to the
intake/exhaust system. C. Checking the boost pressure
A. Checking the air filter The boost pressure should be checked before
removing the turbo charger.
The engine performance and service life are
largely dependent on the condition of the air filter.
A faulty air filter lets dirt particles through, which in
the long run will cause damage to the turbo
charger and engine. A blocked air filter reduces
engine performance and also causes oil leakage
through the sealing ring on the turbo charger shaft.
WARNING: The safety filter located in the main
filter does not have to be cleaned, but must be A
replaced as required (refer to operating
instructions).
B. Checking the intake / exhaust system

IMPORTANT: Leakages in the intake or exhaust
system impair the effect of the turbo charger.
Due to the pressure, even small leaks in the SS00B058
manifold or turbine inlet flange quickly get
bigger. Leakages must therefore be eliminated To check the boost pressure, the screw (1TSW
without delay. 663) is screwed into the intake manifold instead of
1. Check the pipes and sealing surfaces between the thermo-start unit (A). This applies to all
the air filter and exhaust turbo charger as well as engines. In addition, a mini-measuring connector
between the exhaust turbo charger and exhaust (1TSW 640), mini-measuring line (ITSW 635) and
manifold. If the intake manifold is dusty on the pressure gauge (1TSW 5002) have to be used.
inner side, then there is a leakage in the air filter or The boost pressures are specified on page 9.
in the suction pipes. Eliminate the leakage.
2. Clean the sealing surface of the intake manifold.
Use a straightedge to make sure the sealing
surface is level. If the sealing surface is not level or
is scratched, machine or replace the intake
manifold. For engine type 620 make sure the
cylinder heads are parallel to each other.
3. Insert a new seal and secure the intake
manifold. Tighten the intake manifold securing
bolts to a torque of 30 Nm. Secure the air pipes.
4. Make sure the exhaust manifold is airtight.
Tighten the nuts/bolts to a torque of 50 Nm and
check for damage (cracks, deformation, corrosion,
etc.). Also check the connection between the turbo
charger and exhaust manifold.
5. Remove the manifold, if necessary. Clean the
sealing surfaces and remove any carbon deposits.
Make sure the sealing surfaces are level. If the
mounting flanges are twisted or the sealing
surfaces scratched, machine the flange or replace
the exhaust manifold.

2007-55
D. Checking the turbo charger

If it is assumed that the turbo charger is faulty, the
fault can be determined as follows:
1. Carry out a visual check on the turbine and
compressor wheels. The blades must not show any
signs of damage, deformation or wear caused by
foreign objects.
2. Check whether oil leaks through the sealing rings
on the shaft in the turbine / compressor housing.
WARNING: A small amount of oil always comes
out on the compressor side at low idling speeds.
However, there is no need to worry about this
SS99N145
unless a lot of oil is lost.
4. Check the axial play of the shaft. Hold the probe
of the dial test indicator against the end of the shaft
move the shaft axially. Also refer to the play
specified under Technical Data.
If a fault or wear is confirmed, the turbo charger
must be overhauled.
If the engine does not run properly even though the
turbo charger is not faulty and does not show
excessive wear, the fault could have one of the
following causes:
- a blocked air filter
- a leakage in the intake or exhaust system; a
leaking flange seal
- A faulty or maladjusted injection pump
SS99N144 - maladjusted throttle linkage
- faulty or maladjusted injection nozzles
3. Check the running play of the turbine shaft. Hold - insufficient fuel pressure (e.g. caused by a
the probe of a dial test indicator against the shaft blocked fuel filter)
and move the shaft sideways. Also refer to the play - weak compression, incorrect valve clearance
specified under Technical Data.

2007-56
4
3
1 5
SS99N146
Schwitzer turbocharger
1. Compressor housing 5. Bearing bushes
2. Lock nut 6. Turbine housing
3. Compressor wheel 7. Shaft and turbine wheel
4. Bearing housing
E. Fitting the turbo charger 3. Connect the intake / silencer pipe to the turbo
charger.
First, the cause of possible turbo charger damage
must be clarified and eliminated before a new turbo 4. Pour clean engine oil into the bearing housing via
charger is fitted. the oil filler in order to ensure lubrication of the turbo
charger bearings after starting the engine.
For perfect operation of the turbo charger, it is
important that the engine lubrication oil is changed 5. Secure the pressure and oil return pipes. Make
in accordance with the relevant instructions and that sure the turbo charger is held completely by the
the correct quality class is used. The maintenance mounting flange and that the pipes do not put any
specifications for the oil and air filters must also be strain on the turbo charger.
adhered to. 6. Pull out the fuse (for type 320 F15, for types 420
The injection pump setting, which must correspond and 620 F29) for the engine cut-out and start the
with the manufacturer’s specifications, has a major engine several times with the starter. This ensures
influence on turbo charger operation. that there is plenty of oil at all lubrication points
before operation. Re-insert the fuse and start the
1. Check the fastening and tightness of the exhaust engine. Check the pipe connections for leakage.
and intake manifolds. Make sure there are no loose
carbon particles, rust or other foreign bodies on the
exhaust or intake manifolds.
2. Fix the turbo charger onto the exhaust manifold
by means of the flange. Always use new seals.

3A
Section
3A
FUNCTIONAL DESCRIPTION
INJECTION SYSTEM
9105, 9115, 9125, 9145

CS 110, CS 120, CS 130, CS 150
From DBD0075001 onwards
Technische Dokumentation/Training Center June, 2000
A – 4300 St. Valentin, Steyrer Straße 32
3
TABLE OF CONTENTS
SPECIAL TOOLS .....................................................................................................................4

GENERAL INFORMATION ......................................................................................................5
TECHNICAL DATA ..................................................................................................................6
Stanadyne injection pump ..............................................................................................6
Pump type .......................................................................................................................6
Injection sequence ..........................................................................................................6
Cut-out solenoid ..............................................................................................................6
Fuel pump .......................................................................................................................6
Stanadyne injection nozzles ...........................................................................................6
Thermo-start unit ............................................................................................................6
Tightening torques ..........................................................................................................6
FUEL SYSTEM WITH STANADYNE DISTRIBUTOR INJECTION PUMP ..............................7
Injection nozzles .................................................................................................................8
Removing the injection nozzles ......................................................................................8
Checking the injection nozzles .......................................................................................8
Overhauling the injection nozzles ...................................................................................9
Assembly of the injection nozzles in the cylinder head ...................................................9
Assembly of the injection lines ........................................................................................9
Stanadyne distributor injection pump ................................................................................10
Construction of the Stanadyne distributor injection pump ............................................11
How the Stanadyne distributor injection pump works ...................................................12
Removal of the injection pump .....................................................................................13
Assembly of the injection pump and adjustment of the delivery start (static) ...................13
Bleeding the fuel system ...............................................................................................14
Thermo-start system .........................................................................................................14
Bleeding the thermo-start system .................................................................................14
Adjusting the idling speed .................................................................................................15
Measuring the fuel feed pressure .....................................................................................15
Testing the fuel pressure ..............................................................................................15
Checking the delivery start using TIME TRAC (dynamic) .................................................16
TIME TRAC setting and check values ..........................................................................17
Troubleshooting when using the TIME TRAC ..............................................................17
Fuel quality requirements ..................................................................................................18
Bio-diesel fuel ...............................................................................................................18

4
SPECIAL TOOLS
Extractor Mini-measuring connection
SS00B070 SS98J031
1 off 1TSW 662 1 off 1TSW 639 M8x1
Pressure gauge and connection Banjo bolt
SS00B076 SS00E063
1 off 1TSW 645 Connection 1 off 1TSW 665 420
1 off 1TSW 5002 Pressure gauge 1 off 1TSW 666 620
Mini-measuring line Time Trac
SS98J030 SS00B074
1 off 1TSW 635 1 off 1TSW 649

5
GENERAL INFORMATION
This manual only contains general instructions for repairing and servicing the injection system. This applies to the
injection pump in particular, as specially trained personnel with special tools and measuring instruments are
required to repair it. All service and repair work on the injection system requires particular care and cleanliness.
,03257$17 In the case of fuel systems with Stanadyne injection pumps, it is important that the fuel system is
bled of air before starting for the first time. The cut-out solenoid requires fuel for cooling and must not therefore be
energised for more than 40 seconds in a dry state.
SAFETY REGULATIONS
There is always a risk of getting injured •) Naked flames and smoking are not permitted in the
when performing service and repair vicinity of fuel tanks or batteries. Electric sparks
work. Before commencing work, should be avoided.
the following safety regulations
•) Disconnect the cable at the negative battery pole (-)
and instructions must be read.
before carrying out service or repair work on the
•) Never start repair work, which you do not fully electrical system.
understand. •) When checking the injection nozzles, never touch
•) Make sure that the environment is safe to work in. the fuel, which is ejected under high pressure. The
jet will penetrate the skin and cause serious
•) Make sure the location is clean and in a good state.
poisoning. If contact is made with the skin, consult
•) Never use incorrect or unsuitable tools. a doctor without delay!
•) Remove all rings, chains and watches before •) Fuel and lubrication oil can cause skin irritations
commencing work. if contact is made over a longer period.
•) Use state of the art safety equipment. For example, •) Avoid running the engine in idle unnecessarily.
wear goggles when using compressed air for
•) When carrying out service work, take measures to
cleaning.
prevent fuel or other fluids from entering the ground
•) Only use original Case-Steyr spare parts. or drains.
•) Only start the engine from the cab, using the •) Be careful when washing the engine using a
ignition key. washing facility with a high water pressure. Do not
•) Never start the engine with the protective covers wash, for example, the electrical and fuel systems
removed. under high pressure as they can easily be
damaged.
•) It is difficult to see the radiator fan when the engine
is running! Baggy clothes and long hair can get •) Never wash the area around the injection pump
caught in rotating engine parts! when the engine is running.
•) If the engine is started in a confined space,
sufficient ventilation must be provided.
•) Ear muffs must be worn when testing the engine or
working close to the engine.
•) Always switch the engine OFF before carrying out
repair work.

6
TECHNICAL DATA
Stanadyne injection pump

Direction of rotation ........................................................................................................................Clockwise
Pump setting (static)...................................................................................................................See page 13
Pump setting (dynamic)..............................................................................................................See page 17
Type of construction (general).................................................................................... DB 4 (4 pump pistons)
Pump type
420.85 ......................................................................................................................................DB4427-5680
620.94 ......................................................................................................................................DB4629-5675
620.92 .................................................................................................................................. DB4629-5636/A
620.93 ......................................................................................................................................DB4629-5679
Injection sequence
420 ............................................................................................................................................... 1 - 2 - 4 - 3
620 ..................................................................................................................................... 1 - 5 - 3 - 6 - 2 - 4
Cut-out solenoid
Resistance................................................................................................................................... 3.8 Ω ± 10 %
Fuel pump
Type of construction ..........................................................................Diaphragm pump, separate hand lever
Fuel feed pressure (static).................................................................................................................0.48 bar
Min. fuel feed pressure........................................................................................... 0.20 bar / topidlingspeed
Stanadyne injection nozzles

Type .......................................................................................................................Five-hole nozzle (M type)
Opening pressure...........................................................................................................................270 +8 bar
Pressure setting .................................................................................................................................278 bar
Graduation of the adjusting disks ..................................................................................................... 0.05 mm
Change in opening pressure per graduation .....................................................................................5.00 bar
Adjusting disks (refer to spare parts catalogue) ................................................................... 1.00 to 1.90 mm
Thermo-start unit
Heating element res. ...................................................................................................................... 1 Ω ± 10 %
Tightening torques
Pump gear wheel nut .......................................................................................................................... 90 Nm
Injection nozzle union nut.................................................................................................................... 60 Nm
Injection nozzle bracket....................................................................................................................... 15 Nm
Injection line union nut......................................................................................................................... 25 Nm

7
FUEL SYSTEM WITH STANADYNE DISTRIBUTOR INJECTION PUMP
13
12
8 3 7
2
9 10a
6 4
11 10c
Electrics stop
5 10b SS99N151
1. Fuel tank 9. Thermo-start unit

2. Pre-filter 10a. Bleed screw
3. Diaphragm fuel pump 10b. Bleed point and
4. Duplex filter test connection
(420.85 only one filter) 10c. Test connection
5. Distributor injection pump 11. Overflow valve
6. Injection nozzle 12. Gravity valve
7. Tank return line 13. Tank bleed line
8. Thermo-start tank
The electric pump in the main tank pumps fuel into a secondary tank at the rear end of the main fuel tank. This
ensures that the diaphragm fuel pump (3) does not suck in any air, even when the main tank is almost empty. The
diaphragm fuel pump sucks in the fuel through the pre-filter (2) from the secondary tank and pumps it through the
fuel filters (4) to the injection pump (5). In the injection pump, the fuel is injected at high pressure into the
combustion chamber via the injection nozzles (6). Excess fuel in the injection pump is returned to the fuel tank (1)
via the overflow valve (11) and the return line (7). Excess fuel in the injection nozzles flows into the thermo-start
tank (8) via the leakage oil lines. When the thermo-start tank is full, the fuel flows back into the fuel tank (1) via
the return line (7). The gravity valve (12) is used to ventilate/vent the fuel tank.

8
Injection nozzles – opening pressure of the injection nozzle
– buzzing sound and spraying pattern
1 – tightness of the nozzle needle against its
seating surface
2
1. Fuel inlet
2. Leakage oil
connection
3. Pressure adjusting
disk 3
4. Pressure spring
4
5. Thrust bolt
6. Nozzle body 5
7. Pressure chamber 6
8. Nozzle needle 7 SS99N147
9. Spray orifice Opening pressure

8 To fill the injection nozzle, pump the system a few
times. Increase the pressure in the injection nozzle
SS99N149 9 until the buzzing is audible. Check the opening
pressure. If the opening pressure deviates from the
The injection nozzles are equipped with a five-hole specified value, the injection nozzle must be
nozzle. The small amount of leakage fuel used to dismantled to adjust the opening pressure.
lubricate the needle is returned to the fuel tank via A adjustment is made by means of different pressure
the leakage oil line. adjusting disks. The thickness of the adjusting disks
varies between 1.00 and 1.90 mm and they are
Removing the injection nozzles available in graduations of 0.05 mm. A thicker
adjusting disk increases the opening pressure, a
1. Clean the injection nozzles and the surrounding thinner one reduces the opening pressure. Changing
area. Disconnect the pressure lines and the leakage the thickness of the disk by 0.05 mm changes the
oil line. opening pressure by approx. 5.0 bar. Because the
2. Unscrew the nuts on the injection nozzle bracket opening pressure of the injection nozzle drops
and remove the injection nozzle, with the bracket, slightly after being adjusted, it should be set approx.
from the cylinder head. Seal off all connecting points 10 bar higher than the value specified in the technical
by fitting protective caps. data. This value is valid for both new and used
injection nozzles.
3. Remove the sealing washers from the injection
nozzle seating in the cylinder head, if they have not Buzzing properties
already been taken out with the injection nozzle. Testing by means of the hand pump does not fully
correspond to the conditions that the injection nozzle
Checking the injection nozzles is subject to in the engine. The test results are only
reliable for new nozzles. Used nozzles do not buzz at
,03257$17 When checking the injection nozzles certain pump speeds, which is due to the design of
on the test stand, it is not permitted to remain in the the nozzles.
vicinity of the nozzle outlet (e.g. with one’s hands).
The fuel jet, which is ejected at high pressure, can When pumping quickly, however, the buzz is
easily penetrate the skin and cause serious injuries. audible and/or a fine jet of atomised fuel is visible.
Breathing in fuel spray is detrimental to health. The jet is thicker and less defined in the buzz-free
zone.
1. Clean the injection nozzle using cleaning fluid and
a soft brush. The carbon deposits must not be Tightness of the nozzle needle
knocked off or removed in such a way that the nozzle Press the test pump lever slowly, until the pressure
can be damaged. increases to approx. 20 bar below the setting
value. Maintain this pressure for approx.
2. Mount the injection nozzle on the test stand and 10 seconds. If no drops of fuel form at the tip of the
check the following points: nozzle, the nozzle seals correctly. Otherwise,
dismantle the nozzle and clean the seating or
replace the nozzle.
9
Overhauling the injection nozzles
1. Mount the injection nozzle in such a way that it
will not be damaged.
2. Unscrew the nozzle tensioning nut. Remove the
nozzle and the parts in the holder.
3. Clean the nozzle, both inside and outside, in
cleaning fluid. 1
4. Steep blocked spray orifices or clean them using 2
a cleaning needle.
5. Check the movement of the nozzle needle as
follows: 1. Sealing washer
2. Rubber ring
3. Sealing ring
3
SS99N150
2. Fit the injection nozzle in its place in the cylinder

head. Use a new sealing washer.
,03257$17The spraying directions of the injection

nozzle are not symmetrical. It is therefore important
SS99N148 that the injection nozzle is fitted into the cylinder
head correctly. The leakage oil line points towards
Rinse the parts out with fuel or test fluid. Pull the the side of the valve cover.
nozzle needle out off the nozzle body by one third
of the slide face length. The nozzle needle must be 3. Fit the bracket and tighten the nuts evenly to a
able to slide into the valve seat under its own torque of 15 Nm.
weight. Turn the nozzle needle a little and repeat 4. Connect the leakage oil line and the injection
the test. The nozzle needle must not stick in any lines.
position. If it does, rinse the parts and repeat the
test. If the needle sticks again, the nozzle must be :$51,1* Always make sure the correct type of
replaced. injection nozzle is used. Incorrect injection nozzles
6. Before assembly, all parts must be carefully impair engine operation and can cause engine
cleaned in clean fuel or test fluid. damage.
7. Insert the adjusting disk in the nozzle holder.

Assembly of the injection lines
Bear in mind that the opening pressure may
require adjustment. Assemble the injection nozzle, 1. Check the state of the lines before fitting them. If
making sure the thrust bolt and intermediate disk the lines show signs of kinking, breakage or
are in the correct position. abrasion, or the sealing olive is damaged, replace
the line with a new one.
8. Tighten the nozzle tensioning nut by hand and
then to a torque of 60 Nm. 2. When connecting the line, make sure that the
union nut is not cross threaded. If this is not the
Assembly of the injection nozzles in the case, the olive will be damaged.
cylinder head Tighten the union nut for the line to a torque of
25 Nm.
1. Clean the injection nozzle seating in the cylinder
head. If necessary, correct the surface using a 3. Secure the injection line holders.
reamer.

10
Stanadyne distributor injection pump
F
5
6 4
B
A B
3
SS99N152
1 2
1. Type plate
2. Delivery start marks under the cover
3. Fuel inlet
4. Overflow valve / fuel return line
5. Throttle lever
6. Connection for the cable to the cut-out solenoid
Additional equipment for the injection pumps

A. Break-away bolt (Spare part number 142000080712)
B. Sensor for measuring the dynamic delivery start
C. Full-load choke
The full-load choke restricts the full-load flow rate at very low rotational speeds and reduces engine smoke.
D. Load-dependent injection timing device
In some versions, the standard speed-dependent injection timing function has a higher level load-dependent
injection timing. The injection timing device turns the cam ring depending upon the speed and load state, in
order to adjust the start of delivery. This function is controlled by the feed pressure and also by the pressure
after the volume valve.
E. Aneroid control (load pressure dependent full-load stop, 420.85 only)
The aneroid control regulates the fuel flow rate on accelerating, dependent on the available boost pressure.
This effectively reduces smoke emission, especially when revving up quickly from low speeds.
F. Boost pressure (420.85 only)

11
Construction of the Stanadyne distributor injection pump
1. Drive shaft
4 2. Governor
5 centrifugal weights
3. Governor spring
4. Cut-out solenoid
3 5. Overflow valve
7 6. Volume valve
1 7. Cam ring rollers
6 8. Distributor head
9. Pressure control
8 valve
10.Transfer pump
11.Distribution rotor
12.Pressure valve
13.Cam ring
14.Automatic
injection timing
device
15.Centrifugal
governor
16.Pump piston
2 15 SS99N156
12 11 10 9
16
14 13
The rotating parts of the injection pump are the drive shaft, the transfer pump, the distribution rotor and the
centrifugal governor.
The drive shaft rotates in the distribution rotor in the distribution head. The injection pump is fitted with four pump
pistons.
The pump pistons are moved towards each other simultaneously by rollers and pressure pieces, controlled by an
internal cam ring and the fuel is thus pressurised. The number of cams corresponds to the number of cylinders.
The transfer pump is located in the sealing cover. The coarse filter for the fuel feed system and the pressure
control valve for the feed pump are also located in the sealing cover. The face of the governor unit is pressed
against the sleeve and the distribution rotor and forms an axial seal for the feed pump.
The injection pump is designed so that the axial force acts against the face of the transfer pump pressure control
valve.
The distribution rotor has two feed channels and an axial channel (high pressure chamber), in which the pressure
valve is located. A distribution channel is located behind the pressure valve. The distribution channel supplies the
fuel to the injection lines according to the injection sequence.
The distribution head contains the bore hole in which the rotor revolves, the bore hole for the volume valve, the
feed channels and the connections to the fuel injection lines.
The pump is fitted with a mechanical governor. The centrifugal force of the weights is transferred to the volume
valve via linkage rods. The governor switches to zero flow as soon as the cut-out solenoid is de-energised. The
automatic injection timing device is a hydraulically controlled mechanism.
The hydraulically operated injection timing device turns the cam ring radially and the delivery start alters
automatically.

12
How the Stanadyne distributor injection pump works
3
5
8
7 4 2
9
1
13 14
10 12
SS99N155
11 15
18
16 17
Feed pump pressure Injection pressure Housing pressure
1. Fuel tank 10. Governor spring

2. Pre-filter 11. Governor weights
3. Fuel feed pump 12. Overflow valve
4. Fuel filter 13. Distributor head connecting channel
5. Transfer pump 14. Volume valve
6. Pressure control valve 15. Hydraulic head loading channel
7. Automatic injection timing device 16. Distribution rotor
8. Vent hole 17. Pressure valve
9. Cut-out solenoid 18. Injection nozzle
The fuel feed pump (3) sucks in the fuel via the pre-filter (2) and feeds it though the fuel filters (4) to the distributor
injection pump.
In the pump the fuel flows through the inlet filter sieve into the transfer pump (5). Some of the fuel is fed through
the pressure control unit (6) to the intake side of the transfer pump (5).
The feed pressure in the distribution head lies between 1 and 6 bar (speed-dependent). The fuel flows from the
connecting channel to the automatic injection timing device and the ring channel and on to the volume valve (14).
The volume valve, which is controlled by the centrifugal governor, regulates the fuel flow to the ring area, which
contains the pressure openings.
Whilst the rotor revolves, the two rotor inlet channels are adjusted to the pressure channels in the distribution
head so that fuel can flow into the pump chamber. If the rotor continues to revolve, the inlet channels close and
the channel to the injection nozzle is opened.
Whilst the outlet channel is open, the rollers on the cams press the pistons together. The fuel between the pistons
is pressurised and is injected into the combustion chamber via the injection nozzle.
The injection pump uses fuel for lubrication and is therefore not connected to the engine lubrication system.
When fuel reaches the loading channels at feed pump pressure, grooves in the rotor shaft let fuel and trapped air
into the hollow space in the pump housing. Furthermore, an air outlet channel in the distribution head connects
the outlet side of the feed pump to the pump housing. Some of the fuel can then flow back into the fuel tank via
the overflow valve. Excess fuel fills the pump housing, lubricates and cools the internal parts and removes small
air bubbles.

13
Removal of the injection pump
Carefully clean the pump and the surrounding
components. Remove the delivery lines, the supply
line and the throttle cable from the engine speed
lever and disconnect the power connection for the
cut-out solenoid from the pump. Fit the protective
caps on the line connecting flanges and the feed and
overflow valve connections.
Remove the cover on the control housing so that the
pump gear wheel is accessible.
SS00E039
127( If there isn’t a mark on the belt pulley,

read "Replacing the crankshaft belt pulley" in
Chapter 5 of the engine repair manual.
Remove the small cover plate at the side of the
injection pump. Turn the pump shaft until the injection
marks coincide (see arrow in the figure).
1TSW 662
SS00E046
Unscrew the securing nut on the gear wheel.

Remove the gear wheel using the 1TSW 662
extractor. There is no key to locate the gear wheel on
the pump drive shaft. The gear wheel is only
accommodated by a cone. If the engine control has SS00E040
not been removed, the pump drive wheel remains in
contact with the intermediate wheel. The wheels do
not have to be specially marked. Place a new seal on the pump flange. Push the pump
to the correct position on the control housing.
:$51,1* Before removing the pump, disconnect Turn the pump in the direction of rotation until it
the connection to the battery or switch the main makes contact with the slots. Check that both
battery switch OFF (if fitted) in order to prevent injection marks (on the pump and on the belt pulley)
inadvertent starting. Once the pump has been coincide exactly with the reference marks. Secure
removed, the loose gearwheel can damage the the pump in this position. Secure the gear wheel nut.
control wheels or the housing.
Tighten the gear wheel nut to a torque of 90 Nm.
Disconnect the injection pump from the control Loosen the pump retaining screws and turn the
housing. Clean the sealing surfaces. pump against the direction of rotation just enough to
eliminate the tooth flank play. Tighten the pump
Assembly of the injection pump retaining screws and make sure the injection marks
and adjustment of the delivery are in the correct position.
start (static) 127( To avoid premature breaking off, it is
advisable only to tighten the break-away bolt
Turn the crankshaft to a position in which the piston after adjustment by means of the TIME TRAC.
of the first cylinder is at top dead centre of the
compression stroke. Then turn the crankshaft back Fit the small side cover to the pump.
until the mark on the belt pulley passes the injection Secure the cover on the control box.
mark. Slowly turn the crankshaft in the direction of
rotation until the mark on the belt pulley is next to the Remove the protective caps from the line connecting
injection mark. flanges. Use new sealing rings for the banjo bolts. Fix
the throttle cable and the return spring and connect
the cable for the cut-out solenoid.

14
Bleeding the fuel system Continue pumping with the hand pump and open
bleed point 10b on the injection pump until fuel flows
127( This fuel system automatically removes out without bubbles. Close the bleed point.
air bubbles from the filter and injection pump
when the engine is running. If, however, the When the system is bled as described, fuel
system has been opened, the fuel used up immediately flows into the inner feed pump when the
during operation or a new injection pump has starter turns the engine over. The distribution pump
been fitted, then the system must be bled. housing quickly fills up with fuel.
The pump housing contains the cut-out solenoid,
which may not be switched on for more than
40 seconds, if there is no fuel in the upper cavity of
the pump housing.
:$51,1* This is why the fuel system may not be

bled via the overflow valve.
Thermo-start system
To facilitate starting at low temperatures, the system
is equipped with a thermo-start unit. A separate tank
SS99J223 is filled via the nozzle leakage oil line whilst the
engine is running. If pre-glowing is necessary before
starting for the first time, the tank must be filled
10a
manually, as otherwise the heating coil for the
thermo-start unit could get damaged during the
process. In addition, the pre-glowing process would
be ineffective as no fuel would be burnt and no intake
air heated up.
Bleeding the thermo-start system
4
10b
SS99N153
Turn the ignition switch to the first position (up to

40 seconds) to ensure the pan in the fuel tank is full
of fuel. Then loosen bleed screw 10a on the filter.
Operate the hand pump until no more air bubbles
escape through the bleed screw bore hole. Tighten
SS99N047
the bleed screw.
127( If pumping does not have an effect, turn
the engine over until the pump lever is freed
from the drive cam of the cam shaft. 1 2 3
1. Tank filling line
2. To the thermo-start unit
3. Return line to the tank
4. Vent
If the thermo-start line or the tank has been emptied
for repairs, the line must be bled of air.
Fill the tank with pure fuel, e.g. through the vent.
Open the fuel line to the thermo-start unit and let fuel
escape. Tighten the line.

15
Adjusting the idling speed Testing the fuel pressure
Clean the injection pump, filter and fuel lines.
Check whether there is enough fuel in the tank.
2
Check whether the fuel tank vent is functioning.
3 Make sure the fuel lines are not kinked, particularly
1 the fuel hoses.
Connect the 1TSW 5002 pressure gauge to point
10b (for 620.94, 620.92, 620.93) and point 10c (for
420.85) on Page 7. To do so, use the 1TSW 666
banjo bolt for point 10b and the 1TSW 665 banjo bolt
for point 10c, the 1TSW 639 mini-measuring
connection and the 1TSW 635 mini-measuring line.
Run the engine at idling speed. The feed pressure
should reach 0.48 bar.
Run the engine at topidling speed, under/without
SS99N195
load and accelerating under full load. The feed
1. Idling speed adjusting screw pressure may only drop by 0.20 bar during these
tests.
2. Engine speed lever
If the pressure drops below the required value in one
3. Topidling speed adjusting screw
of the tests recommended above, this can have
various causes.
The idling speed can be adjusted via the adjusting
For example:
screw in front of the engine speed lever. The
topidling speed adjusting screw has a lead seal. This •) blocked, kinked or leaking
setting is made at the factory. A subsequent fuel lines
adjustment of the topidling speed is not permissible. •) blocked pre-filter
The same regulations are valid for the lead-sealed
adjusting screw at which the maximum fuel flow rate •) blocked metal mesh filter in the
is adjusted. feed pump
•) defective feed pump
Measuring the fuel feed pressure •) blocked fuel filter
If the engine power is too low, it is possible that not
enough fuel is being injected. Before checking the
injection pump, check whether sufficient fuel is fed
into the pump. This check can be made by reading
the pressure indicated on a pressure gauge under
different engine operating conditions (e.g. idling
speed, topidling speed, under/without load,
acceleration under full load).

16
Checking the delivery start using TIME TRAC (dynamic)
This means that the check will be carried out with the engine running.
To carry out this check, the engine manufacturer introduced an electronic device, the so-called "TIME TRAC".
The TIME TRAC provides detailed instructions, which explain the procedure step by step. This manual contains
the most important information on this new process.
B
A
SS99N196
MP
SR
1. After the static adjustment of the delivery start and 3. Fit adapter B. Place the clip over the carefully
bleeding the system, allow the engine warm up. cleaned brass contact ring around the sensor on the
127( All preliminary work, including the line for the first cylinder and then pull it over the
insertion and removal of the magnetic sensor, contact ring. Tighten the winged screw on the clip and
must be carried out with the engine switched make sure that the under side of the screw touches
OFF. Before starting the engine, make sure the the contact ring.
cables cannot come into contact with moving Connect the cable for the measuring transducer to the
parts or the hot exhaust manifold. "SR" socket on the TIME TRAC.
Connect the cable to a clean, bare part of the engine
2. Remove the protective plug from the opening by means of the alligator clip.
(8 mm diameter) on the left-hand side of the flywheel
4. Switch the TIME TRAC ON by pressing the ON/
casing and insert sensor A until it touches the face of
CLEAR button. "Time Trac" should appear on the
the flywheel. Then pull the sensor back a little
display, followed by "Model TT 1000". The text "R = 0"
(0.5 - 1.0 mm). This prevents the end of the sensor
then appears. The TIME TRAC can now be used as a
being damaged by making contact with the rotating
rev-counter without any further adjustments.
flywheel.
Connect the cable for the magnetic sensor element to
the "MP" socket on the TIME TRAC.

17
5. Press the MAG PROBE button. "Trig Level 30 %" 9. If the engine is running at, for example, 850 rpm
appears on the display. Press the ENTER button to and the timing is 6 ° BDC, "R = 850 MP +6.0" must
keep TRIG LEVEL at 30 %. now appear on the display. The TIME TRAC can now
be used.
6. "Offset 20.0" appears on the display. Press the
ENTER button to keep the offset at 20.0 %. 127( If the TIME TRAC does not recognise the
7. "Calibrate?" appears on the display. Start the signal from the magnetic sensor, "R = 850 no
engine and allow it to run at idling speed. Press the Probe" appears on the display. If the signal from
ENTER button; "R = ___ Set RPM" then appears on the magnetic sensor has been restored, the
the display. correct timing value will be displayed.
10. The delivery start must be measured at topidling
:$51,1*Before starting the engine, make sure
speed (TT HI). This value is valid for setting the
the cables do not touch moving parts.
delivery start. Make the necessary adjustments as
8. When the correct speed is displayed, press the required.
ENTER button. "Calibrating...?" appears briefly on the
The injection timing of the injection pump can be
display.
checked at idling speed (TT LO).
127( If the speed signal does not reach the
measuring instrument (line sensor) or the engine
is not running, the display flashes three times
and indicates: "Eng. Not running", whereupon
the unit reverts to the rev-counter mode. To start
the procedure anew, press MAG PROBE (return
to item 5).
TIME TRAC setting and check values

Tractor Engine Setting value Check value
Crank angle Top idling Crank angle Idling speed
Type Type just before speed rpm just before rpm
TDC TDC
±2
9105,CS110 420.85 10° 2500 ± 50 4° 850 ± 50
±2
9115,CS120 620.94 12° 2500 ± 50 6° 850 ± 50
±2
9125,CS130 620.92 13° 2500 ± 50 6° 850 ± 50
9145,CS150 620.93 18° 2500 ± 50 >10° 850 ± 50
Troubleshooting when using the TIME TRAC

•) If the timing deviates from the specified value by a large margin, check the following:
•) Vibrating injection line; hold the line with your hand.
•) The distance between the magnetic sensor and flywheel is incorrect. Re-adjust the magnetic sensor.
•) The "Offset" or "Trig Level" value is wrong. Re-adjust the unit.
•) Interfering scratches on the flywheel. Smoothen the surface of the flywheel (with the engine switched OFF).
•) Flywheel alignment incorrect: The contact surfaces on the crankshaft or on the flywheel are not even. Remove
the flywheel, check the parts concerned and fit them in the correct position. Repeat the test with the
TIME TRAC.
•) If the flywheel has been replaced, a mark must be made for the TIME TRAC check; refer to Chapter 8
"Flywheel" in the engine repair manual.

18
Fuel quality requirements Power % Fig.2
+5
Requirements
Density, +15 °C 0.82 - 0.86 kg/dm3
Viscosity, +40 °C 1.2 - 4.5 mm2/s
Sulphur content max. 2 g/kg 0
Cetane rating at least 45
Water content max. 200 mg/kg
Fuels used in diesel engines must be free of any

contamination or water (EN 590 standard). Use
winter fuel in good time before the cold period -5
0,84
starts.
0,80 0,85 0,90
Engine power in dependence on fuel properties DENSITY kg/dm3 SS99N023
The engine power output is influenced by various Engine power as a function of the fuel density. The
properties of the fuel. The specified nominal power reference value is 0.84 kg/dm3 at +15 °C.
values are based on fuel with a density of 0.84 kg/
dm3 and a calorific value of 42.7 MJ/kg at a fuel Power % Fig.3
temperature of +15 °C. +5
The following graphs show the percentage

deviation for varying fuel properties.
Power % Fig. 1
+5
0
-2
2 3 4 5 6 7 8
0 VISCOSITY mm2/s SS99N055
Engine power as a function of the fuel viscosity The

reference value is 3 mm2/s at +20 °C.
Bear in mind that the fuel quality only changes in
Figures 2 and 3.
-5 In Figure 1 all dependent properties are effected by
35
the change in temperature. The density and viscosity
10 20 30 40 50 60 of the fuel are specified in the producer's product
FUEL TEMPERATURE °C designation.
SS99N021
The power deviation can be determined as follows:
Engine power as a function of the fuel tempera- The percentage deviation in Fig's. 1, 2 and 3 must be
ture. The reference temperature is +35 °C (devia- added. The specified nominal power is corrected by
tion 0 %). the result.
The fuel temperature is not only dependent on the
ambient conditions but also on the construction of Bio-diesel fuel
the fuel system (capacity and position of the fuel Steyr-Sisu diesel engines can be run on RME fuel
tank, return flow, etc.). without requiring technical modifications. The
precondition for this is that the bio-diesel fuel used
meets the purity requirements specified in the
Austrian standard "Ö 1190".
Further particulars, about differences in service
intervals for example, can be found in the Operating
Instructions.

3001
Chapter
3001
Removing and Fitting the Fuel Injection Pump
9105 / 9115 / 9125 / 9145 up to vehicle No. 03294

CS110 / CS120 / CS130 / CS150 up to DBD0015192
Technical Documentation November, 2000
3001-2
TABLE OF CONTENTS
SPECIAL TOOLS .....................................................................................................................3

GENERAL INFORMATION ......................................................................................................4
TECHNICAL DATA ..................................................................................................................5
Bosch injection pump ........................................................................................................5
Oil fill quantity (when fitting injection pump) ......................................................................5
Pump type .........................................................................................................................5
Injection sequence ............................................................................................................5
Idling speed .......................................................................................................................5
Cut-out solenoid ................................................................................................................5
Starting-fuel solenoid Y16 (420.80 only) ...........................................................................5
Fuel pump .........................................................................................................................5
Stanadyne injection nozzles ..............................................................................................5
Thermo-start unit ...............................................................................................................5
Tightening torques ............................................................................................................5
Removal of the injection nozzle mounting .........................................................................6
Checking the injection nozzles ..........................................................................................6
INJECTION NOZZLE MOUNTING ..........................................................................................6
Overhauling the injection nozzles .....................................................................................7
Fitting the injection nozzle mounting into the cylinder head ..............................................7
Assembly of the injection lines ..........................................................................................7
Injection pump for motor types 620.82, 620.83, 620.84 ....................................................8
Injection pump for engine type 420.80 ..............................................................................8
INJECTION PUMP ...................................................................................................................8
Removal of the injection pump ........................................................................................11
Installation of the injection pump .....................................................................................11
A. Installation when gear wheels are fastened by means of spline and keyway ...........11
Checking start of delivery ..........................................................................................11
Readjustment of start of delivery ...............................................................................12
B. Installation when gear wheels are fastened without spline .......................................12
Bleeding the fuel system of air ...............................................................................................13
Thermo-start system .......................................................................................................14
Bleeding the thermo-start system of air ..........................................................................14
Measuring the fuel feed pressure ....................................................................................14
Checking the overflow valve ...........................................................................................14
Checking the fuel delivery pump .....................................................................................15
Replacing the fuel delivery pump valves .........................................................................15
Adjusting the minimum idling speed ................................................................................15
Fuel quality requirements ................................................................................................16
Bio-diesel fuel ..................................................................................................................16
3001-3
SPECIAL TOOLS
Extractor Mini-measuring connection
SS00B070 SS98J031
1 off 1TSW 662 1 off 1TSW 639 M8x1
Pressure gauge and connection Banjo bolt
SS00B076 SS00E063
1 off 1TSW 645 Connection 1 off 1TSW 667
1 off 1TSW 5002 Pressure gauge
Mini-measuring line Rising pipe
SS98J030 SS00K150
1 off 1TSW 635 1 off 1TSW 241

3001-4
GENERAL INFORMATION
This manual only contains general instructions for repairing and servicing the injection system. This applies to the
injection pump in particular, as specially trained personnel with special tools and measuring instruments are
required to repair it. All service and repair work on the injection system requires particular care and cleanliness.
SAFETY REGULATIONS
There is always a risk of getting injured •) Always switch the engine OFF before carrying out
when performing service and repair repair work.
work. Before commencing work,
•) Naked flames and smoking are not permitted in the
the following safety regulations
vicinity of fuel tanks or batteries. Electrical sparks
and instructions must be read.
should be avoided.
•) Never start repair work which you do not fully
•) Disconnect the cable at the negative battery pole (-)
understand.
before carrying out service or repair work on the
•) Make sure that it is possible to work safely at the electrical system.
location and in the vicinity. •) When checking the injection nozzles, never touch
•) Make sure the location is clean and in a good state. the fuel, which is ejected under high pressure. The
jet will penetrate the skin and cause serious
•) Never use wrong or unsuitable tools.
poisoning. If contact is made with the skin, consult
•) Remove all rings, chains and watches before a doctor without delay!
commencing work.
•) Fuel and lubrication oil can cause skin irritations if
•) Use state of the art safety equipment. For example, contact is made over a longer period.
wear goggles when using compressed air for
cleaning. •) Avoid running the engine in idle unnecessarily.
•) When carrying out service work, take measures to
•) Only use original Case-Steyr spare parts.
prevent fuel or other fluids from entering the ground
•) Only start the engine from the cab, using the or drains.
ignition key.
•) Be careful when washing the engine using a
•) Never start the engine with the protective covers washing facility with a high water pressure. Do not
removed. wash, for example, the electrical and fuel systems
•) It is difficult to see the radiator fan when the engine under high pressure as they can easily be
is running! Loose fitting clothes and long hair can damaged.
get caught in rotating engine parts! •) Never wash the area around the injection pump
•) If the engine is started in a confined space, when the engine is running.
sufficient ventilation must be provided.
•) Ear muffs must be worn when testing the engine or
working close to the engine.

3001-5
TECHNICAL DATA
Bosch injection pump
Direction of rotation ...................................................................................................................... Clockwise
Type of construction (general) ............................................................................................. Bosch A (PES)
Oil fill quantity (when fitting injection pump)

420 ......................................................................................................................................................... 0.4 l
620 ......................................................................................................................................................... 0.6 l
Pump type
Motor type 420.80 ........................................................................................... PES 4A 95D 320RS 2847/G
Motor type 620.84 ......................................................................................... PSE 6A 95D 320RS 2806/EU
Motor type 620.82 .......................................................................................... PSE 6A 95D 320RS 2806/ET
Motor type 620.83 ......................................................................................... PSE 6A 95D 320RS 2806/EM
Injection sequence
420 .............................................................................................................................................. 1 - 2 - 4 - 3
620 ................................................................................................................................... 1 - 5 - 3 - 6 - 2 - 4
Idling speed
420 ............................................................................................................................................. 750 rpm±50
620 ............................................................................................................................................. 750 rpm±50
Cut-out solenoid
Resistance of pull-in coil .......................................................................................................... 0.25 Ω ± 10%
Resistance of holding coil ........................................................................................................... 11 Ω ± 10%
Starting-fuel solenoid Y16 (420.80 only)

Resistance ................................................................................................................................. 2.2 Ω ± 10%
Fuel pump
Type .................................................................................................................. Bosch FP/ KEG 24 AD 504
Type of construction .................................................................. Reciprocating pump, separate hand pump
Fuel pressure (opening pressure for the overflow valve) ........................................................ 0.7 to 1.2 bar
Fuel feed pressure (without overflow valve) ..................................................................................... 2.7 bar
Stanadyne injection nozzles

Type ...................................................................................................................... Five-hole nozzle (S type)
Opening pressure ............................................................................................................................ 230 bar
Pressure setting ............................................................................................................................... 240 bar
Graduation of the adjusting disks ................................................................................................... 0.05 mm
Change in opening pressure per graduation ................................................................................... 5.00 bar
Adjusting disks (refer to spare parts catalogue) ................................................................. 1.00 to 1.90 mm
Thermo-start unit
Heating element res. ..................................................................................................................... 1 Ω ± 10 %
Tightening torques
Pump gear wheel nut ......................................................................................................................... 90 Nm
Injection nozzle union nut .................................................................................................................. 60 Nm
Injection nozzle bracket ..................................................................................................................... 15 Nm
Injection line union nut ....................................................................................................................... 25 Nm

3001-6
INJECTION NOZZLE MOUNTING
– opening pressure of the injection nozzle
1 – buzzing sound and spraying pattern
– tightness of the nozzle needle against its
seating surface
2
1. Fuel inlet
2. Leakage oil
connection
3. Pressure adjusting
disk
3
4. Pressure spring
5. Thrust bolt 4
6. Nozzle body
7. Pressure chamber 5
8. Nozzle needle 6
9. Spray orifice 7 SS99N147
8 Opening pressure
SS99N149
To fill the injection nozzle mounting, pump the system
9 a few times. Increase the pressure in the injection
The injection nozzles are equipped with a five-hole nozzle mounting until the buzzing is audible. Check
nozzle. The small amount of leakage fuel used to the opening pressure. If the opening pressure
lubricate the needle is returned to the fuel tank via deviates from the specified value, the injection nozzle
the leakage oil line. mounting must be dismantled to adjust the opening
pressure.
Removal of the injection nozzle Adjustment is made by means of different pressure
mounting adjusting disks. The thickness of the adjusting disks
varies between 1.00 and 1.90 mm and they are
1. Clean the injection nozzle mounting and the available in graduations of 0.05 mm. A thicker
surrounding area. Disconnect the pressure lines and adjusting disk increases the opening pressure, a
the leakage oil line. thinner one reduces the opening pressure. Changing
2. Unscrew the nuts on the injection nozzle bracket the thickness of the disk by 0.05 mm changes the
and remove the injection nozzle mounting, with the opening pressure by approx. 5.0 bar. Because the
bracket, from the cylinder head. Seal off all opening pressure of the injection nozzle drops
connecting points by fitting protective caps. slightly after being adjusted, it should be set approx.
10 bar higher than the value specified in the technical
3. Remove the sealing washers from the injection
data. This value applies to both new and used
nozzle mounting seating in the cylinder head, if they
injection nozzles.
have not already been taken out with the injection
nozzle mounting. Buzzing properties
Testing by means of the hand pump does not fully
Checking the injection nozzles correspond to the conditions that the injection nozzle
IMPORTANT: When checking the injection nozzles is subject to in the engine. The test results are only
on the test stand, it is not permitted to remain in the reliable for new nozzles. Used nozzles do not buzz at
vicinity of the nozzle outlet (e.g. with one’s hands). certain pump speeds, which is due to the design of
The fuel jet, which is ejected at high pressure, can the nozzles.
easily penetrate the skin and cause serious injuries. When pumping quickly however the buzz is audible
Inhaling atomised fuel is detrimental to health. and/or a fine jet of atomised fuel is visible. The jet is
thicker and less defined in the buzz-free zone.
1. Clean the injection nozzle using cleaning fluid and
a soft brush. The carbon deposits must not be Tightness of the nozzle needle
knocked off or removed in such a way that the nozzle Press the test pump lever slowly, until the pressure
can be damaged. increases to approx. 20 bar below the set value.
2. Mount the injection nozzle mounting on the test Maintain this pressure for approx. 10 seconds. If no
stand and check the following points: drops of fuel form at the tip of the nozzle, the nozzle
seals correctly. Otherwise, dismantle the nozzle and
clean the seating or replace the nozzle.

3001-7
Overhauling the injection nozzles

1. Mount the injection nozzle mounting in such a way
that it will not be damaged.
2. Unscrew the nozzle mounting clamping nut.
Remove the nozzle and the parts in the mounting.
3. Clean the nozzle, both inside and outside, in
cleaning fluid. 1
4. Steep blocked spray orifices in cleaning fluid or 2
clean them using a cleaning needle.
5. Check the movement of the nozzle needle as
follows: 1. Sealing washer
2. Rubber ring
3. Sealing ring
3
SS99N150
2. Fit the injection nozzle mounting in its place in the

cylinder head. Use a new sealing ring.
IMPORTANT: The spraying directions of the injection

nozzle are not symmetrical. It is therefore important
SS99N148 that the injection nozzle mounting is fitted into the
cylinder head correctly. The leakage oil line points
Rinse the parts out with fuel or test fluid. Pull the towards the side of the valve cover.
nozzle needle out off the nozzle body by one third of
the slide face length. The nozzle needle must be able 3. Fit the bracket and tighten the nuts evenly to a
to slide into the valve seat under its own weight. Turn torque of 15 Nm.
the nozzle needle a little and repeat the test. The 4. Connect the leakage oil line and the injection
nozzle needle must not stick in any position. If it lines.
does, rinse the parts and repeat the test. If the
needle sticks again, the nozzle must be replaced. WARNING: Always make sure the correct type of
6. Before assembly, all parts must be carefully injection nozzle is used. Incorrect injection nozzles
cleaned in clean fuel or test fluid. impair engine operation and can cause engine
damage.
7. Insert the adjusting disk in the nozzle holder. Bear
in mind that the opening pressure may require
adjustment. Assemble the injection nozzle mounting,
Assembly of the injection lines
making sure the thrust bolt and intermediate disk are 1. Check the state of the lines before fitting them. If
in the correct position. the lines show signs of kinking, breakage or
8. Tighten the nozzle mounting tensioning nut by abrasion, or the sealing olive is damaged, replace
hand and then to a torque of 60 Nm. the line with a new one.
2. When connecting the line, make sure that the
Fitting the injection nozzle mounting into union nut is not cross threaded. If this is not the case,
the cylinder head the olive will be damaged.
Tighten the union nut for the line to a torque
1. Clean the injection nozzle mounting seating in the
of 25 Nm.
cylinder head. If necessary, correct the surface using
a reamer. 3. Secure the injection line holders.

3001-8
INJECTION PUMP
Injection pump for motor types 620.82, 620.83, 620.84
9
2
6a
1. Oil filler
2. Throttle lever
3. Hand pump
SS00K111 4. Injection pumps
Lubricating oil feed
5. ’O’ ring seal
6a. Lubricating oil return
3 line to engine
4 6b. Lubricating oil return
via timing gear case
7. Driving gear wheel
7 8. Cut-out solenoid
6b 5 9. Rating plate
The Bosch in-line injection pumps for engine types 420 and 620 are of the same basic construction. The
injection pump is mounted on the timing gear case by means of a flange connection. The pump is driven by the
crankshaft intermediate gear wheel and the drive gear wheel on the pump. The injection pump is connected to
the engine’s pressure lubrication system via a separate line. Lubricating oil returns to the engine via the front
part of the pump (6b) to the timing gear case via the return line (6a).
The fuel delivery pressure is provided by a reciprocating pump mounted on the side of the injection pump. This
is driven by means of an eccentric disk on the injection pump camshaft. The fuel flow capacity of the delivery
pump is considerably more than that required by the injection pump. The excess fuel is returned to the fuel tank
via the overflow valve. This serves to cool the injection pump and to bleed the fuel system of air.
1 2
Injection pump for engine type 420.80
The 4 cylinder engines have an additional LDA

(boost-pressure dependent full-load stop) in order
to adapt the injection capacity to the
supercharging pressure.
For cold starting, the 4 cylinder engines are
additionally fitted with a starting-fuel solenoid. This
is energised from terminal 50 on the starter in
order to increase the fuel flow for cold starting.
SS00K112
1. LDA
2. Starting-fuel solenoid (Y16)

3001-9
Two-port pump element

(shown here at full capacity)
1
2 2 3 4 5 6
3 1
5
7
6
A B C
SS00K114
7
A. Bottom dead centre 1. Inlet hole
2. Pump cylinder
B. Start of delivery
3. Start groove
SS00K113 C. End of delivery 4. Control hole
5. Pump piston
6. Control edge
7. Longitudinal groove
1. Pressure valve 4. Regulating rod
mounting The pump element comprises the pump piston and
5. Piston spring the pump cylinder are matched to thousandth of a
2. Pressure valve millimetre. Because of this tolerance the element
6. Roller tappet
3. Pump element must always be replaced as a complete unit. The
7. Camshaft pump cylinder has an inlet hole and a control hole.
The fuel flows through the inlet hole into the high-
The injection pump is designed to deliver the correct pressure chamber. As soon as the control edge on
fuel flow rate to the various cylinders at the the piston clears the control hole the effective
appropriate time. The pump piston is operated by the displacement is completed and the fuel flows out via
roller tappet driven by the pump camshaft and the longitudinal groove and the control edge. The
pushes the fuel through the injection line and into the delivery rate is determined by the position of the
injection nozzle mounting. control edge.
A start groove located on the piston face retards start
of delivery by 8°. (this must be taken into account
when checking start of delivery). This improves cold-
start characteristics of the engine. This function is
fully automatic. After stopping the engine the
regulating rod turns the start groove of the element in
front of the control hole. When the engine is started
and reaches a specified speed, the controller pulls
the regulating rod back into the operating position.

3001-10
Pressure valve mounting and pressure Controller

valve The controller consists of a centrifugal governor
seated on the rear end of the injection pump. The
1 controller regulates the engine speed over its entire
range and detects the speed according to the
position of the centrifugal weights. The desired
speed, determined at the speed adjusting lever
(throttle lever) and the position of the centrifugal
2 weights are transmitted to the regulating rod via the
control linkage. The control characteristic is, in this
5 respect, partially determined by the control spring.
The starting lever, suspended from the upper end of
3
6 the control lever, pulls the control rod into the starting
position, automatically setting the starting flow rate
4 when the engine is stopped.
7 SS00K115 4
3 5
1. Pressure valve 4. Valve bearer

mounting
5. Valve seat
2. Pressure valve spring 7
6. Relief piston
3. Pressure valve
2
7. Longitudinal groove
6
The pressure valve above the pump piston is
designed to close the connection to the injection line
as soon as the control edge clears the control hole 1
and the delivery pressure falls. It’s secondary task is
to lower the pressure in the injection line. This
necessary in order to ensure quick closing of the
nozzle needle. SS00K116 8
9
A relief piston is located under the pressure valve
seat, which relieves the line flow rate during valve
closure, before the valve fully closes the connection. 1. Centrifugal weight 7. Idling auxiliary
The fuel flow rate in the injection line is therefore 2. Control rod spring
increased by the volume of the relief piston and the 3. Starting spring 8. Torque-control
pressure is reduced correspondingly. 4. Adjusting lever spring
5. Idling stop 9. Control lever
6. Governor spring

3001-11
Removal of the injection pump A. Installation when gear wheels are
1. Carefully clean the injection pump and the fastened by means of spline and
surrounding components. keyway
2. Disconnect the injection line, the delivery and
return lines and the lubricating oil lines. Fit protective
caps on all disconnected line connections.
Disconnect the electrical connections from the cut-
out solenoid and the starting fuel solenoid (420.80
only).
WARNING: Before removing the pump, disconnect

the connection to the battery or switch the main
battery switch OFF (if fitted) in order to prevent
inadvertent starting. Once the pump has been
removed, the loose gearwheel can damage the
timing gears or the housing when trying to start. SS00K146
3. Remove the cover on the timing case so that the
pump drive gear wheel is accessible.
1. Before installing the injection pump fit a new
’O’ ring.
2. Grease the ’O’ ring and fit it in the injection pump
such that the spline on the shaft fits into the keyway
in the gear wheel. Tighten the injection pump fixing
nuts. Then tighten the gear wheel nut to a torque
of 90 Nm.
3. Remove the protective caps from the connections
and reconnect the injection lines, delivery and return
lines and the lubricating oil lines.
4. Bleed the injection pump of air.
1TSW 662 Checking start of delivery

The marking for start of delivery to cylinder 1 is on
SS00E046 the front of the crankshaft belt pulley.
4. Unscrew the securing nut on the gear wheel.

Remove the gear wheel from the injection pump
using the 1TSW extractor.
5. Unscrew the injection pump fixing nuts.
If the engine control is not being removed, the pump
drive wheel remains in contact with the intermediate
wheel. The timing gears do not have to be specially
marked.
Disconnect the injection pump from the timing gear
case. Clean the sealing surfaces.
Installation of the injection pump

NOTE: There are two different designs for fastening SS00E039
the gear wheels to the pump, and therefore two
varying installation procedures. NOTE: In order to check start of delivery, or to adjust
A. Installation when gear wheels are fastened by the injection pump, the cut-out solenoid must be
means of spline and keyway removed. If not the check, or adjustment, will be
B. Installation when gear wheels are fastened incorrect.
without spline
(the design excluding spline is recognisable by the
locking bolt mounting; see item X on the following
page).

3001-12
5. Disconnect the injection lines and fit the rising pipe 5. If the injection pump has been renewed, or the
1TSW 241 onto the connection to cylinder 1. lubricating oil drained from the pump, refill the pump
with lubricating oil before starting the engine. Open
1TSW 241 the screw cap on the governor housing using an
Allen key and refill with oil.
SS00K147 SS00K126
NOTE: The specified oil is the same as for the

1. Turn the crankshaft slowly in the normal direction engine.
until cylinder 1 is in its compression stroke.
B. Installation when gear wheels are
2. Turn the crankshaft slowly further in the normal fastened without spline
direction until the fuel in the rising pipe moves but
does not rise. If the injection markings on the
crankshaft belt pulley and the indicator are now X
aligned then the start of delivery is correct. If not the
start of delivery must be readjusted.
Readjustment of start of delivery

1. Unscrew the injection pump fixing nuts and
disconnect the injection lines.
SS00K148
A
Start of delivery to cylinder 1 can be positioned
through an opening in the governor housing by
means of a locking bolt. Install the injection pump as
follows:
1. Turn the crankshaft such that the cylinder 1 piston
SS00K124
is at top dead centre in its compression stroke. Then
turn the crankshaft backwards from its normal
direction until the start of delivery marking on the belt
pulley passes the indicator plate. Then turn the
R crankshaft slowly in its normal direction until the
marking coincides with the indicator plate.
2. Unscrew the plug from the side of the governor
2. If the start of delivery was retarded on checking,
housing. Remove the locking bolt.
turn the injection pump anticlockwise in direction "A".
(injection pump viewed from front). If the start of
delivery was advanced, turn the injection pump
clockwise in direction "R".
3. Re-check the start of delivery and if necessary
turn the injection pump again.
4. When the start of delivery is correct, tighten the
pump fixing nuts and reconnect the injection lines.

3001-13
Bleeding the fuel system of air
1
2
SS00K125
3. Turn the pump shaft until the signal marking is

visible in the middle of the opening. Push the locking
bolt (1) into the opening with the groove at the front
so that it engages with the signal mark. Hand tighten
the nut (2). SS00K117
4. Install the injection pump and tighten the fixing

nuts. 1. Undo the air bleed screw on the filter cover.
WARNING: When the locking bolt is engaged in the Operate the hand pump until the fuel emerging at the
pump, with the groove at the front, do not turn the air bleed screw is free of air bubbles. Now re-tighten
crankshaft, as the end of the bolt can be easily the air bleed screw.
damaged and pieces of the bolt may fall into the
governor housing.
5. When the adjustment is correct, turn the bolt
round, so that the groove faces outward (operating
position) and press the bolt into the opening. Screw
the plug back in.
3. Tighten the nut on the injection pump gear wheel
to a torque of 90 Nm and screw the cover back onto
the timing gear case.
NOTE: It is not necessary to check this adjustment
using the rising pipe.
4. Remove the protective caps from the connections
and reconnect the injection lines, delivery and return
lines and the lubricating oil lines.
5. If the injection pump has been replaced, or the SS00K118
lubricating oil drained from the pump, refill the pump
with lubricating oil before starting the engine. Open 2. Undo the return line banjo bolt.
the screw cap on the governor housing, using an
3. Unscrew the injection pump overflow valve.
Allen key, and refill with oil.
Operate the hand pump until the fuel emerging is
free of air bubbles. Re-tighten the overflow valve and
the banjo bolt.
4. Clean the discharged fuel from the engine.
SS00K126
NOTE: The specified oil is the same as for the

engine.

3001-14
Thermo-start system Measuring the fuel feed pressure

To facilitate starting at low temperatures, the system 1. Clean the injection pump and the filter, as well as
is equipped with a thermo-start unit. A separate tank the interconnecting lines.
is filled via the nozzle leakage oil line whilst the
engine is running. If pre-glowing is necessary before
starting for the first time, the tank must be filled
manually, as otherwise the heating coil for the
thermo-start unit could get damaged during the
process. In addition, the pre-glowing process would
be ineffective as no fuel would be burnt and no intake
air heated up.
Bleeding the thermo-start system of air SS00K119
4
2. Connect the manometer 1TSW 5002 to the banjo
bolt connection on the pump. To do so, use the
1TSW 667 banjo bolt, the 1TSW 639 mini-measuring
connection and the 1TSW 635 mini-measuring line.
3. Run the engine at low idling speed for a period of
time and compare the measured value with the
specified value (0.6...1.0 bar).
If the measured value is below the specified value,
SS99N047
the cause may be as follows:
– defective overflow valve
1 2 3 – blocked fuel filter

– defective fuel delivery pump
1. Tank filling line
– blocked or leaking fuel lines
2. To the thermo-start unit
3. Return line to the tank
4. Vent
Checking the overflow valve
If the fuel delivery pressure does not comply with the
If the thermo-start line or the tank has been emptied specified value, then the overflow valve openeing
for repairs, the line must be bled of air. pressure should be checked.
Fill the tank with pure fuel, e.g. through the vent. 1.Connect the manometer 1TSW 5002 to the banjo
bolt connection on the pump as shown in the above
Open the fuel line to the thermo-start unit and let fuel
diagram.
escape. Tighten the line.
2. Operate the hand pump until the overflow valve
opens. Compare the indicated value on the
manometer at the moment the valve opens with the
specified value (0.6...1.0 bar).
3. If the recorded opening pressure deviates from the
specified value then the overflow valve must be
replaced.
NOTE: If the recorded pressure is clearly below the
specified value, then this could be due to defective
hand pump or fuel delivery pump valves.

3001-15
Checking the fuel delivery pump 4. Rinse the valves in clean fuel and check for proper
operation and possible wear.
5. If necessary replace the valve and reassemble the
pump using new ’O’ rings and seal.
Adjusting the minimum idling speed

B If the engine idling speed deviates from the value
specified in the technical data, or if the engine’s idling
speed is erratic, then the idling speed should be
adjusted as follows:
SS00K149
A 1
1. Connect the manometer 1TSW 5002 to the banjo

bolt connection (A) on the pump. To do so, use the
banjo bolt 1TSW 667, the min-measuring connection
1TSW 639 and the mini-measuring line 1TSW 635.
2
Replace the banjo bolt (B) with an M14x1.25 bolt in
order to blank off the fuel return line.
2. Start the engine The fuel delivery pressure should
now be 2.7 bar. If not then either the springs or the
fuel delivery pump valves are defective.
SS00K127
Replacing the fuel delivery pump valves
1. Clean the fuel delivery pump. Disconnect the fuel 1. Remove the cap from the idling stop (1) and the
lines to the delivery pump. Remove the delivery cap on the idling auxiliary spring adjusting screw (2).
pump. 2. Make sure that the throttle lever is in the idling
position and that the engine is at normal operating
temperature.
3. Start the engine and turn open the idling auxiliary
spring adjusting screw until it no longer affects the
idling speed.
4. Use the idling stop screw to adjust the idling speed
to approx. 20...30 1/min below the nominal value and
then secure the screw.
5. Rev the engine a few times and check that the set
idling speed is maintained.
6. Screw in the idling auxiliary spring adjusting screw
until the idling speed increases to its nominal value.
Secure the adjusting screw in this position.
7. Replace the protective caps and screw them tight.
SS00K120
2. Clamp the pump in a soft jawed vice. Undo the

push-rod body from the pump and remove the piston,
sealing rings and suction valve and the spring.
3. Remove the threaded connection piece, in which
the pressure valve (A) is located, from the discharge
side of the pump housing.

3001-16
Fuel quality requirements Power % Fig.2

+5
Requirements
Density, +15 °C 0.82 - 0.86 kg/dm3
Viscosity, +40 °C 1.2 - 4.5 mm2/s
Sulphur content max. 2 g/kg
0
Cetane rating at least 45
Water content max. 200 mg/kg
Fuels used in diesel engines must be free of any

contamination or water (EN 590 standard). Use
winter fuel in good time before the cold period starts. -5
0,84
Engine power in dependence on
0,80 0,85 0,90
fuel properties
DENSITY kg/dm3 SS99N023
The engine power output is influenced by various
properties of the fuel. The specified nominal power Engine power as a function of the fuel density. The
values are based on fuel with a density of reference value is 0.84 kg/dm3 at +15 °C.
0.84 kg/dm3 and a calorific value of 42.7 MJ/kg at a Power % Fig.3
fuel temperature of +15 °C. +5
The following graphs show the percentage deviation
for varying fuel properties.
Power % Fig.1
+5
0
-2
2 3 4 5 6 7 8
0 VISCOSITY mm2/s SS99N055
Engine power as a function of the fuel viscosity The

reference value is 3 mm2/s at +20 °C.
Bear in mind that the fuel quality only changes in
Figures. 2 and 3.
-5
35
In Figure1 all dependent properties are effected by
10 20 30 40 50 60 the change in temperature. The density and viscosity
FUEL TEMPERATURE °C of the fuel are specified in the producer's product
SS99N021 designation.
Engine power as a function of the fuel The power deviation can be determined as follows:
temperature. The reference temperature is +35 °C The percentage deviation in Fig's. 1, 2 and 3 must be
(deviation 0%). added. The specified nominal power is corrected by
the result.
The fuel temperature is not only dependent on the
ambient conditions but also on the construction of the
Bio-diesel fuel
fuel system (capacity and position of the fuel tank,
return flow, etc.). Steyr-Sisu diesel engines can be run on RME fuel
without requiring technical modifications. The
precondition for this is that the bio-diesel fuel used
meets the purity requirements specified in the
Austrian standard "C 1190". Further particulars,
about differences in service intervals for example,
can be found in the Operating Instructions.

Chapter
4
4
FUNCTIONAL DESCRIPTION AND

TROUBLESHOOTING
Combination instrument
9105, 9115, 9125, 9145

CS100, CS110, CS120, CS130, CS150
Technische Dokumentation/Training Center September, 2001
A-4300 St. Valentin, Steyrer Straße 32
4-2
TABLE OF CONTENTS
SPECIAL TOOLS..................................................................................................................... 3
Combination instrument ...........................................................................................................4
Plug and Terminal Arrangement ...........................................................................................6
TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM ................................................. 7
Connector X9/1 up to vehicle no. 02584 / DBD0013874 .......................................................8
Connector X9/1 from vehicle no. 02585 / DBD0013875 .......................................................9
Connector X9/2 ...................................................................................................................10
Connector X9/3 up to vehicle no. 02584 / DBD0013874 .....................................................11
Connector X9/3 from vehicle no. 02585 / DBD0013875 .....................................................12
TEST VALUES....................................................................................................................... 23
1. Frequencies of speed signal – rear PTO shaft: ...............................................................23
2. Frequencies of the standardised speed signal – rear PTO shaft: ...................................23
3. Frequencies of the speed signal – front PTO shaft: ........................................................23
4. Frequencies of the signal – engine speed indicator: .......................................................23
5. Fuel gauge: .....................................................................................................................23
6. Engine temperature gauge: .............................................................................................24
7. Coolant temperature switch S32: ....................................................................................24
8. Compressed air indicator: ...............................................................................................24
OPERATING AND CODING OF THE DIGITAL INSTRUMENT WITH INTEGRATED
OPERATING HOURS COUNTER ......................................................................................... 25
CALIBRATING THE DRIVING SPEED.................................................................................. 26

4-3
SPECIAL TOOLS
Diagnostics Box "Y" - Adapter
SD01B015
1 off 1TSW 528-1 SD01B019
1 off 1TSW 528-35 (front panel template) 1 off 1TSW 528-34
3 pole "Y" adapter

Multimeter
SD01H014
1 off 1TSW 528-54
SD99M014 "Y" - Adapter (Molex)

1 off 1TSW 516-1
Measurement cables
SD99M013
1 off 1TSW 528-11
SD01H013
1 off 1TSW 528-84
Test lamp
3 pole "Y" adapter
SD01B018
1 off 1TSW 528-2
SD01B016
1 off 1TSW 528-44

4-4
Combination instrument
Sva 7-97221 EN
2.1 4.1
2.2 2 9 5 4.2
3 5 7 1 10 12 14 6 3 5 7
4 6 19 11 13 15 6 8
1 1
3 16 4 17 7 18 8 2
A B C
Edition 09/01
SS01H021
Display Unit A Display Unit B Display Unit C
1. Analogue engine speed display Centralised warning system, 1. Digital driving speed indicator
comprising items.1 to 9
2.1 /L1 Indicator lamp, power-shift 2. Digital display, switchable for
(STEYR – up to vehicle no. 02584) 1. /L20 Indicator lamp, battery charging rear PTO shaft, front PTO shaft
Sva 7-97221 EN
(CASE STEYR – up to vehicle no. DBD0013874) 2. /L21 Indicator lamp, engine oil pressure and operating hours
2.2 /L1 Indicator lamp (only CC-LS hydraulics) 3. /L25 Indicator lamp, engine coolant temperature 3. /L14 Indicator lamp, rear / front differential
Input pressure after the pressure filter (STEYR – up to vehicle no. 02584)
4. /L26 Indicator lamp, engine coolant level
(STEYR – from vehicle no. 02585) (CASE STEYR – up to
(CASE STEYR – from vehicle no. DBD0013875) 5. /L23 Indicator lamp, compressed air vehicle no. DBD00138754)
3. /L2 Indicator lamp, main beam headlights 6. /L24 Indicator lamp, parking brake /L14 Indicator lamp, rear / front differential locks
7. /L27 Indicator lamp, transmission lubrication (STEYR – from vehicle no. 02585)
4. /L3 Indicator lamp, lighting
(STEYR – up to vehicle no. 02584) (CASE STEYR – from vehicle no. DBD0013875)
5. /L4 Indicator lamp, trafficators (CASE STEYR – up to vehicle no. DBD0013874)
6. /L5 Indicator lamp, trafficators, 1st trailer 7. /L27 Indicator lamp, transmission lubrication 4.1 /L15 Indicator lamp, front differential lock
7. /L6 Indicator lamp, trafficators, 2nd trailer and main clutch – overspeed (STEYR – up to vehicle no. 02584)
(STEYR – from vehicle no. 02585) (CASE STEYR – up to
(CASE STEYR – from vehicle no. DBD0013875) vehicle no. DBD00138754)
8. /L28 Indicator lamp, stationary operation 4.2 /L15 Indicator lamp, front axle suspension
9. /L29 Indicator lamp, stop (STEYR – from vehicle no. 02585)
/L22 Indicator lamp, stop (CASE STEYR – from vehicle no. DBD0013875)
10. /L8 Indicator lamp, searchlight 5. Indicator lamp, PTO shaft 540
depending upon version 6. Indicator lamp, PTO shaft 750
11. /L9 Indicator lamp, pre-glowing 7. Indicator lamp, PTO shaft 1000
12. /L10 Indicator lamp, air filter 8. Indicator lamp, PTO shaft 1400
maintenance indicator
13. /L11 Indicator lamp, tank reserve
14. /L12 Indicator lamp, fuel filter heating
15. /L13 Indicator lamp, 4-wheel drive
16. Analogue fuel tank contents gauge
17. Analogue compressed air gauge
18. Analogue coolant
temperature gauge
19. /L7 Indicator lamp, PTO shaft clutch
Edition 09/01
4-5
4-6
Plug and Terminal Arrangement
Sva 7-97221 EN
+15 +15 58
+15 58
"W" X9/1
D+ D+
1 2 3 58
4 58
58 9
X9/5 58D
X9/4 X9/2 "W"
Potential 58
X9/3
X9/6 D+
+15
Edition 09/01
SS01B243
4-7
TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM
To quickly find errors such as e.g.:

display failure or inaccurate displays on the
combination instrument
Using the diagnostic system and the table listed you can
quickly and surely locate the error.
127( The operating limits (tractors with or without Power Shuttle) listed in the following table, must be strictly
observed!
Test conditions:
Start button switched off
Start button switched on

(in position 1)
Engine must be running
X.. Plug
Pin Pin on specified plug
Plug is connected
Plug is not connected
Connect a bulb of the specified

wattage as a load
Procedure if the tachometer is faulty:

a Check the power supply to the display unit A (tachometer) and the signal from terminal "W" of the
alternator (see pages 6, 8 and 9).
b If the display reading still deviates too much, this can be adjusted, using the alignment
potentionmeter.
c Remove the 4 screws and lift unit A (see pages 4 and 6) out of its enclosure.
d Connect a 12 V DC supply to unit A and connect a tachometer signal.
e Start the motor and set it to a constant speed (1000 or 2000 rpm-1), with the aid of an
external tachometer. Make sure that the battery charging indicator lamp has gone out.
f Turn the alignment potentiometer, until display unit A and the external tachometer give the same reading.
Compare the readings at various, different engine speeds.
Setting the speed sensor B8 (front PTO shaft)

The distance between the sensor and the transmitter wheel must be 1 to 1.5 mm.
Adjustment procedure:
a Check the ease of movement of the thread and fit the lock nut.
b Use Loctite 243 to seal the thread.
c With the engine at a standstill, screw the sensor in, to the limit. Subsequently turn the sensor back by
1 revolution (the pitch of the thread is 1.5 mm).
d Hold the sensor in this position and tighten the lock nut to 25 Nm.

4-8
Connector X9/1 up to vehicle no. 02584 / DBD0013874
Cable Measure
Measure-
Sva 7-97221 EN
Designation Pin colour Requirements X9/1 from X9/4 Value
ment
and No. pin to pin
L1 indicator lamp, green
"forward" or "reverse"
Pre-select 1 H111 U 1 7 13 - 14 VDC
pre-selected
forward – reverse

"forward" or "reverse"
Pre-select 2 B112 U 2 7 0 - 0.5 VDC
pre-selected
forward – reverse
L2 indicator lamp, main

3 E113 U Main beam "ON" 3 7 12 - 14 VDC
beam blue
Potential 58 for L3, L100,

4 E114 U Light "ON" 4 7 12 - 14 VDC
L101, L201, L202, L203
Potential 58 to IC dimmer 5 E115 U Light "ON" 5 7 12 - 14 VDC

6 C116 U left and right flashing 6 7 12 - 14 VDC
tractor trafficator

7 C117 U 1. Trailer hooked up 7 7 12 - 14 VDC
trafficator – 1st trailer

8 C118 U 1. and 2nd trailer hooked up 8 7 12 - 14 VDC
Trafficator – 2nd trailer
approx. 7 VDC
Engine speed signal from "Extinguish" load check
terminal "W" – alternator
9 F119 U lamp L20
9 7
approx. 7.5 VAC
Engine speed signal from Engine speed

9 F119 f 9 7 254 Hz
terminal W – alternator n = 1000 min-1
Edition 09/01
Connector X9/1 from vehicle no. 02585 / DBD0013875
Cable Measure
Sva 7-97221 EN
Measure-
ment
and No. pin to pin
L1 Indicator lamp, orange
(only CC-LS hydraulics) Input pressure > 1 bar
1 H111 U 1 7 13 - 14 VDC
Input pressure after the Input pressure < 1 bar
pressure filter
L1 Indicator lamp, orange

(only CC-LS hydraulics) Input pressure > 1 bar 13 - 14 VDC
Input pressure after the
2 B112 U Input pressure < 1 bar
2 7 0 - 0.5 VDC
pressure filter
L2 indicator lamp,
3 E113 U Main beam "ON" 3 7 12 - 14 VDC
main beam blue
Potential 58 for L3, L100,

4 E114 U Light "ON" 4 7 12 - 14 VDC
L101, L201, L202, L203
Potential 58 to IC dimmer 5 E115 U Light "ON" 5 7 12 - 14 VDC

6 C116 U left and right flashing 6 7 12 - 14 VDC
tractor trafficator

7 C117 U 1. Trailer hooked up 7 7 12 - 14 VDC
trafficator – 1st trailer

8 C118 U 1. and 2nd trailer hooked up 8 7 12 - 14 VDC
Trafficator – 2nd trailer
approx. 7 VDC
Signal engine speed from "Extinguish" load check
alternator pin W
9 F119 U lamp L20
9 7
approx. 7.5 VAC
Signal engine speed from Engine speed

9 F119 f 9 7 254 Hz
alternator pin W n = 1000 min-1
Edition 09/01
4-9
4-10
Connector X9/2
Sva 7-97221 EN
Cable
Measure- Measure from
Designation Pin colour Requirements X9/2 X9/4 Value
ment pin to pin
and No.
L7 indicator lamp, orange PTO shaft "ON" 12 - 14 VDC
PTO shaft, rear 1 C121 U 1 7
or (and) front PTO shaft "OFF" approx. 0 VDC
L8 indicator lamp, orange

Light "on" and
Searchlight 2 E122 U 2 7 12 - 14 VDC
searchlight "on"
according to each variant
L9 indicator lamp, orange Pre-glowing

3 C123 U 3 7 approx. 12 VDC
Thermostat pushbutton pressed
Air filter "OK" approx. 12 VDC

air filter (maintenance)
4 B124 U 4 7
Air filter "NOT OK" 0 - 0.3 VDC
Fuel temperature > 5 °C approx. 12 VDC

Fuel pre-warming
5 B125 U 5 7
Fuel temperature < 5 °C 0.5 - 1 VDC
4-wheel drive "OFF" approx. 12 VDC

4-WD
6 B126 U 6 7
4-wheel drive "ON" 0 - 0.3 VDC
Load check lamp lights up

L20 indicator lamp, red approx. 1.5 VDC
Load check of 7 K127 U 7 7
Load check lamp does not
alternator D+ 13 - 14 VDC
light up
Indicator lamp lights up

0 - 0.3 VDC
L21 indicator lamp, red
Engine oil pressure
8 B128 U Indicator lamp does not light
8 7
12 - 14 VDC
up
L23 indicator lamp, red Pressure < 5.5 bar 0 - 0.3 VDC
Compressed Air (supply)
9 B129 U Pressure > 5.5 bar
9 7 12 - 14 VDC
Edition 09/01
Cable Measure
Measure-
ment
and No. pin to pin
Sva 7-97221 EN
L24 indicator lamp, red Handbrake applied 0 - 0.3 VDC
Handbrake
1 B131 U 1 7 12 - 14 VDC
Handbrake open
L25 indicator lamp, red < 106 °C 12 - 14 VDC
2 B132 U 2 7
Engine temperature > 106 °ϑ > 106 °C 0 - 0.3 VDC
L26 indicator lamp, red > min. 13 - 14 VDC

Coolant level
3 B133 U < min.
3 7 0 - 0.3 VDC
L27 indicator lamp, red p < 15 bar 0 - 0.5 VDC

Gearbox lubrication
4 B134 U 4 7 approx. 12 VDC
p > 15 bar
L28 indicator lamp, red enabled 0 - 0.3 VDC

stationary operation
5 B135 U 5 7 12 - 14 VDC
not enabled
Signal line for fuel contents see test values

gauge (M100)
6 F136 R 6 7 Page 23
and signal line for Tank contents

L11 indicator lamp,orange 6 F136 R < Tank reserve 6 7 < 31 Ohms
Tank reserve
Signal line for the

see test values,
compressed air reservoir 7 F137 R 7 7 page 24
gauge (M101)
Signal line for the engine see test values,

temperature gauge (M102)
8 F138 R 8 7 page 24
not connected 9
Edition 09/01
4-11
4-12
Cable Measure
Measure-
Sva 7-97221 EN
ment
and No. pin to pin
L24 indicator lamp, red Handbrake applied 0 - 0.3 VDC

Handbrake
1 B131 U 1 7 12 - 14 VDC
Handbrake open
L25 indicator lamp, red < 106 °C
12 - 14 VDC
Engine temperature 2 B132 U 2 7
> 106 °C 0 - 0.3 VDC
> 106 °ϑ
L26 indicator lamp, red > min. 13 - 14 VDC

Coolant level
3 B133 U 3 7 0 - 0.3 VDC
< min.
L27 indicator lamp, red p < 15 bar

0 - 0.5 VDC
transmission lubrication and 4 B134 U 4 7
p > 15 bar approx. 12 VDC
main clutch overspeed
L28 indicator lamp, red enabled 0 - 0.3 VDC

stationary operation
5 B135 U 5 7 12 - 14 VDC
not enabled
Signal line for fuel contents see test values

gauge (M100)
6 F136 R 6 7 Page 23
and signal line for Tank contents

L11 indicator lamp,orange 6 F136 R < Tank reserve 6 7 < 31 Ohms
Tank reserve
Signal line for the

see test values,
compressed air reservoir 7 F137 R 7 7 page 24
gauge (M101)
Signal line for the engine see test values,

temperature gauge (M102)
8 F138 R 8 7 page 24
not connected 9
Edition 09/01
Cable Measure
Measure-
Sva 7-97221 EN
ment
and No. pin to pin
Supply, combination instrument A1
Plus potential 15/1 F14 8 G148 U 21W Cl. 8 Cl. 7 8 7 13 - 14 VDC
Ground
7 S U 21W Cl. 8 Cl. 7 7 . Batt. - 0 - 0.3 VDC
(testing under load)
Functions
L14 indicator lamp, orange Rear diff. lock "on" 0 - 0.6 VDC
Differential lock, rear
1 B141 U Rear diff. lock "off"
1 7 approx. 8.2 VDC
L15 indicator lamp, orange Front diff. lock "on" 0 - 0.6 VDC
Front differential lock
2 B142 U Front diff. lock "off"
2 7 approx. 8.2 VDC
L16 indicator lamp, PTO shaft 540 preselected 0 - 1 VDC

orange, PTO shaft 540
3 B143 U PTO shaft 540 not preselected
3 7 approx. 8.2 VDC

4 7 approx. 8.2 VDC
L18 indicator lamp, PTO shaft 1000 preselected

0 - 1 VDC
orange, PTO shaft 1000 5 B145 U PTO shaft 1000 not 5 7 approx. 8.2 VDC
preselected

0 - 1 VDC
preselected
not connected 9
Edition 09/01
4-13
4-14
Cable Measure
Measure-
Sva 7-97221 EN
ment
and No. pin to pin
Supply, combination instrument A1
Plus potential 15/1 F14 8 G148 U 21W Cl. 8 Cl. 7 8 7 13 - 14 VDC
Ground
7 S U 21W Cl. 8 Cl. 7 7 . Batt. - 0 - 0.3 VDC
(testing under load)
Functions
L14 indicator lamp, orange Front diff. lock "on" 0 - 0.6 VDC
Differential lock, rear
1 B141 U Front diff. lock "off"
1 7 approx. 8.2 VDC
L15 indicator lamp, orange "Automatic" suspension mode 0 - 0.6 VDC

Front axle suspension
2 B142 U Suspension "off"
2 7 approx. 8.2 VDC

3 7 approx. 8.2 VDC

4 7 approx. 8.2 VDC

0 - 1 VDC
preselected

0 - 1 VDC
preselected
not connected 9
Edition 09/01
Cable Measure
Measure-
Sva 7-97221 EN
ment
and No. pin to pin
not connected 1
Signal for Switching
Pushbutton pressed 0 - 0.3 VDC
hours of operation display,
2 B152 U 2 7
front and rear PTO shafts,
Pushbutton not pressed no value set
Coding and calibrating
approx. 7 VDC
Signal engine speed from
alternator pin W 3 F153 U 3 7
approx. 7.5 VAC

3 F153 f 3 7 254 Hz
not connected 4
Edition 09/01
4-15
4-16
Cable Measure
Measure-
Sva 7-97221 EN
ment
and No. pin to pin
3 - 4 VDC
Signal, front
PTO shaft speed
from sensor B8 5 F155 U PTO shaft is turning 5 7
VAC according to
each PTO shaft
speed
Signal, front PTO shaft Front PTO shaft

5 F155 f 5 7 483 Hz
speed from sensor B8 n = 1000 min-1
3 - 4 VDC
Signal, front
PTO shaft speed
from sensor B8 6 F156 U PTO shaft is turning 6 7
VAC according to
each PTO shaft
speed

6 F156 f 6 7 483 Hz
Sensor B8, speed F155 (X9/5)

signal, front PTO shaft 5 and 6 R 5 1050 Ω ± 10 %
F156 6
Signal, theoretical driving approx. 6.5 VDC
speed 7 F158 U Tractor moves 7 7
from sensor B6
no function - see
circuit diagram
8 F157
not connected 9
Edition 09/01
Cable Measure
Measure-
Sva 7-97221 EN
ment
and No. pin to pin
not connected 1
Signal for Switching
Pushbutton pressed 0 - 0.3 VDC
hours of operation display,
2 B152 U 2 7
front and rear PTO shafts,
Pushbutton not pressed no value set
Coding and calibrating
Signal engine speed from approx. 7 VDC

alternator pin W
3 F153 U 3 7
approx. 7.5 VAC

3 F153 f 3 7 254 Hz
not connected 4
Edition 09/01
4-17
4-18
Cable Measure
Measure-
Sva 7-97221 EN
ment
and No. pin to pin
approx. 4 VDC
Signal, front
5 F155 U PTO shaft is turning 5 7
PTO shaft speed
from sensor B8

5 F155 f 5 7 483 Hz
not connected 6
Signal, theoretical driving approx. 6.5 VDC
speed 7 F157 U Tractor moves 7 7
Sensor B6
no function – see
circuit diagram
8 F158
not connected 9
Edition 09/01
Cable Measure
Measure-
Sva 7-97221 EN
ment
and No. pin to pin
Signal, rear approx. 4 VDC

PTO shaft, rear 1 F161 U PTO shaft is turning 1 7
Sensor B7
Signal, rear
PTO shaft is turning
PTO shaft, rear 1 F161 f 1 7 180 Hz
n = 540 min-1
Sensor B7
no function – see
circuit diagram
2 F162
Edition 09/01
4-19
4-20
Cable Measure
Measure-
Sva 7-97221 EN
ment
and No. pin to pin
Signal for additional v < 0.5 km/h
no value set
equipment according to 3 F163 U 3 7
DIN 9684 and ISO 11786 High (13 VDC)
v > 0.5 km/h
Signal driving speed

standardised according to approx. 6.5 VDC
DIN 9684 and ISO 11786 4 F164 U Tractor moves 4 7
130 impulses / meter
505 Hz (14 km/h)

standardised according to
DIN 9684 and ISO 11786 4 F164 f v = 14 km/h 4 7 505 Hz
505 Hz (14 km/h)
Signal engine speed approx. 6.5 VDC

standardised according to 5 F165 U Engine is turning over 5 7
DIN 9684 and ISO 11786
Signal engine speed Engine speed

standardised according to 5 F165 f 5 7 260 Hz
DIN 9684 and ISO 11786 n = 1000 min-1
Signal rear PTO shaft speed approx. 6.5 VDC

6 F166 U Rear PTO shaft is turning 6 7
40 impulses / revolution
Signal rear PTO shaft speed

standardised according to Speed, rear PTO shaft
6 F166 f 6 7 360 Hz
DIN 9684 and ISO 11786 n = 540 min-1
not connected 7
not connected 8
not connected 9
Edition 09/01
Cable Measure
Measure-
Sva 7-97221 EN
ment
and No. pin to pin
Signal, rear approx. 4 VDC

PTO shaft, rear 1 F161 U PTO shaft is turning 1 7
Sensor B7
Signal, rear
PTO shaft is turning
PTO shaft, rear 1 F161 f 1 7 180 Hz
n = 540 min-1
Sensor B7
no function – see
circuit diagram
2 F162
Edition 09/01
4-21
4-22
Cable Measure
Measure-
Sva 7-97221 EN
ment
and No. pin to pin
Signal for additional v < 0.5 km/h
no value set
equipment according to 3 F163 U 3 7
DIN 9684 and ISO 11786 High (13 VDC)
v > 0.5 km/h

standardised according to approx. 6.5 VDC
DIN 9684 and ISO 11786 4 F164 U Tractor moves 4 7
505 Hz (14 km/h)

DIN 9684 and ISO 11786 4 F164 f v = 14 km/h 4 7 505 Hz
505 Hz (14 km/h)
Signal engine speed approx. 6.5 VDC

standardised according to 5 F165 U Engine is turning over 5 7
Signal engine speed Engine speed

standardised according to 5 F165 f 5 7 260 Hz
DIN 9684 and ISO 11786 n = 1000 min-1
Signal rear PTO shaft speed approx. 6.5 VDC

6 F166 U Rear PTO shaft is turning 6 7
Signal rear PTO shaft speed

standardised according to Speed, rear PTO shaft
6 F166 f 6 7 360 Hz
DIN 9684 and ISO 11786 n = 540 min-1
not connected 7
not connected 8
not connected 9
Edition 09/01
4-23
TEST VALUES
1. Frequencies of speed signal – rear PTO shaft:
Sensor wheel: 20 segments To carry out a check, the frequency can be calculated:
Speed PTO shaft Frequency

540 min-1 180 Hz f .................frequency
f= n*z n .......................speed
750 min -1
250 Hz 60
z ...............no. of teeth
1000 min-1 333 Hz -1
Example: f = 540 min * 20 = 180 Hz
1400 min-1 466 Hz 60
2. Frequencies of the standardised speed signal – rear PTO shaft:

Up to vehicle no. 02584 (Steyr) and vehicle no. 13874 (CASE Steyr) at A12 X12/3 terminal 3
From to vehicle no. 02585 (Steyr) and vehicle no. 13875 (CASE Steyr) at A12 X10/3 terminal 8
at signal plug socket X29 pin 3
Speed PTO shaft Frequency Speed PTO shaft Frequency
540 min-1 360 Hz 1000 min-1 666 Hz
750min-1 500 Hz 1400 min-1 932 Hz
3. Frequencies of the speed signal – front PTO shaft:

Speed Frequency
Front PTO Shaft
1000 min-1 483 Hz Sensor wheel with 29 teeth
4. Frequencies of the signal – engine speed indicator:

Engine speed permissible deviation Pointer angle Frequency from
alternator pin "W"
1000 min-1 ± 100 min-1 67° 254 Hz
2000 min-1 ± 65 min-1 163° 508 Hz
If the voltage at alternator terminal "W" is to be measured, then half of the control voltage (approx. 7 V DC ), will be
displayed, irrelevant of engine speed.
Engine gearing: Alternator = 1 : 2.54 (the alternator has 6 pairs of poles)
5. Fuel gauge:
Sensor (B2/1) Display – Instrument
Diesel level Resistance Pointer angle Display area
empty 10 Ω 0° from 0 - 12° red sector
1/8 (1) 31,2 Ω 7,5°
1/2 95 Ω 30° from 30 - 35° white sector
1 180 Ω 60° from 60 - 65° white sector
1)
If the fuel level is < 1/8, indicator lamp L11 will light up (tank reserve indicator lamp).

4-24
6. Engine temperature gauge:

Sensor (B1) Display – Instrument
Temperature Resistance Pointer angle Display area
45 °C 239 Ω 0° from 0 - 10° white sector
60 °C 134 Ω 0°
75 °C 82 Ω 14°
90 °C 51 Ω 20°
105 °C 33,4 Ω 42° from 42 - 52° red sector
113 °C 26,8 Ω 53°
120 °C 22,4 Ω 60°
7. Coolant temperature switch S32:

Type of contact: Normally open
contact (NOC)
Switch point 106 ± 3 °C(2)
2)
If the coolant temperature is higher than the specified value, L25 will light up (engine coolant indicator lamp).
L22 and L29 (stop indicator lamps) flash and the stationary mode cut-out will stop the engine.
8. Compressed air indicator:

Sensor (B3) Display – Instrument
Pressure in bar Resistance Pointer angle Display area
0 10 Ω 0° from 0 - 13° red sector
2 52 Ω 0°
4 88 Ω 6°
6(3) 124 Ω 24° from 37 - 42° white sector
8 155 Ω 42°
10 184 Ω 60° from 59 - 63° white sector
3)
If the reservoir pressure is < 5.5 bar, L23 will light up (compressed air indicator lamp). L22 and L29 (stop indicator
lamps) flash.

4-25
OPERATING AND CODING OF THE DIGITAL INSTRUMENT WITH

INTEGRATED OPERATING HOURS COUNTER
General information
All functions are called up using the spring-loaded switch (button), marked by the PTO symbol, on the right-hand
side of the instrument panel. To call up the operating functions, you only need to press the button briefly. If the button
is pressed for longer than 10 sec., you can check and correct the coding values.
Operating / function
Ignition ON/Starting/Operation the display shows a small "h" and the cumulative
operating hours.
Press the button again the rear PTO shaft speed will be shown on the display.
Press the button again the front PTO shaft speed will be shown on the display.
Press the button again the operating hours will again be shown on the display.
Coding
– the engine speed indication (operating hours)
– the rear PTO shaft speed indication
– the front PTO shaft speed indication
General information
Each time the button is briefly pressed, the display will be visibly increased by one impulse. If the button is pressed
continually for longer than 1.5 sec's. the impulses will be increased rapidly. When the button is released, "PRO"
appears on the display after 8 sec's. The value set is stored by briefly pressing the button once again and the display
will return to the starting position (operating hours).
Coding the engine speed indication (operating hours)

Press the button for 20 sec's.
The combination of numbers 1 - 1 appears in the upper part of the display, the current value or
the value to be corrected in the lower part of the display. The code adjustment range is 15 -255 impulses.
With tractors 9105-45 and CS110-150 the code number 15 must be stored.
Coding the rear PTO shaft speed indication

The combination of numbers 2 - 2 appears in the upper part of the display, the current value or value to be corrected
appears in the lower part of the display. The code adjustment range is 1 - 99 impulses.
(code number 20 = 20 segment sensor wheel).
Coding the front PTO shaft speed indication

The combination of numbers 3 - 3 appears in the upper part of the display, the current value or value to be corrected
appears in the lower part of the display. The code adjustment range is 1 - 99 impulses.
(code number 29 = 29 segment sensor wheel).

4-26
CALIBRATING THE DRIVING SPEED
Re-calibration is required after replacing tyres or when 3 bars appear on the km/h display.
Measure out a distance of exactly 100 m and mark both ends

clearly.
– Press the switchover button (front PTO shaft / rear
PTO shaft / operating hours) for at least 10 seconds, until
CAL appears in the km/h display.
– Drive vehicle froward and when the tractor’s front axle
passes the 0 mark, press the button briefly.
The display shows COU.
The impulses will be counted to 9999 on the bottom part of

the display, ---- will appear above this, pay no attention to
this.
:$51,1* Minimum speed within the 100 m markings =

2 km/h – it is possible to drive faster.
– When the front axle is in line with the 100 m mark, press
the pushbutton briefly once again – the letters PRO
appear on the display.
– Then press the switchover button once again – the re-
calibration values are stored.
If the driving speed is not displayed, the tractor must be

stopped and the engine must be stopped and then started
again.
If a fault occurs during calibration (delay in pressing the

switch etc.), simply switch the ignition OFF before pressing
the switch for the last time – the programming sequence will
thus not be accepted and the old values remain in effect.
Repeat the procedure.
SS99J173

&LUFXLW'LDJUDP&&/6+\GUDXOLFVZLWK6SUXQJ)URQW$[OH
DQG&6&6
1 Suction filter
2 Pump unit
3 Feed pump 57 cm3
42
4 DBV short circuit 5 bar 41 41
5 Measuring point p-feed pump
6 Pressure filter
7 DBV cooling 1 bar 19
8 DBV 235 bar
9 Adjustable pump 45 cm3 33
10 Filter control switch opens 18 18
>1,0 + 0,2 bar
11 Feed flow slider
39
12 Max. working pressure slider
13 LT41 Priority block
14 Prioriy valve 13 40
15 Shuttle valve
16 Steering servostat 160/80-11/
LDR-175 38
37
17 DBV 175 bar 16
18 Chamber cut-off valve
19 Steering cylinder
14
20 Connection plate
21 Mech. aux. control unit Q4 36
(Priority 0-80 l/min)
22 Mech. aux. control unit Q3
(0 - 80 l/min, no latches)
15
23 EHR control unit
(with SV 220+20 bar) LS R
P
24 Spacer plate
35
(0 - 80 l/min, with latches)
17
26 Electrical aux. control unit
27 End plate (Power-beyond-plate)
28 Pressure-free oil return 24 27
(plug-in connection)
29 Return feed plate
7
30 Brake cooling line
31 Measuring point 20
LS aux. control units
32 Measuring point 6 8 11
p-aux. control units
33 Lifting gear cylinder 32
5
34 Valve block, sprung front axle 12
35 Sol. valve, raise/lower (l/r)
36 Control slider, raise(l/r)
37 Solenoid valve raise/lower (l)
38 Solenoid valve raise/lower (r) 4
39 DBV 250 bar
40 Cut-off valve (pressure relief for
repair work) 31
41 Pressure reservoir
3 10 21 22 23
9
42 Cylinder, sprung front axle 2
29 25 26
28 30 30
0
ss99k009
Sva 7-97700 EN
&LUFXLW'LDJUDP&&/6+\GUDXOLFVZLWK6SUXQJ)URQW$[OHDQG7UDLOHU%UDNH
DQG&6&6
1 Suction filter
2 Pump unit 45
3 Feed pump 57 cm3 44 44
4 DBV short circuit 5 bar
46
5 Measuring point, p-feed pump
6 Pressure filter
48
22
7 DBV cooling 1 bar
8 DBV 235 bar
9 Adjustable pump 45 cm3 47
10 Filter control switch, opens 21 13
>1,0 + 0,2 bar 21 49 36
42
11 Feed flow slider
12 Max. working pressure slider 19 43
13 LT43 priority block
14 Priority valve, steering 16
15 Priority valve hydr. trailer brake
41
16 Proportional valve, hydr. trailer 40
brake
17 Shuttle valve
14 38
18 Shuttle valve 15
LDR-175
39
20 DBV 175 bar
21 Chamber cut-off valve 18
22 Steering cylinder 17
23 Connection plate
24 Mech. aux. control unit Q4 LS P R
37
26 EHR aux. control unit
20
(with SV 220+20 bar)
27 Spacer plate 27 30
(0 - 80 l/min with latches)
30 End plate (Power-beyond-plate)
31 Fressure-free oil return (plug-in 6 23
connection) 11
8
33 Brake cooling line 35
35 Measuring point
36 Lifting gear cylinder
37 Valve block, sprung front axle 5
38 Solenoid valve, raise(l/r)
39 Control slider, raise (l/r) 4 34
40 Solenoid valve raise/lower (l) 26 28 29
41 Solenoid valve raise/lower (r) 10
3 9
42 DBV 250 bar 2 32
43 Cut-off valve (pressure relief for
0 31 50 24 25 33 33
repair work)
44 Pressure reservoir
ss99k011
45 Cylinder, sprung front axle
46 Master brake cylinder, left 49 Wheel brake cylindere, right
47 Master brake cylinder, right 50 Plug-in connection, hydr. trailer brake
48 Wheel brake cylindere, left
Sva 7-97710 EN
&LUFXLW'LDJUDP&&/6+\GUDXOLFVZLWK:KHHO%UDNH
DQG&6&6
1 Suction filter
2 Pump unit
3 Feed pump 57 cm3
39 40 37
5 Measuring point p-feed pump
6 Pressure filter
7 DBV cooling 1 bar
8 DBV 235 bar 22
9 Adjustable pump 45 cm3
13
10 Filter – control switch opens
>1,0 + 0,2 bar
21 41
11 Feed flow slider 21
13 LT44 priority block
14 Priority valve, steering
19
15 Priority valve, 4-wheel brake 16
16 Proportional valve 38
4-wheel brake
17 Shuttle valve
18 Shuttle valve 36
19 Steering servostat 160/80-11/ 14
LDR-175
15
20 DBV 175 bar
22 Steering cylinder 18 42
23 Connection plate 17
25 Mech. aux. control unit Q3‘
26 EHR control unit
(with SV 220+20 bar) 20
27 Spacer plate 26 27 28 29 30
(0 - 80 l/min, with latches)
7
30 End plate (Power-beyond-Plate) 23
31 Pressure-free oil return
(plug-in connection)
32 Return feed plate 6
8 11
33 Brake cooling line 35
34 Measuring point
37 Master brake cylinder, left
38 Master brake cylinder, right 5
39 Wheel brake cylinder, left
40 Wheel brake cylinder, right
4
41 Emergency valve (ATE retention 34
pressure 2 - 5 bar) 10
42 Front axle braking cylinder 3 9
2 32
0 31 24 25 33 33
ss99k010
Sva 7-97720 EN
&LUFXLW'LDJUDP&&/6+\GUDXOLFV+\GU7UDLOHU%UDNHDQG:KHHO%UDNH
DQG&6&6
1 Suction filter
2 Pump unit
3 Feed pump 57 cm3
5 Measuring point, p-feed pump
6 Pressure filter 40 39 38
7 DBV cooling 1 bar
8 DBV 235 bar 22
9 Adjustable pump 45 cm3
10 Filter control switch, opens
>1,0 + 0,2 bar 21 13
11 Feed flow slider
21 42
13 LT43 Priority block
14 Priority valve, steering
15 Priority valve, hydr. trailer brake
16 Proportional valve hydr. trailer 16
brake
37
17 Shuttle valve
18 Shuttle valve 19
LDR-175 14
20 DBV 175 bar 15 36 41
23 Connection plate 18 43
(Priority 0 - 80 l/min)
25 Mech. aux. control unit Q3‘
26 EHR control unit (with SV
220+20 bar)
27 Spacer plate
20
28 Mech. aux. control unit Q3 26 29 30
(0 - 80 l/min, with latches) 27
28
30 End plate (Power-beyond-plate) 7
31 Pressure-free oil return (plug-in 23
connection)
33 HBrake cooling line 6
34 Measuring point 8 11
LS aux. control units 35
35 p-aux. control units
36 Lifting gear cylinder 12
37 Master brake cylinder, left
38 Master brake cylinder, right
39 Wheel brake cylinder, left
40 Wheel brake cylinder, right 5
41 Proportional valve
4-wheel brake
42 Emergency valve (ATE retention
4 34
pressure, 2 - 5 bar)
10
43 Wheel brake cylinder, front axle 3 9
44 Plug-in connection, hydr. trailer 2 32
brake 44 24 25 33 33
0 31
ss99k012
Sva 7-97730 EN
+\GUDXOLFFLUFXLWGLDJUDPXSWRWKH32:(56+877/(YHUVLRQ
DQG&6&6
1A by-pass valve 0,3 bar

1 suction filter
3 tandempump 32 cm³+16 cm³
4 LS steering steering valve
11 connection plate with pressure scale and
175 bar PLV
12 mechanicl auxiliary control unit (depending
on block variant)
13 mechanicl auxiliary control unit (depending
on block variant)
14 EHR control unit with 220+20 bar shock valve
15 spacer
16 electrical or mechanical auxiliary control
unit (depending on block variant)
17 electrical auxiliary control unit
19 end plate from May 1998 with LS connec-
tion for sprung front axle, without sprung
front axle connected to the retutn plate
20 pressure-free oil return (plug-in connection)
21 0,35 bar non-return valve
22 1,5 bar non-return valve
23 return plate
24 lubrication for rear PTO shaft
25 3 bar PLV rear axle lubrication
26 lubrication of rear axle
27 splash buffle
28 steering servostat with 150 bar PLV
29 steering cylinder
30 lifting gear cylinder
34 ∆p-changeover valve
35 pressure scale
38 control slider
39 control slider
44 shuttle valve
46 three-way flow regulator
47 adjustable choke ss98j053
52 slider 73 non-return valve 84 control slider (lowering) 109 Q-control slider

53 adjustable choke 74 shut-off valve 87 adjustable choke
54 shuttle valve 75 shuttle valve 88 control slider
55 PLV 175 bar 79 slider 90 shuttle valve (EHR)
56 choke 80 control slider (raising) 91 slider
60 shut-off valve 81 non-return valve 99 shuttle valve
63 non-return valve 82 load safty valve 220+20 bar 108 PLV 150 bar steering (from 06.97 PLV with 175 bar) Sva 7-96380EN
+\GUDXOLFFLUFXLWGLDJUDPIURPWKH32:(56+877/(YHUVLRQRQZDUGVZLWKVSURQJIURQWD[OH
DQG&6&6
1A by-pass valve 0,3 bar

1 suction filter
3 tandempump 32 cm³+16 cm³
4 LS steering steering valve
11 connection plate with pressure scale
and 175 bar PLV
12 mechanicl auxiliary control unit
(depending on block variant)
13 mechanicl auxiliary control unit
(depending on block variant)
14 EHR control unit with 220+20 bar shock
valve
15 spacer
16 electrical or mechanical auxiliary con-
trol unit (depending on block variant)
17 electrical auxiliary control unit
19A end plate cut in of end plate with end of
1998 (Power Byond)
20 pressure-free oil return (plug-in
connection)
23 oil return plate
27 splash buffle
28 steering servostat with 175 bar PLV
29 steering cylinder
30 lifting gear cylinder
34 ∆p-changeover valve
35 pressure scale
38 control slider
39 control slider
44 shuttle valve
46 three-way flow regulator
47 adjustable choke (Stromregler Q4)
52 slider
53 adjustable choke
54 shuttle valve
55 PLV 175 bar
56 choke
60 shut-off valve
63 non-return valve
73 non-return valve
74 shut-off valve
75 shuttle valve
76 measuring point (p-pump)
77 measuring point (p-LS)
79 slider
80 control slider (raising)
ss98j052
81 non-return valve
82 load safty valve 220+20 bar
84 control slider (lowering) 96 pipe brakecooling 103 solenoid valve left (lower/lift) 108 PLV steering 150 bar
87 adjustable choke 99 shuttle valve 104 solenoid valve right (lower/lift) 109 Q-control slider
88 control slider 100 control unit for sprung front axle 105 PLV 250 bar 110 lubrication crownwheel
90 shuttle valve (EHR) 101 accumulator 106 lock valve (for releasing pressurein case of repair)
91 slider 102 cylinder 107 solenoid valve - lift (left/right) Sva 7-96400EN
Load-Sensing (LS) Block Assembly Drawing for 9105 – 9145 and CS110 – CS150
2-way Block (2 mechanical ACU) 2-way Block (1 mech.- and 1 electrical ACU) 3-way Block (2 mech.- and 1 electrical ACU)
9 3 4 6 9 3 5 6 9 4 6 5
7
7 7
1 1 1
C C C C
C C
B B
B B B B
A A A A A A
Z Z
8 8 Z
ss98k031 ss98k032 ss98k033
4-way Block (2 mech.- and 2 electrical ACU) 4-way Block (3 mech.- and 1 electrical ACU)
4 6 5 9 4 6 3 5
9
7 7
1 1
C C C C
B B B B
A A A A
Z 8 Z
Z 8 Z ss98k034 ss98k035
1 Connecting plate 8 Intermediate plate NOTE: Tightening sequence for the fixing nuts:
2 Q4 mechanical auxiliary control unit with latch 9 Insert plate (in LS channel connecting plate) When assembling the individual blocks, ensure that A» B» C
3 Q3 mechanical auxiliary control unit with latch A Hexagonal nut packing rings are fitted at the positions marked “Z” (one Tightening torques:
3 Q3 mechanical auxiliary control unit without latch B Hexagonal nut packing ring per grub screw). A and B 25+4 Nm
5 Electrical auxiliary control unit C Hexagonal nut C 14+5 Nm
6 EHR valve Z Packing rings
7 End plate Edition 05/99 Sva 7-96980 EN
Chapter
4003
4003
CIRCUIT DIAGRAM
9105a, 9115a, 9125a, 9145a

CS110, CS120, CS130, CS150
post Power Shuttle versions
Technische Dokumentation/Training Center May, 1999
EMPTY PAGE

,1'(;
Index for Circuit diagram........................................................................................................................... 4
Sheet 1...................................................................................................................................................... 6
Sheet 2...................................................................................................................................................... 8
Sheet 3.................................................................................................................................................... 10
Sheet 4.................................................................................................................................................... 12
Sheet 5.................................................................................................................................................... 14
Sheet 6.................................................................................................................................................... 16
Sheet 7.................................................................................................................................................... 18
Sheet 8.................................................................................................................................................... 20
Sheet 9.................................................................................................................................................... 22
Sheet 10.................................................................................................................................................. 24
Sheet 11.................................................................................................................................................. 26
Sheet 12.................................................................................................................................................. 28
Sheet 13.................................................................................................................................................. 30
Sheet 14.................................................................................................................................................. 32
Sheet 15.................................................................................................................................................. 34
Sheet 16.................................................................................................................................................. 36
Sheet 17.................................................................................................................................................. 38
Sheet 18.................................................................................................................................................. 40
Sheet 19.................................................................................................................................................. 42
Sheet 20.................................................................................................................................................. 44
Sheet 21.................................................................................................................................................. 46
Sheet 22.................................................................................................................................................. 48
Sheet 23.................................................................................................................................................. 50
Sheet 24.................................................................................................................................................. 52
Sheet 25.................................................................................................................................................. 54
Sheet 26.................................................................................................................................................. 56
Sheet 27.................................................................................................................................................. 58
Sheet 28.................................................................................................................................................. 60
Sheet 29.................................................................................................................................................. 62
Sheet 30.................................................................................................................................................. 64
Sheet 31.................................................................................................................................................. 66
Sheet 32.................................................................................................................................................. 68
Sheet 33.................................................................................................................................................. 70
Sheet 34.................................................................................................................................................. 72
Sheet 35.................................................................................................................................................. 74
Sheet 36.................................................................................................................................................. 76
Sheet 37.................................................................................................................................................. 78
Sheet 38.................................................................................................................................................. 80
List of Plugs ............................................................................................................................................ 82
List of Plugs ............................................................................................................................................ 83
List of Plugs (at rear)............................................................................................................................... 84
List of Plugs – Instrument Panel ............................................................................................................. 85
List of Plugs – Right-hand Side Panel .................................................................................................... 86
Central Electrics Print ............................................................................................................................. 87
Central Electrics Print ............................................................................................................................. 88
Print – Roof electrics............................................................................................................................... 90
Engine Electrics Print.............................................................................................................................. 92
EHR-D Print (left) .................................................................................................................................... 94
EHR-D Print (operating console) ............................................................................................................ 95
Single Winch Print................................................................................................................................... 96
Relays ..................................................................................................................................................... 97
Switches.................................................................................................................................................. 98
Potentiometers...................................................................................................................................... 100
Sensors................................................................................................................................................. 101
Solenoid Valves .................................................................................................................................... 103
ECCU – Electronic Central Control Unit ............................................................................................... 105
Instrument Test Values ......................................................................................................................... 106
Lamps and Fuses ................................................................................................................................. 107
Operation and Coding the Digital Instrument with Integrated operating Hours Counter ....................... 108
Calibrating the speedometer................................................................................................................. 109
6YD(1 (GLWLRQ
4003-4
Index for Circuit diagram
9105 – 9145
CS110 – CS150
Sheet Sheet
(e.g. 1) (e.g. 1)
Title Section Title Section
(e.g. A) (e.g. A)
4-wheel drive 6B# EHR force sensors 27B
4-Wheel Drive – Management 5B# EHR front control 27F
Air conditioning 16A# EHR- height/control 29B
Air conditioning 16A# EHR lowering speed 31D
Air-sprung seat 24D EHR mixed control 31E
Air-sprung seat 24D EHR position sensors 27C
Automatic pre-glowing 2B# EHR raise/lower indicator 31C
Brake light 5A EHR Raise+lower SV 27D
Centre instrument panel – indicator 21B EHR setpoint 29D
lamps
Centre instrument panel – warning 22B EHR slip control 31H
lamps
Cigarette lighter 24B EHR slip control 28A
Differential lock 6C# EHR stop 29E
Differential lock – management 5C# EHR switchover lift/pressure control 30J#
Digital clock 15B EHR upper limit 31F
Dipped/Main beam switchover 9C Engine cut-out 4B#
Door contact switch 12D Engine cut-out 4B#
Double action auxiliary control unit + 25D Floor level heating 14B
floating position – lever switch operated
Double action auxiliary control unit + 26E Front PTO shaft 34B
floating position – lever switch operated
Double action auxiliary control unit +
floating position – multi-controller 26C Front washer pump 18D
operated
floating position – multi-grip operated 26B Front wiper parallel 18C
Double action auxiliary control unit + Front-end lifting gear, double-action,
floating position – multi-grip operated 25C floating position, ext. operating buttons 24E
Double action auxiliary control unit + Front-end lifting gear, double-action,
floating position (+locking block) 25B floating position, ext. operating buttons 26D
floating position (+locking block) 26A Fuel filter heating 7A
Double winch 36B# Fuel filter heating 7A
Double winch 37B# Fuel pump control 3A
ECCU – supply 35B Gearbox diagnosis 32D
EHR – control panel – print supply 24A Gearbox display 32C
EHR – external buttons 28D Gearbox electronics supply 32C
EHR – interior operated external
28C Gearbox forward/reverse pre-select 33B
buttons
Gearbox forward/reverse solenoid
EHR – lighting, front panel 31J 32B
valve
EHR – slip display 31B Gearbox sensors 33B
EHR auxiliary switch 29G Headlights 9B
EHR box – supply 27A Heated front windscreen 15C
EHR diagnostics display 31A Heated rear screen 15D
EHR external sensor – preparation 27E Horn 18A
EHR fast retract 30C Interior lighting 12F
4003-5
Left instrument panel – analogue

display 22A Searchlight 2 roof, rear, outer 11A#
Left instrument panel – analogue
display 22C Searchlight 4 on trafficator/sidelight 10D#
Left instrument panel – indicator lamps 21A Searchlight 4 roof, rear, inner 10B#
Mirror heating 13A Searchlight 4 roof, rear, outer 10A#
Number plate lighting, roof 12C Searchlight 4, roof, front, twinpower 10C#
Number plate lighting, roof 12C Searchlight, front grill 12A
On-board computer – preparation 19B Searchlight, mudguard 9D
Optistop 5B# Sidelight, front 8C
Power shift gearbox 32A Sidelight, rear 8D
Power socket 40A 19C Single winch 38B#
Power supply 1A# Spot 13C
Power supply + battery master switch 2A# Sprung front axle 35A
Pre-glowing with pushbutton 1B# Standard signal socket 28B
Radio – preparation 15A Start 1C
Rear PTO shaft 34A Stationary operation cut-out 3B#
Rear washer pump 18E Step lighting 12E
Reserves – central print 7B Substitute headlight 9A
Reserves – engine print 12B Supply potential 58 for various switches 24E
Reserves – roof print 13D Trafficator 8B
Right instrument panel – digital display 23A Trafficators 8A
Roof blower motor 17A# Trailer socket 19A
Rotating beacon 13B Winch supply 36A
Safety switch 24C Wiper, angle front 18F
Searchlight 2 on trafficator/sidelight 11D# Wiper, angle rear 18G
Searchlight 2 roof, front, twinpower 11C#
EHR = Electronic Lift Control

ECCU = Electronic Central Control Unit

4003-6
SS99D166
Sheet 1

Electrical equipment Grounding point Designation of Sections
A12 Print, central electrics 1 Battery A# Power supply
A14 Print, engine electrics 2 Instrument panel
A60/3 ECCU start inhibitor B# Pre-glowing with pushbutton
Sva 7-95830 EN
5 Engine compartment
E10/1 Glow plug
C Starting
F30 Fuse, potential 30, ignition 11 Driver's cab frame
F40 Main fuse 100A 13 Carrier frame # several versions available
F47 Fuse, potential 15
F48 Fuse, potential 15, EHR 16 Starter
F49 Fuse, clock
G1 Battery 12V
G2/1 Generator 12V/95A
K5/7/1 Relay potential 15/1 supply
K5/17 Relay, pre-glowing
K8/1 Relay, starter motor
M1 Starter motor
S1 Switch, pre-glow starter
Cable colour or coding in accordance with standard 05449
S2/53 Switch, pre-glowing
S38 Switch, pre-glowing indicator Ident. letter Colour Type of use
W1/7 Pre-glowing contact bridge A Red +30 (potential 30) = Cont. current
X1/1 Plug-in connection, flat, engine cable
B Beige -- Control line (ground)
X1/8 Bulkhead distributor, potential 30 C White + Control line (positive)
X1/11 Screw-on connector, central print 30 D Yellow + 15 Si (Potential 15 safety)
X4/44 Plug-in connection, spark start
E Grey Potential 58 Lighting cable
X5/1 Ground distributor, central print
X6/7 Plug-in connection, rear right, ECCU F Green Signal cable
X9/7 Plug-in connection, motor, chassis, left G Violet + 15 (potential 15.1 or 15.2)
X9/13 Plug-in connection, engine cable Switched current after
X9/21 Plug-in connection, engine cable the pre-glow switch
X16/2 Screw-on connector, engine 30, fused
X16/3 Screw-on connector, engine 30, H Orange VDC, stabilised by the 'E' Box
non-fused K Light blue D+
X18/1 Plug-in connection, instrument cable L Brown Ground via a box
24/1 Plug-in connection, instrument cable
24/2 Plug-in connection, motor block, right N Pink Spare
VERSIONS
X24/3 Plug-in connection, motor block, right – P Colourless Spare
to this Sheet
instrument
1 S Black Ground, directly to a grounding point
X31/1 Plug-in connection, instrument – engine
on Sheet/Sheets
Y16 Solenoid, starting rate (4 cylinder)
2
4003-7
Edition 05/99
4003-8
SS99D167
Sheet 2

Grounding point Designation of Sections
Electrical equipment
1 Battery A# Power supply + battery main switch
A12 Print, central electrics
A14 Print, engine electrics 2 Instrument panel
B# Automatic pre-glowing
Sva 7-95830 EN
A60/3 ECCU start inhibitor 5 Engine compartment
E10/1 Glow plug C Starting
11 Driver's cab frame
F30 Fuse, potential 30, ignition
F40 Main fuse 100A 13 Carrier frame # several versions available
F47 Fuse, potential 15 16 Starter
F48 Fuse, potential 15, EHR
F49 Fuse, clock
G1 Battery 12V
G2/1 Generator 12V/95A
K4/2/1 Timed relay, 40 sec’s. pre-glowing
K8/1 Relay, starter motor
M1 Starter motor
Q1 Battery master switch Cable colour or coding in accordance with standard 05449
S1 Switch, pre-glow starter
Ident. letter Colour Type of use
S2/53 Switch, pre-glowing
S38 Switch, pre-glowing indicator A Red +30 (potential 30) = Cont. current
W1/7 Pre-glowing contact bridge B Beige -- Control line (ground)
X1/2 Plug-in connection, flat, engine cable C White + Control line (positive)
X1/8 Bulkhead distributor, potential 30 D Yellow + 15 Si (Potential 15 safety)
X4/44 Plug-in connection, spark start E Grey Potential 58 Lighting cable
X6/7 Plug-in connection, chassis right, ECCU F Green Signal cable
X9/7 Plug-in connection, motor, chassis, left G Violet + 15 (potential 15.1 or 15.2)
X9/13 Plug-in connection, engine cable Switched current after
X9/21 Plug-in connection, engine cable the pre-glow switch
H Orange VDC, stabilised by the 'E' Box
X16/3 Screw-on connector, engine 30, non-fused
X18/1 Plug-in connection, instrument cable K Light blue D+
X24/2 Plug-in connection, chassis, right
N Pink Spare
X24/3 Plug-in connection, chassis, VERSIONS
right – instrument to this Sheet P Colourless Spare
X31/1 Plug-in connection, instrument – engine 2 S Black Ground, directly to a grounding point
Y16 Solenoid, starting rate (4 cylinder) on Sheet/Sheets
1
4003-9
Edition 05/99
4003-10
SS99D168
Sheet 3

2 Instrument panel A Fuel pump control
A14 Print, engine electrics 4 Distributor, gearbox
B# Stationary operation cut-out
Sva 7-95830 EN
B2/1 Fuel tank content transmitter, left 5 Engine
B2/2 Fuel tank content transmitter, right compartment # several versions available
F21 Fuse, potential D+
F29 Fuse, potential 15, cut-out
F50 Fuse, engine cut-out
K4/1/2 Relay, engine cut-out
K5/1 Relay bridge, engine cut-out
K5/11 Relay potential D+ supply
K5/16 Relay, stationary operation
K5/43 Relay, D+ cut-out
M8/1 Left-hand tank pump motor
M8/2 Right-hand tank pump motor
S2/60 Switch, stationary operation
S6 Switch, engine oil pressure indicator Cable colour or coding in accordance with standard 05449
S32 Switch, water temperature indicator
V3/2 Diode 0.3A interlock
V3/3 Diode 0.3A interlock A Red +30 (potential 30) = Cont. current
V3/7 Diode 0.3A interlock B Beige -- Control line (ground)
V3/8 Diode 2A interlock
C White + Control line (positive)
W1/4 Contact bridge, spark start
X1/4 Plug-in connection, flat, engine cable D Yellow + 15 Si (Potential 15 safety)
X6/10 Plug-in connection, chassis left –
instrument F Green Signal cable
X9/14 Plug-in connection, engine cable G Violet + 15 (potential 15.1 or 15.2)
X10/1 Plug-in connection, instrument cable Switched current after
X14/1 Plug-in connection, cable chassis, left the pre-glow switch
X14/4 Plug-in connection, chassis right – H Orange VDC, stabilised by the 'E' Box
gearbox
X18/2 Plug-in connection, roof supply cable L Brown Ground via a box
X24/1 Plug-in connection, instrument cable
N Pink Spare
X24/2 Plug-in connection, chassis, right VERSIONS
X24/3 Plug-in connection, chassis, right – P Colourless Spare
to this Sheet
instrument 3 S Black Ground, directly to a grounding point
X31/1 Plug-in connection, instrument – engine on SSheetheet/
Y12 Engine cut-out solenoid valve Sheets
4
4003-11
Edition 05/99
4003-12
SS99D169
Sheet 4

2 Instrument panel A Fuel pump control
A14 Print, engine electrics 4 Distributor, gearbox
B# Engine cut-out
Sva 7-95830 EN
B2/1 Fuel tank content transmitter, left 5 Engine
B2/2 Fuel tank content transmitter, right compartment # several versions available
F29 Fuse, potential 15, cut-out
F50 Fuse, engine cut-out
K4/1/2 Relay, engine cut-out
K5/1 Relay bridge, engine cut-out
K5/11 Relay potential D+ supply
M8/1 Left-hand tank pump motor
M8/2 Right-hand tank pump motor
S12 Switch, engine oil pressure indicator Cable colour or coding in accordance with standard 05449
V3/2 Diode 0.3A interlock
V3/3 Diode 0.3A interlock A Red +30 (potential 30) = Cont. current
V3/7 Diode 0.3A interlock B Beige -- Control line (ground)
W1/4 Contact bridge, spark start C White + Control line (positive)
X1/4 Plug-in connection, flat, engine cable D Yellow + 15 Si (Potential 15 safety)
X6/10 Plug-in connection, chassis left –
instrument F Green Signal cable
X14/1 Plug-in connection, cable chassis, left the pre-glow switch
X14/4 Plug-in connection, chassis right –
gearbox K Light blue D+
X18/2 Plug-in connection, roof supply cable
N Pink Spare
X24/1 Plug-in connection, instrument cable VERSIONS
X24/2 Plug-in connection, chassis, right to this Sheet P Colourless Spare
X31/1 Plug-in connection, instrument – engine 4 S Black Ground, directly to a grounding point
Y12 Engine cut-out solenoid valve on Sheet/Sheets
3
4003-13
Edition 05/99
4003-14
SS99D170
Sheet 5

2 Instrument panel A Brake light
A10 Electr. 4-wheel drive/differential locks
Management 4 Distributor, gearbox
B# 4-wheel drive Optistop management
Sva 7-95830 EN
A15 Print, EHR, left 17 Rear mudguard C# Differential lock management
A60 ECCU electronics box
E12 Brake light, left # several versions available
E13 Brake light, right
F11 Fuse, brake lights
F13 Fuse, differential lock
K5/12 Relay, brake light, Optistop
S2/56 Switch, differential lock management
S2/59 Switch, 4-wheel drive management
S5 Switch, brake light
S25 Switch, steering brake
W1/3 Contact bridge, Optistop
W1/5 Contact bridge, low signal
X4/45 Plug-in connection, sprung front axle
X4/57 Plug-in connection, chassis, left Cable colour or coding in accordance with standard 05449
rear-side, trafficator, brake lights
rear-side, trafficator, brake lights A Red +30 (potential 30) = Cont. current
X9/17 Plug-in connection, chassis cable, left B Beige -- Control line (ground)
X14/1 Plug-in connection, cable chassis, left C White + Control line (positive)
X14/2 Plug-in connection, instrument cable D Yellow + 15 Si (Potential 15 safety)
X14/4 Plug-in connection, chassis right – E Grey Potential 58 Lighting cable
gearbox
X14/9 Plug-in connection, chassis right F Green Signal cable
4-wheel Drive – differential lock – G Violet + 15 (potential 15.1 or 15.2)
management – switch Switched current after
X15/19 Plug-in connection, EHR box cable the pre-glow switch
X18/3 Plug-in connection, chassis right, ECCU
Y1 4-wheel drive solenoid valve K Light blue D+
Y10 Differential lock solenoid valve L Brown Ground via a box
N Pink Spare
VERSIONS
to this Sheet P Colourless Spare
on Sheet/Sheets
6
4003-15
Edition 05/99
4003-16
SS99D171
Sheet 6

2 Instrument panel A Brake light
A10 Electr. 4-wheel drive/differential locks m
4 Distributor, gearbox
management B# 4-wheel drive
Sva 7-95830 EN
17 Rear mudguard
A15 Print, EHR, left C# Differential lock
E12 Brake light, left # several versions available
E13 Brake light, right
F11 Fuse, brake lights
K5/12 Relay, brake light, Optistop
S2/27 Switch, 4-wheel drive
W1/3 Contact bridge, Optistop
W1/5 Contact bridge, low signal
W1/6 Contact bridge, control minus
W1/8 Contact bridge, solenoid valve plus
Differential lock Cable colour or coding in accordance with standard 05449
X4/54 Distributor, joystick
X4/57 Plug-in connection, chassis, left
rear-side, trafficator, brake lights A Red +30 (potential 30) = Cont. current
X4/58 Plug-in connection, chassis, right B Beige -- Control line (ground)
rear-side, trafficator, brake lights
X9/17 Plug-in connection, cable, chassis, left
X10/2 Plug-in connection, cable, chassis, right D Yellow + 15 Si (Potential 15 safety)
X14/1 Plug-in connection, cable chassis, left E Grey Potential 58 Lighting cable
X14/4 Plug-in connection, chassis right – F Green Signal cable
gearbox G Violet + 15 (potential 15.1 or 15.2)
X14/9 Plug-in connection, chassis right – Switched current after
4-wheel drive – the pre-glow switch
differential lock – management – switch H Orange VDC, stabilised by the 'E' Box
X15/19 Plug-in connection, EHR box cable
X18/3 Plug-in connection, chassis right, ECCU K Light blue D+
X24/2 Plug-in connection, chassis, right L Brown Ground via a box
Y1 4-wheel drive solenoid valve
N Pink Spare
Y10 Differential lock solenoid valve VERSIONS
P Colourless Spare
to this Sheet
on Sheet/Sheets
5
4003-17
Edition 05/99
4003-18
SS99D172
Sheet 7

5 Engine compartment A Fuel filter heating
A14 Print, engine electrics 22 E box console
B Spares – central print
Sva 7-95830 EN
D1/1 Diode group, fuel filter heating
E32 Fuel filter heating C Ground contact
F10 Fuse 15, roof, front-loader
F15 Fuse, front-loader
F35 Fuse, potential 15, CVT gearbox
F43 Fuse, filter heating
K5/37 Relay, spare, central print
K5/39 Relay, fuel filter heating
S26 Switch, fuel filter heating control
X6/1 Plug-in connection, spare
X9/7 Plug-in connection, motor, chassis, left
X9/14 Plug-in connection, engine cable Cable colour or coding in accordance with standard 05449
X9/15 Plug-in connection, engine cable
X10/2 Plug-in connection, cable, chassis, right
X14/2 Plug-in connection, instrument cable A Red +30 (potential 30) = Cont. current
X18/1 Plug-in connection, instrument cable B Beige -- Control line (ground)
X31/1 Plug-in connection, instrument – engine C White + Control line (positive)
D Yellow + 15 Si (Potential 15 safety)
F Green Signal cable
G Violet + 15 (potential 15.1 or 15.2)
Switched current after
the pre-glow switch
K Light blue D+
L Brown Ground via a box
N Pink Spare
P Colourless Spare
S Black Ground, directly to a grounding point
4003-19
Edition 05/99
4003-20
SS99D173
Sheet 8

2 Instrument panel A Trafficator system
A12 Print, central electrics X18/2 Plug-in connection, roof supply cable
A13 Print, roof electrics X24/1 Plug-in connection, instrument cable 7 Roof panel
B Trafficator
Sva 7-95830 EN
A16 Print, EHR operating console X24/2 Plug-in connection, chassis, right 17 Rear mudguard
E3 Sidelight, front left X24/5 Plug-in connection, EHR B Print C Sidelight, front
E4 Sidelight, rear left
E6 Sidelight, front right D Sidelight, rear
E7 Sidelight, rear right
E14 Trafficator, front right
E15 Trafficator, rear right
E16 Trafficator, rear left
E17 Trafficator, front left
E21/1 Position light, in auxiliary headlamp, left
E21/1 Position light, in auxiliary headlamp,
rightF1Fuse, lighting, potential 58 left
F2 Fuse, light potential 58, right
F16 Fuse, hazard warning lights
F60 Fuse, sidelight, front left
F61 Fuse, sidelight, potential 58 Cable colour or coding in accordance with standard 05449
K2 Trafficator relay
K5/10 Relay, light (potential 58)
S2/5 Switch, hazard warning lights A Red +30 (potential 30) = Cont. current
S4/2 Switch, steering column, trafficator B Beige -- Control line (ground)
X1/30 Plug-in connection, potential 30,
central print X4/55Plug-in connection,
roof frame trafficator/position light, left D Yellow + 15 Si (Potential 15 safety)
X4/56 Plug-in connection, roof frame E Grey Potential 58 Lighting cable
Trafficator/position light right
X4/57 Plug-in connection, chassis, left F Green Signal cable
rear-side, trafficator, brake lights G Violet + 15 (potential 15.1 or 15.2)
X4/58 Plug-in connection, chassis, right, Switched current after
rear-side, trafficator, brake lights the pre-glow switch
X4/.. Plug-in connection, roof switch H Orange VDC, stabilised by the ’E’ Box
rear side, trafficator, brake lights
X9/19 Plug-in connection, cable chassis, right K Light blue D+
X14/1 Plug-in connection, cable chassis, left
N Pink Spare
X14/8 Plug-in connection, instrument, P Colourless Spare
steering column S Black Ground, directly to a grounding point
X15/14 Plug-in connection, roof frame
X16/5 Distributor, ground, roof print
4003-21
Edition 05/99
4003-22
SS99D174
Sheet 9

X14/1 Plug-in connection, cable chassis, left 2 Instrument panel A Auxiliary headlight
A13 Print, roof electrics X14/8 Plug-in connection, instrument, 5 Engine compartment
B Headlight
steering column
Sva 7-95830 EN
A14 Print, engine electrics 8 Console, battery
E1 Headlight, left X15/15 Plug-in connection, roof canopy cable C Dipped/main beam
X15/16 Plug-in connection, roof supply cable 17 Rear mudguard
E2 Headlight, right
E8 Searchlight, left-hand mudguard X18/1 Plug-in connection, instrument cable D Searchlight, mudguard
E9 Searchlight, right-hand mudguard X18/2 Plug-in connection, roof supply cable
E21 Reserve headlight, left X24/1 Plug-in connection, instrument cable
E2 Reserve headlight, right X24/2 Plug-in connection, cable, chassis, right
F3 Fuse, searchlight, mudguard X31/1 Plug-in connection, instrument, engine
F4 Fuse, dipped-beam headlight
auxiliary headlight, left
F5 Fuse, dipped-beam headlight
auxiliary headlight, right
F7 Fuse, dipped-beam
headlight right
F8 Fuse, dipped-beam
headlight, left Cable colour or coding in accordance with standard 05449
F9 Fuse, main-beam headlight
F12 Fuse, headlight flasher
F45 Fuse, supply potential 58 A Red +30 (potential 30) = Cont. current
K5/5 Relay, switchover, main beam headlight B Beige -- Control line (ground)
K5/6 Relay, switchover, dipped beam headlight
K5/9 Relay, searchlight, mudguard
S2/1 Switch, lighting system D Yellow + 15 Si (Potential 15 safety)
S2/17 Switch, reserve headlight E Grey Potential 58 Lighting cable
S2/64 Switch, searchlight, mudguard
S4/1 Switch, steering column, F Green Signal cable
main/dipped beam G Violet + 15 (potential 15.1 or 15.2)
V3/14 Diode 0.1A interlock Switched current after
X3/6 Flat plug-in connection, auxiliary headlight the pre-glow switch
X3/7 Flat plug-in connection, auxiliary headlight H Orange VDC, stabilised by the ’E’ Box
X4/6 Plug-in connection, roof canopy
auxiliary headlight K Light blue D+
X4/7 Plug-in connection, roof canopy L Brown Ground via a box
auxiliary headlight
N Pink Spare
X9/13 Plug-in connection, engine cable P Colourless Spare
X10/1 Plug-in connection, instrument cable S Black Ground, directly to a grounding point
Trafficator/position light, left
X12/15 Plug-in connection, roof canopy cable
4003-23
Edition 05/99
4003-24
SS99D175
Sheet 10

A13 Print, roof electrics X4/22 Plug-in connection, roof canopy cable A# Searchlight, outer rear
E23/1 Searchlight, roof, rear, inner X4/23 Plug-in connection, roof canopy cable
B# Searchlight, inner rear
Sva 7-95830 EN
E23/2 Searchlight, roof, rear, outer X4/24 Plug-in connection, roof canopy cable
E24/1 Searchlight, roof, rear, inner X4/26 Plug-in connection, roof frame C# Searchlight, front, twinpower
E24/2 Searchlight, roof, rear, outer X4/29 Plug-in connection, roof switch
E33 Searchlight, roof, front X4/36 Plug-in connection, roof switch D# Searchlight
twinpower X4/37 Plug-in connection, roof switch trafficator/position light
E34 Searchlight, roof, front X4/38 Plug-in connection, roof switch
twinpower X12/15 Plug-in connection, roof canopy cable # several versions available
E35 Searchlight on the X15/15 Plug-in connection, roof canopy cable
trafficator/position light X15/16 Plug-in connection, roof supply cable
E36 Searchlight on the X16/4 Distributor, central print 30
trafficator/position light
F67 Fuse, searchlight
twinpower
F68 Fuse 2, searchlight, rear
F70 Fuse 4, searchlight,
roof number plate Cable colour or coding in accordance with standard 05449
F73 Fuse, searchlight,
trafficator/position light Ident. letter Colour Type of use
K5/30 Relay 2, searchlight, roof, A Red +30 (potential 30) = Cont. current
rear, outer B Beige -- Control line (ground)
K5/31 Relay, searchlight, twinpower
K5/34 Relay 4, searchlight, number plate, C White + Control line (positive)
roof D Yellow + 15 Si (Potential 15 safety)
K5/38 Relay, searchlight,
S2/63/1 Switch, rear searchlight, 2+2 F Green Signal cable
S2/63/2 Switch, front searchlight, 2+2 G Violet + 15 (potential 15.1 or 15.2)
Diode 3A interlock Switched current after
V3/11 Diode 3A interlock the pre-glow switch
H Orange VDC, stabilised by the ’E’ Box
X3/8 Flat plug-in connection, searchlight, K Light blue D+
twinpower L Brown Ground via a box
X3/9 Flat plug-in connection, searchlight,
twinpower N Pink Spare
VERSIONS
X4/8 Plug-in connection, roof canopy to this Sheet P Colourless Spare
searchlight 10 S Black Ground, directly to a grounding point
X4/9 Plug-in connection, roof canopy on Sheet/Sheets
searchlight 11
4003-25
Edition 05/99
4003-26
SS99D176
Sheet 11

A13 Print, roof electrics X4/9 Plug-in connection, roof canopy A# Searchlight, outer rear
E5/3 Lighting, number plate, roof searchlight
B# Number plate lighting for 2
Sva 7-95830 EN
E5/4 Lighting, number plate, roof
X4/22 Plug-in connection, roof canopy cable searchlight versions up to 05.96
E23/2 Searchlight, roof, rear, outer
E24/2 Searchlight, roof, rear, outer X4/23 Plug-in connection, roof canopy cable
C# Searchlight, front, twinpower
E33 Searchlight, roof, front X4/24 Plug-in connection, roof canopy cable
twinpower X4/26 Plug-in connection, roof frame D# Searchlight
E34 Searchlight, roof, front X4/29 Plug-in connection, roof switch trafficator/position light
twinpower X4/36 Plug-in connection, roof switch
E35 Searchlight on the X4/37 Plug-in connection, roof switch # several versions available
trafficator/position light X4/38 Plug-in connection, roof switch
E36 Searchlight on the X12/15 Plug-in connection, roof canopy cable
trafficator/position light X15/15 Plug-in connection, roof canopy cable
F67 Fuse, searchlight X15/16 Plug-in connection, roof supply cable
twinpower X16/4 Distributor, central print 30
F68 Fuse 2, searchlight, rear
F70 Fuse 4, searchlight,
roof number plate Cable colour or coding in accordance with standard 05449
K5/30 Relay 2, searchlight, roof, A Red +30 (potential 30) = Cont. current
rear, outer B Beige -- Control line (ground)
K5/31 Relay, searchlight, twinpower
K5/34 Relay 4, searchlight, C White + Control line (positive)
roof number plate D Yellow + 15 Si (Potential 15 safety)
K5/38 Relay, searchlight, E Grey Potential 58 Lighting cable
S2/34/1 Switch, searchlight, twinpower F Green Signal cable
S2/34/2 Switch 2, searchlight, twinpower, G Violet + 15 (potential 15.1 or 15.2)
roof, rear Switched current after
S2/34/3 Switch, searchlight the pre-glow switch
V3/11 Diode 3A interlock K Light blue D+
V3/12 Diode 3A interlock L Brown Ground via a box
N Pink Spare
X3/8 Flat plug-in connection, searchlight, VERSIONS
twinpower to this Sheet P Colourless Spare
X3/9 Flat plug-in connection, searchlight, 11 S Black Ground, directly to a grounding point
twinpower on Sheet/Sheets
X4/8 Plug-in connection, roof canopy 10
Searchlight
4003-27
Edition 05/99
4003-28
SS99D177
Sheet 12

2 Instrument panel A Searchlight, front grill
A13 Print, roof electrics
8 Console, battery
A14 Print, engine electrics B Spares, engine print
Sva 7-95830 EN
E5/4 Lighting, number plate, roof C Roof number plate lighting
E19 Interior lighting
E30 Courtesy light, left D Door contact switch
E30 Courtesy light, right
E Courtesy light
E61 Searchlight, front grill
E62 Searchlight, front grill F Interior lighting
front grill
K4/2/2 Timed relay, 40 sec’s. interior lighting
K5/25 Relay, searchlight, front grill
S2/2 Switch, searchlight, front grill
S24/1 Switch, door contact
S2/20 Plug-in connection, front lifting gear 50%
S2/21 Plug-in connection, steering angle Cable colour or coding in accordance with standard 05449
X3/25 Plug-in connection, front position sensor
X4/43 Plug-in connection, number plate lighting A Red +30 (potential 30) = Cont. current
X4/55 Plug-in connection, roof frame B Beige -- Control line (ground)
trafficator/position light, left
Trafficator/position light right D Yellow + 15 Si (Potential 15 safety)
X4/.. Plug-in connection, roof switch E Grey Potential 58 Lighting cable
X9/15 Plug-in connection, engine cable F Green Signal cable
X15/14 Plug-in connection, roof frame Switched current after
X31/1 Plug-in connection, instrument – engine the pre-glow switch
K Light blue D+
N Pink Spare
P Colourless Spare
4003-29
Edition 05/99
4003-30
SS99D178
Sheet 13

A5/1 Rotating beacon, left A Mirror heating
A5/2 Rotating beacon, right B Rotating beacon
Sva 7-95830 EN
E18/1 Heated mirror, left C Spot
E18/2 Heated mirror, right
E20 Spot D Reserves – roof print
F69 Fuse, rotating beacon
F74 Fuse, reserve potential 30
K5/33 Relay, rotating beacon
K5/35 Relay, heated mirror
K5/36 Relay, reserve,
S2/18 Switch, rotating beacon
S2/19 Switch, heated mirror
X4/15 Plug-in connection, mirror heating
X4/16 Plug-in connection, reserve
X4/33 Socket, rotating beacon, left Cable colour or coding in accordance with standard 05449
X4/34 Socket, rotating beacon, right
X4/35 Plug-in connection, rotating beacon switch
X4/39 Plug-in connection, roof switch A Red +30 (potential 30) = Cont. current
X4/43 Plug-in connection, number plate lighting B Beige -- Control line (ground)
the pre-glow switch
K Light blue D+
N Pink Spare
P Colourless Spare
4003-31
Edition 05/99
4003-32
SS99D179
Sheet 14

5 Engine A Supply potential 58, instrument, left
F26 Fuse, heating compartment
B Foot-well heating
Sva 7-95830 EN
M3 Heater blower motor
S50/1 Switch, blower motor, 3 position C Supply potential 58, instrument, right
X4/10 Plug-in connection, flat, engine heating
X11/2 Distributor, instrument potential 58, left
X11/3 Distributor, instrument potential 58, right
X31/1 Plug-in connection, instrument, engine

A Red +30 (potential 30) = Cont. current
the pre-glow switch
K Light blue D+
N Pink Spare
P Colourless Spare
4003-33
Edition 05/99
4003-34
SS99D180
Sheet 15

19 Shock absorber, roof A Provision for radio
A6 Radio
A12 Print, central electrics B Digital clock
Sva 7-95830 EN
B14 Left-hand loudspeaker C Heated windscreen, front
B15 Right-hand loudspeaker
E25 Heated windscreen, front D Heated screen, rear
E26 Heated screen, rear
E Courtesy, interior lighting, high-top
F72 Fuse, spot, interior lighting,
heated mirror
E76 Fuse, heated screen, rear
E77 Fuse, heated windscreen, front
K5/29 Relay, roof print, potential 15
K6/7 Relay, heated screen, rear
K6/8 Relay, heated windscreen, front
P7 Digital clock
S2/16/1 Switch, heated screen, rear
S2/16/2 Switch, heated windscreen, front
W6 Aerial Cable colour or coding in accordance with standard 05449
X4/19 Plug-in connection,
heated windscreen, front
X4/20 Plug-in connection, heated screen, rear A Red +30 (potential 30) = Cont. current
X4/41 Plug-in connection, roof switch B Beige -- Control line (ground)
X4/42 Plug-in connection, roof switch
X12/15 Plug-in connection, roof canopy cable D Yellow + 15 Si (Potential 15 safety)
X15/14 Plug-in connection, roof frame E Grey Potential 58 Lighting cable
X18/1 Plug-in connection, instrument cable F Green Signal cable
X18/2 Plug-in connection, roof supply cable G Violet + 15 (potential 15.1 or 15.2)
the pre-glow switch
K Light blue D+
N Pink Spare
P Colourless Spare
4003-35
Edition 05/99
4003-36
SS99D181
Sheet 16

A12 Print, central electrics A# Air-conditioning high-top
A13 Print, roof electrics # several versions available
Sva 7-95830 EN
A14 Print, engine electrics
A20 Air conditioning control
A21 Blower driver
F42 Fuse, air conditioning
F66 Fuse, air conditioning blower motor
K5/26 Relay, reserve
K5/27 Relay, air-conditioning compressor
K5/32 Relay, roof blower motor
M12 Air conditioning condenser
R9 Temperature sensor
R10 Air conditioning control potentiometer
R11 Roof blower motor potentiometer
S30 Switch, air conditioning pressure
W2 Screened cable, air conditioning Cable colour or coding in accordance with standard 05449
X2/14 Plug-in connection, air-conditioning
X2/15 Plug-in connection, flat,
EHR lifting gear/pressure A Red +30 (potential 30) = Cont. current
S2/20 Plug-in connection, front lifting gear 50% B Beige -- Control line (ground)
X3/14 Flat plug-in connection, roof supply
X3/40 Plug-in connection, air cond. control
X3/41 Plug-in connection, temperature sensor D Yellow + 15 Si (Potential 15 safety)
X3/42 Plug-in connection, blower potentiometer E Grey Potential 58 Lighting cable
X9/11 Plug-in connection, roof air cond.
X9/14 Plug-in connection, engine cable F Green Signal cable
X9/16 Plug-in connection, air-conditioning G Violet + 15 (potential 15.1 or 15.2)
X15/16 Plug-in connection, roof supply cable Switched current after
X18/1 Plug-in connection, instrument cable the pre-glow switch
X18/2 Plug-in connection, roof supply cable H Orange VDC, stabilised by the 'E' Box
Y13 Magnetic coupling, air conditioning K Light blue D+
N Pink Spare
VERSIONS
on Sheet/Sheets
17
4003-37
Edition 05/99
4003-38
SS99D182
Sheet 17

A12 Print, central electrics A# Roof blower motor
A13 Print, roof electrics # several versions available
Sva 7-95830 EN
F66 Fuse, air conditioning blower motor
K5/26 Relay, reserve
K5/27 Relay, air-conditioning compressor
M10 Roof blower motor
S2/54/3Switch, blower motor, positions 1-2-3
S2/58/2Switch, blower motor ON
X2/15 Plug-in connection, flat,
EHR lifting gear/pressure
X9/11 Plug-in connection, roof air cond.
X9/14 Plug-in connection, engine cable Cable colour or coding in accordance with standard 05449
X18/2 Plug-in connection, roof supply cable B Beige -- Control line (ground)
the pre-glow switch
K Light blue D+
N Pink Spare
VERSIONS
on Sheet/Sheets
16
4003-39
Edition 05/99
4003-40
SS99D183
Sheet 18

2 Instrument panel A Horn
A13 Print, roof electrics 5 Engine
B steering column switch
Sva 7-95830 EN
F25 Fuse, wiper, horn compartment
F63 Fuse, rear wiper C Parallel wiper, front
F64 Fuse, front wiper, hinged windscreen
H1 Horn D Washer pump, front
K3 Wiper interval relay
E Washer pump, rear
K5/2 Relay, roof-mounted wiper, front
M2/1 Parallel wiper motor, front F# Wiper, front
M2/2 wiper motor, front
M4/2 wiper motor, rear G# Wiper, rear
M5 Washer pump motor, rear
M6 Washer pump motor, front # several versions available
S2/30 Switch, rear washer/wiper
S4/3 Switch, steering column, washer/wiper
X9/9 Plug-in connection, roof canopy cable Cable colour or coding in accordance with standard 05449
X9/10 Plug-in connection, rear wiper
X9/12 Plug-in connection, instrument – wiper
X14/8 Plug-in connection, instrument, B Beige -- Control line (ground)
steering column
X18/1 Plug-in connection, instrument cable D Yellow + 15 Si (Potential 15 safety)
X18/2 Plug-in connection, roof supply cable E Grey Potential 58 Lighting cable
X31/1 Plug-in connection, instrument, engine F Green Signal cable
the pre-glow switch
K Light blue D+
N Pink Spare
P Colourless Spare
4003-41
Edition 05/99
4003-42
SS99D184
Sheet 19

15 Instrument panel A Trailer socket
sockets
F17 Fuse, reserve potential 30 for B Provision for on-board computer
Sva 7-95830 EN
on-board computer 17 Rear mudguard
F20 Fuse, potential 15, socket C Power socket 40A
F22 Fuse, power socket
F28 Fuse, reserve potential 15 for
on-board computer
X2/4 Plug-in connection, potential 15 socket
X10 Plug-in connection, 7-pole, trailer
X10/3 Plug-in connection, on-board computer
provision
X14 Flat power socket
the pre-glow switch
K Light blue D+
N Pink Spare
P Colourless Spare
4003-43
Edition 05/99
4003-44
SS99D185
Sheet 20

2 Instrument panel A Supply potential 15/1, instrument
A13 Print, roof electrics B Brake valve, Italy
Sva 7-95830 EN
A15 Print, EHR, left C Reserve roof print (high-top)
F14 Fuse, potential 15/1
H50/1 Trailer brake indicator D Reserve Print, EHR, left
H50/2 Trailer brake indicator
K5/50 Relay, trailer brake valve
S50 Switch, trailer brake valve
X4/43 Plug-in connection, number plate lighting
X6/54 Plug-in connection, trailer brake valve
X10/4 Plug-in connection, chassis,
right, instrument aux. contr. unit
Y50 Trailer brake valve solenoid valve Ident. letter Colour Type of use
the pre-glow switch
K Light blue D+
N Pink Spare
P Colourless Spare
4003-45
Edition 05/99
4003-46
SS99D186
Sheet 21

2 Instrument panel A Instrument left – display
/L1 Indicator, 0.4 bar, variable pump
/L2 Main beam indicator 3 Implement carrier
A Instrument centre – display
Sva 7-95830 EN
/L3 Lighting indicator 4 Distributor, gearbox
/L4 Tractor trafficator indicator C Instrument right – display
5 Engine
/L5 1st trailer trafficator repeater
compartment
/L6 2nd trailer trafficator repeater
/L7 PTO shaft clutch indicator 11 Driver's cab frame
/L8 Searchlight indicator 17 Rear mudguard
/L9 Pre-glowing indicator
/L10 Air filter indicator
/L11 Tank reserve indicator
/L12 Fuel heater indicator
/L13 4-wheel drive indicator
/L14 Rear differential lock indicator
/L15 Sprung front axle indicator
/L16 540 PTO shaft indicator
/L18 1000 PTO shaft indicator Cable colour or coding in accordance with standard 05449
A1/ Combination instrument
S3 Switch, air filter indicator A Red +30 (potential 30) = Cont. current
S23 Switch, 0.4 bar supply B Beige -- Control line (ground)
S41/1 Switch, PTO shaft N/E indicator
S41/2 Switch, PTO shaft N/E indicator C White + Control line (positive)
S42 Switch, 540 PTO shaft indicator D Yellow + 15 Si (Potential 15 safety)
S43 Switch, 1000 PTO shaft indicator E Grey Potential 58 Lighting cable
X9/4 Plug-in connection, instrument cable G Violet + 15 (potential 15.1 or 15.2)
X14/4 Plug-in connection, chassis right, gearbox Switched current after
X14/6 Plug-in connection, chassis right the pre-glow switch
PTO shaft indicator
right – instrument K Light blue D+
X31/1 Plug-in connection, instrument, engine L Brown Ground via a box
N Pink Spare
P Colourless Spare
4003-47
Edition 05/99
4003-48
SS99D187
Sheet 22

2 Instrument panel A Instrument left, analogue
/L20 Generator charging indicator
/L21 Engine oil pressure indicator 4 Distributor, gearbox
B Instrument centre, warning display
Sva 7-95830 EN
/L22 Stop indicator 17 Rear mudguard
/L23 Compressed air indicator C Instrument centre, analogue
/L24 Handbrake indicator
/L25 Cooling water temperature indicator
/L26 Cooling water level indicator
/L27 Engine oil indicator
/L28 stationary operation indicator
/L29 Stop indicator
/L35 Display lighting
/M2 Rev-counter
/M100 Fuel gauge
/M101 Compressed air gauge
/M102 Water temperature gauge Cable colour or coding in accordance with standard 05449
B1 Engine temperature transmitter A Red +30 (potential 30) = Cont. current
B3 Compressed air transmitter B Beige -- Control line (ground)
S7 Switch, handbrake indicator
S12 Switch, compressed air indicator C White + Control line (positive)
S22 Switch, cooling water level indicator D Yellow + 15 Si (Potential 15 safety)
X3/39 Distributor, instrument terminal E Grey Potential 58 Lighting cable
K3/54 Plug-in connection, trailer brake valve
X6/10 Plug-in connection, chassis left, F Green Signal cable
instrument G Violet + 15 (potential 15.1 or 15.2)
X9/2 Plug-in connection, instrument cable the pre-glow switch
X9/15 Plug-in connection, engine cable K Light blue D+
X14/4 Plug-in connection, chassis right, gearbox L Brown Ground via a box
N Pink Spare
right – instrument
X31/1 Plug-in connection, instrument – engine P Colourless Spare
4003-49
Edition 05/99
4003-50
SS99D188
Sheet 23

2 Instrument panel A Instrument right, digital
/A1 Digital instrument
/L201 Display lighting 5 Engine
Sva 7-95830 EN
/L202 Display lighting compartment
B8 Hall transmitter, front PTO shaft
S2/57 Switch, digital switchover
S2/22 Plug-in connection,
front PTO shaft transmitter
X3/33 3-way distributor, chassis right – gearbox
X3/40 Distributor, neutral, front PTO shaft
X9/5 Distributor, instrument cable
X9/6 Distributor, instrument cable
X9/21 Distributor, engine cable
X14/1 Distributor, cable chassis, left
X24/2 Distributor, cable, chassis, right Cable colour or coding in accordance with standard 05449
X24/3 Distributor, chassis, right, instrument
X31/1 Distributor, instrument, engine
the pre-glow switch
K Light blue D+
N Pink Spare
P Colourless Spare
4003-51
Edition 05/99
4003-52
SS99D189
Sheet 24

17 Rear mudguard A Supply, EHR operating console
A16 Print, EHR operating console B Cigarette lighter
Sva 7-95830 EN
E11 Cigarette lighter
F18 Fuse, cigarette lighter C Safety switch
M7 Compressed air seat motor
S2/11 Switch, safety D Air-sprung seat
X2/3 Plug-in connection, flat, air sprung seat
E Supply potential 58 for various switches
X2/6 Plug-in connection, switch lighting
X3/12 Plug-in connection, cigarette lighter
X3/23 Plug-in connection, air-sprung seat
X4/4 Plug-in connection, safety switch
X9/19 Plug-in connection, cable chassis, right
X24/5 Plug-in connection, EHR B Print

the pre-glow switch
K Light blue D+
N Pink Spare
P Colourless Spare
4003-53
Edition 05/99
4003-54
SS99D190
Sheet 25

22 E box console A Auxiliary control unit power supply
/3 Switch, auxiliary control unit 1, yellow, left
/6 Switch, auxiliary control unit 1, yellow, left B# ECCU dual-action auxiliary control unit
Sva 7-95830 EN
A16 Print, EHR operating console
(+shut-off valve)
A60/7 ECCU auxiliary control unit 2
S11/ Multi-controller C Auxiliary control unit actuation,
S16 Switch lever for auxiliary control unit
multi-controller
X4/27 Plug-in connection, D Auxiliary control unit actuation,
auxiliary control unit, yellow, lever switch
multi-controller
X4/44 Plug-in connection, spark start
X5/17 5-way distributor, chassis right, gearbox
ECCU auxiliary control unit
X11/5 Distributor console, potential 15
X11/6 Distributor console, potential 15, safety
X14/5 Plug-in connection, chassis right, Cable colour or coding in accordance with standard 05449
multi-controller Ident. letter Colour Type of use
Y2/1 Solenoid valve control unit A Red +30 (potential 30) = Cont. current
Y2/2 Solenoid valve control unit B Beige -- Control line (ground)
Y2/3 Solenoid valve control unit
Y2/4 Solenoid valve interlock block
the pre-glow switch
K Light blue D+
N Pink Spare
VERSIONS
P Colourless Spare
to this Sheet
on Sheet/Sheets
26
4003-55
Edition 05/99
4003-56
SS99D191
Sheet 26

22 E box console A ECCU, 1st auxiliary control unit,
/4 Switch, auxiliary control unit 2, green,
RAISE dual-action +shut-off valve)
Sva 7-95830 EN
/5 Switch, auxiliary control unit 2, green,
B 1st auxiliary control unit actuation
LOWER
/11 Switch, auxiliary control unit, Joystick
floating position
C 1st auxiliary control unit actuation
A60/6 ECCU auxiliary control unit 1
S11/ Multi-controller multi-controller
S14/3 Front lifting gear external pushbutton D 1st auxiliary control unit actuation
LOWER
Front-end lifting gear
S15/3 Front lifting gear external pushbutton
RAISE external pushbutton, post 11.97
S16 Switch lever for auxiliary control unit
E 1st auxiliary control unit actuation
S36 Switch, joystick
X4/28 Plug-in connection, auxiliary control unit, Toggle switch
green, multi-controller
X5/18 5-way distributor, chassis right, gearbox Cable colour or coding in accordance with standard 05449
X9/23 Plug-in connection, external pushbutton
Front lifting gear
X10/7 Plug-in connection, A Red +30 (potential 30) = Cont. current
ECCU auxiliary control unit B Beige -- Control line (ground)
X11/6 Distributor console, potential 15, safety
Y2/1 Solenoid valve control unit D Yellow + 15 Si (Potential 15 safety)
Y2/2 Solenoid valve control unit E Grey Potential 58 Lighting cable
Y2/3 Solenoid valve control unit
Y2/4 Solenoid valve interlock block F Green Signal cable
the pre-glow switch
K Light blue D+
N Pink Spare
VERSIONS
on Sheet/Sheets
25
4003-57
Edition 05/99
4003-58
SS99D192
Sheet 27

20 EHR box A Supply, EHR box
A14 Print, engine electrics B Power sensors
Sva 7-95830 EN
A15 Print, EHR, left
A55 Control unit, EHR D C Position sensors
B9/1 Position transmitter, rear lifting gear
B10/1 Power sensor transmitter, left D EHR RAISE+LOWER solenoid valve
B10/2 Power sensor transmitter, right
E Provision for external sensor
B11 EHR pressure transmitter
B13 External transmitter F EHR, front control
F33 Fuse, potential 15, EHR
F46 Fuse, EHR
S29 EHR switchover, Front/Rear
X3/11 Plug-in connection, external sensor
X6/9 Plug-in connection, chassis right,
chassis left
X9/17 Plug-in connection, cable, chassis, left Cable colour or coding in accordance with standard 05449
EHR lifting gear/pressure
X12/8 Plug-in connection, EHR box cable B Beige -- Control line (ground)
X12/9 Plug-in connection, EHR box cable C White + Control line (positive)
X24/2 Plug-in connection, cable, chassis, right E Grey Potential 58 Lighting cable
X55 Plug-in connection, flat, EHR box cable F Green Signal cable
Y6 Solenoid valve, EHR (RAISE)
Y7 Solenoid valve, EHR (RAISE) G Violet + 15 (potential 15.1 or 15.2)
the pre-glow switch
K Light blue D+
N Pink Spare
P Colourless Spare
4003-59
Edition 05/99
4003-60
SS99D193
Sheet 28

5 Engine compartment A Slip control
A15 Print, EHR, left 17 Rear mudguard
B Standard signal socket
Sva 7-95830 EN
A16 Print, EHR operating console 20 EHR box
A55 Control unit, EHR D C EHR internally actuated
22 E box console
B16 Radar sensor external pushbutton
S2/15/5Switch, interior lighting,
external pushbutton D EHR external pushbutton
S14/1 External pushbutton, left, "LOWER"
S14/2 External pushbutton, right, "LOWER"
S15/1 External pushbutton, left, "RAISE"
S15/2 External pushbutton, right, "RAISE"
W1/1 Contact bridge
X2/9 Plug-in connection, 15 socket
S2/33 Plug-in connection, radar signal
X4/12 Plug-in connection, radar sensor
X4/47 Plug-in connection, EHR switch
X6/8 Plug-in connection, signal socket
X6/9 Plug-in connection, chassis right, Cable colour or coding in accordance with standard 05449
chassis left
X9/17 Plug-in connection, cable, chassis, left A Red +30 (potential 30) = Cont. current
X9/18 Plug-in connection, cable, chassis, left B Beige -- Control line (ground)
EHR lifting gear/pressure D Yellow + 15 Si (Potential 15 safety)
X12/8 Plug-in connection, EHR box cable E Grey Potential 58 Lighting cable
X12/10 Plug-in connection, EHR box cable F Green Signal cable
X12/32 Plug-in connection, EHR box cable G Violet + 15 (potential 15.1 or 15.2)
X14/1 Plug-in connection, cable chassis, left Switched current after
X24/2 Plug-in connection, cable, chassis, right H Orange VDC, stabilised by the ’E’ Box
X29 Standard signal socket K Light blue D+
X55 Plug-in connection, flat, EHR box cable L Brown Ground via a box
N Pink Spare
P Colourless Spare
4003-61
Edition 05/99
4003-62
SS99D194
Sheet 29

/1 Switch, EHR range A EHR actuation, transport
/2 Switch, EHR control B EHR actuation, control
Sva 7-95830 EN
/13 Switch, safety
A15 Print, EHR, left C EHR fast retract
A55 Control unit, EHR D D EHR setpoint
A60/4 ECCU/EHR functions
E EHR Stop
E41 Setpoint potentiometer lighting
E42 Setpoint potentiometer lighting F#
E47 Stop button lighting
R3/2 Resistance 560 OHM
R3/7 Resistance 560 OHM Cable colour or coding in accordance with standard 05449
R6/1 Setpoint potentiometer
S2/72 Switch, fast retract A Red +30 (potential 30) = Cont. current
S11/ Multi-controller B Beige -- Control line (ground)
S33 Switch, EHR stop
X2/5 Plug-in connection, EHR stop
X2/6 Plug-in connection, switch lighting D Yellow + 15 Si (Potential 15 safety)
X3/24 Plug-in connection, reserve E Grey Potential 58 Lighting cable
X5/6 Plug-in connection, EHR setpoint F Green Signal cable
X6/6 Plug-in connection, chassis right, EHR G Violet + 15 (potential 15.1 or 15.2)
X9/17 Plug-in connection, cable, chassis, left Switched current after
X12/8 Plug-in connection, EHR box cable H Orange VDC, stabilised by the ’E’ Box
multi-controller K Light blue D+
X14/7 Plug-in connection, chassis right, ECCU L Brown Ground via a box
N Pink Spare
X24/5 Plug-in connection, EHR B Print VERSIONS
X55 Plug-in connection, flat, EHR box cable to this Sheet P Colourless Spare
on Sheet/Sheets
30
4003-63
Edition 05/99
4003-64
SS99D195
Sheet 30

/1 Switch, EHR range A EHR actuation, transport
/2 Switch, EHR control B EHR actuation, control
Sva 7-95830 EN
/13 Switch, safety
A15 Print, EHR, left C EHR fast retract
A55 Control unit, EHR D D EHR setpoint
A60/4 ECCU/EHR functions
E EHR Stop
E42 Setpoint potentiometer lighting F# EHR pressure control
E47 Stop button lighting # several versions available
R3/7 Resistance 560 OHM Cable colour or coding in accordance with standard 05449
S2/72 Switch, fast retract A Red +30 (potential 30) = Cont. current
S11/ Multi-controller B Beige -- Control line (ground)
S20 Switch, EHR lifting gear/pressure
X2/5 Plug-in connection, EHR stop D Yellow + 15 Si (Potential 15 safety)
X2/6 Plug-in connection, switch lighting E Grey Potential 58 Lighting cable
X5/5 Plug-in connection, cable, chassis, right F Green Signal cable
X5/6 Plug-in connection, EHR setpoint G Violet + 15 (potential 15.1 or 15.2)
X6/6 Plug-in connection, chassis right, EHR Switched current after
X9/17 Plug-in connection, cable, chassis, left the pre-glow switch
X9/31 Plug-in connection, EHR box cable H Orange VDC, stabilised by the ’E’ Box
X14/5 Plug-in connection, chassis right, K Light blue D+
multi-controller L Brown Ground via a box
N Pink Spare
X18/3 Plug-in connection, chassis right, ECCU VERSIONS
X24/5 Plug-in connection, EHR B Print to this Sheet P Colourless Spare
X55 Plug-in connection, flat, EHR box cable 29 S Black Ground, directly to a grounding point
on Sheet/Sheets
30
4003-65
Edition 05/99
4003-66
SS99D196
Sheet 31

A16 Print, EHR operating console A EHR diagnostics display
A55 Control unit, EHR D B EHR – slip display
Sva 7-95830 EN
E44 Upper limit potentiometer lighting
E45 Mixing potentiometer lighting C EHR RAISE/LOWER display
E46 Lowering speed potentiometer lighting
E50 Diagnosis front panel lighting D EHR lowering speed
H2/1 Diagnosis display
E EHR mixed control
H2/2 Slip display
H2/3 Raise display F EHR, upper limit
H2/4 Lower display
N1/3 Diagnosis lamp G EHR damping OFF/EXCESS LIFT
N1/4 Diagnosis lamp
R4/1 Resistance 10 KOHM H EHR slip control
R4/2 Resistance 10 KOHM
J EHR – lighting, front panel
R6/2 Upper limit potentiometer
R6/3 Mixing potentiometer
R6/4 Lowering speed potentiometer Cable colour or coding in accordance with standard 05449
R7/3 Resistance 20 OHM A Red +30 (potential 30) = Cont. current
S2/7/3 Switch, EHR – auxiliary B Beige -- Control line (ground)
S2/73 Switch, slip control
V4/5 EHR blocking diode
V4/6 EHR blocking diode D Yellow + 15 Si (Potential 15 safety)
X2/6 Plug-in connection, switch lighting E Grey Potential 58 Lighting cable
lowering speed potentiometer F Green Signal cable
X3/17 Plug-in connection, G Violet + 15 (potential 15.1 or 15.2)
end position potentiometer Switched current after
X3/18 Plug-in connection, mixing potentiometer the pre-glow switch
X3/20 Plug-in connection, supply H Orange VDC, stabilised by the 'E' Box
X4/2 Plug-in connection, diagnosis/slip
X4/3 Plug-in connection, RAISE/LOWER K Light blue D+
X5/2 Plug-in connection, supplementary circuit L Brown Ground via a box
X5/3 Plug-in connection, ASC switch
N Pink Spare
X12/32 Plug-in connection, EHR box cable P Colourless Spare
X55 Plug-in connection, flat, EHR box cable S Black Ground, directly to a grounding point
4003-67
Edition 05/99
4003-68
SS99D180
Sheet 32

17 Rear mudguard A Power shift transmission
/9 Switch, power shift-HIGH
/10 Switch, power shift-LOW B Transmission, F/R solenoids
Sva 7-95830 EN
A13 Print, roof electrics C Transmission display
A68 Transmission electronics box
F19 Fuse, transmission potential 30 D Transmission diagnosis
F24 Fuse, transmission potential 15
P6 Display, power shift transmission F/R
S11 Multi-controller
X2/16 Plug-in connection, roof frame supply
right, diagnosis
multi-controller
X18/4 Plug-in connection, chassis right, ECCU Cable colour or coding in accordance with standard 05449
Y3 Proportional solenoid valve A Red +30 (potential 30) = Cont. current
Y21 Solenoid valve, power shift B Beige -- Control line (ground)
Y22 Solenoid valve, power shift
Y23 Solenoid valve, power shift C White + Control line (positive)
Y24 Solenoid valve, power shift D Yellow + 15 Si (Potential 15 safety)
Y25 Solenoid valve, power shift E Grey Potential 58 Lighting cable
Y26 Solenoid valve, driving direction – forward
Y27 Solenoid valve, driving direction – reverse F Green Signal cable
the pre-glow switch
K Light blue D+
N Pink Spare
P Colourless Spare
4003-69
Edition 05/99
4003-70
SS99D198
Sheet 33

4 Distributor, gearbox A Transmission, F/R pre-select-neutral
/7 Switch, forward
/8 Switch, reverse B Transmission sensors
Sva 7-95830 EN
A60/5 ECCU F/R switchover
A68 Transmission electronics box
B4 Transmitter, N/Clutch
B5 Hall transmitter, power shift output
B6 Hall transmitter, speed
B7 Hall transmitter, rear PTO shaft
B12 Hall transmitter, engine speed
B17 Angle of turn sensor clutch
B32 Transmitter, engine oil temperature
S4/4 Switch, steering column, F/R
S8 Switch, seat, transmission
S11/ Multi-controller
S1 Switch, pre-glow start
S21 Switch, transmission oil pressure 18bar
S46 Switch, clutch
X3/34 3-way distributor, chassis right – gearbox Cable colour or coding in accordance with standard 05449
X3/37 3-way distributor, chassis right – gearbox A Red +30 (potential 30) = Cont. current
X5/15 3-way distributor, chassis right, gearbox B Beige -- Control line (ground)
X6/7 Plug-in connection, aux. instrument, D Yellow + 15 Si (Potential 15 safety)
steering column E Grey Potential 58 Lighting cable
right, auxiliary F Green Signal cable
instrument G Violet + 15 (potential 15.1 or 15.2)
X11/8 11-way distributor, chassis right, gearbox Switched current after
X11/10 11-way distributor, potential 15 – chassis the pre-glow switch
right H Orange VDC, stabilised by the 'E' Box
X14/4 Plug-in connection, chassis right –
gearbox K Light blue D+
X14/5 Plug-in connection, chassis right, L Brown Ground via a box
multi-controller
N Pink Spare
X18/4 Plug-in connection, chassis right, ECCU P Colourless Spare
X24/4 Plug-in connection, chassis right, ECCU S Black Ground, directly to a grounding point
4003-71
Edition 05/99
4003-72
SS99D199
Sheet 34

4 Distributor, gearbox A Rear PTO shaft
A60/1 ECCU PTO shaft, front/rear
H3 Indicator, PTO shaft management active B Front PTO shaft
Sva 7-95830 EN
S2/70/1 Switch, front PTO shaft
S2/70/2 Switch, rear PTO shaft
S2/71 Switch, PTO shaft management
S17/1 External pushbutton, rear, ON
S17/2 External pushbutton, rear PTO shaft, ON
S19/1 External pushbutton, rear PTO shaft, OFF
S19/2 External pushbutton, rear PTO shaft, OFF
chassis left
PTO shaft
switch
X11/1 Distributor console, potential D+
gearbox Cable colour or coding in accordance with standard 05449
X24/5 Plug-in connection, EHR B Print A Red +30 (potential 30) = Cont. current
Y4 Solenoid valve, front PTO shaft B Beige -- Control line (ground)
Y5 Solenoid valve, rear PTO shaft
the pre-glow switch
K Light blue D+
N Pink Spare
P Colourless Spare
4003-73
Edition 05/99
4003-74
SS99D200
Sheet 35

2 Instrument panel A Sprung front axle
A60 ECCU electronics box 22 E box console
B ECCU supply
Sva 7-95830 EN
X61 Electronics, sprung front axle
/F31 Fuse, sprung front axle
potential 30
F32 Fuse, sprung front axle
potential 15
F34 Fuse, potential 15, ECCU
S2/15/1 Switch, front axle UP/DOWN
S2/15/2 Switch, front axle ON

the pre-glow switch
K Light blue D+
N Pink Spare
P Colourless Spare
4003-75
Edition 05/99
4003-76
SS99D201
Sheet 36

6 Distributor, for the A Supply, winch
winch
A33/2 E box, forestry B# Double winch
Sva 7-95830 EN
S2/66/2 Switch, winch, brake 2
S16/2 Switch, winch, clutch 2 # several versions available
X3/20 Plug-in connection, supply
X5/9 Distributor potential 58, winch
X12/13 Plug-in connection, double winch

the pre-glow switch
K Light blue D+
N Pink Spare
VERSIONS
on Sheet/Sheets
37,38
4003-77
Edition 05/99
4003-78
SS99D202
Sheet 37

6 Distributor, A Winch supply
A33/1 E box, forestry
for the winch
S2/66/1 Switch, winch, brake 1 B# Double winch
Sva 7-95830 EN
S16/1 Switch, winch, clutch 1

the pre-glow switch
K Light blue D+
N Pink Spare
VERSIONS
on Sheet/Sheets
36, 38
4003-79
Edition 05/99
4003-80
SS99D203
Sheet 38

6 Distributor, f A Winch supply
or the winch
A33/1 E box, forestry B Single winch
Sva 7-95830 EN
S2/7/5 Switch, winch capstan
S2/67 Switch, winch brake
X5/9 Distributor potential 58, winch
X7/5 Plug-in connection, single winch

the pre-glow switch
K Light blue D+
N Pink Spare
VERSIONS
P Colourless Spare
to this Sheet
on Sheet/Sheets
36, 37
4003-81
Edition 05/99
4003-82
List of Plugs
3 $ $
$
$
$
$
$
SS99F144
$
' $
.
$
$ ;
SS99F145

4003-83
List of Plugs
; (
(
(
(
;
;
(
(
(
(

(
(
SS99F146
( ;
( ;
;
(
( ; ; ;
; ; ;
;
;
; ;
; ;
;
; (
; (
;
;
;
;
;
;
;
; (
; (
; (
; (

SS99F147

4003-84
List of Plugs (at rear)
; ( ( ( ( ;

$ ; ; ; ; $
; ; ;

SS99F148

4003-85
List of Plugs – Instrument Panel
; ; ; ; ; ; ;

;
;
;
;SUH
;SUH
;
;
;
;
;
;
SS99F149

4003-86
Sva 7-95830 EN
6
; ;
; ;
;
; ;
;
6
$
; ;
List of Plugs – Right-hand Side Panel
; ;
;
;
;
;
;
6
;
SS99F150
Edition 05/99
4003-87
Central Electrics Print
SS98M055
Relays – Central Electrics

A10 4-wheel drive/Differential Management K5/11 D+ supply
K2 Flasher unit K5/12 Brake light/Optistop
K3 Wiper/Washer (Interval) K5/16 Stationary stop
K5/5 Switchover relay for high beam K5/19 Stationary operation stop
K5/6 Switchover relay for dipped beam K5/20 Stationary operation stop
K5/7/1 Potential 15/1 K5/24 Front loader
K5/7/2 Potential 15/2 K5/37 Reserve
K5/9 Searchlight mudguard K5/43 D+ switch OFF
K5/10 Light (Potential 58)

4003-88
Central Electrics Print
SS98M055
List of Plugs – Central Electrics

V3/2 Diode 0.3A interlock X4/44 Plug-in connection, spark start
V3/3 Diode 0.3A interlock X4/45 Plug-in connection, sprung front axle
V3/7 Diode 0.3A interlock X5/1 Ground distributor, central print
V3/8 Diode 2A interlock X6/1 Plug-in connection, spare
V3/14 Diode 0.1A interlock X10/1 Plug-in connection, instrument cable
V3/16 Diode 0.1A interlock X10/2 Plug-in connection, cable, chassis, right
W1/3 Contact bridge, Optistop on-board computer provision
W1/4 Contact bridge, spark start X10/4 Plug-in connection, chassis right,
W1/5 Contact bridge, low signal instrument aux.
X1/6 Plug-in connection, flat, instrument cable X14/2 Plug-in connection, instrument cable
X1/8 Screw-on connector, instrument – engine X18/1 Plug-in connection, instrument cable
X1/11 Screw-on connector, central print 30 X18/2 Plug-in connection, roof supply cable
X1/30 Plug-in connection, potential 30, central print X24/1 Plug-in connection, instrument cable
X2/4 Plug-in connection, potential 15 socket X24/2 Plug-in connection, cable, chassis, right

4003-89
Fuses – Central electrics print
SS98F061
F1 58 L Parking lamp, left .............................................................................................7.5 Amps

F2 58 R Parking lamp, right ..........................................................................................7.5 Amps
F3 Searchlight mudguard...............................................................................................10 Amps
F4 Dipped beam left roof spare head lamp...................................................................7.5 Amps
F5 Dipped beam right roof spare head lamp.................................................................7.5 Amps
F7 Dipped beam right head lamp..................................................................................7.5 Amps
F8 Dipped beam left head lamp ....................................................................................7.5 Amps
F9 Main beam ............................................................................................................ 15 Ampere
F10 Roof potential 15, Front loader ...................................................................................5 Amps
F11 Brake lamp................................................................................................................10 Amps
F12 Head lamp flasher.....................................................................................................15 Amps
F13 Differential front and rear ..........................................................................................10 Amps
F14 Flasher, E-control unit, Pneumatic seat suspension .................................................15 Amps
F15 Front loader...............................................................................................................10 Amps
F16 Hazard warning flasher .............................................................................................10 Amps
F17 Reserve potential 30 ...................................................................................................5 Amps
F18 Cigar lighter..............................................................................................................7.5 Amps
F19 Pot. 30 for transmission electronics .........................................................................7.5 Amps
F20 Reserve potential 30 .................................................................................................10 Amps
F21 D+, Fuel pump ............................................................................................................5 Amps
F22 Power outlet socket............................................................................................... 40 Ampere
F24 Pot. 15 for transmission electrics ............................................................................. 10 Amps
F25 Screen wipers, Horn ................................................................................................7,5 Amps
F26 Heating......................................................................................................................15 Amps
F29 Engine stop .................................................................................................................5 Amps
F30 Ignition switch supply ................................................................................................20 Amps
F31 Potential 30 sprung front axle ...................................................................................10 Amps
F32 Potential 15/2 sprung front axle ..................................................................................5 Amps

4003-90
Print – Roof electrics
SS99G154
Relays – Roof electrics

K4/2/2 Time relay 40 sec, Interior lamp – delay
K5/2 Front screen wiper (only on hinged windscreen)
K5/29 Terminal 15
K5/30 Searchlight, rear roof, 2 off
K5/31 Searchlight front roof TWIN POWER
K5/32 Blower motor – Air conditioning
K5/33 Rotating beacon
K5/34 4 Searchlight rear roof, Number plate lighting
K5/35 Heated mirror
K5/36 Reserve
K5/38 Reserve Searchlight
List of Plugs – Roof electrics

V3/10 Diode 3A interlock X4/38 Plug-in connection, roof switch
X4/5 Plug-in connection, chassis, left X4/43 Plug-in connection, number plate lighting
X4/15 Plug-in connection, mirror heating X6/2 Plug-in connection, roof frame
X4/16 Plug-in connection, reserve X9/9 Plug-in connection, roof canopy cable
X4/17 Plug-in connection, roof frame X9/10 Plug-in connection, rear wiper
X4/18 Plug-in connection, roof frame X9/11 Plug-in connection, roof air cond.
X4/19 Plug-in connection, heated windscreen, X12/15 Plug-in connection, roof canopy cable
front X15/14 Plug-in connection, roof frame
X4/20 Plug-in connection, heated screen, rear X15/15 Plug-in connection, roof canopy cable
X4/26 Plug-in connection, roof frame X15/16 Plug-in connection, roof supply cable
X4/29 Plug-in connection, roof switch X16/4 Distributor, central print 30
X4/35 Plug-in connection, rotating beacon switch

4003-91
Fuses – Roof electrics
SS98C146
F60 Parking lamp left front 3 Amps

F61 Parking lamp right front 5 Amps
F63 Rear wiper 7.5 Amps
F64 Wiper front on hinged windscreen 7.5 Amps
F65 Air conditioning 5 Amps
F66 Blower motor/ Air conditioning 20 Amps
F67 TWIN POWER 20 Amps
F68 Searchlight rear 2 10 Amps
F69 Rotating warning lamp 15 Amps
F70 4 Searchlight rear, Number-plate lighting 10 Amps
F71 Rotating warning lamp 3 Amps
F72 Spot, Radio, Interior lighting, Heated mirror 10 Amps
F3 Searchlight 10 Amps
F74 Reserve potential 30 20 Amps
F76 Heated rear screen 25 Amps
F77 Heated front windscreen 25 Amps

4003-92
Engine Electrics Print
SS99G155
Relays – Engine Electrics

K4/1/2 Engine stop 3 sec (timed relay)
K4/2/1 Timed relay, 40 sec’s. pre-glowing
K5/1 Engine stop, potential 31
K5/17 Pre-glowing (without suppresser diode)
K5/25 Searchlight, front grill
K5/26 Reserve
K8/1 Neutral position (terminal 50 starter)
K8/2 Pre-glowing
S38 Switch, pre-glowing indicator

4003-93
List of Plugs – Engine Electrics
W1/7 Pre-glow contact bridge

S2/20 Plug-in connection, front lifting gear 50%
S2/21 Plug-in connection, steering angle
S2/22 Plug-in connection, front PTO shaft transmitter
X3/25 Plug-in connection, front position sensor
X16/3 Screw-on connector, engine 30, non-fused
Fuses – Engine Electrics
SS98C145
F40 Main fuse ............................................................................................................................ 100 Amps

F41 Reserve potential 30 ............................................................................................................ 15 Amps
F43 Fuel preheater ..................................................................................................................... 20 Amps
F44 Searchlights front grill ........................................................................................................... 15 Amps
F45 Parking lamp ....................................................................................................................... 7.5 Amps
F46 EHR ....................................................................................................................................... 5 Amps
F47 Pre-glowing, Engine stop ....................................................................................................... 3 Amps
F48 EHR ....................................................................................................................................... 5 Amps
F49 Clock ...................................................................................................................................... 3 Amps
F50 Stop solenoid ....................................................................................................................... 40 Amps

4003-94
EHR-D Print (left)
SS99G156
List of Plugs – EHR-D Print (left)

W1/1 Contact bridge

X6/8 Plug-in connection, signal socket
X9/22 Plug-in connection, EHR lifting gear/pressure

4003-95
EHR-D Print (operating console)
SS99G157
List of Plugs – EHR-D Print (operating console)

N1/3 Diagnosis lamp X3/18 Plug-in connection,
N1/4 Diagnosis lamp mixing potentiometer
R3/2 Resistance 560 OHM X3/23 Plug-in connection, air-sprung seat
R3/3 Resistance 560 OHM X3/24 Plug-in connection, reserve
R3/4 Resistance 560 OHM X4/2 Plug-in connection, diagnosis/slip
R3/5 Resistance 560 OHM X4/3 Plug-in connection, RAISE/LOWER
R3/6 Resistance 560 OHM X4/4 Plug-in connection,
R3/7 Resistance 560 OHM number plate lighting
R3/8 Resistance 560 OHM X5/2 Plug-in connection,
R4/1 Resistance 10 KOHM supplementary circuit
R4/2 Resistance 10 KOHM X5/3 Plug-in connection, ASC switch
R5/1 Resistance 261 OHM X5/5 Plug-in connection, cable chassis,
R7/1 Resistance 20 OHM right
R7/2 Resistance 20 OHM X5/6 Plug-in connection, EHR setpoint
R7/3 Resistance 20 OHM X9/19 Plug-in connection, cable chassis,
right
V4/5 EHR blocking diode X9/31 Plug-in connection, EHR box cable
V4/6 EHR blocking diode X12/32 Plug-in connection, EHR box cable
X2/5 Plug-in connection, EHR stop

X2/6 Plug-in connection, switch lighting
X3/4 Distributor, neutral, front PTO shaft
X3/12 Plug-in connection, cigarette lighter
lowering speed potentiometer
end position potentiometer

4003-96
Single Winch Print
SS99G158

4003-97
Relays
Miniature relay: (Messr’s. Wehrle)
Centre zero relay / Normally open

Centre zero relay without diode (K5/17)
Rated voltage: ....................................12 VDC

Load:................................................... 20/30 A
Suppression.......................................... 390 Ω
SS99G151
Continuous duty.................................... 100%
Resistance 85 – 86:..................... 65 Ω ± 10%
Power relay: (Messr’s. Wehrle)
Rated voltage: ....................................12 VDC

Load:........................................................ 70 A
Suppression.......................................... 560 Ω
Continuous duty.................................... 100 %
Resistance 85 – 86:.................................80 Ω
SS99G150
Centre zero – micro-relay:

(Messr's. Wehrle)
Rated voltage: ............................................12 VDC

Load:........................................................... 15/25 A
Suppression.................................................. 680 Ω
Continuous duty............................................ 100%
SS99G152 Resistance 85 – 86................ 90 Ω ± 10% at 23 °C
Time relay 40 sec, K4/2/1 and K4/2/2:

(Messr’s. Wehrle and Son)

Load:.................................................................. 5 A
Continuous duty............................................ 100%
SS99G153

4003-98
Switches
Push-rod switch – Start inhibit (green S19):
Rated voltage:.............................................12 VDC

Switching current ............................................0.5 A
Switching power..............................................10 W
Continuous current .....................................300 mA
Type of contact ............................. Normally closed
SS99G159
Push-rod operated reed switch – clutch pedal:

(black S46)

Switching current ............................................0.5 A
Switching power..............................................10 W
Continuous current .....................................300 mA
Type of contact ............................... Normally open
SS99G160
safety switch – Air-cond. system (S30):

High pressure contact ................. opens at 31.5 bar
Low pressure contact.......................closes at 2 bar
SS99G174
Stop solenoid (Y12):

Pull-in coil res. ..................................0.25 Ω ± 10%
Hold-on coil res. ................................... 11 Ω ± 10%
ss99g144

4003-99
Engine oil pressure switch (red S21):

Switch makes at above 14.5 bar
Type of contact ............................... Normally open
SS99G167
Engine oil pressure switch (S6):
Opens at ...................................................... 0.5 bar

SS99H186
Hydraulic filter indicator switch (S23):
Pressure filter dirty indicator, post variable

pump (CC hydraulic system)
Opens at ...................................................1 +0.2 bar

SS99J026
Starting rate solenoid (Y16):
Only for 9105 and CS110

Supply voltage: ...........................................12 VDC
Resistance.......................................... 2.2 Ω ± 10%
SS99H187
Thermo-start unit (E10/1):

Heating element res. ............................. 1 Ω ± 10%
SS99H188

4003-100
Potentiometers
Air-cond. roof blower motor potentiometer
(R11):
Res. measured A – C ....................... 10 KΩ ± 20%

Res. measured A – B.................. 0 – 10 KΩ ± 20%
SS99G170
Air-cond. potentiometer (R10):
Potentiometer with integrated air-cond. – ON/OFF

switch
Res. potentiometer ........................... 10 KΩ ± 20%

Res. measured A – B.................. 0 – 10 KΩ ± 20%
SS99G171
EHR potentiometer (R6/1,R6/2,R6/3,R6/4):
The 4 EHR potentiometers are identical in value.

The differences lie in the wiring and length of the
shaft
Res. potentiometer ..........................4700 Ω ± 20%

Res. measured A – B.................0 – 4700 Ω ± 20%
SS99G172

4003-101
Sensors
Angle of turn sensor, for sprung front axle,
left and right:

Operating current.......................................... 15 mA
Output signal .......................................... 4 – 20 mA
1 = ground
2 = supply .....................................12 VDC ('E' box)
3 = signal, axle lowered ............................... > 5 mA
SS99G169 axle raised ........................ < 18.68 mA
Main clutch angle of turn sensor (B17):
Rated voltage: ..............................................5 VDC

Load resistance ..........................................> 200 Ω
1 = ground
2 = supply .......................................5 VDC ('E' box)
3 = signal .........................................0.7 to 4.2 VDC
SS99G161
EHR angle of turn sensor (B9/1):
1 = ground
2 = signal ...............................approx. 2.5 to 7 VDC
3 = supply ................................ 9.5 VDC (EHR box)
SS99H182
EHR force measuring bolts (B10/1,B10/2):
Measurement range:40KN (Bosch end number:545)

60KN (Bosch end number:543)
1 = ground
2 = signal .........................................2.5 to 7.5 VDC
(not loaded, approx. 4.7 VDC)
SS99H181
3 = supply ................................ 9.5 VDC (EHR box)

4003-102
Hall sensor, front PTO shaft (B8):

Current consumption ....................................15 mA
Operating range ...............................1 Hz to 25 kHz
SS99G176
1 = supply
2 = signal
3 = ground
Hall sensor, engine oil temperature (B32):
Supply voltage: .............................................5 VDC

I max ................................................................7 mA
Measurement range.........................-50 to +150 °C
Temp. °C Resistance Ω
MIN NORMAL MAX
-50 500 515 530
0 800 815 830
25 985 1000 1015
SS99G163
100 1661 1696 1731
150 2131 2211 2291
Speed Hall sensor (B4,B5,B6,B7,B12):
1 = supply
2 = signal
3 = ground

Current consumption ....................................21 mA
Operating range .................................2 Hz to 5 kHz
B4 = Main clutch output (L = 53 mm)

B5 = Power shift output (L = 95 mm)
SS99G162 B6 = Driving speed (L = 125 mm)
B7 = PTO shaft (L = 40 mm)
B12 = Engine speed (L = 40 mm)
The design and function of the sensors is identical.
The only difference being in length.

4003-103
Solenoid Valves
Solenoid valve for sprung front axle:

Suppression.....................................double Z diode
Continuous duty............................................ 100%
Resistance............................... 8 Ω ± 10% at 23 °C
127(The values of the 3 solenoid valves used are
identical, they must however be connected
correctly.
SS99G173
Solenoid valves (Y21 to Y27):

Continuous duty............................................ 100%
Resistance...................................28 ± 2 Ω at 20 °C
Hold-on valves Y23 and Y24 have a steel housing

SS99G164 and thus their own SP number.
The electrical values are identical.
4-wheel drive solenoid valve (Y1), Bosch:

Continuous duty............................................ 100%
Resistance.......................... 10.3 Ω ± 10% at 20 °C
SS99G165
Inhibit solenoid valve Y10),

front PTO shaft (Y4),
rear PTO shaft (Y5), Messr’s Hytos:

Continuous duty............................................ 100%
Resistance............................... 8 Ω ± 10% at 20 °C
SS99G166

4003-104
Solenoid valve EHR control unit (Y6,Y7):
Proportional solenoid: .................................12 VDC

I max. ................................................................3.5 A
Current control ................... Pulse width modulation
Coil res........................................................... 1.7 Ω
SS99J021
Solenoid valve (directional control valve)

Auxiliary control unit (Y2/1,Y2/2,Y2/3):

Resistance ..........................................4.4 Ω ± 10%
Power...........................................................32.7 W
Continuous duty ............................................ 100%
SS99J017
Solenoid valve, shut-off valve

Auxiliary control unit (Y2/4):

Resistance .......................................... 5 Ω ± ± 10%
Power...........................................................28.8 W
SS99J025 Continuous duty ............................................ 100%

4003-105
ECCU – Electronic Central Control Unit
SS99G175
List of Plugs
X6/7 Plug-in connection, aux. instrument, steering column
X10/7 Plug-in connection, ECCU auxiliary control unit

4003-106
Instrument Test Values
Fuel gauge B2/1 and B2/2

Diesel level Resistance Ω Pointer angle Display range
0 10 0° from 0 – 12°, red area
1/8 31,2 7,5°
1/2 95 30° from 30 – 35°, white area
1 180 60° from 60 – 65°, white area
Water temperature gauge

Temperature °C Resistance Ω Pointer angle Display range
45 239 0° from 0 – 10°, white area
60 134 0°
75 82 14°
90 51 20°
105 33,4 42° from 42 – 52°, red area
113 26,8 53°
120 22,4 60°
Switch, cooling water temperature (S32):
Switching temp. .......................105 °C

Type of contact ........... Normally open
Compressed air indicator

Pressure in bar Resistance Ω Pointer angle Display range
0 10 0° from 0 – 13°, red area
2 52 0°
4 88 6°
6 124 24° from 37 – 42°, white area
8 155 42°
10 184 60° from 59 – 63°, white area
Tractormeter
Frequency at generator
Engine speed 1/min Permissible deviation Pointer angle terminal "W"
1000 ± 100 67° 260 Hz
2000 ± 65 163° 500 Hz

4003-107
Lamps and Fuses
Rotating beacon H1 12V – 55 W 1-34-772-051
Searchlight H3 12 V – 55 W 90003452243
Headlight, roof headlight H4 12V – 60/55 W 90003450013
Trafficators, front and rear,

brake light P25-1 12 V – 21 W 90003452245
Roof number plate light L 12 V – 5 W 90003452276
Cab interior light L 12V – 10 W 90003452249
Front sidelights, tail light G 12 V – 5 W 90003452216
Cigarette lighter H 12 – V 2 W 90003452207
Digital tractor meter 12 V / 2 W 35700580708
Instrument lighting and

indicator lamps 12 V / 1.2 W 90003450031
Toggle switch EHR,

diagnosis LED W5/1.2 – 12 V – 1.2 W 90003452250
Courtesy light,
EHR console lighting T4/4 12 V 4 W 90003452212
3A violet 1-40-258-203 20A yellow 1-40-258-120

5A beige 1-40-258-105 25A white 1-40-258-125
7.5A brown 1-40-258-107 30A green 1-40-258-130
10A red 1-40-258-110 40A orange 1-40-258-140
15A light blue 1-40-258-115
40A 1-40-177-040
100A 1-40-277-014

4003-108
Operation and Coding the Digital Instrument with Integrated
operating Hours Counter
General information
All functions are called up using the spring-loaded switch (button), marked by the PTO symbol, on the right-hand
side of the instrument panel. The switch need only be pressed briefly to call up operating functions. If it is held
pressed for longer than 10 sec’s. coding values can be checked and/or corrected.
Operating / function
ignition ON/Starting/Operation the display shows a small "h" and the cumulative operating hours.
Press the button again the rear PTO shaft speed will be shown on the display.
Press the button again the front PTO shaft speed will be shown on the display.
Press the button again the operating hours will again be shown on the display.
Coding
the engine speed (operating hours)
the rear PTO shaft speed indication
the front PTO shaft speed indication
General information
Each time the button is briefly pressed, the display will be visibly increased by one impulse. If the button is
pressed continually for longer than 1.5 sec’s. the impulses will be increased rapidly. When the button is released,
"PRO" appears on the display after 8 sec’s. The value set is stored by briefly pressing the button once again and
the display will return to the starting position (operating hours).
Coding the engine speed indication (operating hours)
Press the button for 20 sec’s.
The combination of numbers 1 – 1 appears in the upper part of the display, the current value or value to be
corrected appears in the lower part of the display. The code adjustment range is 15 – 255 impulses. Tractors
9105 – 9145 or CS110 – 150 have the code number 15.
Coding the rear PTO shaft speed indication
corrected appears in the lower part of the display. The code adjustment range is 1 – 100 impulses. The code
number 20 must be set and stored for all models (code number 20 = 20 teeth on the measuring wheel).
Coding the rear PTO front speed indication
corrected appears in the lower part of the display. The code adjustment range is 1 – 100 impulses. The code
number 29 must be set and stored for all models.

4003-109
Calibrating the speedometer
Re-calibration is required after replacing tyres or when 3 bars appear on the km/h display.
Measure out a distance of exactly 100 m and mark

both ends clearly.
– Press the pushbutton/switchover (Rear PTO/

Front PTO/Operating hours) for at least
10 seconds, until CAL appears on the km/h
display.
– Start to drive and when the tractor’s front axle is

in line with the 0 mark, press the pushbutton
briefly – the letters COU will then appear on the
display.
The impulses will be counted to 9999 on the bottom

part of the display, ---- will appear above this, pay
no attention to this.
:$51,1* Minimum speed within the 100 m
markings = 2 km/h – it is possible to drive faster.
– When the front axle is in line with the 100 m

mark, press the pushbutton briefly once again –
the letters PRO appear on the display.
– Bring the tractor to a halt and if the programming

sequence was carried out correctly, press the
pushbutton briefly once again – the tractor will
then store the new, calibrated count.
If a fault occurs during calibration (delay in pressing

the switch etc.) – simply switch the ignition OFF
before pressing the switch for the last time, the
programming sequence will thus not be accepted
and the old values remain in effect.
Repeat the procedure.
SS99H185

Chapter
4004
CIRCUIT DIAGRAM
9105, 9115, 9125, 9145,

CS100, CS110, CS120, CS130, CS150
from DBD0077249 onwards
4004
CNH Österreich GmbH Sva 6-50950 EN © 2002 CNH Österreich GmbH

Technical Documentation / Training Center June, 2002
4004-2
TABLE OF CONTENTS
Index for Circuit Diagram ......................................................................................................... 4
Page 1 ..................................................................................................................................... 6
Page 2 ..................................................................................................................................... 8
Page 3 ................................................................................................................................... 10
Page 4 ................................................................................................................................... 12
Page 5 ................................................................................................................................... 14
Page 6 ................................................................................................................................... 16
Page 7 ................................................................................................................................... 18
Page 8 ................................................................................................................................... 20
Page 9 ................................................................................................................................... 22
Page 10 ................................................................................................................................. 24
Page 11 ................................................................................................................................. 26
Page 12 ................................................................................................................................. 28
Page 13 ................................................................................................................................. 30
Page 14 ................................................................................................................................. 32
Page 15 ................................................................................................................................. 34
Page 16 ................................................................................................................................. 36
Page 17 ................................................................................................................................. 38
Page 18 ................................................................................................................................. 40
Page 19 ................................................................................................................................. 42
Page 20 ................................................................................................................................. 44
Page 21 ................................................................................................................................. 46
Page 22 ................................................................................................................................. 48
Page 23 ................................................................................................................................. 50
Page 24 ................................................................................................................................. 52
Page 25 ................................................................................................................................. 54
Page 26 ................................................................................................................................. 56
Page 27 ................................................................................................................................. 58
Page 28 ................................................................................................................................. 60
Page 29 ................................................................................................................................. 62
Page 30 ................................................................................................................................. 64
Page 31 ................................................................................................................................. 66
Page 32 ................................................................................................................................. 68
Page 33 ................................................................................................................................. 70
Page 34 ................................................................................................................................. 72
Page 35 ................................................................................................................................. 74
Page 36 ................................................................................................................................. 76
Page 37 ................................................................................................................................. 78
Page 38 ................................................................................................................................. 80
Page 39 ................................................................................................................................. 82
Page 40 ................................................................................................................................. 84
Page 41 ................................................................................................................................. 86
Page 42 ................................................................................................................................. 88
Page 43 ................................................................................................................................. 90
List of plugs, left..................................................................................................................... 92
List of plugs, right................................................................................................................... 93
List of plugs (at rear).............................................................................................................. 94
List of plugs on instrument carrier.......................................................................................... 95
List of plugs on the right-hand side of the cab ....................................................................... 96
Central Electrics Print A12..................................................................................................... 97
Print – Roof electrics A13 .................................................................................................... 100
Print A14, engine electrics ................................................................................................... 102
Print – EHR Left, A15 (Distribution Print)............................................................................. 104
EHR-D Print, operating console, A16 .................................................................................. 104
Print, single/double winch A33/1 and A33/2 ........................................................................ 105
4004-3
Instrument carrier for low-top version................................................................................... 106
Relays .................................................................................................................................. 107
Components, gearbox electrics / electronics ....................................................................... 108
Components, electronic 3-point hitch control ....................................................................... 111
Components, air conditioning system .................................................................................. 113
Components, engine / fuel system....................................................................................... 115
Components, sprung front axle ............................................................................................ 116
Components, hydraulics....................................................................................................... 117
Components, brake.............................................................................................................. 118
Components, cab ................................................................................................................. 119
ECCU – Electronic Central Control Unit............................................................................... 120
Test Values .......................................................................................................................... 121
Lamps and Fuses................................................................................................................. 122
Operation and coding of the digital instrument
with integrated operating hours counter ............................................................................... 123
Calibrating the ”Driving speed” display ................................................................................ 124

4004-4
Index for Circuit Diagram
9105 – 9145
CS100 – CS150
Page Page
(e.g. 1) (e.g. 1)
Title Title
Section Section
(e.g. A) (e.g. A)
40A power socket 23C Front sidelights 8C
4-WD 6B Front twinpower roof worklight 12C
4-WD management, Optistop 5B Front washer pump 21D
Air conditioning system for high-top 19A Fuel pump control 3A
Air-sprung seat 28D Gearbox diagnosis 36D
Gearbox display
Automatic pre-glowing 2B Gearbox electronics box supply 36C/37C
Gearbox forward / reverse solenoid
Auxiliary headlight 10A valve 36B
Auxiliary headlight for low-top 11A Gearbox power-shift 36A
Brake light 5A Gearbox sensors 38B
Cigarette lighter 28B Headlights 10B
Clock 17B Heated rear window 17D
Combination instrument 25 - 27A Heated windscreen 17C
Differential lock 6C Horn 21A
Differential lock management 5C Interior light 14F
Dipped/Main beam changeover 10C Interior light for low-top 18C
Door contact switch 14D Italy brake valve 24B
Double-action auxiliary valve with
floating position and interlock block 29B/30B Mirror heating 16A
ECCU supply 40B Mobile socket 28B
EHR box supply, 30 and 15/1 31A Number plate lighting on roof 13B/14C
EHR diagnostics display 35A On-board computer preparation 23B
EHR external pushbutton 32D Opti-Stop 5B
EHR lift/pressure changeover switch 34F Parallel wiper 21C
EHR lighting, front panel 35J Parallel wiper for low-top 22C
EHR lowering speed 35D Power supply 1A
EHR mixed control 35E Power supply with battery main switch 2A
EHR position sensors 31C Pre-glowing with pushbutton 1B
EHR power sensors 31B Radio preparation 17A
EHR preparation, external sensors 31E Radio preparation for low-top 18A
EHR quick-drop 33C Rear outer roof worklight 12A
EHR Raise/Lower indicator 35C Rear PTO shaft 39A
EHR Raise/Lower solenoid valve 31D Rear sidelights 8D
EHR Raise/Lower switch 32C Rear washer pump 21E
EHR setpoint 33D Reserves – central print 7B
EHR slip indicator 35B Reserves – engine print 14B
EHR stop 33E Reserves – roof print 16D/24C
EHR traction control 35H / 32A Roof blower motor 20A
EHR Transport/Control 33A/B Rotating beacon 16B
EHR upper limit 35F Safety switch 28C
Engine cut-off 4B Spot 16C
Entrance light 14E Sprung front axle 40A
External pushbutton, front hitch 30D Standard front wiper 21F
Floor-level heating 15C Standard rear wiper 21G
Front PTO shaft 39B Standard signal socket 32B
4004-5
Start 1C Supply, roof electrics for low-top 18B

Stationary operation cut-off 3B Trafficator system 8A
Steering column switch 21B Trafficators 8B
Supply, auxiliary valves 29A Trailer socket 23A
Supply, D+, EHR box 33F Winch supply 41A
Supply, potential 15/1, combination
24A Worklight on flasher/sidelight 12D
instrument
Supply, potential 58 for various
28E Worklight, front grill 14A
switches
Supply, potentials 30, 31, 15/1 and 15/2 1D Worklight, mudguard 10D
Supply, print, EHR operating console 28A
EHR = Electronic 3-point hitch control

ECCU = Electronic Central Control Unit

Edition 06/2002 Sva 6-50950 EN
Page 1
Ground with gearbox in

neutral
12 V with driving switch
on Start
12 V with gearbox in
neutral and driving
switch on Start
SS02D101
4004-6
Electrical equipment 1 Battery A# Power supply
(5) Weld point, engine cable, potential 31 X1/11 Screw-on connector, central print, 11 Driver’s cab frame
A12 Print, central electrics B# Pre-glowing with pushbutton
Sva 6-50950 EN
potential 30 13 Carrier frame
A14 Print, engine electrics X16/2 Screw-on connector, engine print 30, C Starting
A60/3 ECCU starter interlock fused 16 Starter
E10/1 Flame glow plug X16/3 Screw-on connector, engine print 30, D Supply, potentials 30, 31, 15/1 and 15/2
F30 Fuse, potential 30, starter switch not fused
F40 Main fuse100 A X18/1 Plug-in connection, round, # several versions available
F47 Fuse, potential 15 instrument cable
F48 Fuse, potential 15/2, EHR X24/1 Plug-in connection, round,
F49 Fuse, clock / radio (potential 30) instrument cable
G1 Battery, 12 V X24/2 Plug-in connection, round, cable,
G2/1 Generator, 14V/95A chassis, right
K5/7/1 Relay potential 15/1 supply X24/3 Plug-in connection, round, instrument
K5/7/2 Relay potential 15/2 supply Chassis, right, instrument
K8/1 Relay, starter
K8/2 Relay, pre-glowing Cable colour or coding in accordance with standard 05449
M1 Starter
S1 Starter switch Ident. letter Colour Type of use
S2/53 Switch, pre-glowing A Red +30 (potential 30) = Cont. current
S38 Reed relay (pre-glow indicator) B Beige -- Control line (ground)
X0/16/2 Weld point, instrument, potential 58R C White + Control line (positive)
X0/16/3 Weld point, instrument, potential 31 D Yellow + 15 Si (Potential 15 safety)
X0/16/4 Weld point, instrument, potential 31
X1/2 Plug-in connection, flat, engine cable F Green Signal cable
X1/8 Plug-in connection, flat switched current after
(potential 30 to starter switch) the starter switch
X1/11 Screw-on connector, potential 30
on central print H Orange VDC, stabilised, from the ’E’ Box
X1/12 Screw-on connector, potential 30 K Light blue D+
on bulkhead L Brown Ground via a box
X4/44 Plug-in connection, round, spark start
X5/1 Distributor, ground, central print M Grounding strip
VERSIONS
X6/7 Plug-in connection, reverse, right, ECCU N Pink Spare
to this page
X9/7 Plug-in connection, round, engine,
1 P Colourless Spare
chassis, left
on page/pages S Black Ground, directly to a grounding point
X9/13 Plug-in connection, round, engine cable
X9/21 Plug-in connection, round, engine cable 2
Edition 06/2002
4004-7
Page 2
Variant for version

with low-top
Ground with gearbox
in neutral
12 V with driving switch
on Start
12 V with gearbox in
neutral and driving
switch on Start
SS02D102
4004-8
(5) Weld point, engine cable, potential 31 X16/2 Screw-on connector, engine print 30, 1 Battery A# Power supply + battery main switch
A12 Print, central electrics fused 11 Driver’s cab frame
A14 Print, engine electrics B# Automatic pre-glowing
Sva 6-50950 EN
X16/3 Screw-on connector, engine print 30, 13 Carrier frame
A60/3 ECCU starter interlock not fused C Starting
E10/1 Flame glow plug X18/1 Plug-in connection, round, instrument 16 Starter
F30 Fuse, potential 30, starter switch cable # several versions available
F40 Main fuse, 100 A X24/1 Plug-in connection, round, instrument
F47 Fuse, potential 15 cable
F48 Fuse, potential 15/2, EHR X24/2 Plug-in connection, round, cable, chassis,
F49 Fuse, clock right
G1 Battery, 12 V X24/3 Plug-in connection, round, instrument –
G2/1 Generator, 14 V / 95 A chassis, right
K4/2/1 40 sec. time relay, pre-glowing X31/1 Plug-in connection, round, instrument –
K5/7/1 Relay potential 15/1 supply engine
K8/1 Relay, starter
M1 Starter
Q1 Main switch, battery
S1 Starter switch Ident. letter Colour Type of use
S2/53 Switch, pre-glowing A Red +30 (potential 30) = Cont. current
S38 Reed relay (pre-glow indicator)
W1/7 Pre-glow contact bridge B Beige -- Control line (ground)
X0/16/2 Weld point, instrument, potential 58R C White + Control line (positive)
X0/16/3 Weld point, instrument, potential 31 D Yellow + 15 Si (Potential 15 safety)
X1/1 Plug-in connection, flat, engine cable E Grey Potential 58 Lighting cable
X1/2 Plug-in connection, flat, engine cable F Green Signal cable
X1/8 Plug-in connection, flat
switched current after
(potential 30 to starter switch)
the starter switch
X1/11 Screw-on connector, potential 30
on central print H Orange VDC, stabilised, from the 'E' Box
X1/12 Screw-on connector, potential 30 K Light blue D+
on bulkhead
X4/44 Plug-in connection, round, spark start
X5/1 Distributor, ground, central print M Grounding strip
VERSIONS
X6/7 Plug-in connection, chassis, right, ECCU N Pink Spare
to this page
X9/7 Plug-in connection, round,
engine, chassis, left
X9/21 Plug-in connection, round, engine cable 1
Edition 06/2002
4004-9
4004-10
SS02D103
Page 3

(5) Weld point, engine cable, potential 31 X18/1 Plug-in connection, round, A Fuel pump control
A12 Print, central electrics instrument cable
A14 Print, engine electrics B# Stationary operation cut-out
X18/2 Plug-in connection, round, cable,
Sva 6-50950 EN
B2/1 Fuel tank level transmitter, left roof supply # several versions available
F21 Fuse, potential D+ X24/1 Plug-in connection, round,
F29 Fuse, potential 15, cut-off instrument cable
F50 Fuse, engine cut-off X24/2 Plug-in connection, round, cable,
K4/1/2 Relay, engine cut-off chassis, right
K5/1 Relay, engine cut-off bridge X24/3 Plug-in connection, round, instrument
K5/11 Relay, potential D+ supply chassis, right
K5/16 Relay, stationary operation X31/1 Plug-in connection, round,
K5/19 Relay, stationary operation instrument – engine
K5/20 Relay, stationary operation Y12 Engine cut-off solenoid
M8/1 Left-hand fuel pump motor
M8/2 Right-hand fuel pump motor
S6 Switch, engine oil pressure indicator
V3/2 Diode 3 A interlock Ident. letter Colour Type of use
V3/3 Diode 3 A interlock A Red +30 (potential 30) = Cont. current
V3/7 Diode 3 A interlock
W1/4 Spark start contact bridge C White + Control line (positive)
X0/16/2 Weld point, instrument, potential 58 R D Yellow + 15 Si (Potential 15 safety)
X0/16/4 Weld point, instrument, potential 31 E Grey Potential 58 Lighting cable
X0/17/10Weld point, chassis, right, potential 31 F Green Signal cable
X0/17/11 Weld point, chassis, right, potential D+ G Violet + 15 (potential 15.1 or 15.2)
X1/4 Plug-in connection, flat, engine cable switched current after
X2/7 Plug-in connection, flat, chassis, right – the starter switch
fuel pump, auxiliary tank
X4/44 Plug-in connection, round, spark start H Orange VDC, stabilised, from the 'E' Box
X6/10 Plug-in connection, chassis, K Light blue D+
left – instrument
X10/1 Plug-in connection, round, M Grounding strip
instrument cable VERSIONS
N Pink Spare
X14/1 Plug-in connection, round, cable, to this page
chassis, left
X14/2 Plug-in connection, instrument cable on page/pages S Black Ground, directly to a grounding point
4
Edition 06/2002
4004-11
4004-12
SS02D104
Page 4

(5) Weld point, engine cable, potential 31 X18/1 Plug-in connection, round, A Fuel pump control
A12 Print, central electrics instrument cable
A14 Print, engine electrics X18/2 Plug-in connection, round, cable, B# Engine cut-off
Sva 6-50950 EN
B2/1 Fuel tank level transmitter, left roof supply
X24/1 Plug-in connection, round, # several versions available
F29 Fuse, potential 15, cut-out instrument cable
F50 Fuse, engine cut-off X24/2 Plug-in connection, round, cable,
K4/1/2 Relay, engine cut-off chassis, right
K5/1 Relay, engine cut-off bridge X24/3 Plug-in connection, round, instrument –
K5/11 Relay, potential D+ supply chassis, right
K5/16 Relay, stationary operation X31/1 Plug-in connection, round,
K5/19 Relay, stationary operation instrument – engine
K5/20 Relay, stationary operation Y12 Engine cut-off solenoid
M8/1 Left-hand fuel pump motor
M8/2 Right-hand fuel pump motor
S12 Switch, engine oil pressure indicator
S32 Switch, water temperature indicator Cable colour or coding in accordance with standard 05449
V3/2 Diode 3 A interlock Ident. letter Colour Type of use
V3/3 Diode 3 A interlock A Red +30 (potential 30) = Cont. current
V3/8 Diode 3 A interlock B Beige -- Control line (ground)
W1/4 Spark start contact bridge C White + Control line (positive)
X0/16/2 Weld point, instrument, potential 58 R D Yellow + 15 Si (Potential 15 safety)
X0/16/4 Weld point, instrument, potential 31 E Grey Potential 58 Lighting cable
X0/17/10Weld point, chassis, right, potential 31 F Green Signal cable
X0/17/11 Weld point, chassis, right, potential D+
X2/7 Plug-in connection, flat, chassis, right –
the starter switch
fuel pump, auxiliary tank
X4/44 Plug-in connection, round, spark start H Orange VDC, stabilised, from the 'E' Box
X6/10 Plug-in connection, chassis, K Light blue D+
left – instrument
instrument cable VERSIONS
to this page N Pink Spare
chassis, left 4 P Colourless Spare
X14/2 Plug-in connection, instrument cable on page/pages S Black Ground, directly to a grounding point
3
Edition 06/2002
4004-13
Page 5 4004-14
Sva 6-50950 EN
Ground for EHR control
12 V at v > 14 km/h
12 V when rear diff. lock ON

12 V during diff. lock
12 V when brake not operated

12 V when 4 WD switch on
Management, v > 14 km/h
505 Hz at 14 km/h
Ground for steering brake

Ground for diff. lock ON
12 V when diff. lock ON
management
Ground for 4 WD ON
12 V when 4 WD OFF
12 V when 4 WD OFF
SS02D105
Edition 06/2002
A10 Electronics, 4-wheel drive/differential lock A Brake light
management
A12 Print, central electrics B# 4-wheel drive Opti Stop management
Sva 6-50950 EN
C# Differential lock management
E12 Brake light, left
E13 Brake light, right # several versions available
F11 Fuse, brake light
K5/12 Relay, brake light/Opti-Stop
S2/59 Switch, 4-wheel drive management
S25 Switch, steering brake
(for diff. lock management)
W1/3 Opti-Stop contact bridge
W1/5 Contact bridge, Low signal
X0/17/14Weld point, chassis, right, potential 31
X4/14 Plug-in connection, chassis, right Cable colour or coding in accordance with standard 05449
(brake light switch) Ident. letter Colour Type of use
X4/45 Plug-in connection, sprung front axle A Red +30 (potential 30) = Cont. current
left – instrument B Beige -- Control line (ground)
X10/2 Plug-in connection, round, cable, C White + Control line (positive)
chassis, right D Yellow + 15 Si (Potential 15 safety)
chassis, left E Grey Potential 58 Lighting cable
X14/9 Plug-in connection, chassis, right –
4-WD / differential management switch
X18/3 Plug-in connection, chassis, right, ECCU
the starter switch
chassis, right H Orange VDC, stabilised, from the 'E' Box
Y1 4-wheel drive solenoid valve K Light blue D+
Y10 Differential lock solenoid valve
M Grounding strip
VERSIONS
on page/pages
6
Edition 06/2002
4004-15
Page 6 4004-16
Sva 6-50950 EN
Ground for 4 WD ON
12 V when 4 WD OFF
12 V when 4 WD OFF
SS02D106
Edition 06/2002
A10 Electronics, 4-wheel drive/differential lock A Brake light
management
A12 Print, central electrics B# 4-wheel drive
Sva 6-50950 EN
C# Differential lock
E13 Brake light, right # several versions available
F11 Fuse, brake light
K5/12 Relay, brake light/Opti-Stop
S2/27 Switch, 4-wheel drive
W1/3 Opti-Stop contact bridge
W1/5 4-WD management contact bridge
W1/6 Ground contact bridge
(differential lock indicator)
W1/8 Contact bridge, solenoid valve plus,
differential lock
X0/17/14Weld point, chassis, right, potential 31 Ident. letter Colour Type of use
X4/14 Plug-in connection, chassis, right A Red +30 (potential 30) = Cont. current
X4/54 Distributor, Multi-Controller joystick
left – instrument C White + Control line (positive)
X10/2 Plug-in connection, round, cable, D Yellow + 15 Si (Potential 15 safety)
chassis, right
X14/1 Plug-in connection, round, cable, E Grey Potential 58 Lighting cable
chassis, left F Green Signal cable
X14/9 Plug-in connection, chassis right, 4-WD/ switched current after
differential lock management switch the starter switch
X24/2 Plug-in connection, round, cable, H Orange VDC, stabilised, from the 'E' Box
chassis, right K Light blue D+
Y1 4-wheel drive solenoid valve
Y10 Differential lock solenoid valve
M Grounding strip
VERSIONS
N Pink Spare
to this page
5
Edition 06/2002
4004-17
4004-18
SS02D107
Page 7

A12 Print, central electrics B Reserves – central print
F10 Fuse 15, roof, front-loader
F15 Fuse, front loader
Sva 6-50950 EN
F27 Trafficators
F35 Fuse, potential 15, gearbox CVT
K5/37 Relay, central print, reserve
X5/1 Distributor, ground, central print
X6/1 Plug-in connection, spare
chassis, right
instrument cable
roof supply cable
the starter switch
H Orange VDC, stabilised, from the ’E’ Box
K Light blue D+
M Grounding strip
N Pink Spare
P Colourless Spare
Edition 06/2002
4004-19
4004-20
SS02D108
Page 8

A12 Print, central electrics X15/16 Plug-in connection, round, cable, 7 Roof panel A Trafficator system
A13 Print, roof electrics roof supply
A16 Print, EHR operating console B# Trafficator
Sva 6-50950 EN
X16/5 Screw-on connection, ground, roof print
E3 Sidelight, front left X18/2 Plug-in connection, round, cable, C# Sidelight, front
E4 Sidelight, rear left roof supply
E6 Sidelight, front right X24/1 Plug-in connection, instrument cable D Sidelight, rear
E7 Sidelight, rear right X24/2 Plug-in connection, chassis, right
E14 Trafficator, front right X24/5 Plug-in connection, EHR-D print
E15 Trafficator, rear right
E21/1 Position light, in auxiliary headlamp, left
E22/1 Position light, in auxiliary headlamp,
right
F1 Fuse, light potential 58 left
F2 Fuse, light potential 58, right
F60 Fuse, sidelight, front left
F61 Fuse, sidelight, potential 58
K2 Trafficator relay Ident. letter Colour Type of use
K5/10 Relay, light (potential 58) A Red +30 (potential 30) = Cont. current
S2/5 Switch, hazard warning lights
S4/2 Switch, steering column, trafficator
X0/16/1 Weld point, instrument, potential 58, left C White + Control line (positive)
X0/16/2 Weld point, instrument, potential 58, right D Yellow + 15 Si (Potential 15 safety)
X0/17/12Weld point, chassis, right, potential 31 E Grey Potential 58 Lighting cable
X0/23/1 Weld point, chassis, left, potential 31 F Green Signal cable
X1/30 Plug-in connection, potential 30, G Violet + 15 (potential 15.1 or 15.2)
central print switched current after
X4/.. Plug-in connection, roof switch the starter switch
instrument cable H Orange VDC, stabilised, from the ’E’ Box
X10/19 Plug-in connection, flat, cable, K Light blue D+
EHR-D print
chassis, left M Grounding strip
X14/2 Plug-in connection, instrument cable VERSIONS
X14/8 Plug-in connection, instrument,
steering column
X15/14 Plug-in connection, round, roof frame on page/pages S Black Ground, directly to a grounding point
9
Edition 06/2002
4004-21
4004-22
SS02D109
Page 9

A12 Print, central electrics X24/2 Plug-in connection, round, cable, A Trafficator system
A16 Print, EHR operating console chassis, right
E3 Sidelight, front left B# Trafficator for low-top
X24/5 Plug-in connection, EHR-D print
Sva 6-50950 EN
E4 Sidelight, rear left X14/8 Plug-in connection, instrument, C# Sidelight, front for low-top
E6 Sidelight, front right steering column
E7 Sidelight, rear right X15/15 Plug-in connection, roof canopy cable D Sidelight, rear
E14 Trafficator, front right X15/16 Plug-in connection, roof supply cable
E15 Trafficator, rear right X18/1 Plug-in connection, instrument cable
E16 Trafficator, rear left X18/2 Plug-in connection, roof supply cable
E17 Trafficator, front left X24/1 Plug-in connection, instrument cable
F1 Fuse, light potential 58, left X24/2 Plug-in connection, cable, chassis, right
F2 Fuse, light potential 58, right X31/1 Plug-in connection, instrument, engine
F82 Sidelight, front left
F83 Sidelight, front right
K2 Trafficator relay
K5710 Relay, light (potential 58)
S2/5 Switch, hazard warning lights
S4/2 Switch, steering column, trafficator
X0/16/1 Weld point, instrument, potential 58, left Ident. letter Colour Type of use
X0/16/2 Weld point, instrument, potential 58, right A Red +30 (potential 30) = Cont. current
X0/19/4 Weld point, low-top 31 C White + Control line (positive)
X0/19/5 Weld point, low-top 31 D Yellow + 15 Si (Potential 15 safety)
X0/23/1 Weld point, chassis, left, potential 31
X1/30 Plug-in connection, potential 30, E Grey Potential 58 Lighting cable
central print F Green Signal cable
X10/19 Plug-in connection, flat, cable, switched current after
EHR-D print the starter switch
chassis, left H Orange VDC, stabilised, from the ’E’ Box
steering column
X15/16 Plug-in connection, round, cable, M Grounding strip
roof supply VERSIONS
N Pink Spare
X18/2 Plug-in connection, round, cable, to this page
roof supply
X24/1 Plug-in connection, round, on page/pages S Black Ground, directly to a grounding point
instrument cable 8
Edition 06/2002
4004-23
4004-24
SS02D110
Page 10

(8) Weld point, engine cable, potential 31 X4/40 Plug-in connection, round, roof switch A# Auxiliary headlight
A12 Print, central electrics X9/13 Plug-in connection, round, engine cable
A13 Print, roof electrics B Headlight
Sva 6-50950 EN
A14 Print, engine electrics instrument cable C Dipped beam, main beam
E1 Headlight, left X12/15 Plug-in connection, round, roof
E2 Headlight, right canopy cable D# Worklight, mudguard
E8 Worklight, left-hand mudguard X14/1 Plug-in connection, round, cable,
E9 Worklight, right-hand mudguard chassis, left
E21 Auxiliary headlight, left X14/8 Plug-in connection, instrument,
E22 Auxiliary headlight, right # several versions available
steering column
F3 Fuse, worklight, mudguard X15/15 Plug-in connection, round, roof
F4 Fuse, dipped-beam canopy cable
auxiliary headlight, left X15/16 Plug-in connection, round, cable,
F5 Fuse, dipped-beam roof supply
auxiliary headlight, right X18/1 Plug-in connection, round,
F7 Fuse, dipped-beam, headlight instrument cable
right X18/2 Plug-in connection, round, cable,
F8 Fuse, dipped beam left, headlight, left roof supply
F9 Fuse, main-beam Cable colour or coding in accordance with standard 05449
F12 Fuse, headlight flasher instrument cable Ident. letter Colour Type of use
F45 Fuse, supply, potential 58 X24/2 Plug-in connection, round, cable, A Red +30 (potential 30) = Cont. current
K5/5 Relay, switchover, main beam chassis, right
K5/6 Relay, switchover, dipped beam B Beige -- Control line (ground)
K5/9 Relay, worklight, mudguard instrument – engine C White + Control line (positive)
S2/1 Switch, lighting system
S2/17 Switch, auxiliary headlight
S2/64 Switch, worklight, mudguard E Grey Potential 58 Lighting cable
S4/1 Switch, steering column, F Green Signal cable
main/dipped beam
X0/16/1 Weld point, instrument, potential 58,
the starter switch
left
X0/16/3 Weld point, instrument, potential 31 H Orange VDC, stabilised, from the 'E' Box
X0/17/12Weld point, chassis, right, potential 31 K Light blue D+
X3/6 Flat plug-in connection, auxiliary headlight L Brown Ground via a box
X3/7 Flat plug-in connection, auxiliary headlight M Grounding strip
VERSIONS
X4/6 Plug-in connection, round, roof canopy – N Pink Spare
to this page
auxiliary headlight
X4/7 Plug-in connection, round, roof canopy –
on page/pages
auxiliary headlight S Black Ground, directly to a grounding point
11
Edition 06/2002
4004-25
4004-26
SS02D111
Page 11

(8) Weld point, engine cable, potential 31 X4/7 Plug-in connection, round, roof canopy – A# Auxiliary headlight for low-top
A12 Print, central electrics auxiliary headlight
A14 Print, engine electrics B Headlight
Sva 6-50950 EN
E1 Headlight, left X10/1 Plug-in connection, round, C Dipped beam, main beam
E2 Headlight, right instrument cable
E8 Worklight, left-hand mudguard X14/1 Plug-in connection, round, cable, D Worklight, mudguard
E9 Worklight, right-hand mudguard chassis, left
E21 Auxiliary headlight, left X14/8 Plug-in connection, instrument,
E22 Auxiliary headlight, right steering column
F3 Fuse, worklight, mudguard # several versions available
F4 Fuse, dipped-beam, roof supply
auxiliary headlight, left X18/1 Plug-in connection, round,
F5 Fuse, dipped-beam, auxiliary headlight, instrument cable
right X18/2 Plug-in connection, round, cable,
F7 Fuse, dipped-beam, headlight, roof supply
right X24/1 Plug-in connection, round,
F8 Fuse, dipped beam left, headlight, left instrument cable
F9 Fuse, main-beam X24/2 Plug-in connection, round, cable,
F12 Fuse, headlight flasher Cable colour or coding in accordance with standard 05449
chassis, right
F45 Fuse, supply, potential 58 X31/1 Plug-in connection, round, Ident. letter Colour Type of use
K5/5 Relay, switchover, main beam instrument – engine A Red +30 (potential 30) = Cont. current
K5/6 Relay, switchover, dipped beam
K5/9 Relay, worklight, mudguard B Beige -- Control line (ground)
S2/1 Switch, lighting system C White + Control line (positive)
S2/38 Switch, auxiliary headlight D Yellow + 15 Si (Potential 15 safety)
S2/64 Switch, worklight, mudguard
S4/1 Switch, steering column, E Grey Potential 58 Lighting cable
main/dipped beam F Green Signal cable
left
the starter switch
X0/17/12Weld point, chassis, right, potential 31 H Orange VDC, stabilised, from the 'E' Box
X0/19/1 Weld point, low-top 56a K Light blue D+
X0/19/2 Weld point, low-top 15
X0/23/1 Weld point, chassis, left, potential 31 M Grounding strip
VERSIONS
X3/6 Flat plug-in connection, auxiliary headlight N Pink Spare
to this page
X3/7 Flat plug-in connection, auxiliary headlight
on page/pages
auxiliary headlight S Black Ground, directly to a grounding point
10
Edition 06/2002
4004-27
4004-28
SS02D112
Page 12
for low-top version

A13 Print, roof electrics X4/22 Plug-in connection, round, roof A# Rear outer worklight
E23/1 Worklight, roof, rear, inner canopy cable
E23/2 Worklight, roof, rear, outer B# Rear inner worklight
Sva 6-50950 EN
X4/23 Plug-in connection, round, roof
E24/1 Worklight, roof, rear, inner canopy cable C# Front worklight, twin-power
E24/2 Worklight, roof, rear, outer X4/24 Plug-in connection, round, roof
E33 Worklight, roof, front, canopy cable D# Worklight, trafficator/position-
twin-power X4/26 Plug-in connection, round, roof frame light
E34 Worklight, roof, front, X4/29 Plug-in connection, round, roof switch
twin-power X4/36 Plug-in connection, round, roof switch
E35 Worklight on trafficator/position X4/37 Plug-in connection, round, roof switch # several versions available
light X4/38 Plug-in connection, round, roof switch
E36 Worklight on trafficator/position X12/15 Plug-in connection, round, roof
light canopy cable
F67 Fuse, worklight, twin-power X15/15 Plug-in connection, round, roof
F68 Fuse, 2 worklights, rear canopy cable
F70 Fuse, 4 worklights, X15/16 Plug-in connection, round, cable,
roof number plate roof supply
F73 Fuse, worklight X16/4 Screw-on connector, roof print 30 Cable colour or coding in accordance with standard 05449
K5/30 Relay, 2 worklights, roof, rear, Ident. letter Colour Type of use
outer A Red +30 (potential 30) = Cont. current
K5/31 Relay, worklight, twin-power
K5/34 Relay, 4 worklights, number plate on
roof C White + Control line (positive)
K5/38 Relay, worklight, D Yellow + 15 Si (Potential 15 safety)
S2/63/1 Switch, rear worklight, 2+2 E Grey Potential 58 Lighting cable
S2/63/2 Switch, front worklight, 2+2 F Green Signal cable
V3/10 Diode 3 A interlock G Violet + 15 (potential 15.1 or 15.2)
V3/11 Diode 3 A interlock switched current after
V3/12 Diode 3 A interlock the starter switch
X3/8 Flat plug-in connection, worklight, H Orange VDC, stabilised, from the 'E' Box
twin-power K Light blue D+
X3/9 Flat plug-in connection, worklight,
twin-power
X4/8 Plug-in connection, round, roof canopy – M Grounding strip
VERSIONS
worklight N Pink Spare
to this page
worklight
13
canopy cable
Edition 06/2002
4004-29
4004-30
SS02D113
Page 13
for low-top version

A13 Print, roof electrics X4/9 Plug-in connection, round, roof canopy – A# Rear outer worklight
E5/3 Lighting, number plate, roof worklight
E5/4 Lighting, number plate, roof B# Number plate lighting for
Sva 6-50950 EN
E23/2 Worklight, roof, rear, outer canopy cable 2 worklights, up to 05.96
E24/2 Worklight, roof, rear, outer X4/22 Plug-in connection, round, roof
E33 Worklight, roof, front, C# Front worklight, twin-power
canopy cable
twin-power X4/23 Plug-in connection, round, roof D# Worklight, trafficator/
E34 Worklight, roof, front, canopy cable
twin-power position-light
E35 Worklight on trafficator/position canopy cable
light X4/26 Plug-in connection, round, roof frame
E36 Worklight on trafficator/position X4/29 Plug-in connection, round, roof switch # several versions available
light X4/36 Plug-in connection, round, roof switch
F67 Fuse, worklight, twin-power X4/37 Plug-in connection, round, roof switch
F68 Fuse, 2 worklights, rear X4/38 Plug-in connection, round, roof switch
F70 Fuse, 4 worklights, X12/15 Plug-in connection, round, roof
roof number plate canopy cable
F73 Fuse, worklight X15/15 Plug-in connection, round, roof Cable colour or coding in accordance with standard 05449
trafficator/position light canopy cable
K5/30 Relay, 2 worklights, roof, rear, X15/16 Plug-in connection, round, cable, Ident. letter Colour Type of use
outer roof supply A Red +30 (potential 30) = Cont. current
K5/31 Relay, worklight, twin-power X16/4 Screw-on connector, roof print 30 B Beige -- Control line (ground)
K5/34 Relay, 4 worklights, number plate on
roof C White + Control line (positive)
K5/38 Relay, worklight, D Yellow + 15 Si (Potential 15 safety)
S2/34/1 Switch, worklight, twinpower E Grey Potential 58 Lighting cable
S2/34/2 Switch, 2 worklights, roof, F Green Signal cable
rear G Violet + 15 (potential 15.1 or 15.2)
S2/34/3 Switch, worklight, switched current after
trafficator/position light the starter switch
V3/11 Diode 3 A interlock H Orange VDC, stabilised, from the 'E' Box
V3/12 Diode 3 A interlock K Light blue D+
X3/8 Flat plug-in connection, worklight,
twin-power M Grounding strip
X3/9 Flat plug-in connection, worklight, VERSIONS
twin-power
worklight on page/pages S Black Ground, directly to a grounding point
12
Edition 06/2002
4004-31
4004-32
SS02D114
Page 14

(8) Weld point, engine cable, potential 31 2 Instrument panel A Worklight, front grill
A13 Print, roof electrics 8 Battery console
A14 Print, engine electrics B Reserves – engine print
Sva 6-50950 EN
C# Number plate lighting on roof
E19 Interior lighting D# Door contact switch
E30 Step light, left
E61 Worklight, front grill E# Entrance (step) light
E62 Worklight, front grill
F44 Fuse, worklight, front grill F# Interior light
K4/2/2 Time relay, 40 secs., interior lighting
K5/25 Relay, worklight, front grill
S2/2 Switch, worklight, front grill # several versions available
left
X2/20 Reserve
X2/21 Reserve Ident. letter Colour Type of use
X3/25 Reserve A Red +30 (potential 30) = Cont. current
X4/18 Plug-in connection, round, roof frame
X4/43 Plug-in connection, round, number
plate light C White + Control line (positive)
X4/.. Plug-in connection, round, roof switch D Yellow + 15 Si (Potential 15 safety)
canopy cable E Grey Potential 58 Lighting cable
X9/15 Plug-in connection, round, engine cable F Green Signal cable
X9/21 Plug-in connection, round, engine cable G Violet + 15 (potential 15.1 or 15.2)
X15/14 Plug-in connection, round, roof frame switched current after
X31/1 Plug-in connection, round, the starter switch
instrument – engine
H Orange VDC, stabilised, from the 'E' Box
K Light blue D+
M Grounding strip
VERSIONS N Pink Spare
to this page
P Colourless Spare
14
18
Edition 06/2002
4004-33
4004-34
SS02D115
Page 15

A Worklight, front grill
(5) Weld point, engine cable, potential 31 B Reserve – engine print
Sva 6-50950 EN
(8) Weld point, engine cable, potential 31
A12 Print, central electrics C Foot-well heating
F26 Fuse, heating
F44 Fuse, worklight, front grill
K5/25 Relay, worklight, front grill
M3 Heater blower motor
S2/2 Switch, worklight, front grill
S50/1 Switch, 3-stage blower motor
left
X1/26 Plug-in connection, flat, central
print – blower motor Cable colour or coding in accordance with standard 05449
X2/20 Reserve
X2/21 Reserve
X3/25 Reserve A Red +30 (potential 30) = Cont. current
X4/10 Plug-in connection, flat, heater B Beige -- Control line (ground)
blower motor
X9/21 Plug-in connection, round, engine cable D Yellow + 15 Si (Potential 15 safety)
X14/2 Plug-in connection, instrument cable E Grey Potential 58 Lighting cable
the starter switch
K Light blue D+
M Grounding strip
N Pink Spare
P Colourless Spare
Edition 06/2002
4004-35
4004-36
SS02D116
Page 16

A Mirror heating
A5/1 Rotating beacon, left B Rotating beacons
Sva 6-50950 EN
A5/2 Rotating beacon, right
A13 Print, roof electrics C Spot
E18/1 Heated mirror, left
E18/2 Heated mirror, right D Reserves – roof print
E20 Spot
F69 Fuse, rotating beacon
K5/33 Relay, rotating beacon
K5/35 Relay, heated mirror
K5/36 Reserve relay
S2/18 Switch, rotating beacon
S2/19 Switch, heated mirror
X4/15 Plug-in connection, round, mirror heating
X4/16 Plug-in connection, round, reserve Cable colour or coding in accordance with standard 05449
X4/33 Socket, rotating beacon, left
X4/34 Socket, rotating beacon, right
X4/35 Plug-in connection, round, switch, A Red +30 (potential 30) = Cont. current
rotating beacon B Beige -- Control line (ground)
X4/39 Plug-in connection, round, roof switch
X4/43 Plug-in connection, round, number
plate light D Yellow + 15 Si (Potential 15 safety)
X6/2 Plug-in connection, round, roof frame E Grey Potential 58 Lighting cable
canopy cable F Green Signal cable
the starter switch
K Light blue D+
M Grounding strip
N Pink Spare
P Colourless Spare
Edition 06/2002
4004-37
4004-38
SS02D117
Page 17

19 Shock absorber, A# Radio preparation
roof
A6 Radio B Digital clock
Sva 6-50950 EN
A13 Print, roof electrics C Heated windscreen
B14 Left-hand loudspeaker
B15 Right-hand loudspeaker D Heated rear window
E25 Heated windscreen
E26 Heated rear window
F72 Fuse, spot, interior lighting, heated mirror # several versions available
F76 Fuse, heated rear window
F77 Fuse, heated windscreen
K6/7 Relay, heated rear window
K6/8 Relay, heated rear window
P7 Digital clock
S2/16/1Switch, heated rear window
S2/16/2Switch, heated windscreen
W6 Aerial Cable colour or coding in accordance with standard 05449
heated windscreen
X4/20 Plug-in connection, round, heated A Red +30 (potential 30) = Cont. current
rear window B Beige -- Control line (ground)
X4/41 Plug-in connection, round, roof switch
X4/42 Plug-in connection, round, roof switch C White + Control line (positive)
X6/2 Plug-in connection, round, roof frame D Yellow + 15 Si (Potential 15 safety)
X12/15 Plug-in connection, round, roof E Grey Potential 58 Lighting cable
canopy cable
X15/14 Plug-in connection, round, roof frame F Green Signal cable
X15/16 Plug-in connection, round, cable, G Violet + 15 (potential 15.1 or 15.2)
roof supply switched current after
instrument cable
roof supply K Light blue D+
M Grounding strip
VERSIONS
on page/pages
14, 18
Edition 06/2002
4004-39
4004-40
SS02D118
Page 18

7 Roof panel A# Radio preparation, for low-top
(7) Distributor, ground, low-top 19 Shock absorber,
B Roof supply, for low-top
Sva 6-50950 EN
A6 Radio roof
A12 Print, central electrics C# Interior lighting, for low-top
B14 Left-hand loudspeaker
B15 Right-hand loudspeaker
E19 Interior lighting
# several versions available
F10 Fuse 15, roof, front light
F80 Fuse, interior lighting
F85 Fuse, radio
W6 Aerial
X15/16 Plug-in connection, round, cable, Cable colour or coding in accordance with standard 05449
roof supply
instrument cable A Red +30 (potential 30) = Cont. current
X18/2 Plug-in connection, round, cable, B Beige -- Control line (ground)
roof supply
the starter switch
K Light blue D+
M Grounding strip
VERSIONS
14, 17
Edition 06/2002
4004-41
4004-42
SS02D119
Page 19

A# Air conditioning, high-top
A12 Print, central electrics X18/1 Plug-in connection, round,
Sva 6-50950 EN
A13 Print, roof electrics instrument cable
A14 Print, engine electrics X18/2 Plug-in connection, round, cable, # several versions available
A20 Air conditioning, control roof supply
A21 Speed control, blower motor X31/1 Plug-in connection, round,
F41 Fuse, reserve potential 30 instrument – engine
F42 Fuse, reserve potential 30 Y13 Magnetic coupling, air conditioning
F65 Fuse, air conditioning system system
F66 Fuse, blower, air conditioning system
K5/26 Reserve relay
K5/27 Relay, bridge air conditioning, compressor
M12 Evaporator, air conditioning system
R9 Temperature sensor, air conditioning
system
R10 Potentiometer, air conditioning system,
temperature setting Cable colour or coding in accordance with standard 05449
R11 Potentiometer, blower motor
(speed setting)
S30 Safety switch, air conditioning system A Red +30 (potential 30) = Cont. current
(pressure switch) B Beige -- Control line (ground)
W2 Screened cable, air conditioning system
X2/15 Plug-in connection, flat, EHR lift/pressure
X2/20 Reserve D Yellow + 15 Si (Potential 15 safety)
X3/14 Flat plug-in connection, roof supply E Grey Potential 58 Lighting cable
X3/40 Plug-in connection, air conditioning,
control unit F Green Signal cable
X3/41 Plug-in connection, round, G Violet + 15 (potential 15.1 or 15.2)
air conditioning temperature sensor switched current after
X3/42 Plug-in connection, round, potentiometer, the starter switch
blower motor H Orange VDC, stabilised, from the ’E’ Box
X9/11 Plug-in connection, round, roof air
conditioning system K Light blue D+
X9/14 Plug-in connection, round, engine cable L Brown Ground via a box
X9/16 Plug-in connection, round, air conditioning
M Grounding strip
system VERSIONS
X15/16 Plug-in connection, round, cable, to this page N Pink Spare
roof supply 19 P Colourless Spare
20
Edition 06/2002
4004-43
4004-44
SS02D120
Page 20

A# Blower motor, roof
Sva 6-50950 EN
A14 Print, engine electrics # several versions available
F42 Fuse, air conditioning system
F65 Fuse, air conditioning system
F66 Fuse, blower, air conditioning system
K5/26 Reserve relay
K5/27 Relay, air conditioning, compressor
M10 Roof blower motor
S2/54/3Switch, blower (speed levels 1-2-3)
S2/58/2Switch, blower ON / OFF
X9/11 Plug-in connection, round, roof air
conditioning system Cable colour or coding in accordance with standard 05449
air conditioning system A Red +30 (potential 30) = Cont. current
X15/16 Plug-in connection, round, cable, B Beige -- Control line (ground)
roof supply
roof supply D Yellow + 15 Si (Potential 15 safety)
X31/1 Plug-in connection, round, E Grey Potential 58 Lighting cable
the starter switch
K Light blue D+
M Grounding strip
VERSIONS
on page/pages
19
Edition 06/2002
4004-45
4004-46
SS02D121
Page 21

(8) Weld point, engine cable, potential 31 A Horn
A13 Print, roof electrics B Steering column switch
Sva 6-50950 EN
F25 Fuse, wiper, horn
C Parallel wiper, front
F63 Fuse, rear wiper
F64 Fuse, front wiper D Washer pump, front
(for hinged windscreen)
H1 Horn E Washer pump, rear
K3 Interval relay
K5/2 Relay, roof-mounted wiper, front F# Standard wiper, front
M2/1 Parallel wiper motor, front G# Standard wiper, rear
M2/2 Standard wiper motor, front
M4/2 Standard wiper motor, rear
M5 Washer pump motor, rear
M6 Washer pump motor, front # several versions available
S2/30 Switch, rear washer/wiper system
S4/3 Switch, washer/wiper system
(steering column)
X0/16/4 Weld point, instrument, potential 31 Cable colour or coding in accordance with standard 05449
X0/23/1 Weld point, chassis, left, potential 31 Ident. letter Colour Type of use
X4/1 Plug-in connection, round, roof frame A Red +30 (potential 30) = Cont. current
X6/10 Plug-in connection, round, B Beige -- Control line (ground)
left – instrument C White + Control line (positive)
X9/9 Plug-in connection, round, roof D Yellow + 15 Si (Potential 15 safety)
canopy cable
X9/10 Plug-in connection, round, rear wiper E Grey Potential 58 Lighting cable
steering column
the starter switch
roof supply
X18/1 Plug-in connection, round, H Orange VDC, stabilised, from the 'E' Box
instrument cable K Light blue D+
roof supply
VERSIONS
instrument cable N Pink Spare
to this page
on page/pages
22
Edition 06/2002
4004-47
4004-48
SS02D122
Page 22

(8) Weld point, engine cable, potential 31 A Horn
F25 Fuse, wiper, horn B Steering column switch
Sva 6-50950 EN
F84 Fuse, front wiper, hinged windscreen
C# Parallel wiper, front, for low-top
H1 Horn
K3 Interval relay D Washer pump, front
K5/2 Relay, roof-mounted wiper, front
M2/1 Parallel wiper motor, front E Washer pump, rear
M2/2 Standard wiper motor, front
M5 Washer pump motor, rear F# Standard wiper, front, for low-top
M6 Washer pump motor, front
S4/3 Switch, washer/wiper system
(steering column) # several versions available
X4/1 Plug-in connection, round, roof frame Cable colour or coding in accordance with standard 05449
X6/10 Plug-in connection, chassis, Ident. letter Colour Type of use
left – instrument A Red +30 (potential 30) = Cont. current
X14/8 Plug-in connection, instrument, B Beige -- Control line (ground)
steering column C White + Control line (positive)
roof supply
X18/1 Plug-in connection, round, E Grey Potential 58 Lighting cable
instrument cable F Green Signal cable
roof supply
the starter switch
instrument cable
X31/1 Plug-in connection, round, H Orange VDC, stabilised, from the 'E' Box
instrument, engine K Light blue D+
M Grounding strip
VERSIONS
on page/pages
21
Edition 06/2002
4004-49
Potential 58
Potential 30
Potential 15
Signal, speed – radar
Signal, speed – gearbox
Signal, rear PTO shaft speed
Signal, EHR in ”Control”
Ground
Page 23
Signal > 0.5 km/h

Signal, engine speed
SS02D123
4004-50
A12 Print, central electrics A Trailer socket
on-board computer B On-board computer preparation
Sva 6-50950 EN
F20 Fuse, potential 15, socket
C Power socket, 40 A
F22 Fuse, power socket
on-board computer
X1/6 Plug-in connection, flat, instrument cable
X2/4 Plug-in connection, potential 15, socket
X5/1 Distributor, ground, central print
X10 7-pole socket, trailer
on-board computer
preparation
chassis, left
X14/2 Plug-in connection, instrument cable Cable colour or coding in accordance with standard 05449
X24/2 Plug-in connection, round, cable, Ident. letter Colour Type of use
chassis, right A Red +30 (potential 30) = Cont. current
the starter switch
K Light blue D+
M Grounding strip
N Pink Spare
P Colourless Spare
Edition 06/2002
4004-51
+ supply, combination
instrument
+ supply /L1
+ supply, sensor B8
+ supply A16
+ supply, radar sensor
Page 24
SS02D124
4004-52
A12 Print, central electrics 2 Instrument panel A Supply potential 15/1, instrument
F14 Fuse, potential 15/1 B Italy brake valve
Sva 6-50950 EN
H50/1 Trailer brake indicator lamp
C Reserve roof print
H50/2 Trailer brake indicator lamp
K5/50 Relay, trailer brake valve
S50 Switch, trailer brake valve
number plate light
trailer brake valve
X10/4 Plug-in connection, chassis cable,
right – potential 15/1
Y50 Trailer brake valve, solenoid valve

the starter switch
K Light blue D+
M Grounding strip
N Pink Spare
P Colourless Spare
Edition 06/2002
4004-53
4004-54
SS02D125
Page 25

(8) Weld point, engine cable, potential 31 X14/6 Plug-in connection, chassis, right – A Instrument left, display
/L1 Indicator lamp, 1+0.2 bar feed pressure PTO indicator
/L2 Indicator lamp, main beam X24/3 Plug-in connection, round, B Instrument centre, display
Sva 6-50950 EN
/L3 Indicator lamp, lighting instrument – chassis, right
X31/1 Plug-in connection, round, C Instrument right, display
/L4 Indicator lamp, tractor trafficators
/L5 Indicator lamp, trafficators, 1st trailer instrument – engine
/L6 Indicator lamp, trafficators, 2nd trailer
/L7 Indicator lamp, PTO shaft clutch
/L8 Indicator lamp, worklight
/L9 Indicator lamp, pre-glowing
/L10 Indicator lamp, air filter
/L11 Indicator lamp, tank reserve
/L12 Indicator lamp, fuel heater
/L13 Indicator lamp, 4-wheel drive
/L14 Indicator lamp, rear differential lock
/L15 Indicator lamp, sprung front axle
/L16 Indicator lamp, 540 PTO shaft
/L19 Indicator lamp, 1400 PTO shaft Ident. letter Colour Type of use
/A1 Combination instrument A Red +30 (potential 30) = Cont. current
S3 Switch, air filter indicator
S23 Switch, indicator, feed pressure 1+0.2 bar
(hydraulic system) C White + Control line (positive)
S41/1 Switch, indicator, Normal/Eco PTO shaft D Yellow + 15 Si (Potential 15 safety)
S41/2 Switch, indicator, Eco/Normal PTO shaft
S42 Switch, indicator, 540 PTO shaft
S43 Switch, indicator, 1000 PTO shaft F Green Signal cable
X0/16/1 Weld point, instrument, potential 58, G Violet + 15 (potential 15.1 or 15.2)
left switched current after
X0/16/2 Weld point, instrument, potential 58, the starter switch
right
X0/16/4 Weld point, instrument, potential 31 H Orange VDC, stabilised, from the ’E’ Box
X0/17/10Weld point, chassis, right, potential 31 K Light blue D+
X0/17/12Weld point, chassis, right, potential 31 L Brown Ground via a box
instrument cable M Grounding strip
X9/2 Plug-in connection, round, N Pink Spare
instrument cable
P Colourless Spare
instrument cable S Black Ground, directly to a grounding point
Edition 06/2002
4004-55
Page 26 4004-56
Sva 6-50950 EN
Distributor for version
with ”Italy” trailer brake
SS02D126
Edition 06/2002
A1 Combination instrument X9/3 Plug-in connection, round, A Instruments, left – analog
A14 Print, engine electrics instrument cable
B1 Engine temperature transmitter B Instruments, left – warning indicators
Sva 6-50950 EN
B3 Compressed air transmitter X9/15 Plug-in connection, round, engine cable D Instruments centre – analog
/L20 Indicator lamp, generator X24/3 Plug-in connection, round, instrument –
/L21 Indicator lamp, engine oil pressure chassis, right
/L22 Indicator lamp, stop X31/1 Plug-in connection, round, instrument –
/L23 Indicator lamp, compressed air engine
braking system
(reservoir pressure < 5.5 bar)
/L24 Indicator lamp, handbrake
/L25 Indicator lamp, coolant temperature
/L26 Indicator lamp, coolant level
/L27 Indicator lamp, gearbox
(control pressure < 14.5 bar)
/L28 Indicator lamp, stationary operation
/L29 Indicator lamp, stop
/L100 Display lighting Ident. letter Colour Type of use
/L101 Display lighting A Red +30 (potential 30) = Cont. current
/M2 Rev-counter
/M100 Fuel tank level indicator
/M101 Compressed air indicator C White + Control line (positive)
(reservoir pressure) D Yellow + 15 Si (Potential 15 safety)
/M102 Coolant temperature indicator
S7 Switch, handbrake indicator E Grey Potential 58 Lighting cable
S12 Switch, compressed air indicator F Green Signal cable
S22 Switch, cooling water level indicator G Violet + 15 (potential 15.1 or 15.2)
X0/16/4 Weld point, instrument, potential 31 switched current after
X0/16/6 Weld point, instrument, the starter switch
instrument console
X0/17/12Weld point, chassis, right, potential 31 H Orange VDC, stabilised, from the 'E' Box
X0/23/1 Weld point, chassis, left, potential 31 K Light blue D+
X3/54 Plug-in connection, round, trailer
brake valve
X6/10 Plug-in connection, chassis, M Grounding strip
left – instrument N Pink Spare
P Colourless Spare
instrument cable
X9/2 Plug-in connection, round, S Black Ground, directly to a grounding point
instrument cable
Edition 06/2002
4004-57
4004-58
SS02D127
Page 27

/A1 Digital instrument A Instrument right, digital
Sva 6-50950 EN
S2/57 Switch, digital changeover
right
right
X0/16/5 Weld point, instrument – PTO
X0/17/7 Weld point, chassis, right – rear PTO
PTO transmitter, front
X2/46 Plug-in connection, flat, sprung
front axle
X9/5 Plug-in connection, round, Ident. letter Colour Type of use
instrument cable A Red +30 (potential 30) = Cont. current
instrument cable
X9/21 Plug-in connection, round, engine cable C White + Control line (positive)
chassis, left
chassis, right F Green Signal cable
X24/3 Plug-in connection, round, G Violet + 15 (potential 15.1 or 15.2)
instrument – chassis, right switched current after
K Light blue D+
M Grounding strip
N Pink Spare
P Colourless Spare
Edition 06/2002
4004-59
4004-60
SS02D128
Page 28

A12 Print, central electrics A Supply, EHR operating console
E11 Cigarette lighter B Cigarette lighter
Sva 6-50950 EN
E11/1 Mobile socket and mobile socket
F18 Fuse, cigarette lighter
M7 Compressed air seat motor C Safety switch
S2/11 Safety switch D Air-sprung seat
X0/17/12Weld point, chassis, right, potential 31x
X2/3 Plug-in connection, flat, compressor, E Supply, potential 58
driver’s seat (for various switches)
X2/6 Plug-in connection, round, switch lever
X6/11 Plug-in connection, mobile socket, left
X6/13 Plug-in connection, flat, cable,
cigarette lighter
EHR-D print
chassis, right
the starter switch
K Light blue D+
M Grounding strip
N Pink Spare
P Colourless Spare
Edition 06/2002
4004-61
12 V when auxiliary valve on Raise
12 V on operating Raise
12 V on operating Raise and Lower
(lever switch)
12 V for auxiliary valve
Raise and Lower
12 V on operating Lower
12 V when auxiliary valve is in lowering
and floating position
12 V on operating floating position
12 V when lever switch is in lowering
12 V on lowering and in floating position
Page 29
SS02D129
4004-62
/3 Switch, auxiliary valve 1 – yellow, left A Supply, auxiliary valve
/6 Switch, auxiliary valve 1 – yellow, right
A16 Print, EHR operating console B ECCU double-action auxiliary valve
Sva 6-50950 EN
A60/7 ECCU, auxiliary valve 2 floating position (+ interlock block)
S11/ Multicontroller
S16 Switch, auxiliary valve, lever C Auxiliary valve, operation,
X0/1/1 Weld point, multi-controller joystick, multi-controller
double-action, floating position
D Auxiliary valve, operation,
X0/1/2 Weld point, multi-controller joystick,
double-action, floating position lever switch
X0/17/2 Weld point, chassis, right, potential 31
X0/17 Plug-in connection, auxiliary valve, ECCU
EHR-D print
X14/1 Plug-in connection, chassis, right,
15 / 15 – safety / 31 ground Ident. letter Colour Type of use
X14/5 Plug-in connection, chassis, right – A Red +30 (potential 30) = Cont. current
multi-controller
Y2/1 Solenoid valve, control unit C White + Control line (positive)
Y2/2 Solenoid valve, control unit D Yellow + 15 Si (Potential 15 safety)
Y2/3 Solenoid valve, control unit
Y2/4 Solenoid valve, interlock block E Grey Potential 58 Lighting cable
the starter switch
K Light blue D+
M Grounding strip
VERSIONS
30
Edition 06/2002
4004-63
12 V when auxiliary valve on Raise
12 V on operating Raise
12 V on operating Raise and Lower
(lever switch)
12 V for auxiliary valve
Raise and Lower
12 V on operating Lower
12 V when auxiliary valve is in lowering
12 V on operating floating position
12 V when lever switch is in lowering and
floating position
12 V on lowering and in floating position
Page 30
SS02D130
4004-64
/4 Switch, auxiliary valve 2 – green, Raise A ECCU 1st auxiliary valve
/5 Switch, auxiliary valve 2 – green double-action, floating position
Lower
Sva 6-50950 EN
+ interlock block
/11 Switch, auxiliary valve,
floating position B Operation of 1st auxiliary valve,
A60/6 ECCU, auxiliary valve 1 joystick
S14/3 Lower front hitch external pushbutton C Operation of 1st auxiliary valve,
S15/3 Raise front hitch external pushbutton multi-controller
S16 Switch, auxiliary valve, lever
S36 Switch, multi-controller joystick, D Operation of 1st auxiliary valve,
X0/1/1 Weld point, multi-controller joystick, front hitch external pushbutton, from 11/97
X0/1/2 Weld point, multi-controller joystick, E Operation of 1st auxiliary valve,
double-action, floating position lever switch
X0/17/12Weld point, chassis, right, potential 31 Ident. letter Colour Type of use
X4/28 Plug-in connection, front hitch A Red +30 (potential 30) = Cont. current
external pushbutton
X4/30 Plug-in connection, front hitch
external pushbutton C White + Control line (positive)
(optional: on control unit, green or yellow) D Yellow + 15 Si (Potential 15 safety)
X10/7 Plug-in connection, auxiliary valve, ECCU
chassis, left F Green Signal cable
Y2/1 Solenoid valve, control unit G Violet + 15 (potential 15.1 or 15.2)
Y2/2 Solenoid valve, control unit switched current after
Y2/3 Solenoid valve, control unit the starter switch
Y2/4 Solenoid valve, interlock block
K Light blue D+
M Grounding strip
VERSIONS
on page/pages
29
Edition 06/2002
4004-65
4004-66
SS02D131
Page 31

A12 Print, central electrics 22 Console for A Supply, EHR box
A14 Print, engine electrics EHR box
A15 Print, EHR, left B Power sensors
Sva 6-50950 EN
A55 Control unit, EHR D
C Position sensor
B9/1 Position sensor, rear 3-point hitch
B10/1 Power sensor, left D EHR Raise+Lower solenoid valve
B10/2 Power sensor, right
B11 Pressure sensor, EHR E Preparation, external sensor
B13 External position sensor
F33 Fuse, EHR (potential 15/1) F EHR, front control
F46 Fuse, EHR (potential 30)
R1/1 Resistor, 2000 ohms
S29 Changeover, EHR – front/rear
X0/23/1Weld point, chassis, left, potential 31
right – chassis, left Ident. letter Colour Type of use
X6/15 Plug-in connection, flat, chassis, A Red +30 (potential 30) = Cont. current
right – EHR print
engine – chassis, left C White + Control line (positive)
X9/13 Plug-in connection, round, engine cable D Yellow + 15 Si (Potential 15 safety)
X10/10 Plug-in connection, round, chassis, right
(EHR functions) E Grey Potential 58 Lighting cable
X10/5 Plug-in connection, EHR F Green Signal cable
(auxiliary functions) G Violet + 15 (potential 15.1 or 15.2)
X18/5 Plug-in connection, flat, chassis, switched current after
left – EHR print the starter switch
X18/6 Plug-in connection, flat, chassis, left –
EHR print H Orange VDC, stabilised, from the 'E' Box
X24/2 Plug-in connection, round, cable, K Light blue D+
chassis, right
Y6 Solenoid valve, EHR (Raise)
Y7 Solenoid valve, EHR (Lower) M Grounding strip
N Pink Spare
P Colourless Spare
Edition 06/2002
4004-67
Ground
Signal, speed
Radar sensor
Signal, speed
Gearbox
Signal, lifting height 50 %
Rear 3-point hitch
Signal, speed
Rear PTO shaft
Potential 15
Page 32
SS02D132
4004-68
(5) Weld point, engine cable, potential 31 22 Console for A Traction control
A12 Print, central electrics EHR box
A15 Print, EHR, left B Standard signal socket
Sva 6-50950 EN
C Switch, EHR-D Raise / Lower
B16 Radar sensor
S2/15/5 Switch, EHR-D Raise / Lower (in the cab)
(in cab) D EHR external pushbutton
S14/1 Lower external pushbutton, left
S14/2 Lower external pushbutton, right
S15/1 Raise external pushbutton, left
S15/2 Raise external pushbutton, right
W1/1 Contact bridge
X0/17/16Weld points, chassis, right – Raise /
Lower
X2/1 Plug-in connection, flat, switch, neutral
X2/33 Plug-in connection, round, radar signal
X4/12 Plug-in connection, round, radar sensor Cable colour or coding in accordance with standard 05449
X6/3 Plug-in connection, chassis, Ident. letter Colour Type of use
right – chassis, left A Red +30 (potential 30) = Cont. current
X6/8 Plug-in connection, round, signal socket
X6/15 Plug-in connection, flat, chassis, left – B Beige -- Control line (ground)
EHR print C White + Control line (positive)
X6/16 Plug-in connection, flat, EHR print D Yellow + 15 Si (Potential 15 safety)
engine – chassis, left E Grey Potential 58 Lighting cable
X10/10 Plug-in connection, round, chassis, right F Green Signal cable
(EHR functions)
chassis, left
the starter switch
X14/3 Plug-in connection, flat, EHR print
X18/5 Plug-in connection, flat, chassis, left – H Orange VDC, stabilised, from the 'E' Box
EHR print K Light blue D+
chassis, right
X24/5 Plug-in connection, EHR-D print M Grounding strip
X29 Standard signal socket, round N Pink Spare
X55 Plug-in connection, flat, EHR box cable
P Colourless Spare
Edition 06/2002
4004-69
Page 33 4004-70
Sva 6-50950 EN
12 V on pressing "Transport" button
approx. 6.4 V for "Transport"
approx. 4.8 V for "Control"
approx. 3.3 V for "Quick-drop"
Ground for "Control"

Ground for "Transport"
approx. 6.4 V on pressing "Transport" button
approx. 3.3 V on pressing "Quick-drop" button

approx 4.8 V when button is not pressed
12 V on pressing "Control" button

SS02D133
Edition 06/2002
/1 Switch, EHR lift A EHR operation Transport/Control
/2 Switch, EHR control (signals for management functions)
/13 Switch, safety
Sva 6-50950 EN
A16 Print, EHR operating console B EHR operation Transport/Control
A60/4 ECCU EHR activation – C EHR Quick-drop
Transport / Control
E41 Setpoint potentiometer lighting D EHR setpoint
E EHR stop
E47 Stop button lighting F# Supply, D+, EHR box
R1/5 Resistor, 2000 ohms # several versions available
R1/11 Resistor, 2000 ohms Cable colour or coding in accordance with standard 05449
S2/72 Switch, quick-drop Ident. letter Colour Type of use
S11/ Multicontroller A Red +30 (potential 30) = Cont. current
X0/17/1 Weld point, chassis, right, B Beige -- Control line (ground)
potential +15/2 C White + Control line (positive)
X0/17/8 Weld point, chassis, right, drive inhibitor
X0/23/2 Weld point, chassis, left, potential D+
X2/5 Plug-in connection, round, EHR stop E Grey Potential 58 Lighting cable
X2/6 Plug-in connection, round, switch lighting F Green Signal cable
X5/5 Plug-in connection, round, cable, G Violet + 15 (potential 15.1 or 15.2)
chassis, right switched current after
X5/6 Plug-in connection, round, EHR setpoint the starter switch
X10/10 Plug-in connection, round, chassis, right H Orange VDC, stabilised, from the 'E' Box
(EHR functions)
X14/5 Plug-in connection, chassis, right – K Light blue D+
multi-controller L Brown Ground via a box
M Grounding strip
X24/3 Plug-in connection, round, instrument – VERSIONS
chassis, right to this page N Pink Spare
X24/5 Plug-in connection, EHR-D print 33 P Colourless Spare
X24/31 Plug-in connection, flat, EHR print on page/pages
X55 Plug-in connection, flat, EHR box cable S Black Ground, directly to a grounding point
34
Edition 06/2002
4004-71
Page 34 4004-72
Sva 6-50950 EN
12 V on pressing "Transport" button
approx. 6.4 V for "Transport"
approx. 4.8 V for "Control"
approx. 3.3 V for "Quick-drop"
Ground for "Control"

Ground for "Transport"
approx. 6.4 V on pressing "Transport" button
approx. 3.3 V on pressing "Quick-drop" button

approx 4.8 V when button is not pressed
12 V on pressing "Control" button

SS02D134
Edition 06/2002
/1 Switch, EHR lift A EHR operation Transport/Control
/2 Switch, EHR control (signals for management functions)
/13 Switch, safety
Sva 6-50950 EN
A15 Print, EHR, left B EHR operation Transport/Control
A55 Control unit, EHR D C EHR Quick-drop
A60/4 ECCU EHR activation - D EHR setpoint
Transport / Control
E41 Setpoint potentiometer lighting E EHR stop
E43 Setpoint potentiometer lighting F# EHR operation, lift / pressure
R1/11 Resistor, 2000 ohms Ident. letter Colour Type of use
R6/1 Setpoint potentiometer A Red +30 (potential 30) = Cont. current
S2/72 Switch, quick-drop
S20 Switch, EHR lift/pressure C White + Control line (positive)
S33 Switch, EHR stop D Yellow + 15 Si (Potential 15 safety)
X2/6 Plug-in connection, round, switch lighting
X3/24 Plug-in connection, round, reserve E Grey Potential 58 Lighting cable
X5/5 Plug-in connection, round, cable, F Green Signal cable
chassis, right G Violet + 15 (potential 15.1 or 15.2)
X5/6 Plug-in connection, round, EHR setpoint switched current after
X6/6 Plug-in connection, chassis, right, EHR the starter switch
chassis, left H Orange VDC, stabilised, from the 'E' Box
X9/31 Plug-in connection, round, EHR box cable K Light blue D+
X12/8 Plug-in connection, round, EHR box cable
multi-controller M Grounding strip
VERSIONS
X18/3 Plug-in connection, chassis, right, ECCU N Pink Spare
to this page
X55 Plug-in connection, flat, EHR box cable
33
Edition 06/2002
4004-73
4004-74
SS02D135
Page 35

A16 Print, EHR operating console A EHR diagnostics display
E44 Lighting, upper limit potentiometer B EHR – slip indicator
Sva 6-50950 EN
E45 Lighting, mixing potentiometer
C EHR raise/lower display
E46 Lighting, potentiometer,
lowering speed D EHR lowering speed
E50 Lighting, diagnosis front panel
H2/1 Diagnosis display E EHR mixed control
H2/2 Traction control display
H2/3 Raise display F EHR, upper limit
H2/4 Lower display H EHR traction control
R6/2 Upper limit potentiometer J EHR lighting, front panel
R6/3 Mixed control potentiometer
R6/4 Lowering speed potentiometer
S2/73 Switch, traction control
X2/6 Plug-in connection, round, switch lighting
X3/16 Plug-in connection, round, potentiometer,
lowering speed
X3/17 Plug-in connection, round, potentiometer, Ident. letter Colour Type of use
limit A Red +30 (potential 30) = Cont. current
X3/18 Plug-in connection, round, potentiometer,
mixed control
X4/2 Plug-in connection, round, diagnosis/ C White + Control line (positive)
traction control D Yellow + 15 Si (Potential 15 safety)
X4/3 Plug-in connection, round, Raise/Lower
X5/2 Plug-in connection, round, auxiliary switch E Grey Potential 58 Lighting cable
X5/3 Plug-in connection, round, switch, F Green Signal cable
traction control G Violet + 15 (potential 15.1 or 15.2)
X24/31 Plug-in connection, flat, EHR print switched current after
X55 Plug-in connection, flat, EHR box cable the starter switch
K Light blue D+
M Grounding strip
N Pink Spare
P Colourless Spare
Edition 06/2002
4004-75
4004-76
SS02D136
Page 36

/9 Switch, change up power-shift level A Gearbox power-shift
/10 Switch, change down power-shift level
A12 Print, central electrics B Gearbox forward/reverse solenoids
Sva 6-50950 EN
C# Gearbox display
A68 E box, gearbox control
F19 Fuse, gearbox, potential 30 Supply, E box, gearbox control
F24 Fuse, gearbox, potential 15 D Gearbox, diagnosis
P6 Display, gearbox control
X0/17/1 Weld point, chassis, right – gearbox,
potential 15
potential 30
X2/16 Plug-in connection, round, supply,
roof frame
aux. instruments – chassis, right
X14/5 Plug-in connection, chassis, right – Ident. letter Colour Type of use
Multi-controller A Red +30 (potential 30) = Cont. current
roof supply
chassis, right D Yellow + 15 Si (Potential 15 safety)
Y3 Proportional solenoid valve E Grey Potential 58 Lighting cable
Y21 Power-shift solenoid valve F Green Signal cable
Y22 Power-shift solenoid valve G Violet + 15 (potential 15.1 or 15.2)
Y23 Power-shift solenoid valve switched current after
Y24 Power-shift solenoid valve the starter switch
Y25 Power-shift solenoid valve
Y26 Forward driving direction solenoid valve H Orange VDC, stabilised, from the 'E' Box
Y27 Reverse driving direction solenoid valve K Light blue D+
M Grounding strip
VERSIONS
37
Edition 06/2002
4004-77
4004-78
SS02D137
Page 37

/9 Switch, change up power-shift level A Gearbox power-shift
/10 Switch, change down power-shift level
A12 Print, central electrics B Gearbox forward/reverse solenoids
Sva 6-50950 EN
A68 E box, gearbox control
C# Gearbox display for low-top
F19 Fuse, gearbox, potential 30
F24 Fuse, gearbox, potential 15 D Gearbox, diagnosis
P6 Display, gearbox control
potential 15
potential 30
X0/19/5 Weld point, low-top, potential 31
X2/16 Plug-in connection, round, supply,
roof frame
Multi-controller
X18/2 Plug-in connection, round, cable, Ident. letter Colour Type of use
roof supply A Red +30 (potential 30) = Cont. current
chassis, right
X24/5 Plug-in connection, EHR-D print C White + Control line (positive)
Y3 Proportional solenoid valve D Yellow + 15 Si (Potential 15 safety)
Y22 Power-shift solenoid valve
Y23 Power-shift solenoid valve E Grey Potential 58 Lighting cable
Y24 Power-shift solenoid valve F Green Signal cable
Y25 Power-shift solenoid valve G Violet + 15 (potential 15.1 or 15.2)
Y26 Forward driving direction solenoid valve switched current after
Y27 Reverse driving direction solenoid valve the starter switch
K Light blue D+
M Grounding strip
VERSIONS
36
Edition 06/2002
4004-79
Page 38 4004-80
Sva 6-50950 EN
12 V in
"Neutral"
12 V in
"Forward"
12 V in
"Reverse"
12 V on pressing
"Neutral" button
12 V on pressing
"Forward" button
12 V on pressing
"Reverse" button
SS02D138
Edition 06/2002
/7 "Forward" button X14/5 Plug-in connection, chassis, right – A Operation, gearbox control:
/8 "Reverse" button Multi-controller Foward/Reverse/Neutral/Drive inhibitor
A60/5 ECCU – Forward/Reverse changeover X14/7 Plug-in connection, chassis right, ECCU
Sva 6-50950 EN
A68 Gearbox electronics box X24/3 Plug-in connection, round, B Sensors, gearbox control
B4 Output speed sensor, instrument – chassis, right
main clutch X24/4 Plug-in connection, chassis, right,
B5 Output speed sensor, ECCU
power-shift gearbox
B6 Speed sensor
B12 Input speed sensor,
power-shift gearbox
B17 Angle of rotation (position) sensor,
clutch pedal
B32 Temperature sensor, transmission oil
S4/4 Forward/Reverse lever switch (on
steering column)
S8 Switch in driver's seat (gearbox control)
S11 Multi-controller
S19 Neutral switch
S21 Switch, gearbox oil pressure 18 bar Ident. letter Colour Type of use
S46 Switch, clutch pedal A Red +30 (potential 30) = Cont. current
potential 15 B Beige -- Control line (ground)
X0/17/10Weld point, chassis, right, potential 31 C White + Control line (positive)
X0/17/14Weld point, chassis, right, potential 31 D Yellow + 15 Si (Potential 15 safety)
X0/17/15Weld point, chassis, right – gearbox,
potential 15 E Grey Potential 58 Lighting cable
X0/17/2 Weld point, chassis, right – seat switch F Green Signal cable
X0/17/3 Weld point, chassis, right – start inhibitor
X0/17/4 Weld point, chassis, right – Forward
X0/17/5 Weld point, chassis, right – Reverse
the starter switch
X0/17/8 Weld point, chassis, right –
drive inhibitor H Orange VDC, stabilised, from the 'E' Box
X0/17/9 Weld point, chassis, right, potential 31 K Light blue D+
for sensors B17 and B32
X0/17/13Weld point, ground, gearbox electronics
X6/7 Plug-in connection under instrument M Grounding strip
carrier N Pink Spare
(Forward/Reverse lever switch)
X10/4 Plug-in connection, chassis, right – P Colourless Spare
auxiliary instruments S Black Ground, directly to a grounding point
Edition 06/2002
4004-81
12 V when PTO
shaft is ”ON”
Ground when no
EHR external
button is pressed
Signal, speed of
rear PTO shaft
Ground for EHR
"Control"
Signal, speed of
front PTO shaft
Engine speed
signal
Page 39
12 V when rear
PTO shaft is ”ON”
Driving speed
signal
12 V when front
PTO shaft is ”ON”
SS02D139
4004-82
A60/1 ECCU – front/rear PTO shaft A Rear PTO shaft
B7 Speed sensor, rear PTO shaft
B8 Speed sensor, front PTO shaft B Front PTO shaft and front transmitter
Sva 6-50950 EN
H3 Indicator, PTO shaft management active
C Rear transmitter
S2/70/1 Switch, front PTO shaft
S2/70/2 Switch, rear PTO shaft
S2/71 Switch, PTO shaft management
S17/1 External pushbutton, rear PTO shaft, On
S17/2 External pushbutton, rear PTO shaft, On
S19/1 External pushbutton, rear PTO shaft, Off
S19/2 External pushbutton, rear PTO shaft, Off
X0/17/11 Weld point, chassis, right, potential D+
X0/17/7 Weld point, chassis, right –
rear PTO shaft
X0/23/2 Weld point, chassis, left, potential D+
X3/22 Plug-in connection, flat, chassis, right -
front PTO shaft solenoid valve
X10/10 Plug-in connection, round, chassis, right Ident. letter Colour Type of use
(EHR functions) A Red +30 (potential 30) = Cont. current
rear PTO shaft On/Off B Beige -- Control line (ground)
chassis, left D Yellow + 15 Si (Potential 15 safety)
X24/4 Plug-in connection, chassis, right, ECCU E Grey Potential 58 Lighting cable
Y4 Solenoid valve, front PTO shaft F Green Signal cable
Y5 Solenoid valve, rear PTO shaft
the starter switch
K Light blue D+
M Grounding strip
N Pink Spare
P Colourless Spare
Edition 06/2002
4004-83
12 V for
DOWN
12 V for UP
12 V
5 – 18 mA
(signal current)
GROUND
12 V
5 – 18 mA
(signal current)
GROUND
GROUND
Page 40
12 V for UP / DOWN, left

GROUND
12 V for INHIBIT
12 V when main
12 V for UP switch pressed to
right
GROUND
12 V at v > 14 km/h
12 V for UP / DOWN, right
SS02D140
4004-84
A12 Print, central electrics 13 Carrier frame A Sprung front axle
A61 Sprung front axle electronics B Supply, ECCU
Sva 6-50950 EN
F31 Sprung front axle fuse
potential 30
potential 15/2
F34 Fuse, potential 15/1, ECCU
S2/15/1 Switch, front axle up/down
S2/15/2 Switch, front axle On
X0/8/1 Weld point, instrument, potential 58R
X0/8/2 Weld point, sprung front axle,
potential 31
X0/8/3 Weld point, sprung front axle,
potential 15/2
X2/46 Plug-in connection, flat, sprung
front axle Ident. letter Colour Type of use
X4/45 Plug-in connection, sprung front axle A Red +30 (potential 30) = Cont. current
X12/20 Plug-in connection, round, sprung
front axle B Beige -- Control line (ground)
X18/3 Plug-in connection, chassis, right, ECCU C White + Control line (positive)
X24/1 Plug-in connection, round, D Yellow + 15 Si (Potential 15 safety)
instrument cable
chassis, right F Green Signal cable
the starter switch
K Light blue D+
M Grounding strip
N Pink Spare
P Colourless Spare
Edition 06/2002
4004-85
Page 41 4004-86
Sva 6-50950 EN
Supply from
power socket:
see page 19/C
Scope of winch
manufacturer
SS02D141
Edition 06/2002
A16 Print, EHR operating console 6 Distributor A Supply, winch
A33/2 E box, forestry for winch
S2/66/2 Switch, winch, brake 2 B# Double winch
Sva 6-50950 EN
X3/20 Plug-in connection, round, supply
X5/9 Distributor, winch, potential 58 # several versions available
X12/13 Plug-in connection, round, double winch

D Yellow + 15 Si (Poteafety)
the starter switch
K Light blue D+
M Grounding strip
VERSIONS
N Pink Spare
to this page
42, 43
Edition 06/2002
4004-87
Page 42 4004-88
Sva 6-50950 EN
Scope of winch
manufacturer
SS02D142
Edition 06/2002
A33/1 E box, forestry 6 Distributor A Supply, winch
S22/66/1Switch, winch, brake 1 for winch
S16/1 Switch, winch, clutch 1 B# Double winch
Sva 6-50950 EN

the starter switch
K Light blue D+
M Grounding strip
VERSIONS
N Pink Spare
to this page
41, 43
Edition 06/2002
4004-89
Page 43 4004-90
Sva 6-50950 EN
Supply from
power socket:
see page 19/C
Scope of winch
manufacturer
SS02D143
Edition 06/2002
A16 Print, EHR operating console 6 Distributor A Supply, winch
A33/1 E box, forestry for winch
S2/7/5 Switch, winch capstan B# Single winch
Sva 6-50950 EN
S2/67 Switch, winch brake
X3/20 Plug-in connection, supply # several versions available
X5/9 Distributor, winch, potential 58

the starter switch
K Light blue D+
M Grounding strip
VERSIONS
N Pink Spare
to this page
41, 42
Edition 06/2002
4004-91
4004-92
List of plugs, left
X2/16 E4
E8
A12 E12
E11/1 E16
X4/10
7
E1 A14
E61
8
A15
E3 A55
E17
E30
X2/.. E35 SS02D189
A12 Print, central electrics E61 Worklight, front grill

A14 Print, engine electrics X2/16 Plug-in connection, round, supply,
A15 Print, EHR, left roof frame
A55 E box, EHR-D X4/10 Plug-in connection, flat, heater blower motor
E1 Worklight, left X2/.. Plug-in connection, round,
E3 Sidelight, front left (coolant level switch)
E4 Sidelight, rear left (7) Distributor, ground, low-top
E8 Worklight, left-hand mudguard (8) Weld point, engine cable, potential 31
E11/1 Cigarette lighter, left (for mobile)
E30 Step light, left
E35 Worklight on the trafficator/position light

4004-93
List of plugs, right
X3/7 X3/9 X3/8 X3/6

X4/1 X4/7 X4/9 X4/8 X4/6
P6
A13
A16
A1
A68
E7 X31/1 X1/12
E9 X4/28
E13 E2
E15 S6
E62
A60
A33/2
A33/1
E6
E14 X9/7
X14/5
E36 A61
X12/20
X3/.. 11 13 16
X3/.. SS02D190
A1 Instrument carrier X3/8 Plug-in connection, flat, worklight,

A13 Print, roof electrics, for high-top twin-power
(Instrument carrier for low-top – Page 106) X3/9 Flat plug-in connection, worklight,
A16 Print, EHR operating console twin-power
A61 Electronics, sprung front axle X4/1 Plug-in connection, round, roof frame
A33/1 E box, forestry X4/6 Plug-in connection, round, roof canopy –
A33/2 E box, forestry auxiliary headlight
A60 ECCU electronics box X4/7 Plug-in connection, round, roof canopy –
A68 Transmission electronics box auxiliary headlight
E2 Headlight, right X4/8 Plug-in connection, round, roof canopy –
E6 Sidelight, front right worklight
E7 Sidelight, rear right X4/9 Plug-in connection, round, roof canopy –
E9 Worklight, right-hand mudguard worklight
E13 Brake light, right X4/13 Plug-in connection, round,
E14 Trafficator, front right aux. instruments –
E15 Trafficator, rear right chassis, right
E36 Worklight on the trafficator/position light X4/28 Plug-in connection, front hitch
E62 Worklight, front grill external pushbutton
P6 Display, gearbox power-shift X9/7 Plug-in connection, round, engine,
forward/reverse chassis, left
S6 Oil pressure switch X14/5 Plug-in connection, chassis, right –
X1/12 Screw-on connector, potential 30 Multi-controller
on bulkhead X12/20 Plug-in connection, round, sprung
X3/.. Plug-in connection, sensor, front axle
sprung front axle X31/1 Plug-in connection, round,
X3/6 Flat plug-in connection, auxiliary headlight instrument – engine
X3/7 Flat plug-in connection, auxiliary headlight

4004-94
List of plugs (at rear)
X4/33 E23/2 E23/1 E24/1 E24/2 X4/34

A5/1 X4/22 X4/21 X4/23 X4/24 A5/2
X10 X14 X29
SS02D191
A5/1 Rotating beacon, left X4/33 Socket, rotating beacon, left

A5/2 Rotating beacon, right X4/34 Socket, rotating beacon, right
E23/1 Worklight, roof, rear, inner X10 Socket, 7-pole, trailer
E23/2 Worklight, roof, rear, outer X14 Flat power socket
E24/1 Worklight, roof, rear, inner X29 Standard signal socket, round
E24/2 Worklight, roof, rear, outer

canopy cable
canopy cable
canopy cable
canopy cable

4004-95
List of plugs on instrument carrier
X9/1 X9/3 X9/2 X9/6 X9/5 X9/4

S46
B17
X24/3 X4/14
X14/8
X6/10 X6/7
X10/4
SS02D187
B17 Angle of rotation sensor, clutch pedal X9/4 Plug-in connection, round, instrument cable
S46 Plunger-operated switch, clutch pedal X9/5 Plug-in connection, round, instrument cable
X9/6 Plug-in connection, round, instrument cable
X4/14 Plug-in connection, chassis, right X10/4 Plug-in connection, chassis right,
(brake light switch) auxiliary instruments
X6/7 Plug-in connection under instrument carrier X14/8 Plug-in connection under instrument carrier
(Forward/Reverse lever switch) X24/3 Plug-in connection, round, instrument
X6/10 Plug-in connection, chassis, chassis, right, instrument
left – instrument

4004-96
List of plugs on the right-hand side of the cab
S41/1
S41/2
X10/9
X2/7
X3/22 X6/.. X14/9
X4/..
X14/1
X4/13
S12 X6/..
X14/5 B3 FHW X24/5
X4/.. A60
X6/7 X14/6
X10/7 X10/10
SS02D188
X10/7 KH (X10/3)
X14/7 S42
X18/3 S43 X6/3
X24/4
A60 ECCU electronics box X10/10 Plug-in connection, round, chassis, right –
B3 Transmitter, pressure indicator EHR functions
FHW Plug-in connection (X4/30), external (up to DBD00..... designated X10/3)
button – front hitch (optional: on control unit,
green or yellow) X10/7 Plug-in connection, ECCU auxiliary valve
KH Plug-in connection, joystick X10/9 Plug-in connection, chassis right,
(optional: on control unit, green or yellow) rear PTO shaft On/Off
S12 Compressed air switch X14/1 Plug-in connection, round, cable,
S41/1 Switch, indicator, PTO shaft Neutral/On chassis, left
S41/2 Switch, indicator, PTO shaft On/Neutral X14/5 Plug-in connection, chassis, right –
S42 Switch, indicator, 540 PTO shaft Multi-controller
S43 Switch, indicator, 1000 PTO shaft X14/6 Plug-in connection, chassis, right –
X2/7 Plug-in connection, flat, chassis, right – PTO indicator
fuel pump, auxiliary tank X14/7 Plug-in connection, chassis right, ECCU
X3/22 Plug-in connection, diagnostic X14/9 Plug-in connection, chassis, right –
X4/13 Plug-in connection, round, aux. 4-WD / differential management switch
instruments – chassis, right X18/3 Plug-in connection, chassis, right, ECCU
X4/27 Plug-in connection, external sensor X24/4 Plug-in connection, chassis, right, ECCU
X4/.. Multi-controller button (green control unit) X24/5 Plug-in connection, EHR-D print
X4/.. Multi-controller button (yellow control unit)
X6/.. Lever switch (green control unit)
X6/.. Lever switch (yellow control unit)
X6/7 Plug-in connection, reverse, right, ECCU

4004-97
Central Electrics Print A12
SS02D168
List of plugs
V3/2 Diode 0.3 A interlock X4/44 Plug-in connection, spark start
V3/3 Diode 0.3 A interlock X4/45 Plug-in connection, sprung front axle
V3/7 Diode 0.3 A interlock X5/1 Ground distributor, central print
V3/8 Diode 2 A interlock X6/1 Plug-in connection, spare
V3/14 Diode 0.1 A interlock X10/1 Plug-in connection, instrument cable
V3/16 Diode 0.1 A interlock X10/2 Plug-in connection, cable, chassis, right
X10/3 Plug-in connection, on-board computer
W1/3 Contact bridge, Opti-Stop provision
W1/4 Contact bridge, spark start X10/4 Plug-in connection, chassis right,
W1/5 Contact bridge, low signal instrument
X1/6 Plug-in connection, flat, instrument cable X14/2 Plug-in connection, instrument cable
X1/8 Plug-in connection, flat X18/1 Plug-in connection, instrument cable
(potential 30 to starter switch) X18/2 Plug-in connection, roof supply cable
X1/11 Screw-on connection, central print 30 X24/1 Plug-in connection, instrument cable
X1/26 Plug-in connection, flat X24/2 Plug-in connection, cable, chassis, right
supply, heating blower
X1/30 Plug-in connection, potential 30, central print

4004-98
Relays
SS02D186
A10 4-wheel drive/Differential Management K5/11 D+ supply

K2 Flasher unit K5/12 Brake light/Opti-Stop
K3 Wiper/Washer (Interval) K5/16 Stationary cut-off
K5/5 Switchover relay for high beam K5/19 Stationary operation cut-off
K5/6 Switchover relay for dipped beam K5/20 Stationary operation cut-off
K5/7/1 Potential 15/1 K5/24 Front loader
K5/7/2 Potential 15/2 K5/37 Reserve
K5/9 Worklight mudguard K5/43 D+ switch OFF
K5/10 Light (Potential 58)

4004-99
Fuses
SS02D169
F1 58 L Parking lamp, left .............................................................................................7.5 Amps

F2 58 R Parking lamp, right ..........................................................................................7.5 Amps
F3 Worklight mudguard ..................................................................................................10 Amps
F4 Dipped beam left roof spare headlight .....................................................................7.5 Amps
F5 Dipped beam right roof spare headlight......................................................................5 Amps
F7 Dipped beam right headlight ....................................................................................7.5 Amps
F8 Dipped beam left headlight ......................................................................................7.5 Amps
F9 Main beam ................................................................................................................15 Amps
F10 Roof potential 15, Front loader ...................................................................................5 Amps
F11 Brake lamp................................................................................................................10 Amps
F12 Headlight flasher .......................................................................................................15 Amps
F13 Differential front and rear ..........................................................................................10 Amps
F14 Trafficators, E-control unit, Pneumatic seat suspension ...........................................15 Amps
F15 Front loader...............................................................................................................10 Amps
F16 Hazard warning flasher .............................................................................................15 Amps
F18 Cigarette lighter........................................................................................................7.5 Amps
F19 Pot. 30 for transmission electronics .........................................................................7.5 Amps
F21 D+, Fuel pump ............................................................................................................5 Amps
F22 Power outlet socket...................................................................................................40 Amps
F24 Pot. 15 for transmission electrics ............................................................................. 10 Amps
F25 Screen wipers, horn .................................................................................................7.5 Amps
F26 Heating......................................................................................................................15 Amps
F27 Trafficators ...............................................................................................................7.5 Amps
F29 Activation, engine cut-off, fuel pump........................................................................7.5 Amps
F30 Ignition switch supply ................................................................................................20 Amps
F31 Potential 30 sprung front axle ...................................................................................10 Amps
F32 Potential 15/2 sprung front axle ..................................................................................5 Amps
F33 Potential 15, EHR .......................................................................................................5 Amps
F34 Potential 15, ECCU...................................................................................................25 Amps

4004-100
Print – Roof electrics A13
SS99G154
Relays
K4/2/2 Time relay 40 sec, interior lamp – delay
K5/2 Front screen wiper (only on hinged windscreen)
K5/29 Terminal 15
K5/30 Worklight, rear roof, 2 off
K5/31 Worklight, front, roof TWIN-POWER
K5/32 Blower motor – air conditioning
K5/33 Rotating beacon
K5/34 4 Worklights, rear, roof, number plate lighting
K5/35 Heated mirror
K5/36 Reserve
K5/38 Reserve, worklight
List of plugs
V3/10 Diode 3 A interlock X4/38 Plug-in connection, roof switch
X4/5 Plug-in connection, chassis, left X4/43 Plug-in connection, number plate lighting
X4/15 Plug-in connection, mirror heating X6/2 Plug-in connection, roof frame
X4/16 Plug-in connection, reserve X9/9 Plug-in connection, roof canopy cable
X4/17 Plug-in connection, roof frame X9/10 Plug-in connection, rear wiper
X4/18 Plug-in connection, roof frame X9/11 Plug-in connection, roof air cond.
X4/19 Plug-in connection, heated windscreen X12/15 Plug-in connection, roof canopy cable
X4/20 Plug-in connection, heated rear window X15/14 Plug-in connection, roof frame
X4/26 Plug-in connection, roof frame X15/15 Plug-in connection, roof canopy cable
X4/29 Plug-in connection, roof switch X15/16 Plug-in connection, roof supply cable
X4/35 Plug-in connection, rotating beacon switch X16/4 Screw-on connector, roof print 30

4004-101
Fuses
SS98C146
F60 Parking lamp, front left 3 Amps

F61 Parking lamp, front right 5 Amps
F63 Rear wiper 7.5 Amps
F64 Wiper front on hinged windscreen 7.5 Amps
F65 Air conditioning 5 Amps
F66 Blower motor / Air conditioning 20 Amps
F67 Worklight TWIN-POWER 20 Amps
F68 Worklight rear 2 10 Amps
F69 Rotating beacon 15 Amps
F70 4 worklights, rear, number-plate lighting 10 Amps
F71 Rotating beacon 3 Amps
F72 Spot, Radio, Interior lighting, Heated mirror 10 Amps
F73 Worklight 10 Amps
F74 Reserve potential 30 20 Amps
F76 Heated rear window 25 Amps
F77 Heated windscreen 25 Amps

4004-102
Print A14, engine electrics
SS02D170
Relays
K4/1/2 Engine cut-off 3 sec (time relay)
K4/2/1 Pre-glowing 40 sec (time relay)
K5/1 Engine cut-off potential 31
K5/17 Pre-glowing (without diode)
K5/25 Worklight, front grill
K5/26 Reserve
K8/1 Neutral position (terminal 50 starter)
K8/2 Pre-glowing
S38 Switch, pre-glowing indicator

4004-103
List of plugs

X2/20 Reserve
X2/21 Reserve
X2/22 Plug-in connection, PTO shaft transmitter, front
X3/25 Reserve
X9/16 Plug-in connection, air conditioning system
X16/3 Screw-on connector, engine 30, not fused
Fuses
SS98C145
F40 Main fuse ............................................................................................................................. 100 Amps

F41 Reserve potential 30 .............................................................................................................. 15 Amps
F43 Fuel preheater........................................................................................................................ 20 Amps
F44 Worklights, front grill............................................................................................................... 15 Amps
F45 Parking lamp ......................................................................................................................... 7.5 Amps
F46 EHR ......................................................................................................................................... 5 Amps
F47 Pre-glowing, Engine cut-off ...................................................................................................... 3 Amps
F48 EHR ......................................................................................................................................... 5 Amps
F49 Clock ........................................................................................................................................ 3 Amps
F50 Stop solenoid ......................................................................................................................... 40 Amps

4004-104
Print – EHR Left, A15 (Distribution Print)
SS00C170
List of plugs
X2/1 Plug-in connection, flat, neutral switch X14/3 Plug-in connection, EHR distribution print
X4/27 Plug-in connection, external sensor X18/5 Plug-in connection, EHR distribution print
X6/8 Plug-in connection, signal socket X18/6 Plug-in connection, EHR distribution print
X6/15 Plug-in connection, EHR distribution print
X6/16 Plug-in connection, EHR distribution print
X10/5 Plug-in connection, EHR
(auxiliary functions)
EHR-D Print, operating console, A16
SS00C169
List of plugs
X2/5 Plug-in connection, EHR stop X5/2 Plug-in connection, aux. switch
X2/6 Plug-in connection, switch lighting X5/3 Plug-in connection, traction control switch
X3/16 Plug-in connection, potentiometer, X5/5 Plug-in connection, cable, chassis, right
lowering speed X5/6 Plug-in connection, EHR setpoint
X3/17 Plug-in connection, potentiometer, X6/13 Plug-in connection, operating console,
limit cigarette lighter
X3/18 Plug-in connection, potentiometer, X10/19 Plug-in connection, EHR print
mixed control X14/10 Plug-in connection, EHR print, spare
X4/2 Plug-in connection, diagnosis/ X24/31 Plug-in connection, EHR print,
traction control operating console
X4/3 Plug-in connection RAISE/LOWER

4004-105
Print, single/double winch A33/1 and A33/2
SS99G158

4004-106
Instrument carrier for low-top version
SS02D175
List of relays and plugs

K5/2 Windscreen wiper, front X16/4 Screw connector, potential 30
K5/29 Potential 15 (7) Ground rail
K5/31 Worklight front roof
TWIN-POWER
Fuses
F67 Worklight TWIN-POWER ................................................................................... 20 Amps
F80 Interior light, rotating beacon ............................................................................ 7.5 Amps
F81 Switch, lighting, rear washer/wiper ...................................................................... 3 Amps
F82 Parking lamp, front............................................................................................... 3 Amps
F83 Parking lamp, front right....................................................................................... 3 Amps
F84 Screen wipers, front......................................................................................... 7.5 Amps
F85 Radio ................................................................................................................ 7.5 Amps

4004-107
Relays
Miniature relays (Messrs Wehrle)
Relays without free-wheeling diode (K5/17)
Contacts ......................... Changeover contact

Continuous duty.................................... 100 %
Rated voltage .....................................12 VDC
SS99G151
Load........................................... max. 20/30 A
Resistance 85 - 86.......................... 65 Ω ± 10%
Interference-suppression resistance .... 390 Ω
Power relays (Messrs Wehrle)
Contact ...................................... Make contact

Continuous duty.................................... 100 %
Rated voltage .....................................12 VDC
Load................................................ max. 70 A
Resistance 85 - 86...................................80 Ω
Interference-suppression resistance .....560 Ω
SS99G150
Micro-relays (Messrs Wehrle)
Contacts .................................. Changeover contact

Continuous duty............................................. 100 %
Rated voltage .............................................. 12 VDC
Load.................................................... max. 15/25 A
Resistance 85 - 86.......................90 Ω±10% at 23 °C
SS99G152 Interference-suppression resistance ............. 680 Ω
Time relays K4/2/1 and K4/2/2

(Messrs Hella)
Contacts .................................. Changeover contact

Hold time ...................................................... 40 sec.
Continuous duty............................................. 100 %
Load........................................................... max. 5 A
SS99G153

4004-108
Components, gearbox electrics / electronics
E box, gearbox control A68
(Test values: see Chapter 6002)
SS02D176
4-wheel drive and differential lock

management A10
Pin assignment
(Test values: see Chapter 6003)
SS99J071
Plunger-operated switch, start inhibitor S19

(Green in colour)
Contact ............................................. Break contact

Rated voltage...............................................12 VDC
Switching current ................................ max. 500 mA
Switching capacity .................................. max. 10 W
SS99G159 Continuous current ............................. max. 300 mA
Resistance (switch not operated).......... approx. 4 Ω
Plunger-operated switch, clutch pedal S46

(Reed switch / black)
Contact ...............................................Make contact

Switching current ................................ max. 500 mA
Switching capacity .................................. max. 10 W
Continuous current ............................. max. 300 mA
Resistance (switch operated)................ approx. 4 Ω
SS99G160

4004-109
Pressure switch, control pressure –
gearbox S21
Contact ............................................... Make contact

SS99G167
Switching point ..................................... p > 14.5 bar
Angle of rotation sensor, clutch pedal B17
Pin 2 (+ supply from E box A68).................... 5 VDC

Pin 1 (supply from E box A68)......................Ground
Pin 3 ....................................................Signal (VDC)
Pedal not depressed........................................ > 0.7
Pedal fully depressed ..............................< 4.2 VDC
Load resistance ...........................................> 200 Ω
127( The adjustment is made by turning the
SS99G161
sensor.
Sensor, gearbox oil temperature B32
Type.................................................................. PTC
Measuring range............................... -50 to +150 °C
Pin 1 ....................................................Signal (VDC)
127(Test values: see Page 121
SS99G163
Solenoid valve, main clutch Y3

Proportional pressure control valve
Control range......................................... 1.5 - 18 bar

Voltage....................................................8 - 15 VDC
Control current (from A68)....... 400 - 1060 mA (DC)
Type of current control........ Pulse-width modulation
Max. current.............................................1.2 A (DC)
Ohmic resistance R ......................................5.3±3 Ω
SS02D149
Tightening torques:
Valve insert ................................................. 10±2 Nm
Plastic nuts (magnet fastening) .................... 5±3 Nm

4004-110
Gearbox solenoid valves Y21 to Y27
Continuous duty ............................................. 100 %

Resistance .................................... 28 ± 2 Ω at 20 °C
Interference suppression .....................in E box A68
127( Valves Y23 und Y24 have a steel housing
SS99G164
and thus have their own spare part number. The
electrical values are identical from Y21 to Y27.
Differential lock solenoid valve Y10,

4-wheel drive Y1, rear PTO shaft Y5 and
front PTO shaft Y4
(Messrs Hytos)
Continuous duty ............................................. 100 %

Resistance ................................... 8 Ω ± 10% at 20 °C
SS99G166 Interference suppression ........Z-diodes, antiparallel
Speed sensors
Type ....................................................... Hall sensor
Installation lengths:
B12 input, power-shift gearbox ..................... 40 mm
B5 output, power-shift gearbox ..................... 95 mm
SS02D144 B4 output, main clutch .................................. 53 mm
B6 driving speed ......................................... 125 mm
B7 rear PTO shaft ......................................... 40 mm
Pin 3 (+ supply)............................................12 VDC
Pin 1 (supply) ............................................... Ground
Current consumption ............................ max. 21 mA
Pin 2....................................... Signal (square-wave)
127(Test values: see Chapter 6002.
Exception: Sensor B7
(Test values: see Chapter 6D)
Speed sensor, front PTO shaft B8

Type ....................................................... Hall sensor
Operating range ..................................... 1 to 25 kHz

Pin A (+ supply) ...........................................12 VDC
Pin C (supply) .............................................. Ground
SS00G041 Current consumption ............................ max. 15 mA
Pin B ...................................... Signal (square-wave)
127(Test values: see Chapter 6D

4004-111
Components, electronic 3-point hitch control
E box EHR-D A55
Pin assignment and test values: see Chapter 8B
SS00G040
EHR angle of rotation sensor B9/1
Pin 3 (+ supply from E box A55)................. 9.5 VDC

Pin 2 (signal).......................... approx. 2.5 to 7 VDC
Load resistance ............................................. > 3 kΩ
sensor.
SS02D146
EHR power sensors B10/1,B10/2
Type................................... Bosch End Number 543

Rated load ......................................................60 KN
Pin 3 (+ supply from E box A55)................. 9.5 VDC

SS02D147
Pin 2 (signal)....................... approx. 2.5 to 7.5 VDC
Sensor not under load ................... approx. 4.7 VDC
Load resistance ........................................... > 10 kΩ
EHR potentiometers R6/1,R6/2,R6/3,R6/4

The test values are identical for all potentiometers
Pin A - C (resistance) .............................4.7 kΩ±20%

Pin A - B (resistance)........................0 – 4.7 kΩ±20%
SS99G172

4004-112
Radar sensor B16
Fitting angle .......................................................35°

Pin 1 (+ supply)............................................12 VDC
Pin 2 (supply) ............................................... Ground
Pin 3 (signal, square-wave) ........ 505 Hz at 14 km/h
Pin 4 (enable): in plug X4/12 connected to
Pin 1
127( Every change of the beam angle in relation
to the ground mutilates the signal value.
SS02D148 Turn the ignition switch to position 0 before working
in the beam range of the sensor!
Solenoid EHR control valves Y6 and Y7
Proportional solenoid: ..................................12 VDC

I max. .................................................................3.5 A
Current control .................... Pulse-width modulation
Ohmic resistance R ............................ approx.1.7 Ω
Interference suppression .....................in E box A55
SS99J021

4004-113
Components, air conditioning system
Control, air conditioning system A20
X4/10
X3/40 – Pin A (supply)................................. 12 VDC
X3/40 – Pin B (supply)..................................Ground
X3/40 – Pin C ..................................... Output signal
(Activation of magnetic coupling, compressor)
X3/41 – Pin A/B ................Temperature sensor (R9)

X3/41 – Pin C ....................................Screening, R9
X3/41
SS02D150 X3/10 – Pin A/B ..........................Potentiometer R10
X3/40
(Temperature setting)
X4/10 – Pin C/D.............. Switch, air cond. ON/OFF
Switching points, magnetic coupling Y13, compressor:
Potentiometer R10 (temperature setting) in position:
minimum cooling ....................................................................Resistance >18 kΩ (compressor switches off)
minimum cooling ....................................................................Resistance <16 kΩ (compressor switches on)
maximum cooling ...................................................................Resistance >27 kΩ (compressor switches off)
maximum cooling ...................................................................Resistance <25 kΩ (compressor switches on)
Control, speed of blower motor A21

(only for air conditioning optional equipment)
X9/11 – Pin 1(supply) .................................. 12 VDC

X9/11 – Pin 6 (supply) ..................................Ground
X3/42 – Pin A/C ............. Supply, potentiometer R11

X3/42 – Pin B.......................... Signal, speed setting
X2/20 – Pin A/B ... Plug-in connection, blower motor

SS02D166
X3/42
Potentiometer, air-cond. roof blower

motor R11
(for setting the speed of the roof blower motor)
Pin A - C (resistance) ..............................15 kΩ±20%

Pin A - B (resistance)......................... 0 - 15 kΩ±20%
SS00N099

4004-114
Potentiometer, air-cond. R10
Potentiometer for setting the temperature, with

integrated switch (air cond. ON/OFF)
Resistance (nominal) ..............................10 KΩ±20%

Pin A - B (resistance) ......................... 0 - 10 kΩ±20%
Pin C - D ......................................... Switch ON/OFF
Contact ...............................................Make contact
SS00N098
Safety switch, air cond. system S30

Contact, high-pressure ...................... Break contact
Switching point..................................... p > 31.5 bar
Contact, low-pressure ......................... Make contact
Switching point........................................... p > 2 bar
SS99G174
Temperature sensor, air conditioning

system R9
SS99J157 Type ..................................................................NTC

Resistance A - B .................. approx. 11 kΩ at 20 °C
Switching points, magnetic coupling Y13,

compressor:
see Page 113
Air conditioning compressor coupling Y13

Resistance ............................................... 3.8 Ω±10%
SS00J091

4004-115
Components, engine / fuel system
Pressure switch, engine oil pressure S6
Contact .............................................. Break contact

Switching point ....................................... p > 0.5 bar
SS00C166
Air filter service switch S3

Switching point ................> 65±3 mbar low pressure
SS02D172
Coolant temperature switch S32

(for indicator lamp and stationary operation cut-off)
Flat plug-in lug .............................................4.8 mm

SS99J172
B1 S32 Switching point ........................................ ϑ > 106 °C±3
Sensor, coolant temperature indicator B1

(Test values: see Page 121)
Flat plug-in lug .............................................6.3 mm

Ground via housing (with ground connection)
Tightening torque.................................. max. 20 Nm
Transmitter, fuel tank level B 2/1

Pin 2 ......................................................Level signal
Pin 3 .............................................................Ground
Fuel pump (s) M8/1 M8/2
Pin 1 ................................................ + supply, motor

Pin 3 .............................................................Ground
Rated voltage .......................................12 - 14 VDC
Current consumption ................................. max. 1 A
SS02D145
Feed pressure ...................................... p = 0.15 bar
Flow rate............................................... max. 110 l/h
Thermostart (starting aid) E10/1
Supply voltage ............................................. 12 VDC

Heating element resistance ........ 1 Ω±10% (at 20 °C)
127( There must be no signs of fuel escaping
SS99H188 from the Thermostart when the engine is running
(check for leakage).

4004-116
Cut-out solenoid Y12
(integrated in Stanadyne injection pump)

Coil resistance .............................3.8 Ω±10% (at 20°)
,03257$17 The cut-out solenoid must never be
activated for longer than 40 seconds in a dry state.
This must be observed after fitting an injection
pump, as the cooling of the coil by the fuel is only
ensured after running the engine for the first time.
SS99J069
Components, sprung front axle

E box A61
(integrated in the cover on the hydraulics control
block for the front axle suspension)
Test values: see Chapter 5A and 5B
Angle of rotation sensor, sprung front axle

(left and right)
Pin 2 (+ supply from E box A61) ..................12 VDC

Pin 1 (supply from E box A61) ..................... Ground
Pin 3...................................................... Signal (mA)
sensor. Settings for sensors: see Chapter 5A / 5B
SS99G169
Solenoid valves for sprung front axle

Continuous duty ............................................. 100 %
Resistance .....................................8 Ω±10% at 23 °C
Insulation resistance ..................................> 100 kΩ
Interference suppression ........Z-diodes, antiparallel
SS99G173

4004-117
Components, hydraulics
Hydraulics pressure switch, micro-filter S23
(for indicating the contamination level of the
pressure filter)
Contact .............................................. Break contact

Switching point .....................................p > 1+0.2 bar
SS02D192
Solenoid, electric auxiliary valve

(Y2/1, Y2/2, Y2/3)
Continuous duty............................................. 100 %

Resistance.............................................. 4.4 Ω ± 10%
Power output ................................................ 32.7 W
Interference suppression ........ Z-diodes, antiparallel
SS99J017
Solenoid, electric auxiliary valve

(Y2/4)
Continuous duty............................................. 100 %

Resistance................................................... 5 Ω±10%
SS99J025 Power output ................................................ 28.8 W
Interference suppression ........ Z-diodes, antiparallel

4004-118
Components, brake
Switch, brake light S5 / S25
for version with management (4-wheel drive and
differential lock)
Power output............................................. max. 5 W

Current .................................................... max. 0.5 A
SS02D171
Pin 1................................................. Supply, ground
Brake pedals not depressed:
Pin 1 - 2 ................................................. Interruption
Both brake pedals depressed (see graphic symbol):
Pin 1 - 2 ................................................ approx. 4 Ω
One brake pedal depressed (steering brake):
Pin 1 - 3 ................................................ approx. 4 Ω
Switch, compressed air S12

B3 (for compressed air indicator lamp)
Flat plug-in lug ............................................ 4.8 mm
Switching point........................................ p > 5.5 bar
Transmitter, pressure indicator B3

S12 (for compressed air reservoir pressure indicator)
SS99J078
Flat plug-in lug ............................................ 6.3 mm

Ground via housing (with ground connection)
Trailer brake solenoid valve, Italy Y50
Continuous duty ............................................. 100 %

Resistance ............................................. 8.5 Ω ± 10%
Insulation resistance .............................. >100 kΩ
SS99J171
Pressure switch, trailer brake, Italy S50

Switching capacity ................................ max. 100 W
Switching point..........................................10±0.5 bar
Safety.................................................... pma 300 bar
Thread ........................................................... G 1/4”
SS02D192

4004-119
Components, cab
Reed switches S42, S43

Current................................................ max. 500 mA
Reed changeover switches S41/1, S41/2
Contact .................................... Changeover contact

Current................................................ max. 500 mA
SS99J079
Mirror heating E18/1 and E18/2
Power output..................................................... 20 W
Rated voltage................................................ 12 VDC
Current ................................................. approx. 1.7 A
Resistance ................................................ 7.2 Ω±20%
SS00J092
Heated windscreen E25
Power output................................................... 280 W

Current .................................................. approx. 23 A
SS00J093
Heated screen, rear, E26
Power output................................................... 220 W

Current .................................................. approx. 18 A
SS00J039

4004-120
ECCU – Electronic Central Control Unit
SS99G175
List of plugs
X10/7 Plug-in connection, ECCU auxiliary valve

4004-121
Test Values
Fuel tank level transmitter B2/1 Display – Instrument M100

Diesel level Resistance Ω Pointer angle Display area
0 10 ± 2,5 0° from 0 - 12° red sector
1/8 30 ± 3 7.5°
±3
1/4 48
1/2 84.5 ± 5 30° from 30 - 35° white sector
3/4 118 ± 6
1 180 ± 12 60° from 60 - 65° white sector
Sensor, coolant temperature display B1 Display – Instrument M102

Temperature °C Resistance Ω Pointer angle Display area
45 239 0° from 0 - 10° white sector
60 134 0°
75 82 14°
90 51 20°
105 33.4 42° from 42 - 52° red sector
113 26.8 53°
120 22.4 60°
Transmitter, compressed air indicator B3 Display – Instrument M101

Pressure in bar Resistance Ω Pointer angle Display area
0 10 0° from 0 - 13° red sector
2 52 0°
4 88 6°
8 155 42°
Tractormeter
Frequency at alternator
Engine speed rpm Permissible deviation Pointer angle
terminal "W"
1000 ± 100 67° 250 Hz
2000 ± 65 163° 500 Hz
Sensor, gearbox oil temperature B32

Temperature °C Characteristic resistance in Ω (at test current of 1 mA)
minimum nominal maximum
0 800 815 830
25 985 1000 1015
40 1150*
100 1661 1696 1731
150 2131 2211 2291
* Signal voltage at 1150 ohms approx. 1.75 VDC (switching point, power-shift control mode)

4004-122
Lamps and Fuses
Rotating beacon H1 12V - 55W 1-34-772-051
Worklight H3 12 V - 55W 90003452243
Headlight, roof headlight H4 12V - 60/55W 90003450013
Trafficators, front and rear,

brake light P25-1 12 V - 21W 90003452245
Roof number plate light L 12 V - 5W 90003452276
Cab interior light L 12V - 10W 90003452249
Front sidelights, tail light G 12 V - 5W 90003452216
Cigarette lighter H 12V 2W 90003452207
Digital tractormeter 12V/2W 35700580708
Instrument lighting and

indicator lamps 12V/1.2W 90003450031
Toggle switch, EHR diagnosis

LED W5/1.2-12V-1.2W 90003452250
Foot step light, EHR console

lighting T4/4 12 V 4W 90003452212
3A violet 1-40-258-203 20A yellow 1-40-258-120

5A beige 1-40-258-105 25A white 1-40-258-125
7.5A brown 1-40-258-107 30A green 1-40-258-130
10A red 1-40-258-110
15A light blue 1-40-258-115
40A 1-40-177-040
100A 1-40-277-014

4004-123
Operation and coding of the digital instrument
with integrated operating hours counter
General information
All functions are called up using the spring-loaded switch (button) with the PTO symbol, on the right-hand side of
the instrument panel. To call up the various displays, you only need to press the button briefly. If the button is
pressed for longer than 10 sec., you can check and correct the calibration codes.
Operation and displays
Turn ignition switch to position ”1” The display shows a small "h" and the cumulative
(or after starting the engine) operating hours.
Press the button once The rear PTO shaft speed is shown on the display.
Press the button again The front PTO shaft speed is shown on the display.
Press the button once again The operating hours are shown on the display.
Coding
the ”Operating hours” (engine speed) display
”Rear PTO shaft speed” display
”Front PTO shaft speed” display
General information
Each time the button is briefly pressed, the display is (visibly) increased by one step. If the button is pressed
continually for longer than 1.5 sec's. the impulses are increased rapidly. When the button is released, "PRO"
appears on the display after 8 sec's. The value set is stored by briefly pressing the button once. ”Operating
hours” then appears on the display.
Coding the ”Operating hours” display

The combination of numbers 1-1 appears on the upper display, the current code or code to be corrected appears
on the lower display. The adjustable bandwidth is 15 - 255. Tractors 9105 - 9145 / CS100 - 150 require code 15.
(1 revolution at the engine crankshaft amounts to 15 impulses at terminal ”W” on the alternator)
Coding the ”Rear PTO shaft speed” display
(There are 20 segments on the circumference of the transmitter wheel on the rear PTO shaft)
Coding the ”Front PTO shaft speed” display
(A gear wheel in the front PTO shaft gearbox, which is also used as the transmitter wheel, has twenty teeth
(t = 20))

4004-124
Calibrating the ”Driving speed” display
If the tyre size is changed on the rear wheels of the tractor, or if three horizontal lines appear on the driving speed
display, then the display must be recalibrated.
Procedure:
- Measure out a distance of exactly 100 m and
mark both ends clearly
- Press the pushbutton for selecting the ”Rear PTO/

Front PTO shaft speed/Operating hours” display
until CAL (calibrate) appears on the km/h display.
(at least 10 secs.)
- Drive the tractor. When the front axle reaches the

first mark (0 metres), press the button once. The
display then reads COU (count).
- The lower display now counts up to 9999. ---- is

then displayed, which can be ignored.
- When the front axle of the tractor reaches the

second mark (100 metres), press the button once.
The display then reads PRO (program).
- Press the button once again – the new calibration

value is stored. The momentary speed is shown
on the display. When the tractor is at a standstill,
0.0 km/h is displayed.
- If a fault occurs during calibration (e.g. delay in

pressing the button, etc.), then proceed as
follows:
Do not store the new calibration value. Switch the
engine off. Start the engine and repeat the whole
procedure. Store the calibration value after COU
is displayed.
SS99H185

Chapter
5
5
FUNCTIONAL DESCRIPTION, TROUBLESHOOTING
AND SETTINGS
Front Axle with Independent Suspension 20.25S
9105, 9115, 9125 and 9145

CS110, CS120, CS130 and CS150
Training Center / Technical Documentation April 2000
5-2
TABLE OF CONTENTS
SPECIAL TOOLS ......................................................................................................................... 3
GENERAL DESCRIPTION .......................................................................................................... 4
COMPONENTS ........................................................................................................................... 5
OPERATION ................................................................................................................................ 6
Main Switch, Suspension ON / OFF .................................................................................... 6
Auxiliary switch .................................................................................................................... 6
Indicator lamp on the instrument panel ............................................................................... 6
FUNCTION OF THE SUSPENSION ............................................................................................ 7
Calibration procedure .......................................................................................................... 7
Control Function .................................................................................................................. 8
AXLE SENSORS ......................................................................................................................... 9
General Remarks ................................................................................................................ 9
Testing the "Sensor Settings" ............................................................................................ 10
Adjusting the Sensors ........................................................................................................ 12
LOWERING THE FRONT AXLE MANUALLY ........................................................................... 13
ERROR CODES ........................................................................................................................ 14
TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM ................................................... 15
Measurement table ............................................................................................................ 16
Test – solenoid valve control ............................................................................................. 18
Circuit Diagram, Sprung Front Axle ................................................................................... 19
Sva 7-97101 EN Edition 04-00

5-3
SPECIAL TOOLS
SD00C040 SD00D004
MULTIMETER 1TSW 516-1 INTERMEDIATE CABLE 1TSW 528-3
SD00C038 SD00D005
MEASURING CABLES 1TSW 528-11 "Y" ADAPTER, 12 POLE 1TSW 528-83
SD00C039 SD00D006
MEASUREMENT ADAPTER 1TSW 528-82 "Y" ADAPTER, 2 POLE 1TSW 528-6
SD00D003
DIAGNOSTIC BOX, 100 POLE 1TSW 528-1

5-4
GENERAL DESCRIPTION
4-wheel drive planetary steering axle with independent suspension, cast main housing with
front cover, centrally located swing bearing and drive, bevel drive pinion borne in the main
housing, differential fitted from the front end, differential drive gear secured in the main housing
by bridge type bracket.
Mechanical differential lock 100%, shift mechanism integrated into the front cover, electro-
hydraulically operated.
Independent suspension at both sides through: two trapezoidal links, one hydraulic cylinder, one
hydro-reservoir and one torsion bar acting in opposition to the hydro-reservoir.
One control block, fitted with three solenoid valves and the two hydro-reservoirs, each of
1,4 litres capacity, is located on the right-hand side of the vehicle chassis and forms the link
between the two hydraulic system cylinders. Connected in parallel to the hydraulic system (load
sensing).
Each side and thus the movement of each wheel, within the total spring travel range of 90 mm,
is actively monitored by an angle of rotation sensor.
The sensor signal is decisive for the reaction of the hydraulics to increase or decrease the
charge in the reservoir This firstly forms the basis for the weight independent height control and
secondly, actively assists the function of the hydro-reservoir when necessary.
Conversion of the sensor signals, to control the hydraulics or solenoid valves respectively, is
carried out in the electronic circuitry, designed as an independent element on the hydraulic
control block.

5-5
COMPONENTS
8
6
X 12/20
3
2 3
5
7
SS00C149
1
2
1 4 SS00C150
1. TRAPEZOIDAL LINK 5. CONTROL BLOCK
2. HYDRAULIC CYLINDER 6. SOLENOID VALVE
3. HYDRO-RESERVOIR 7. ANGLE OF ROTATION SENSOR
4. TORSION BAR 8. ELECTRONICS

5-6
OPERATION
Main Switch, Suspension ON / OFF
This switch has the following positions:
Switch pressed to the left
Suspension OFF (suspension inhibited) SS00B184
The suspension lowers the axle to the limit of the Indicator lamp
suspension cylinder.
Recommended mode for driving in hilly terrain and Main switch
contour lines.
Stipulated mode prior to opening the system. Auxiliary
(reservoir pressure-free) switch
Switch in the mid position

Suspension ON (100% spring travel), indicator
lamp lights. The suspension goes to or remains in
the middle of the total range of travel, independent SS00B187
of weight.
,03257$17 In this operating mode and at a speed of between 0 and 14 km/h, it is possible, to
freely select any desired height adjustment (ground clearance) within the total suspension range.
If a manual adjustment is made, the indicator lamp will go out. This switch position activates an
automatic function in the electronics, which overrides any manual height selection and returns
the suspension to 100% travel if a speed of 14 km/h is exceeded.
Switch pressed briefly to the right (pushbutton function)

End the calibration procedure.
Activating 100% spring travel, under any operating conditions.
Pushbutton function, held pressed for 10 sec’s. (until the indicator lamp blinks at regular
intervals)
Start the calibration procedure.
Auxiliary switch (pushbutton function only, pressed to the left – lower, to the right – raise)
Holding the button pressed
Active at 100% suspension travel – alteration of ground clearance in the respective direction.
During the calibration procedure – stipulating the upper and lower limits of suspension travel.
Push-button pressed briefly
Height control OFF
127( When the tractor is started, the function which was last in use will take effect. The tractor
speed must however exceed 14 km/h for the height control to activate.
Indicator lamp on the instrument panel

Lamp does not light: Suspension OFF or suspension without height control.
Lamp lights: 100% suspension travel and height control active.
Lamp blinks regularly – confirms calibration procedure.
Lamp blinks irregularly: an error code will be presented (see error code list Page 14)

5-7
FUNCTION OF THE SUSPENSION

The suspension can be operated in several operating modes. The relevant operating mode is
indicated by the indicator lamp on the instrument panel as follows:
Indicator lamp OFF
System switched OFF, reservoir or system free of pressure.
Axle at its limit, no suspension or suspension inhibited.
Manual height adjustment (ground clearance adjustment) has been made. Suspension from
the newly selected position only through the reservoir. Suspension travel is hereby restricted,
in one direction, to the remaining travel up to the limit. Changes in weight and leakage are not
compensated for.
Indicator lamp lit
Height control from the middle of the total suspension travel, 100% suspension travel up and
down, independent of load and leakage, is or remains available through active reservoir
pressure adaptation.
Indicator lamp blinks regularly (1 Hz)
Calibration process active.
Indicator lamp blinks irregularly (3 Hz)
An error code will be displayed
The blink pattern is interrupted by a long and a short pause.
Example: Error code 21 – long pause, blinks twice, short pause, blinks once.
:$51,1* If a fault occurs, a fault code is given and at the same time, the valve control will be
switched OFF and the suspension will remain in the present position. When the fault has been
rectified, the error code must be acknowledged by switching the ignition switch from OFF to ON.
Calibration procedure
This serves to stipulate the upper and lower end limits of the suspension on both sides. If the
control system does not receive any recognisable data, the calibration procedure will be
automatically activated when the supply voltage is switched ON.
The calibration procedure can also be selected by the driver at any time (as described in the
Operating Manual). Calibration itself is always carried out in the following way:
Hold the main switch, pressed to the right, for at least 10 sec's. (indicator lamp must blink
regularly).
Select and hold the auxiliary switch to the "raise" position until the upper limit is reached.
Select and hold the auxiliary switch to the "lower" position until the lower limit is reached.
To complete the procedure, press the main switch briefly to the right.
The indicator lamp must now be lit.
The suspension moves to the centre of its travel – the procedure is complete.
When the indicator lamp once again starts to blink, repeat the procedure.

5-8
Control Function
6 Tu ON Tu OFF
ON OFF
STol
SNom
STol
OFF
ON
S = Total suspension travel Tl ON Tl OFF

SS00C151
SNom = Calculated mean value
Tu = Upper tolerance
Tl = Lower tolerance
STol = Tolerance range
For active control, the position of the suspension is acquired every 100 ms.
The electronics recognise whether the suspension is within the fixed tolerance range, program-
med in the E-Box, by the sensor signals received or whether it makes significant changes for brief
periods of time. The basis for this is the mean value (S Nom) calculated from the relevant sensor
signal from the total spring travel.
If this range is exceeded, in either direction, for longer than 2.5 sec’s. the valves will be regulated
and the corresponding change in reservoir pressure will be initiated. The valves will only then stop
being regulated, when the position signals acquired are once again within the tolerance range.
How often and for how long the valves will be regulated is always dependent upon the sensor
signals received and can not be influenced by the driver.
,03257$17 The basis for trouble-free function is the acquisition of the total spring travel during
the calibration procedure. The basis for this is provided by the correct initial set-up of the sensors.

5-9
AXLE SENSORS
General Remarks
Adjustment must always be carried out, when one or both of the sensors have been replaced or
if the sensor fastening was loosened.
Prior to adjusting the sensors, ensure that the drive wheel (rubber wheel) is correctly fitted and
the guide wheel has freedom of movement, not only externally in the bolt but also internally on
the sensor. The tightening torque of the securing bolts must also be strictly adhered to.
If either of the above mentioned items is not adhered to, or carried out incorrectly, the function will
be impaired due to deformation of the sensor housing.
The following limits are valid for the basic adjustment of both sensors:
Suspension (axle) at its lower limit ........................................................................ >5 mA <6.5 mA
Suspension ( axle) at its upper limit ....................................................................... <18.68 mA
,03257$17 After one or both sensors have been replaced, a re-calibration must be carried out
so that the electronics can acquire the new or current signal for total suspension travel and
calculate the new mean value If calibration is not carried out, the suspension will assume the mid
position of the old calibration value. The result of this will be, that the amount of suspension travel
will be uneven or totally incorrect.
127( The total suspension travel will be recognised, by way of the signal current, by the E-Box
during calibration, the deviation from the upper or lower basic setting must be at least 9.05 mA.

5 - 10
Testing the "Sensor Settings" Connect the measuring cables 1TSW 528-11
to the multimeter 1TSW 516-1 in order to test
,03257$17 Sensors settings tests must be the voltage. In order to test the power supply
carried out from the driver’s seat. for the right-hand sensor, connect the
measuring cables to the sockets in the red
STEP 1 field of the test adapter (red cable to red
Put the tractor on solid, level ground and apply socket, blue cable to black socket).
the parking brake. Lower the axle to its lower
mechanical limit and switch the engine OFF. STEP 4
Place chocks in front of and behind the rear Start the tractor and read the supply voltage
wheels. value off the multimeter.
STEP 2 127( Before starting the tractor, make sure

that all measuring cables are interconnected,
that the multimeter is switched ON and set to
2 "VDC" (DC Voltage).
127( A value of at least 12 Volts (battery
voltage) must be indicated. If this value is not
1 reached, check the fuse F32 on the central
3
print. If the fuse is ok, the procedure for "Trou-
bleshooting using the Diagnostic System"
must be followed (see Page 15).
1TSW 528-82
STEP 5
SD00D018
In order to test the left-hand sensor, connect
Remove the protective cover from the control the measuring cables to the sockets in the
block. Separate the plug-in connector and blue field and repeat STEP 4.
connect the measurement adapter 1TSW
528-82 into the sensor line. STEP 6
127( The right-hand sensor is tested using
the measurement adapter sockets in the red
field (2) and the left-hand sensor using the
sockets in the blue field (3).
STEP 3
1TSW 516-1
4
SD00D020
4 Switch the engine OFF. In order to test the

right-hand sensor’s signal current, remove the
plug-in jumper from the red field on the
1TSW 528-11 measurement adapter 1TSW 528-82 and
replace it with the measuring cables
SD00D019 1TSW 528-11. Plug the measuring cables into
Insert the plug-in jumpers (4) into the sockets the multimeter 1TSW 516-1 sockets "40 mA"
in both the red and blue fields on the and "COM".
measurement adapter 1TSW 528-82.

5 - 11
,03257$17 Before starting the tractor,
make sure that all measuring cables are :$51,1* Never leave the engine
running in confined spaces. Provide
interconnected, that the multimeter is adequate ventilation under all cir-
switched ON and set to "ADC" (DC Amps).
cumstances. SM100A
If, in spite of this, error code 21 or 22 is
displayed, check the fuse in the multimeter
(40 mA measuring range). STEP 8
Press the auxiliary switch to the right until the
STEP 7 axle has reached the upper mechanical limit.
Read the value indicated off the multimeter
and make a note of it.
Main switch
STEP 9
Auxiliary The following values should be indicated:

Lower limit ................................ min. 5.00 mA
Upper limit ............................. max. 18.68 mA
The difference between the values indicated
must not be less than 9.05 mA.
127( If the values indicated are outside the
SS00B187
given values, the sensors must be newly
Start the tractor and allow it to run at idling adjusted (see Page 12).
speed. Press the main suspension switch
briefly to the right and wait until the axle is in STEP 10
the mid position. Disconnect the measurement adapter 1TSW
Press the auxiliary switch to the left until the 528-82 and re-connect the sensor cable
axle has reached the lower mechanical limit. connectors. Re-fit the protective cover to the
Read the value indicated off the multimeter control block.
and make a note of it.
,03257$17 If an error code is displayed
and the front axle can not be lowered using
either the main or auxiliary switches, the front
axle must be lowered manually (see Page
13).

5 - 12
Adjusting the Sensors ter is switched ON and set to "ADC" (DC

Amps). If this point is not observed, an error
STEP 1 code will be displayed.
Put the tractor on solid, level ground and apply
the parking brake. Lower the axle to its lower STEP 4
mechanical limit and switch the engine OFF.
Place chocks in front of and behind the rear 5
wheels.
STEP 2
1
2
1
SD00C034
3
Remove the sensor covers (5) from both si-
des.
1TSW 528-82 Turn the ignition switch to ON and loosen the
sensor securing screws. Adjust the sensor, so
SD00D018
that the multimeterindicates a value of
Remove the protective cover from the control 6 mA ±0,5. Tighten the securing screws to a
block. Separate the plug-in connector and torque of 169 Nm.
connect the measurement adapter 1TSW
528-82 into the sensor line. STEP 5
Check the reading on the multimeter and
STEP 3 repeat STEP 4 if necessary.
STEP 6
4 Turn the ignition switch to OFF. To adjust the
left-hand sensor, plug the measuring cables
into the sockets in the blue field and insert the
plug-in jumper into the sockets in the red field.
STEP 7
Repeat STEP 4 and STEP 5 to adjust the left-
hand sensor.
SD00C035 STEP 8
To adjust the right-hand sensor, remove the Re-fit the sensor covers to both sides and
plug-in jumper from the measurement adap- tighten the securing screws to a torque of
ter’s red field and replace it by the measuring 13 Nm.
cables 1TSW 528-11.
127( Seal the sensor covers using a
Plug the measuring cables into the multimeter
surface sealing compound.
1TSW 516-1 sockets "40 mA" and "COM". In-
sert the plug-in jumper (4) into the sockets in STEP 9
the blue field.
Disconnect the measurement adapter 1TSW
,03257$17 Before turning the ignition 528-82 and re-connect the sensor cable
switch to ON, make sure that all measuring connectors. Re-fit the protective cover to the
cables are interconnected, that the multime- control block.

5 - 13
LOWERING THE FRONT AXLE MANUALLY

,03257$17 If the front axle can not be lowered, using either the main or auxiliary switches,
because of a defect, the front axle must be lowered manually by means of the discharge valve.
STEP 1 STEP 3
Put the tractor on firm, level ground, apply the
parking brake and switch the motor OFF.
Place chocks in front of and behind the rear
wheels.
STEP 2
SD00D022
Loosen the locking nut and turn the valve

screw (2) out by approx. one turn. The axle will
sink to the lower mechanical limit and the
1 pressure reservoirs will be relieved of
pressure.
SD00D021
Remove the protective cover from the control STEP 4

block. Remove the plastic cover (1) from the When the reservoirs are pressure-free, close
discharge valve. the valve screw and tighten the locking nut.
Re-fit the plastic cap to the discharge valve.

5 - 14
ERROR CODES
Indication of an error code by the indicator lamp in the instrument panel blinking at 3 Hz.
127( In the calibration mode, the indicator lamp blinks regularly at a frequency of 1 Hz. This is
not an error code.
The following error codes can be displayed:
Error Code Fault Location/ System Reaction Possible Fault
Cause
Left-hand sensor Axle remains in the • Cable defective or sensor disconnected
signal not ok current position • Short circuit or short to earth
21 • Sensor incorrectly adjusted
• Signal <4 mA or >19.68 mA
Right-hand sensor Axle remains in the • Cable defective or sensor disconnected
signal not ok current position • Short circuit or short to earth
22 • Sensor incorrectly adjusted
• Signal <4 mA or >19.68 mA
No power supply to the Axle remains in the • Cable or plug defective
E-box. current position • Potential 30, fuse defective:
(potential 30 is pre power shuttle versions - F17
31 missing) post Power Shuttle versions - F31
Left-hand control valve Axle remains in the • Cable defective or solenoid disconnected
does not function current position • Short circuit in the solenoid or cable
• E-Box output stage defective
Right-hand control Axle remains in the • Cable defective or solenoid disconnected
32 valve does not function current position • Short circuit in the solenoid or cable
• E-Box output stage defective

5 - 15
TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM

127( If an electrical fault occurs, which is not indicated by an error code, this can be quickly
and simply localised using the diagnostic system. The complete electrical circuit for the front axle
with independent suspension can be checked using the diagnostic system.
Troubleshooting is carried out using a measurement table, in which the individual measurements
are described precisely. Measurement requirements are represented by simple symbols (see
"Symbol legend").
,03257$17 If these measurement requirements are not adhered to, this can lead to incorrect
measurement results and to damage to electrical / electronic components.
Special tools required:
Order No. Designation Use

1TSW 528-1 Diagnostic box, 100 pole General
1TSW 528-3 Intermediate cable Connection between diagnostic
box and 12 pole ’Y’ adapter
1TSW 528-83 12 pole ’Y’ adapter For X12/20 (electronics – A61 on
the control block)
1TSW 528-6 2 pole 'Y' adapter Solenoid valve on the control
block
1TSW 528-11 Measuring cable 1.5 m, red, blue General
1TSW 516-1 Multimeter General
Test lamp with 45 W bulb As a load during various
measurements
Symbol legend:
Ignition switch "OFF"
Ignition switch "ON"
Engine running
Plug connected to the electronics box
Plug disconnected from the electronics box
Connect the test lamp, with prescribed wattage, as a load

5 - 16
Measurements
V Voltage
∆V Voltage drop
R Resistance
∞ Resistance infinity = open circuit (multimeter indication OL)
Measurement table
Measurement
Cable colour
Measure
X12/20
Pin
Designation Requirements from pin Value

to pin
Power supply, electronics box A61

----- 45W 6 9 -----
Ground 9 B max. 1.0
∆V 45W 9 Battery -ve pole
VDC
----- 45W 8 10 -----

Ground 10 B max. 1.0
∆V 45W 10 Battery -ve pole
VDC
G315 A313
12 - 14
Permanent plus F31 10 A 6 V 45W 6 9
VDC
12 - 14
Permanent plus F32 5 A 8 V 45W 8 10
VDC
Input signals from the main switch S2/15/2
Suspension inhibited
C307
12 - 14
Main switch (S2/15/2) 4 V Switch pressed to the 4 9
VDC
in position 2 left
Suspension active
C307
Main switch (S2/15/2) 4 V Main switch in mid 4 9 0 VDC

in position 0 position
Suspension active
C308
Main switch (S2/15/2) 5 V Main switch in mid 5 9 0 VDC

in position 0 position
Calibration
C308
12 - 14
Main switch (S2/15/2) 5 V Main switch pressed to 5 9
VDC
in position 1 the right

5 - 17
Measurement
Cable colour
Measure
X12/20
Pin
to pin
Input signals from the auxiliary switch S2/15/1
C302 C301
2 V 2 9 0 VDC
Auxiliary switch (S2/15/1)
in position 0 Auxiliary switch not
3 V 3 9 0 VDC
pressed
Lower front axle

C301 12 - 14
Auxiliary switch (S2/15/1) 2 V Auxiliary switch 2 9
VDC
in position 2 pressed to the left
Raise front axle

C302
12 - 14
Auxiliary switch (S2/15/1) 3 V Auxiliary switch 3 9
VDC
in position 1 pressed to the right
Input signal – resume "suspension active"

127( For this test, it is necessary that the driving speed is indicated correctly. If necessary, carry out speedo-
meter calibration.
C281
Switching voltage from A10

12 V 12 9 6 - 6.6 VDC
ADM at v = > 14 km/h:
C281
Switching voltage from A10 approx. 0

12 V 12 9
ADM at v = < 14 km/h: VDC
Output signal to indicator lamp L15 "front axle suspension"
approx. 0
B142
Indicator lamp L15

11 V Main switch pressed 11 9 VDC
lights
briefly to the right (ground)
B142
Indicator lamp L15

11 V Main switch pressed to 11 9 7 - 11 VDC
does not light
the left

5 - 18
Test – solenoid valve control

To carry out these tests, the multimeter 1TSW 516-1 must be connected to the individual solenoid
valves using the "Y" adapter 1TSW 528-6 and the measuring cables 1TSW 528-11.
Test the solenoid valves in accordance with the table below.
Solenoid valve energised 12 - 14 VDC
Solenoid valve not energised 0 VDC
Function SV SV SV
blue plug green plug black plug
Raise front axle (auxiliary switch pressed to the right)
Lower front axle (auxiliary switch pressed to the left)
Control – increase pressure right and left
Control – raise right only
Control – raise left only
Control – decrease pressure right and left
Control – decrease pressure right only
Control – decrease pressure left only
Resistance and insulation tests on the valve solenoids

Measurement
Measure
to pin
R 1 2 on the solenoid 8 Ω ± 10%

Valve solenoid-
plugs blue, green R 1 valve housing •
and black
R 2 valve housing •
Solenoid valve – blue plug Solenoid valve – green plug

(raise / lower left) (raise / lower right)
SS00D001
Solenoid valve – black plug

(raise left / right)

5 - 19
Circuit Diagram, Sprung Front Axle
FROM A10
ADM /
6.5 V AT v > 14 km/

POT. 15/
12 V FOR
12 V FOR
PRESSED TO RIGHT
POT.
12 V -MAIN SWITCH
12 V FOR
GROUND FOR
SUSPENSION
5 - 18 mA (SIGNAL
5 - 18 mA (SIGNAL
12 V FOR RAISE/
RAISE/LOWER
12 V FOR
12 V FOR
LOWER
GROU
GROU
GROU
GROU
GROU
GROU
GROU
12 V
12 V
SV - BLUE SV - BLACK SV -
AXLE SENSORS
SS00C179
Electrical equipment Ground

A1 Combination instrument 2 Instrument panel
A61 Sprung front axle electronics
potential 30
potential 15/2
L 15 Sprung front axle indicator lamp
S2/15/1 Auxiliary switch RAISE/LOWER
S2/15/2 Main switch
X9/4 Plug-in connection, combination instrument
X24/1 Plug-in connection line, combination instrument

5 - 20

Kapitel / Section
5001
5001
WERKSTATTHANDBUCH
WORKSHOP MANUAL
VORDERACHSE - FRONT AXLE

Typ 20.20 / 20.25
9105, 9115, 9125, 9145

CS110, CS120, CS130, CS150
CASE STEYR Landmaschinentechnik GmbH Sva 7-71500 GE/EN © 1999 Case Steyr Landmaschinentechnik GmbH
Technische Dokumentation Juni, 1999
CASE CS110 - CS150 ; Steyr 9105 - 9145 LTA - TYP 20.20, 20.25
Ausführungen Possibilitys
9105 / 9115 und CS110 / CS120 B 342.01 Typ 20.20

B 343.34 Typ 20.20 FR
9125 / 9145 und CS130 / CS150 B 342.02 Typ 20.25

B 343.35 Typ 20.25 FR
FR = mit nasser Scheibenbremse / with oil immersed break discs
CASE STEYR Landmaschinentechnik, Abteilung Technische Dokumentation

Alle Rechte vorbehalten.
Diese Druckschrift darf ohne unsere schriftliche Genehmigung weder ganz noch auszugsweise vervielfältigt werden.
Änderungen vorbehalten.
CASE STEYR Landmaschinentechnik, Dept. Techn. Publication.

All rights reserved.
This publication may not be produced in any form, in whole or in part, without ourwritten approval.
Subject to change without notice.
2
LTA - TYP 20.20, 20.25 CASE CS110 - CS150 ; Steyr 9105 - 9145 A
Inhalt der Bereiche / Index of sections
Bereich Beschreibung Description Seite

Section Page
A Achsbeschreibung Description - axle

Spezifikation Specifications and features 4
B Bereichsansichten Section view 6
C Anzugsdrehmomente Torque settings 10
D Schmierung Lubrication 12
E Spezialwerkzeuge Special tools 13
F Demontage, Montage Disassembling, reassembling 19

und Einstellungen and setting operations
3
A CASE CS110 - CS150 ; Steyr 9105 - 9145 LTA - TYP 20.20, 20.25
ACHSBESCHREIBUNG
Allrad Planetenlenkachse - Achsbrücke gegossen, Zentralantrieb, Achseinsatz mit Achsbrücke

verschraubt.
Mechanische 100% Sperre elektrohydraulisch betätigt.
Endantriebe, Planetengetriebe mit oder ohne nasser Scheibenbremse.
SPEZIFIKATION
DIFFERENTIAL Typ 20.20 Typ 20.25
Übersetzung z= 12/32 14/32

Zahnflankenspiel mm 0,17 - 0,24 0,18 - 0,23
Einstellscheiben für Triebling (in 0,1 Abstufung) mm 2,5 - 3,4 2,5 - 3,4
Rollmoment der Trieblingslager auf Ø = 34,80 mm N P = 92 - 137 P 92 - 137
Rollmoment des gesamten Differentials N (P+34,5)-(P+48,8) (P+40)-(P+60)
LENKUNG Typ 20.20 Typ 20.25
Kolbenstange Ø mm 32 32
Zylinderbohrungs Ø mm 65 65
Hub nach beiden Seiten mm 130 130
Max. Arbeitsdruck bar 150 150
Vorspur mm 0 bis -2 0 bis -2
Einschlagwinkel ° 50° 50°
ENDANTRIEBE Typ 20.20 Typ 20.25
Übersetzung i= 1:6 1 : 6,923

Radlagereinstellung keine (Teile müssen maßhaltig sein)
Bremsscheibenstärke mm 10 10
Mindeststärke der Bremsscheibe (Verschleißgrenze) mm 8,9 8,9
4
LTA - TYP 20.20, 20.25 CASE CS110 - CS150 ; Steyr 9105 - 9145 A
DESCRIPTION - AXLE
Steering drive axle - monobloc housing in nodular cast iron - centre differential with mechanical
locking device hydraulic operated.
Planetary reduction final drives with or without oil immersed brake discs.
Steering cylinder integrated in the differential support.
SPECIFICATION & FEATURES
BEVEL DRIVE - DIFFERENTIAL Type 20.20 Type 20.25
Ratio T 12/32 14/32

Backlash mm 0,17 to 0,24 0,18 - 0,23
Shims thickness for bevel pinion position mm 2,5 to 3,4 2,5 - 3,4
Bevel pinion bearing pre-load measured on
diameter D = 34.80 mm N P = 92 - 137 P = 92 - 137
Bevel gear set (total) bearing pre-load
(measured on the pinion queue) N (P+34,5)-(P+48,8) (P+40)-(P+60)
STEERING Type 20.20 Type 20.25
Piston rod diameter Ø mm 32 32

Cylinder bore diameter Ø mm 65 65
Stroke for each side mm 130 130
Max. pressure travel bar 150 150
Toe - in mm 0 to -2 0 to -2
Steering angle ° 50° 50°
FINAL DRIVES Type 20.20 Type 20.25
Epicyclic reduction ratio T= 1:6 1 : 6,923

Wheel bearing setting 'Set right' System
Brake disc thickness mm 10 10
Brake disc max. wear - Thickness mm 8,9 8,9
5
B CASE CS110 - CS150 ; Steyr 9105 - 9145 LTA - TYP 20.20, 20.25
ENDANTRIEB OHNE BREMSE 20.20 FINAL DRIVE WITHOUT BRAKE 20.20
ss97g451
ENDANTRIEB MIT BREMSE 20.20FR FINAL DRIVE WITH BRAKE 20.20FR
ss97g452
6
LTA - TYP 20.20, 20.25 CASE CS110 - CS150 ; Steyr 9105 - 9145 B
ENDANTRIEB OHNE BREMSE 20.25 FINAL DRIVE WITHOUT BRAKE 20.25
ss97g453
ENDANTRIEB MIT BREMSE 20.25FR FINAL DRIVE WITH BRAKE 20.25FR
ss97g454
7
B CASE CS110 - CS150 ; Steyr 9105 - 9145 LTA - TYP 20.20, 20.25
DIFFERENTIAL MIT SPERRE 100% DIFFERENTIAL WITH 100% DIFF LOCK
ss97g455
8
LTA - TYP 20.20, 20.25 CASE CS110 - CS150 ; Steyr 9105 - 9145 B
NOTIZEN - NOTES
9
C CASE CS110 - CS150 ; Steyr 9105 - 9145 LTA - TYP 20.20, 20.25
ANZUGSDREHMOMENTE
(nach Positionsnummern von Seite 6, 7 und 8)
BESCHREIBUNG Gewinde Nm
DIFFERENTIAL - ACHSGEHÄUSE
bis auf richtige

1 Nutmutter am Triebling M 40 x 1,5 Lagervorspannung
2 Achseinsatzbefestigung (Schrauben wahlweise) M 12 x 33 169
M 12 x 75 169
3 Sicherung bei Einstellmutter für Tellerradlager M 6 x 10 13
4 Tellerradbefestigung (Loctite 270 verbauen) M 10 x 75 78 + Loctite 270
5 Gehäuseentlüftung M 10 x 1 10
6 Ölfüll- und Niveauschraube M 22 x 1,5 70
7 Bügel für Tellerradlager am Achseinsatz M 14 x 75 266
8 Deckel für Differentialsperreschaltung M 8 x 20 27,6
9 Fixierschraube für Buchse zur Pendellagerung M 16 70
ACHSSCHENKELBOLZEN
10 Befestigung der Achschenkelbolzen M 14 190

11 Einstellschraube für Lenkeinschlag M 16 150
12 Kontermutter auf Spurstange M 24 x 1,5 250
13 Spurstangengelenk M 20 x 1,5 220
14 Verschraubung Kugelgelenk-Kolbenstange M 20 x 1,5 300
15 Befestigungsschrauben für Lenkzylinder M 12 x 45 120
ENDANTRIEBE
16 Hohlrad - Befestigungsschrauben M 14 x 1,5 x 65 220

17 Radbolzen M 22 x 1,5 70 + Loctite 270
18 Befestigungsschrauben für Planetenträger M 8 25
19 Verschlußschraube M 30 80
20 Sicherungsschrauben Planetenräder (nur bei 20.25) M 10 x 50 79
Radmuttern (nach 50 Betriebsstunden nachziehen) 300
10
LTA - TYP 20.20, 20.25 CASE CS110 - CS150 ; Steyr 9105 - 9145 C
TIGHTENING TORQUE
(refer to page 6, 7 and 8 for identification)
DESCRIPTION Thread Nm
BEVEL GEAR - DIFFERENTIAL - AXLE HOUSING
as per
1 Input shaft ring nut M 40 x 1,5 pre-load
2 Bolt - differential support to axle housing (optional) M 12 x 33 169
M 12 x 75 169
3 Bolt - differential side ring nut lock plate M 6 x 10 13
4 Bolt - crown wheel to differential carrier (use Loctite 270 ) M 10 x 75 78 + Loctite 270
5 Axle housing breather M 10 x 1 10
6 Plug - oil fill and level M 22 x 1,5 70
7 Bolts - half collar to differential support M 14 x 75 266
8 Bolts - differential locking device covers M 8 x 20 27,6
9 Bolt - pivot bushing stop M 16 70
KING PIN - STEERING RODS
10 Bolts - king pin to swivel housing M 14 190

11 Bolt - steering stop lock nut M 16 150
12 Nuts - tie rod to ball joint M 24 x 1,5 250
13 Nuts - ball joint to swivel housing M 20 x 1,5 220
14 Ball joint to steering piston rod M 20 x 1,5 300
15 Bolts - steering cylinder to differential carrier M 12 x 45 120
FINAL DRIVES
16 Bolts - wheel hub bearings M 14 x 1,5 x 65 220

17 Stud - planetary gear carrier M 22 x 1,5 70 + Loctite 270
18 Screw - planetary carrier to wheel hub M 8 25
19 Whell hub drain plug M 30 80
20 Safety screws planetary gear (only 20.25) M 10 x 50 79
Nuts - wheel rim to final drive (re-tighten after 50 hours) 300
11
D CASE CS110 - CS150 ; Steyr 9105 - 9145 LTA - TYP 20.20, 20.25
SCHMIERUNG
LUBRICATION
Ölspezifikation MIL-L-2105 C und API GL 5 für Differential und Endantriebe.

Use oil with specifications MIL-L-2105 C and API GL 5 on differential and on final drives.
Typ 20.20 Typ 20.25
FÜLLMENGEN Liter Liter

QUANTITY Lts. Lts.
Differential 6,2 8,0

Differential
Endantriebe je Seite 1,5 (2,0)* 1,5 (2,0)*
Final reduction oil q.ty. for each side
* mit Bremse
* with brake
ÖLKONTROLLE und WECHSEL

CHECK and CHANGE OF OIL
Laut Serviceplan (Betriebsanleitung / Kundendienstheft)

According the maintenance schedule (Operating instructions / Service manual)
SCHMIERVORSCHRIFT
GREASING
siehe Betriebsanleitung oder Kundendienstheft

According the maintenance schedule of the operators manual)
12
LTA - TYP 20.20, 20.25 CASE CS110 - CS150 ; Steyr 9105 - 9145 E
SPEZIALWERKZEUGE
SPECIAL TOOLS
SPEZIALWERKZEUGE Kategorie I
Diese Spezialwerkzeuge sind für eine Reparatur unbedingt erforderlich!
SPEZIALWERKZEUGE Kategorie II
Spezialwerkzeuge mit Maßskizzen zur Selbstanfertigung!
SPECIAL TOOLS Category I

The following special purpose tools are absolutely necessary for repair!
SPECIAL TOOLS Category II
Special-purpose tools with sketches for self manufacturing!
13
E CASE CS110 - CS150 ; Steyr 9105 - 9145 LTA - TYP 20.20, 20.25
SPEZIALWERKZEUGE Kategorie I
1. TSW 173 Montagehülse für Lenkzylinder

2. TSW 174 Kalibrier- u. Montagehülse für Lenkzylinder
3. TSW 504 Nutmutternschlüssel für Trieblingsmutter
+ TSW 162-2 und 1397 270169 (Gegenhalter in Verbindung mit Muffe)
4. TSW 532 Schlüssel für Ringmutter - Differential
5. TSW 549* Setzer für Kassettendichtring der Radnabe
SPEZIALWERKZEUGE Spezialwerkzeug Kategorie II
6. TSW 550* Setzer für Wellendichtring im Achsgehäuse

Setzer für Wellendichtring - Triebling
Setzer für Wellendichtring im Achsschenkel (Typ 20.20)
7. TSW 551* Setzer für Wellendichtring im Achsschenkel (Typ 20.25)
8. TSW 552* Setzer für Lagerbüchse im Achsgehäuse
Setzer für Lagerbüchse im Achsschenkel (Typ 20.25)
9. TSW 553* Setzer für Lagerbüchse im Achsschenkel (Typ 20.20)
10. TSW 539* Werkzeug zur Lagerdistanz-Ermittlung (Triebling)
* in Verbindung mit Universalgriff TSW 18390
SPECIAL TOOLS Category I
1. TSW 173 Mounting sleeve for steering cylinder

2. TSW 174 Calibrating and mounting sleeve for steering cylinder
3. TSW 504 Wrench for bevel pinion ring nut
+ TSW 162-2 and 1397 270169 (counterholder with sleeve)
4. TSW 532 Wrench for differential side ring nut
5. TSW 549* Driver for cassette oil seal
SPECIAL TOOLS Category II
6. TSW 550* Driver for axle housing oil seal

Driver for bevel pinion oil seal
Driver for bevel pinion axle housing oil seal
7. TSW 551* Driver for bevel pinion axle housing oil seal
8. TSW 552* Driver for axle housing bush
Driver for axle housing oil seal
9. TSW 553* Driver for swivel housing bush
10. TSW 539* Kit for bevel distance measurement (pinion)
* Universal handles TSW 18390
14
Spezialwerkzeug für Lenkzylinder Special tools for steering cylinder

Kategorie I Category I
1
TSW 173
ss97g456 ss97g458
2
TSW 174
ss97g457 ss97g459
Spezialwerkzeug Kategorie I 4 Special tools Category I 5

TSW 532 TSW 549
ss97g460
3
TSW 504
ss97g461
ss97g462
15
Spezialwerkzeuge Kategorie II Special tools Category II
6 7
Beschriften: X Beschriften: X
TSW 550 ss97g463 TSW 551 ss97g464
Beschriften: X
TSW 552 ss97g465
Beschriften: =
Marking:
16
Beschriften: X
TSW 553 ss97g466
10
ss97g468
1 = Pos. 10 2x
2 = SK Schraube M12 x 110 - 8,8 - A3C DIN 931
3 = SK Mutter M12 - 8 - A3C DIN 934
Beschriften: X
TSW 539 ss97g467
Beschriften: =
Marking:
17
NOTIZEN - NOTES
18
LTA - TYP 20.20, 20.25 CASE CS110 - CS150 ; Steyr 9105 - 9145 F
DEMONTAGE - EINSTELLUNGEN UND MONTAGE

DISASSEMBLING - SETTING OPERATIONS AND REASSEMBLING
Inhalt Seite Index of pages Page
Vorwort 19 Foreword 19
Planeten-Endantriebe - 20.20 21 Epicyclic reduction - 20.20 20
Radnabe - 20.20 22 Wheel hub - 20.20 22
Radnabe mit Bremse - 20.20 23 Wheel hub with breake - 20.20 23
Planeten-Endantriebe - 20.25 24 Epicyclic reduction - 20.25 24
Radnabe - 20.25 25 Wheel hub - 20.25 25
Radnabe mit Bremse - 20.25 26 Wheel hub with breake - 20.25 26
Achsschenkelträger und Swivel housing king pins 28
Achsschenkelbolzen 28 Drive shaft 29
Antriebswelle 29 Steering cylinder and toe-in 30
Lenkzylinder und Vorspur 30 Differential assembly 31
Achseinsatz 31 Setting the bevel distance 32
Tragbildeinstellung 32 Pre-load of pinion bearings 33
Einstellung d. Trieblingslager 33 Crown wheel / pinion backlash 34
Einstellung Zahnflankenspiel 34 Differential bearing pre-load 35
Einstellung d. Differentaillager 35 Differential - 20.20 36
Differential - 20.20 36 Differential - 20.25 37
Differential - 20.25 37 Locking differential 38
Differentialsperre 38 Axle housing 39
Achsbrücke 39
VORWORT FOREWORD
DEMONTAGE - MONTAGE DISASSEMBLY - REASSEMBLY
Bei Reparaturen an Endantrieb, Radlagerung, The overhauling of final drives, wheel hubs and
Achsschenkelbolzen und Bremsen, kann die king pins can be completed without remove the
Achse im Fahrzeug eingebaut bleiben. axle from the vehicle.
Wenn die Achse aus dem Fahrzeug ausgebaut Should it be necessary to remove the axle
werden muß, ist auf die Sicherheit für die Per- assembly, adequate supporting of the vehicle
son zu achten. must be ensured to work with safety.
KASSETTENDICHTRINGE CASSETTE SEAL
- Einbau nur mit Spezialwerkzeug - Assembly only with special tools

- gummierte Innenfläche mit Spiritus Wasser- - moisten rubberized inner side with a mixture
gemisch benetzen. of water an spirit.
19
F CASE CS110 - CS150 ; Steyr 9105 - 9145 LTA - TYP 20.20, 20.25
WELLENDICHTRINGE OIL SEAL FOR ROTATING SHAFT
Vor der Montage von Wellendichtringen ist auf For an installation of oil seal adhere to the
folgendes zu achten: following recommendation:
- Wellendichtring vor der Montage eine 1/2 - Before installation soak the seal for half hour
Stunde in jenes Öl legen, welches er abzu- in the same oil that will be used in the
dichten hat. housing to be sealed.
- Lauffläche für Wellendichtring reinigen und auf - Clean the shaft and ensure the seal area of
Beschädigung prüfen. the same is not damage, fitting or grooved.
- Lippen müßen zur Ölseite eingebaut werden. - Place the sealing lips towards the oil side.
- Bei mehrlippigen Ringen, Fett zwischen die - Lubricate the seal lip (oil is better than
Lippen geben. grease) and fill with grease the space
between oil lip and dust lip of dual lip seals.
- Einbau nur mit Setzer vornehmen. Keinesfalls - Install the oil seal using a suitable seal
direkt auf den Dichtring schlagen. driver. Avoid hammering directly on the seal.
- Dichtlippen bei der Montage auf die Laufflä- - To ,avoid damages to the seal lip caused
che vor Beschädigung schützen. by the shaft: adequately protect the same
during shaft assembly procedure.
"O" RING "O" RING
- Vor dem Einbau immer ölen, Wellen beim - Ensure adequate lubrification of these seals
Durchschieben drehen. before inserting them in their seats to avoid
twisting during shaft assembly.
EINSTELLSCHEIBEN SHIMS
- Für jede Einstellung die Scheiben entspre- - For each adjustment select the correct shim's
chend bestimmen. by individual measurement.
- Scheiben vor der Verwendung immer mes- - Do not thrust pack measurement or the
sen. thickness indicated on the shim.
LAGER BEARINGS
- Für eine korrekte Montage auf 80° - 90° C - For a correct assembly it is suggested:
anwärmen und mit Setzer montieren. Warming from 80° C to 90° C before
installation in their respective seats.
SPANNSTIFT ROLL PIN
- Spannstift immer so montieren, daß die Öff- - When installing split cut roll pin ensure the
nung in die Belastungsrichtung zeigt. cut is oriented towards the direction of the
- Spannstifte in Spiralform haben keine beson- force acting on the roll pin.
dere Einbaurichtung. - Spiral type roll pin do not require any
precaution.
DICHTUNGSMATERIAL SEALING COMPOUND
- Flächen mit Silikon oder Loctite 510 abdich- - On area to be sealed use Silastik or Loctite
ten. 510, ensuring both side to be sealed are
- Die Flächen müssen rein und fettfrei sein. clean, dry and totally free from grase and oil.
20
PLANETENENDANTRIEB 20.20 EPICYCLIC REDUCTION GEARS 20.20
ss97g469
- Öl ablassen - Drain the hub oil

- Beide Befestigungsschrauben (20) entfernen - Unscrew the two screws (20) and remove the
und Planetenträger von der Radnabe abzie- planetary carrier assembly from the hub.
hen.
- Nadellager (15) und Anlaufscheiben (16) auf - Inspect the needle bearings (15) and the
Verschleiß prüfen und wenn nötig austau- thrust washer (16) for wear and replace if
schen. necessary.
- Die Bolzen (17) der Planetenräder sind in den - The planetary gear shafts (17) are fitted to
Planetenträger eingepreßt und als Einzelstük- the carrier with interference. In case of wear
ke nicht austauschbar. Bei Beschädigung or demage replace the carrier assembly.
ganzen Träger tauschen.
- Montagehinweis: Teile der Nadellager mit Fett - Hint for reassembling: if necessary hold the
positionieren. needle bearing in position with grease.
- Öl füllen, auf die richtige Spezifikation und - Refill the hub with correct oil, see
Menge achten. specification. The drain level plug bore
position, must be at the top.
- Ölstand kontrollieren. Verschlußstopfen dazu - Check the oil level with the plug at the hori-
waagrecht stellen. zontal line.
21
RADNABE 20.20 WHEEL HUB 20.20
ss97g470
- Schrauben (10) entfernen. - Unscrew the bolts (10).

- Hohlrad mit 3 Schrauben M 10 abdrücken und - Use 3 bolts M 10 as puller, on the threaded
Radnabe abnehmen. holes of the wheel carrier to remove the assy
crown gear / wheel carrier.
- Zum Abmontieren des Hohlradträgers vom - Remove the lock ring (6) to separate the
Hohlrad Sicherungsring (6) entfernen. crown gear.
- Kassettendichtring (1) austauschen. - Replace the cassette seal (1).
- O-Ring (5) nach jeder Demontage kontrollie- - Inspect the "O" ring (5) and replace if
ren bzw. erneuern. necessary.
- Die Radlagereinstellung basiert auf den sehr - The special arrangement "Set Right" of the
engenToleranzen und braucht daher nicht ein- bearings does not require specific setting of
gestellt werden. pre-load or clearance because the interested
surfaces are machined to fine tolerances.
- Vor der Montage auf Maßhaltigkeit der Teile - In any case befor reassembling of new parts
achten. it is better to check the following dimensions.
- Teile mit Abweichung austauschen. - Replace the incorrect items.
A = 17,95 - 18,00 mm
B = 64,257 - 64,325 mm
C = 21,43 mm
D = 23,070 - 23,172 mm
ss97g472
Spezialwerkzeug: Special tools:

Setzer f. Kassettendichtring (1) TSW 549 Driver for cassette oil seal (1) TSW 549
22
RADNABE MIT BREMSE 20.20 WHEEL HUB WITH BRAKES 20.20
ss97g471
- Sicherungsring (14), Sonnenrad (15) sowie - Unscrew the retaining ring (14),
Schrauben (17) entfernen. sun gear (15) and bolts (17).
- Hohlrad mit 3 Schrauben M 10 abdrücken; - Use 3 bolts M 10 as puller, on the threaded
Bremse und Radnabe abnehmen. holes of the wheel carrier to remove the assy
crown gear / wheel carrier and brakes.
- Zum Ausbau der Bremsteile aus dem Hohl- - Remove the locking rings (12) to separate
rad Sicherungsring (12) entfernen. the crown gear, the reaction plates and the
brake discs.
- Vor dem Herausnehmen des Bremskolben - Unscrew the bolts (30) to split the brake
Schrauben (30) entfernen. piston.
- Bremsmanschetten prüfen bzw. austauschen. - Check the piston seals for damages or wear.
Replace if required.
- Bremsenteile kontrollieren und wenn nötig - Inspect all different parts for wear or
austauschen. damages in particular the brake disc.
- O-Ringe (29) und Kassettendichtring (40) er- - Replace the "O" ring (29) and the cassette
neuern. seal (40).

23
PLANETENENDANTRIEB 20.25 EPICYCLIC REDUCTION GEARS 20.25
ss97g473
- Öl ablassen. - Drain the hub oil

- Beide Befestigungsschrauben (23) entfernen - Unscrew the two screws (23) and remove the
und Planetenträger von Radnabe abziehen. planetary carrier assembly from the hub.
- Nadellager (19) und Anlaufscheibe (20) auf - Inspect the needle bearings (19) and the
Verschleiß prüfen und wenn nötig, austau- thrust washer (20) for wear and replace if
schen. necessary.
- Die Bolzen (22) der Planetenräder sind in den - The planetary gear shafts (22) are fitted to
Planetenträger eingepreßt und als Einzelstük- the carrier with interference. In case of wear
ke nicht austauschbar. Bei Beschädigung or demage replace the carrier assembly.
ganzen Träger tauschen.
- Montagehinweis: Teile der Nadellager mit Fett - Hint for reassembling: if necessary hold the
positionieren. needle bearing in position with grease.
- Öl füllen, auf die richtige Spezifikation und - Refill the hub with correct oil, see
Menge achten. specification. The drain level plug bore
- Ölstand kontrollieren. Verschlußstopfen dazu position, must be at the top.
waagrecht stellen. - Check the oil level with the plug at the hori-
zontal line.
24
RADNABE 20.25 WHEEL HUB 20.25
ss97g474
- Schrauben 12 entfernen. - Unscrew the bolts (12).

- Hohlrad mit 3 Schrauben M10 abdrücken und - Use 3 bolts M 10 as puller, on the threaded
Radnabe abnehmen. holes of the wheel carrier to remove the assy
crown gear / wheel carrier.
- Zum Abmontieren des Hohlradträgers vom - Remove the lock ring (6) to separate the
Hohlrad Sicherungsring (6) entfernen. crown gear.
- Kassettendichtring (1) austauschen. - Replace the cassette seal (1).
- O-Ring (5) nach jeder Demontage kontrollie- - Inspect the "O" ring (5) and replace if
ren bzw. erneuern. necessary.
- Die Radlagereinstellung basiert auf den sehr - The special arrangement "Set Right" of the
engen Toleranzen und braucht daher nicht ein- bearings does not require specific setting of
gestellt werden. pre-load or clearance because the interested
surfaces are machined to fine tolerances.
- Vor der Montage auf Maßhaltigkeit der Teile - In any case befor reassembling of new parts
achten. it is better to check the following dimensions.
- Teile mit Abweichung austauschen. - Replace the incorrect items.
A = 17,95 - 18,00 mm
B = 64,257 - 64,325 mm
C = 21,43 mm
D = 23,070 - 23,172 mm
ss97g472

25
RADNABE MIT BREMSE 20.25 WHEEL HUB WITH BREAKES 20.25
ss97g475
- Sicherungsring (17) und Ringe (15, 16) ent- - Remove the retaining ring (17) and the
fernen. rings (15,16).
- Schraube (19) entfernen. - Unscrew the bolt (19).
- Hohlrad mit 3 Schrauben M10 abdrücken, - Use 3 bolts M 10 as puller, on the threaded
Bremse und Radnabe abnehmen. holes of the wheel carrier to remove the assy
crown gear / wheel carrier and brakes.
- Zum Ausbau der Bremsteile aus dem Hohl- - Remove the locking rings (13) to separate
rad Sicherungsringe (13) entfernen. the crown gear, the reaction plates and the
brake discs.
- Vor dem Heruasnehmen des Bremskolben - Unscrew the bolts (30) to split the brake
Schrauben (30) entfernen. piston.
- Bremsmanschetten prüfen bzw. austauschen. - Check the piston seals for damage or wear.
Replace if required.
- Bremsteile kontrollieren und wenn nötig, aus- - Inspect all different parts for wear or
tauschen. damages in particular the brake disc.
- O-Ringe (12) und Kassettendichtring (37) - Replace the "O" ring (12) and the cassette-
erneuern. seal (37).

26
NOTIZEN - NOTES
27
ACHSSCHENKELTRÄGER UND SWIVEL HOUSINGS KING PINS

ACHSSCHENKELBOLZEN
- Das untere Achsschenkellager (1) ist auf den - The pivot bearing (1) (at the bottom) has to
Achsschenkelbolzen aufgepreßt. Der Lager- be assembled under the press for the race
ring wird zumEinbau in die Achsbrücke ab- placed on the king pin and in cold conditions
gekühlt. ( as in azote bath) for the race placed on the
axle.
- Die Lagerbüchse (2) muß zum Einbau in die - The top bearing (2) is an angular bushing
Achsbrücke abgekühlt werden. and must be cooled (as in azote bath) before
mounting in the axle seat.
ss97g476
ss97g477
ACHSSCHENKELLAGER SWIVEL PIN BEARING
Für die Achsschenkellager ist keine Einstellung No particular setting operation is required for
nötig. Die Tellerfedern (3,4) sind zwischen den the king pin bearing. The belleville springs (3,4)
Bolzen (9 bzw. 12) und der Achsbrücke einge- are being assembled between the bolts and the
baut, wodurch sowohl die Lagervorspannung als axle housing seats. The belleville springs have
auch die Abdichtung bewerkstelligt wird. the purpose of preloading and sealing the
system.
Spezialwerkzeuge: Special tools:

Setzer für Büchse (7) TSW 553 (20.20) Driver for bushing (7) TSW 553 (20.20)
Setzer für Büchse (7) TSW 552 (20.25) Driver for bushing (7) TSW 552 (20.25)
Setzer für Dichtring (6) TSW 550 (20.20) Driver for oil seal (6) TSW 550 (20.20)
Setzer für Dichtring (6) TSW 551 (20.25) Driver for oil seal (6) TSW 551 (20.25)
28
ANTRIEBSWELLE DRIVE SHAFT
ss97g478
Keilwellenprofile kontrollieren. Inspect the shaft splines for wear or damage.

Bei Verschleiß der Gelenke diese austauschen. Replace the spiders if wear occured to inner
needles or to the other components.
Anmerkung: Die Reparatur der Universal- Note: overhaul of the two universals joints
gelenke ist gleich jener, konventioneller Gelenk- follows conventional workshop practice.
wellen.
29
LENKZYLINDER STEERING CYLINDER
ss97g479
- Kolbenstange (21) auf Verschleiß bzw. Be- - Inspect the steering piston rod (21) for wear
schädigung prüfen. or damages.
- Bei Undichtheiten immer beide Seiten ab- - If any leakage is evident, replace the seal
dichten (Dichtsatz 23) kit (23).
- Spurstangengelenke auf Verschleiß prüfen - Inspect the track rod ends and track rod to
und wenn nötig erneuern. piston rod ball joint.
VORSPUR TOE-IN
Die Vorspur ist auf 0 bis -2 mm einzustellen. The Toe-in value is P = A from 0 to -2 mm
Nach einer Reparatur wie folgt vorgehen: After a complete overhauling of the steering
rods line follow the procedure here below
indicated to set the toe-in:
- Die beiden Gelenke (8) montieren und auf - Install the ball joints (8) on the steering piston
richtiges Moment anziehen. rod and tighten them to the correct torque.
- Screw each end (6 and 9) to the ball joint (8)
- Die Gelenke (8) soweit in die Spurstangen of the same quantity until a total length near
(6 und 9) einschrauben bis die Vorspur an- to the toe-in setting value is reached.
nähernd erreicht ist. - Install the ball joint ends (6 and 9) into the
- Spurstangen (6 und 9) am Gehäuse montie- swivel housing and check for the rod steering
ren. Lenkzylinderweg nach beiden Seiten cylinder is central.
kontrollieren und wenn nötig angleichen. - Tighten the nuts (18) to the correct torque.
- Die Mutter (18) auf richtiges Drehmoment - Complete the setting operation rotating each
festziehen. ball joint end (8) until the adjustement is
- Vorspur durch drehen der Kugelgelenke (8) correct.
richtig stellen. - Tighten the lock nuts (7) to the correct torque.
- Kontermuttern (7) auf das richtige Drehmo-

ment festziehen.
30
ACHSEINSATZ DIFFERENTIAL ASSEMBLY
ss97g480
Zur Demontage desAchseinsatzes Antriebswel- To remove the differential assembly, unscrew

len links und rechts entfernen. the bolts left and right for on bench overhauling.
Trieblingslager (7) und Differentiallager kontrol- Inspect the pinion bearings (7) and the diffe-
lieren bzw. erneuern. rential side bearings for wear or damage.
Die Nutmutter (1), die Distanzbüchse (4) und die In case of bevel gears replacement, ring nut
Scheibe (3) sowie der Wellendichtring sind (1), collapsible spacer (4) and washers (3) must
nach jeder Demontage zu erneuern. be replaced.
Replace the oil seal to avoid oil leak.
Die Einstellung ist wie folgt vorzunehmen: The setting operations to do for this group are
as follows:
1. Tragbild einstellen 1. Setting the bevel distance

2. Trieblingslager einstellen (Rollmoment) (contactreflection)
3. Zahnflankenspiel einstellen 2. Setting the pre-load of pinion bearings
4. Differentiallager einstellen (Rollmoment) 3. Setting the pinion / crown wheel back-lash
4. Setting the differential bearing preload

Schlüssel für Nutmutter (1) TSW 504 Wrench for pinion ring nut (1) TSW 504
Setzer für Dichtring (13) TSW 550 Driver for oil seal (13) TSW 550
Schlüssel für Ringmutter (Differential) Wrench for differential ring nut (differential)
TSW 532 TSW 532
ACHTUNG: Tellerrad immer auf die richtige Please note that crown wheel can be fitted
Seite einbauen. (in Fahrtrichtung links) both rh and lh of the pinion always ensure
correct position. (lh side from drivers view)
31
TRAGBILDEINSTELLUNG SETTING THE BEVEL DISTANCE
- Lageraußenringe (1und 2) in das Gehäuse - Install the pinion bearings in the differential
einsetzen support casing and lightly clamp the
- Lager (3 und 4) mit der Vorrichtung - bearings using tool (TSW 539) so that the
(TSW 539) auf leichtes Rollmoment vorspan- bearing cones can just be turned by hand.
nen. Do not overtighten.
- Mit einem Tiefenmaß und Lineal Maß A er- - Measure dimension A with a depth indicator
mitteln (gemessen von Planfläche Lager- and a ruler (measured from plane surface
deckel zu Lagerinnenring) of bearing cap to bearing inner ring).
Einstellscheibe (X) wie folgt errechnen:
Determinate the required thickness of shim (X)

X = A - B (Trieblingsmaß) using the following calculation:
- Triebling einbauen "errechnete Einstell- X =A- B

scheiben nicht vergessen"
- Select the calculated shim thickness from
Wichtig: Lager müssen gut sitzen the range available, and install on the pinion
shaft.
- Press the inner bearing into the pinion shaft,
ensuring that it is fully seated.
Position des Trieblingsmaßes B

Position of gear protrusion dimension
ss97g482
Paarungsnummer
Position of spiral gear - pinion mating
ss97g481 number

Tiefenmaß und Vorrichtung TSW 539 Kit for bevel distance measurement TSW 539
32
VORSPANNUNG DES TRIEBLINGSLAGER PRE-LOAD OF PINION BEARINGS
- Vorspannung des Trieblingslagers ohne - The specified pinion bearing pre-load has
Wellendichtring durch Abrollen messen. to be measured on the diameter of the pinion
queue without flange and seal.
- Die Einstellung wird durch Festziehen der Nut- - Fix the ring nut in order to have the above
mutter erreicht. pre- load value.
- Rollmoment mit einem Rollmomentprüfer - To check the pre-load setting use a spring
oder einer Federwaage prüfen. balance with a cord wrapped around the
pinion queue.
- Nutmutter zum Triebling durch Einschlagen si- - Secure the ring nut on pinion shaft spline
chern. (avoid use of sharp punches or chisels).
92 - 137 N ss97g483

Nutmutternschlüssel TSW 504 Wrench for pinion ring nut TSW 531
33
ZAHNFLANKENSPIEL FÜR TRIEBLING CROWN WHEEL / PINION BACKLASH

UND TELLERRAD
Die Einstellung wird durch gegenläufiges Ver- See specifications for the correct amount of
drehen der Nutmuttern an den Differentiallagern back-lash. The adjustment is made by turning
erreicht. the side ring nuts.
Wenn sich die Nutmuttern zu schwer drehen las- The ring nuts push against the bearings and
sen, müssen die Schrauben zum Lager- move the crown wheel toward or away from the
befestigungsbügel leicht gelöst werden. bevel pinion.
When you make this adjustment the ring nuts
can be difficult to move. It will then be necessary
to loosen the bearing cap nuts a small amount.
Die Schrauben nur so weit lösen als unbedingt Do not loose the nuts more than necessary.
nötig.
Einstellvorgang wie folgt vornehmen: Do the procedure as follows:
- Tellerradseitige Ringmutter im Uhrzeigersinn - Turn the right nut on the crown wheel side of
drehen bis nur mehr ein leichtes Zahnflanken- the differential in a clockwise direction. At the
spiel spürbar ist. same time hit the bearing caps lightly with a
soft faced hammer to aligne the bearings.
- Zweite Ringmutter anziehen bis Widerstand - Turn the other ring nut in a clockwise
spürbar wird und Lager dabei mit Plastik- direction. At the same time hit the bearings
hammer immer etwas entspannen. caps lightly with a soft faced hammer to align
the bearings.
- Meßuhr im rechten Winkel zur Tellerrad- - Put the dial gauge in position so that the pro-
verzahnung ansetzen. be is in contact with and at 90° to a tooth on
the crown wheel.
- Zahnflankenspiel an mindestens 3-4 Positio- - Check the amount of backlash between the
nen messen. crown wheel and the pinion.
- Bei unterschiedlichen Spiel ist das kleinste - Make a note of the clearance, if the amount
gemessene Spiel ausschlaggebend. of clearence is different, put the probe of the
dial gauge on the tooth that has the smallest
clearance.
- Gegebenenfalls die Position des Tellerrades - Move the crown wheel toward or away from
soweit verändern bis das richtige Zahn- the pinion by moving each ring nut an equal
flankenspiel erreicht ist. amount. Do this until the dial gauge shows
the prescribed clearance.
34
LAGERVORSPANNUNG DER DIFFERENTIAL BEARING PRE - LOAD

DIFFERENTIALLAGER
Die Vorgangsweise ist wie folgt: Adjust the differential side bearing pre-load
using the following method:
- Nach der Einstellung des richtigen Zahn- - With the crown wheel in mesh with the pinion
spieles über den Triebling das gesamte Dif- and the backlash correctly set, rotate the
ferential drehen, gleich der Messung der pinion with a cord wrapped around the pinion
Trieblingslagervorspannung. queue and using a spring balance, record
the effort required to rotate the pinion and
the differential components.
- Beide Ringmuttern immer gleichmäßig anzie- - Tighten each differential side bearing
hen bis das richtige Rollmoment erreicht ist adjuster ringnut by equal amounts, to pre-
(siehe nachstehende Angabe). serve the backlash adjustment. Install the
adjuster ringnut lock tabs.
- Schrauben zur Lagerbrücke auf richtiges - Tight the half collar bolts to the torque
Drehmoment festschrauben. specification.
- Zahnflankenspiel nochmals kontrollieren. - Recheck to make sure that the backlash is

correct.
- Das gesamte Rollmoment von (Differential - The total amount of the pre-load to find (dif-
+Trieblingslager) wird immer auf den Schaft- ferential + pinion bearings) on the diameter
durchmesser des Trieblings (34,80 mm) be- 34,80 mm of the pinion queue must be.
zogen.
T = Rollmoment des gesamten Differential T = Total amount of pre-load on differential

bearings
P = Rollmoment des Trieblings P = Pre-load of pinion bearings
T = ( P + 39 N) - ( P + 60 N) T = ( P + 39 N ) to ( P + 60 N )
35
DIFFERENTIAL DIFFERENTIAL
DIFFERENATIALSPERRE 20.20 LOCKING DIFFERENTIAL 20.20
ss97g484
- Schaltring (13) und die Sperrstifte (12) aus- - Remove the sleeve (13) and recover the 4
bauen und kontrollieren. pins (12). Inspect the parts for wear or
damage.
- Anlaufscheiben (4,5) auf Verschleiß prüfen. - Inspect the thrust washer (4,5) for wear.
- Die restlichen Teile im besonderen den Bol- - Inspect the other items of the differential and
zen (2) überprüfen bzw. alle schadhaften Tei- in particular the shaft (2).
le austauschen.
- Die Schrauben (7) mit Loctite 270 sichern. - Use Loctite 270 fixing the bolts which fasten
the crown wheel to differential housing.
36
DIFFERENTIAL DIFFERENTIAL
DIFFERENTIALSPERRE 20.25 LOCKING DIFFERENTIAL 20.25
ss97g485
- Schaltring (12) und die Sperrstifte (11) aus- - Remove the sleeve (12) and recover the 4
bauen und kontrollieren. pins (11). Inspect the parts for wear or
damage.
- Anlaufscheiben (3,4) auf Verschleiß prüfen. - Inspect the thrust washer (3,4) for wear.
- Die restlichen Teile, im besonderen die Bol- - Inspect the other items of the differential and
zen (2) überprüfen bzw. alle schadhaften Tei- in particular the shafts (2).
le austauschen.
- Die Schrauben (6) mit Loctite 270 sichern. - Use Loctite 270 fixing the bolts which fasten
the crown wheel to differential housing.
37
SCHALTUNG DER DIFFERENTIALSPERRE DIFFERENTIAL LOCKING DEVICE
ss97g486
ss97g487
- Schrauben (1), Deckel (11) und Deckel (7) - Unscrew the bolts (1) to remove the piston
abnehmen. housing (11) and the cover (7).
- O-Ringe (2) und (10) austauschen. - Inspect the 'O' rings (2) and (10). Replace if
required.
- Alle Teile der Sperrschaltung, im besonderen - Inspect the fork and the other items of the
die Schaltgabel kontrollieren bzw. erneuern. locking device for wear or damage.
- Deckel (7) mit Loctite 510 abdichten. - Use Loctite 510 between housing and cover
(7).
Während der Montage ist folgendes zu beach- During reassembly:

ten:
- Schaltweg des Schaltringes bestimmen. - Check for the correct operating of the locking
engagement sleeve.
- Dazu Kolben (9) mit der flachen Seite zur - To do this install the piston (9) with the flate
Schaltstange (8) ohne Deckel (11) einschie- surface towards the rod and without its cover
ben. Kolben bis auf Anlage am Gehäuse hin- (11). Then push the piston completely
eindrücken damit die Distanz zwischen Aus- towards the housing in order to operate the
gleichsgehäuse und Schaltring gemessen locking device and measure the distance
werden kann. Das Maß soll nicht größer als between sleeve and differential housing.
2 mm sein. This distance should be of 2 mm maximum.
- Ist das Maß größer, muß der Kolben mit der - If this value is greater reverse the position of
erhabenen Seite zur Schaltstange eingebaut the piston. (The relief has to be towards the
werden. rod).
- Alle weiteren Montagearbeiten in umgekehr- - All further steps for reassembly have to be
ter Reihenfolge der Demontage durchführen. done in reverse order of disassembly.
38
ACHSBRÜCKE AXLE HOUSING
ss97g488
- Lagerbüchsen (4,5,24,28) kontrollieren. - Inspect the pivot bushings (4,5,24,28).

- Anlaufscheiben (3, 27) kontrollieren. - Inspect the thrust rings (3, 27). Replace the
Dichtring (23) austauschen. seal (23) if necessary.
- Entlüftung (2) auf Funktion prüfen. - Inspect the breather pipe (4) for a correct
valve working.
- Öl bei Verschlußstopfen (6) ablassen . - Drain the oil from the plug (6) on the diffe-
(bei Achseinsatz unten) rential support.
- Büchse (13) und Dichtring (14) kontrollieren - Inspect the axle housing bush (13) and the
und wenn nötig austauschen. oil seal (14) for wear and replace if
necessary.
- Öleinfüllschraube (6) ist zugleich Niveau- - Refill and check the oil level from the plug
schraube. (bei Achsbrücke mitte) (6) placed on the axel housing.
- Zum Abdichten der Flanschfläche zwischen - Use Loctite 510 between differential support
Einsatz und Achsbrücke Loctite 510 verwen- and axle housing.
den.

Setzer für Dichtring (14) TSW 550 Driver for oil seal (14) TSW 550
Setzer für Büchse (13) TSW 552 Driver for bushing (13) TSW 552
39
CASE CS110 - CS150 ; Steyr 9105 - 9145 LTA - TYP 20.20, 20.25
40
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Technical Documentation April 2000
5002-2
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TECHNICAL DATA .................................................................................................................................................... 3
SPECIAL TIGHTENING TORQUES .......................................................................................................................... 3
SPECIAL TOOLS ....................................................................................................................................................... 4
GENERAL NOTES ..................................................................................................................................................... 5
PLANETARY DRIVE .................................................................................................................................................. 5

Removing and Fitting ....................................................................................................................................... 5
Disassembly/Re-assembly ............................................................................................................................... 6
WHEEL HUB .............................................................................................................................................................. 7

Disassembly/Re-assembly ............................................................................................................................... 7
Sectional drawing through the planetary gear and wheel hub ................................................................................... 9
PIVOT BEARING HOUSING .................................................................................................................................... 10

Removing and Fitting ..................................................................................................................................... 10
Disassembly/Re-assembly ............................................................................................................................. 11
KING PIN HOUSING ................................................................................................................................................ 12

Disassembly ................................................................................................................................................... 16
Assembly ....................................................................................................................................................... 18
Sectional drawing, through the pivot bearing housing and the king pin housing ...................................................... 20
DRIVE SHAFTS ....................................................................................................................................................... 21

4-WHEEL DRIVE AXLE ........................................................................................................................................... 22

PIVOTED BEARING ................................................................................................................................................ 25

Disassembly ................................................................................................................................................... 26
Assembly ....................................................................................................................................................... 28
Adjusting the Torsion Bars ............................................................................................................................. 32
AXLE HOUSING ...................................................................................................................................................... 35

Disassembly ................................................................................................................................................... 35
DIFFERENTIAL UNIT .............................................................................................................................................. 40

Disassembly ................................................................................................................................................... 40
Assembly ....................................................................................................................................................... 40
Adjusting the Pinion Shaft .............................................................................................................................. 42
Pinion Shaft Unit ............................................................................................................................................ 44
Fitting the Differential Unit .............................................................................................................................. 46
Adjusting the Crown Wheel Tooth Flank Play ................................................................................................ 48
Adjusting the Differential Bearing Pre-Tension .............................................................................................. 49
TRACK ALIGNMENT ............................................................................................................................................... 51

5002-3
7(&+1,&$/'$7$
DIFFERENTIAL
Number of teeth – pinion shaft / diff. Master gear ...................................................................................... 14 / 32
Differential transmission ratio ................................................................................................................. 2.286 / 1
Pinion shaft initial bearing tension (measured at the pinion shaft Ø = 34.8 mm) ................................ 92 to 137 N
Pinion Bearing and Differential
Total initial bearing tension (measured at the pinion shaft Ø = 34.8 mm) ........................ 92 (+20) to 137 (+30) N
Differential master gear tooth flank play ..................................................................................... 0.18 to 0.23 mm
Compensating washer thickness for pinion height .............................. at least 2.5 mm to a maximum of 3.4 mm
PLANETARY DRIVE
Planetary drive transmission ratio ........................................................................................................... 6.923 / 1
Total transmission ratio (differential + planetary drive) ......................................................................... 15.824 / 1
STEERING
Steering lock .................................................................................................................................................... 50°
DIFFERENTIAL LOCK
Type ........................................................................................................................................ 100% elliptical lock
Differential operating pressure .................................................................................................................... 18 bar
WHEEL ALIGNMENT
Axle fully lowered ................................................................................................................ -11 to -16 mm toe-out
LUBRICANT
Grease ............................................................... NL GI 2 or equivalent multi-purpose lithium soap based grease
All-wheel axle capacity
Type of oil .................................................................................. SAE 80W-90EP gearbox oil (API GL4 - GL5)
Planetary drive ..................................................................................................................................... 1.5 litres
Differential ........................................................................................................................................... 2.2 litres
63(&,$/7,*+7(1,1*72548(6
Differential housing and axle fixing bolt ......................................................................................................... 169 Nm
Bolt for locking plate with locking ring ............................................................................................................. 13 Nm
Securing bolt for ring gear on the differential housing (locked with Loctite 270) ............................................. 78 Nm
Air bleed plug .................................................................................................................................................. 10 Nm
Oil filler/level plugs .......................................................................................................................................... 60 Nm
Securing bolt for differential cover ................................................................................................................. 266 Nm
Kingpin securing bolt ..................................................................................................................................... 190 Nm
Steering stop locking nut ............................................................................................................................... 150 Nm
Securing bolt, steering cylinder to axle housing ............................................................................................ 120 Nm
Ball head connection on the steering cylinder ............................................................................................... 300 Nm
Track rod locking nut ..................................................................................................................................... 250 Nm
Lock nut for ball head on the pivot bearing housing ...................................................................................... 220 Nm
Securing bolt, planetary gear on the pivot bearing housing .......................................................................... 220 Nm
Wheel bolts (locked with Loctite 543) .............................................................................................................. 70 Nm
Countersink screw – planetary gear carrier ..................................................................................................... 25 Nm
Front wheel nuts ............................................................................................................................................ 380 Nm
Outer union nut on the drive shaft ................................................................................................................. 175 Nm
Securing bolt on the planetary gear ................................................................................................................ 79 Nm
Securing screw for potentiometer cover .......................................................................................................... 13 Nm
Securing screws for potentiometer .................................................................................................................... 3 Nm

5002-4
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1. GAUGING TUBE CAS1839/1 11. SLEEVE FITTING TOOL CAS2717
2. ALIGNMENT ADAPTER CAS2489-4 12. SLEEVE FITTING TOOL CAS2718
3. GRIP CAS1596A-4 13. SLEEVE FITTING TOOL CAS2719
4. BOLT CAS1596A-7 14. GRIP CAS2555
5. MEASUREMENT CYLINDER CAS2489-2
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6. PINION NUT WRENCH CAS1885A 15. GRIP CAS1924
7. DOLLY CAS2483 16. FITTING TOOL, CARTRIDGE SEALING RING 1TSW 549
8. WRENCH AND FITTING TOOL CAS2714 17. SLEEVE FITTING TOOL CAS2716
18. FITTING TOOL, CARTRIDGE SEALING RING CAS2723
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9. WRENCH CAS2713
10. FITTING TOOL, CARTRIDGE SEALING RING CAS2720

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• Planetary drive, see page 5.
• Wheel hub, see page 7.
• Pivot bearing housing, see page 10.
• Kingpin housing, see page 12.
• Drive shafts, see page 21.
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The following points must be observed prior to removing the planetary gear unit:
• Put the tractor on firm, level ground, apply the parking brake and fully lower the front axle onto its lowest
mechanical limit. Switch the motor OFF and remove the ignition key.
• Place chocks in front of and behind the rear wheels.
• Loosen the front wheel nuts. Place a jack under the centre of the front axle, raise the tractor and lower it
onto suitable front axle support trestles. Remove the front wheels.
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67(3 67(3

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Turn the drain/level plug (1) to point downwards. Place Remove the two countersunk screws (2).
a container, with a minimum capacity of 1.5 litres, under
127( :KHQUHILWWLQJWKHVFUHZV WLJKWHQWKHPWR
the wheel hub.
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Remove the drain/level plug (1) and remove the ‘O’
ring. Drain the oil.
67(3
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WKDWWKHGUDLQOHYHOSOXJ LVSRVLWLRQHGKRUL]RQWDOO\WR Tap the planetary gear carrier surface (3) with a soft-
WKHFHQWUHRIWKHD[OH)LOOWKHZKHHOKXEZLWKWKHFRU faced hammer and remove the planetary gear carrier.
UHFW W\SH RI RLO WR WKH SUHVFULEHG OHYHO UHIHU WR WKH Remove the ‘O’ ring and dispose of it.
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1. SECURING BOLT 5. PLANETARY GEAR

2. WASHER 6. NEEDLE BEARING
3. THRUST WASHER 7. THRUST WASHER
4. SECURING PIN
67(3 67(3
Make alignment markings on the planetary gears (5) Clean all component parts in a cleaning solvent and dry
and the shaft. with compressed air. A protective face mask MUST be
worn when doing this. Check all component parts for
67(3 wear or damage and replace as necessary.
Remove the securing bolt (1), the washer (2), the thrust 127( 5HDVVHPEOHSDUWVLQWKHVDPHPDQQHUEXWLQ
washer (3) and the securing pin (4). Remove the WKHUHYHUVHRUGHU
planetary gear (5), the needle bearing (6) and the thrust
washer (7). Repeat the procedure for the remainder of
the planetary gears.
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5002-7
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The following work must be carried out prior to disassembling the wheel hub:
• Remove the planetary gear unit, refer to page 5.
67(3
Remove the securing bolts (8). Fit two of the securing
bolts to the threaded holes (A) in the crown gear
carrier (9). Tighten the bolts evenly to loosen the crown
ring carrier.
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8. SECURING BOLT 13. CARTRIDGE SEALING RING

9. CROWN WHEEL CARRIER 14. CIRCLIP
10. OUTER BEARING 15. CROWN WHEEL
11. WHEEL HUB 16. SLEEVE
12. INNER BEARING A. THREADED HOLE

5002-8
67(3 67(3
Use a soft-faced hammer to loosen the wheel hub from
the bearings Remove the outer bearing (10), the wheel
hub (11) and the inner bearing (12).
67(3

',(
Remove the inner circlip (14) and the crown wheel

carrier (9) from the crown wheel (15).

67(3
'3)
Check the bearings (10 and 12) and the sleeve (16) for
Remove the cartridge sealing ring (13) and dispose wear or damage and replace as necessary. Use a
of it. hydraulic press to remove the sleeve (16).
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Wheel hub alignment is based on extremely small
tolerances and does not therefore require adjustment.
Before fitting, check that components dimensions are
within tolerance. Parts which are out of tolerance must
be replaced.
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5002-9
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1. SECURING BOLT 9. CROWN WHEEL CARRIER

2. WASHER 10. OUTER BEARING
3. THRUST WASHER 11. WHEEL HUB
4. SECURING PIN 12. INNER BEARING
5. PLANETARY GEAR 13. CARTRIDGE SEALING RING
6. NEEDLE BEARING 14. CIRCLIP
7. THRUST WASHER 15. CROWN WHEEL
8. SECURING BOLT 16. SLEEVE

5002-10
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The following items must be carried out if work is to be carried out on the pivot bearing housing.
• Remove the planetary gear unit, refer to page 5.
• Remove the wheel hub, refer to page 7.
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1. NUT 7. PIVOT BEARING HOUSING

2. BALL HEAD CONNECTION 8. DISK SPRING
3. SECURING BOLT 9. DISK SPRING
4. KING PIN 10. THRUST WASHER
5. SECURING BOLT 11. SHAFT SEALING RING
6. KING PIN 12. SLEEVE
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5002-11
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Loosen the nut (1). Remove the ball head connection 127( 7KHVWHSVDUHQXPEHUHGLQRUGHURIGLVDVVHP
(2) from the pivot bearing housing (7) using the appro- EO\ 5HDVVHPEO\ LV FDUULHG RXW LQ UHYHUVH RUGHU WR
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67(3
Remove the king pin securing bolt (3) and the king
pin (4).
67(3
If the planetary gear unit and wheel hub are still fitted,
support the pivot bearing housing (7) with suitable
lifting gear.
67(3
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Remove the upper king pin securing bolt (5) and the
king pin (6).
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Remove the pivot bearing housing (7) from the king pin
housing. Remove the disk springs (8) and (9) and thrust

washer (10). Mark the disk springs for reassembly. &$6
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127( 5HILW SDUWV LQ WKH VDPH PDQQHU EXW LQ WKH bearing housing (7) and dispose of it. Check the sleeve
UHYHUVHRUGHU,IWKHSODQHWDU\JHDUXQLWDQGWKHZKHHO (12) for wear or damage and replace as necessary.
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5002-12
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Before the king pin housing can be removed, the following work must be carried out:
• Put the tractor on firm, level ground, apply the parking brake and use the auxiliary switch RAISE/LOWER to fully
lower the front axle to its lowest limit. Switch the motor OFF and remove the ignition key.
,03257$17 ,IZRUNLVRQO\WREHFDUULHGRXWRQWKHGLIIHUHQWLDOFDUU\RXW67(3DQG67(37KHQFDUU\RXW
67(3WR67(3WRUHPRYHWKHSODQHWDU\JHDUKRXVLQJWKHZKHHOKXEWKHSLYRWEHDULQJKRXVLQJDQGWKHNLQJSLQ
KRXVLQJDVRQHXQLW
,03257$17 )RUUHDVVHPEO\WKHNLQJSLQKRXVLQJPXVWEHIXOO\UHDVVHPEOHGEHIRUHWKHWRUVLRQEDUVDUHDGMXVWHG
UHIHUWRSDJH
67(3 67(3
Remove the lower king pin securing bolt (3) and the
king pin (6).
67(3
If the planetary gear unit and wheel hub are still fitted,
support the pivot bearing housing (7) with suitable lifting
gear.
67(3
Remove the upper king pin securing bolt (5) and the
king pin (6).
6'%
127( :KHQUHDVVHPEOLQJJUHDVHWKHNLQJSLQV
Jack the front end of the tractor up and lower the centre ZLWK1/*,JUHDVH7LJKWHQWKHNLQJSLQVHFXULQJ
of the axle onto suitable support trestles. Do NOT place EROWV DQG WRDWRUTXHRI1P
the trestles under the swinging arms. Loosen the front
wheel nuts and remove the front wheels
67(3
127( :KHQ UHILWWLQJ WKH IURQW ZKHHOV WLJKWHQ WKH
Remove the pivot bearing housing (7) from the king pin
QXWVWRDWRUTXHRI1P
housing. Remove the disk springs (8) and (9) and thrust
washer (10). Mark the disk springs for reassembly.
67(3
127( :KHQUHDVVHPEOLQJILOOWKHEHDULQJEXVKHVLQ
Loosen the nut (1). Separate the ball head connection WKH NLQJ SLQ KRXVLQJ ZLWK JUHDVH 1/ *, )LW WKH
using the appropriate tools. Remove the nut and the WKUXVW ZDVKHU ZLWK WKH JURRYHG VLGH XS )LW WKH
ball head from the pivot bearing housing (7). GLVNVSULQJV DQG ZLWKWKHFRQFDYHVLGHWRZDUGV
127( :KHQ UHDVVHPEOLQJ ILW D QHZ QXW DQG WKHNLQJSLQKRXVLQJ UHIHUWRSDJH
WLJKWHQLWWRDWRUTXHRI1P 127( ,I WKH SODQHWDU\ JHDU XQLW DQG WKH ZKHHO KXE
DUHVWLOOILWWHGHQVXUHWKDWWKHWHHWKRQWKHGULYHVKDIW
DUHVHDWHGFRUUHFWO\LQWKHSODQHWDU\JHDUXQLW

5002-13
7LJKWHQLQJWRUTXH 1P

7LJKWHQLQJWRUTXH 1P

7LJKWHQLQJWRUTXH 1P

'5'
1. NUT 6. KING PIN

2. BALL HEAD CONNECTION 7. PIVOT BEARING HOUSING
3. SECURING BOLT 8. DISK SPRING
4. KING PIN 9. DISK SPRING
5. SECURING BOLT 10. THRUST WASHER

5002-14
67(3 67(3
Remove the securing bolts (11) and sleeves (12). Check the sleeve (38) in the king pin housing for wear or
Loosen the lock nut (14) and turn the adjusting screw damage. If it is necessary to remove the sleeve, use a
(13) out as far as it will go. Remove the cover (15) and blind-hole puller.
the circlip (16).
,03257$17 7RUHDVVHPEOHSODFHWKHVOHHYH LQ
DFRQWDLQHUZLWKGU\LFHDQGWKHQLQVHUWLWLQWRWKHNLQJ
67(3 SLQKRXVLQJ*UHDVHWKHVOHHYH DQGILOOWKHKROHIRU
If the planetary gear unit and wheel hub and the pivot WKHNLQJSLQZLWKJUHDVH 1/*,
bearing housing are still fitted, support the pivot bearing
housing and wheel hub with suitable lifting gear. :$51,1* $OZD\V ZHDU SURWHFWLYH JORYHV
67(3 WR SUHYHQW IURVWEXUQ ZKHQ KDQGOLQJ SDUWV
ZKLFKKDYHEHHQGHHSIUR]HQ SM118A
Remove the cover (17) and the circlip (18) from the
housing (25). Remove the torsion bar (19) with housing
(20) and seal (21). Check the pin (22) for wear or
damage and replace as necessary.

67(3
Remove the securing bolts (23) and sleeves (24).
Screw the bolt (23) into the threaded hole in the
housing (25) and pull the housing off.
67(3
Make alignment markings on the bolt (28) and king pin
housing. Loosen the lock nut (26) and remove the
securing bolt (27). Remove the bolt (28) and pivot the
swinging arm (29) downwards. Remove the ’O’ ring
from the bolt (28) and dispose of it. ',.
67(3 Check the bearing (39) on the lower king pin for wear or
Make alignment markings on the bolt (33) and king pin damage. A hydraulic press must be used, if it is
housing. Loosen the lock nut (31) and remove the necessary to remove the bearing.
securing bolt (32). Remove the bolt (33) from the upper 127( 7R UHDVVHPEOHSODFH WKHEHDULQJ VLQQHUULQJ
swinging arm. Remove the ‘O’ ring (34) and dispose LQ D FRQWDLQHU ZLWK GU\ LFH DQG WKHQ LQVHUW LW LQWR
of it. WKHNLQJSLQ KRXVLQJ *UHDVHWKHEHDULQJ DQGILOO
127( :KHQUHDVVHPEOLQJILWQHZµ2¶ULQJV DQG WKHKROHIRUWKHNLQJSLQZLWKJUHDVH 1/*,
DQGDSSO\JUHDVH 1/*, WRWKHEROWV DQG
(QVXUHWKDWWKHPDUNLQJVRQWKHEROWVDUHDOLJQHG :$51,1* $OZD\V ZHDU SURWHFWLYH JORYHV
WR WKRVH RQ WKH KRXVLQJ 7LJKWHQ WKH VHFXULQJ EROWV
and WRDWRUTXHRI1P7LJKWHQWKHORFN
WR SUHYHQW IURVWEXUQ ZKHQ KDQGOLQJ SDUWV
ZKLFKKDYHEHHQGHHSIUR]HQ SM118A
QXWV and WRDWRUTXHRI1P
67(3
Remove the king pin housing from the axle. When
disassembling, the hydraulic cylinder piston will come
completely out of the cylinder. Catch the piston and
inner drive shaft when disassembling.
127( :KHQUHDVVHPEOLQJHQVXUHWKDWWKHK\GUDXOLF
SLVWRQ LV LQVHUWHG LQWR WKH F\OLQGHU FRUUHFWO\ (QVXUH
WKDW WKH WHHWK RQ WKH LQQHU GULYH VKDIW PHVK FRUUHFWO\
ZLWKWKHGLIIHUHQWLDO
67(3
Remove the shaft (35) and remove the swinging arm
(29) from the axle. Remove the ‘O’ rings (36) from the
axle housing and dispose of them. Remove the sealing
rings (37) and dispose of them (when reassembling, fit
the sealing rings (37) with to sealing lip facing towards
the swinging arm).
127( :KHQ UHDVVHPEOLQJ REVHUYH WKH SURFHGXUH
IRUDGMXVWLQJWKHWRUVLRQEDUUHIHUWRSDJH

5002-15
67(3 127( 5HILW SDUWV WKH NLQJ SLQ KRXVLQJ WKH VDPH
PDQQHUEXWLQWKHUHYHUVHRUGHU
Check the washers (40) and sleeves (41) at the bearings
for the upper and lower swinging arms for wear and
damage and replace as necessary.
127( 8VH WKH VSHFLDO WRRO &$6 WR LQVHUW QHZ
VOHHYHV)LWQHZZDVKHUV DQGILOOWKHVOHHYHV
ZLWKJUHDVH 1/*,
7LJKWHQLQJWRUTXH 1P

7LJKWHQLQJWRUTXH 1P

/2&7,7(

/2&7,7(

66%

/2&7,7(

11. SECURING BOLT 20. HOUSING 29. LOWER SWINGING ARM 38. SLEEVE
12. SLEEVE 21. SEALING RING 30. ’O’ RING 39. BEARING
13. ADJUSTING SCREW 22. PIN 31. LOCK NUT 40. WASHER
14. LOCK NUT 23. SECURING BOLT 32. SECURING BOLT 41. SLEEVE
15. COVER 24. SLEEVE 33. BOLT
16. CIRCLIP 25. HOUSING 34. ’O’ RING
17. COVER 26. LOCK NUT 35. SHAFT
18. CIRCLIP 27. SECURING BOLT 36. ’O’ RING
19. TORSION BAR 28. BOLT 37. SEALING RING

5002-16
'LVDVVHPEO\
127( 7KHSDUWVDUHQXPEHUHGLQRUGHURIGLVDVVHPEO\
67(3 67(3
Remove the inner drive shaft from the king pin housing. Remove the ‘O’ ring (47) and dispose of it. Remove the
Remove the ‘O’ ring (42) and dispose of it. Ensure that outer needle bearing (49) and the cartridge sealing ring
the circlip (43) remains seated on the inner drive shaft. (50) from the drive shaft, using a standard puller.
67(3 67(3
Remove the inner bearing ring from the needle bearing
(53), the spacer ring (51) and the cartridge sealing ring
(52), using an inside puller. Remove the outer bearing
ring from the needle bearing (53) using an inside puller.
Remove the shim rings (54) and the circlip (55).
&$6 Remove the outer bearing ring from the needle bearing
(49).
67(3
Clean all component parts in a cleaning solvent and dry
with compressed air. A protective face mask MUST be
'3.
wear or damage and replace as necessary.
Bend the tab on the locking washer (45) back. Use the
socket wrench CAS2713 to remove the union nut (44).
Remove the locking washer (45) and dispose of it.
67(3
'3)
Use a hydraulic press to remove the drive shaft (46)

from the king pin housing. Support the drive shaft
during removal.
127( 7KHGULYHVKDIW LVILWWHGZLWKDVHDOLQJSOXJ
DWRQHHQG'2127H[HUWIRUFHDJDLQVWWKLVSOXJ

5002-17

'6'
42. ’O’ RING 47. ’O’ RING 52. CARTRIDGE SEALING RING
43. CIRCLIP 48. SPACER RING 53. INNER BEARING
44. SLOTTED ROUND NUT 49. OUTER BEARING 54. SHIM RINGS
45. LOCKING WASHER 50. CARTRIDGE SEALING RING 55. CIRCLIP
46. DRIVE SHAF’T 51. SPACER RING

5002-18
$VVHPEO\
67(3 67(3
&$6

''. 6'%
Select the number of shim rings, so that the total Fill the king pin housing with 32 g of grease (NL GI 2).
thickness of the shim ring package (54) is 0.5 mm. Fit Insert the spacer ring and the needle bearing (53) into
the circlip (55) and push the 0.5 mm shim ring package the king pin housing. Position the king pin housing onto
(54) against the inside of the circlip. To re-insert the a hydraulic press and support the needle bearing (53)
outer bearing rings of needle bearings (49) (53) into the with a pipe (A). Use the hydraulic press to press the
king pin housing, use a hydraulic press and the socket drive shaft carefully into the king pin housing, until it
wrench CAS 2713. Ensure that the bearing rings are bottoms.
pressed snugly against the circlip and the shim rings.
127( $OLJQWKHSLSH $ SUHFLVHO\WRWKHEHDULQJ
127( (QVXUH WKDW WKH FRUUHFW QXPEHU RI VKLP ULQJV VR WKDW WKH WKUHDG RQ WKH GULYH VKDIW ZLOO QRW EH
DUH ILWWHG 6KLP ULQJV DUH DYDLODEOH LQ D VL]HV RI GDPDJHGZKHQLWLVEHLQJSUHVVHGLQ
PPPPDQGPP
67(3
67(3
&$6
&$6
&$6
&$6

'3.
''.
Fit a new ’O’ ring to the drive shaft (46). Push the spacer
Grease the needle bearing with NL GI 2 grease and sleeve (51) into the cartridge sealing ring (52). Fit the
insert it into the king pin housing. Insert the cartridge spacer sleeve (51) and the cartridge sealing ring (52)
sealing ring (50) with sleeve CAS2720 into the king pin into the king pin housing, using the sleeve CAS 2720.
housing.

5002-19
67(3 67(3
Fit a new ‘O’ ring (42) and ensure that the circlip (43) is
seated correctly in the groove in the inner drive shaft.
Fit the inner drive shaft into the king pin housing.
&$6
'3.
Insert a new locking washer (45), with the convex side

towards the union nut. Fit the slotted round nut (44) with
the chamfered side at the bottom. Tighten the slotted
round nut (44) to a torque of 175 Nm, using the hooked
wrench CAS 2713. Lock the slotted round nut (44) with
the locking washer (45).

7LJKWHQLQJWRUTXH 1P
',)
42. ’O’ RING 47. ’O’ RING 52. CARTRIDGE SEALING RING
43. CIRCLIP 48. SPACER RING 53. INNER BEARING
44. SLOTTED ROUND NUT 49. OUTER BEARING 54. SHIM RINGS
45. LOCKING WASHER 50. CARTRIDGE SEALING RING 55. CIRCLIP
46. DRIVE SHAF’T 51. SPACER RING

5002-20
6HFWLRQDOGUDZLQJWKURXJKWKHSLYRWEHDULQJKRXVLQJDQG
WKH NLQJ SLQ KRXVLQJ

$

',(
A. KING PIN HOUSING 31. LOCK NUT 46. DRIVE SHAFT

6. KING PIN 32. SECURING BOLT 49. OUTER BEARING
8. DISK SPRING 33. BOLT 50. CARTRIDGE SEALING RING
9. DISK SPRING 38. SLEEVE 52. CARTRIDGE SEALING RING
10. THRUST WASHER 39. BEARING 53. INNER BEARING

5002-21
'5,9(6+$)76
GLVDVVHPEO\
The following work must be done before carrying out work on the drive shafts:
• Remove the pivot bearing housing, see page 10.
127( ,QRUGHUWRUHPRYHWKHGULYHVKDIWIURPWKHSLYRWEHDULQJKRXVLQJWKHSODQHWDU\JHDUXQLWDQGWKHZKHHOKXE
QHHGQRWEHUHPRYHG
• Remove the king pin housing, see page 12.
• In order to remove the drive shaft, the king pin housing must be disassembled, see page 16.

'6'
1. CIRCLIP (16) 4. OUTER DRIVE SHAFT (2)

2. BEARING RINGS (16) 5. BEARING (4)
3. INNER DRIVE SHAFT (3) 6. FORK

5002-22
:+((/'5,9($;/(
5HPRYLQJDQG)LWWLQJ
Before the 4-wheel drive axle can be removed, the following preparatory work must be carried out:
• Put the tractor on firm, level ground, apply the parking brake and use the switch RAISE/LOWER to fully lower the
front axle to its lowest limit. Switch the motor OFF and remove the ignition key.
• Disconnect the battery (negative pole first).
127( :KHQUHFRQQHFWLQJFRQQHFWWKHSRVLWLYH SROH V ILUVW
67(3 127( :KHQUHILWWLQJWKHGUDLQSOXJ WLJKWHQLWWRD

WRUTXHRI1P6FUHZWKHILOOHUSOXJ RXWDQGILOORLO
WRWKHUHFRPPHQGHGOHYHOUHIHUWRWKH7HFKQLFDO'DWD
RQSDJH7LJKWHQWKHILOOHUSOXJWRDWRUTXHRI1P
67(3
6''
Place a hydraulic jack under the centre of the axle and

raise the tractor. Lower the front of the tractor onto
suitable support trestles and remove the front wheels.
127( :KHQ UHILWWLQJ WKH IURQW ZKHHOV WLJKWHQ WKH 6''
QXWVWRDWRUTXHRI1P
Loosen the securing bolts (3) and remove the front
mudguard (if fitted).
67(3
66%
Place a container, with a capacity of at least 2.5 litres

under the oil drain plug (1), screw the oil drain plug out
and drain the oil.

5002-23
67(3 67(3

6'' 6''
Mark the steering cylinder connection hoses (4), Loosen the securing screws (7) and remove the potentio-
disconnect them and fit protective caps. Mark the meter covers (8) (both sides).
hydraulic hoses to the axle suspension cylinder, 127( :KHQ UHILWWLQJ WKH VHFXULQJ VFUHZV WLJK
disconnect them and fit protective caps. Disconnect the WHQWKHPWRDWRUTXHRI1P
hydraulic hose to the differential lock (if fitted) and fit
protective caps. 67(3
127( ,QRUGHUWRSUHYHQWWKHORVVRIK\GUDXOLFRLOWKH
K\GUDXOLF KRVHV PXVW EH VHFXUHO\ WLHG ZLWK WKH RSHQ
HQGVXSZDUGV WRZDUGVWKHFDE
67(3
6''
Mark the connectors (9) (both sides) and disconnect

them.
67(3
6''
Remove the brackets (6) for the hydraulic lines from the
4-wheel drive shaft protector (left and right).

6''
Remove the 4-wheel drive shaft protector. Remove the

4-wheel drive shaft (10) from the front axle.

5002-24
67(3 67(3

6'' 6''
127( %HIRUH WKHIURQW D[OH LV UHILWWHG WKH OHIWKDQG

VHQVRU FDEOH PXVW EH URXWHG RYHU WKH D[OH
KRXVLQJ

6''
Place a hydraulic jack under the centre of the front axle.

Loosen the front and rear bearing block securing bolts
(11 and 12).
127( 7KH UHDU EHDULQJ EORFN LV ILWWHG ZLWK WZR
VOHHYHV VHHSDJH
127( )RUUHDVVHPEO\OLJKWO\FRDWWKHVHFXULQJEROWV
DQG ZLWK/2&7,7(DQGWLJKWHQWKHPWRD
WRUTXHRI1P
67(3
6''
Slowly lower the hydraulic jack under the front axle and
pull it out from under the tractor.

5002-25
3,927('%($5,1*
GLVDVVHPEO\&OHDQDOOFRPSRQHQWSDUWVLQDFOHDQLQJVROYHQWDQGGU\ZLWKFRPSUHVVHGDLU ZHDUD)$&(0$6.
&KHFNDOOFRPSRQHQWSDUWVIRUZHDURUGDPDJHDQGUHSODFHDVQHFHVVDU\
127( ,IWKHVOHHYHV DUHUHSODFHGHQVXUHFRUUHFWDOLJQPHQWRIWKHJUHDVHDFFHVVKROHZKHQUHDVVHPEOLQJ

$

66%
1. FRONT BEARING BLOCK 5. REAR BEARING BLOCK 9. THRUST WASHER

2. SLEEVE 6. SLEEVE 10. GREASE NIPPLE
3. SLEEVE 7. ’O’ RING 11. SCREW-IN SUPPORT
4. THRUST WASHER 8. SLEEVE 12. SLEEVE
)LWWLQJ,QVWUXFWLRQVIRUWKH3,927('%($5,1*
Raise the tractor, so that the axle can pivot through to the limits.
Position the axle (A) so that it seats against the bearing block (5). Loosen the front bearing block (1) securing bolts.
Drive the bearing block (1) to the limit on the axle housing and tighten the front bearing block securing bolts to the
prescribed torque (see STEP 12, page 24).
Pivot the axle several times and measure the axial play of the pivoted bearing..
3HUPLVVLEOHD[LDOSOD\........................................................................ 0 - 1 mm
127( ,IWKHD[LDOSOD\H[FHHGVPPLQVSHFWWKUXVWZDVKHUV DQG DQGEHDULQJEORFNV DQG IRUZHDU
DQGUHSODFHDVQHFHVVDU\

5002-26
'LVDVVHPEO\
Before work can be carried out on the differential, the following preparatory work must be carried out:
• Remove the king pin housing as a complete unit together with the planetary gear unit, the wheel hub and pivot
bearing housing. Remove the king pin housing as a complete unit together. To do this, proceed in accordance with
STEP 7 to STEP 15 on page 14.
67(3 67(3
Make alignment markings on the potentiometer (2) and Remove the sealing ring (16), sleeves (16) and (17)
the upper swinging arm (9). Loosen the securing from the upper and lower swinging arms (9) and (20).
screws (1) and remove the potentiometer from the axle. Remove the sealing ring (18), sleeves (19) from the
Remove the washers (3) and the rubber disk (4). upper and lower swinging arms (9) and (20).
67(3 67(3
Make alignment markings on the bolt (8) and axle Inspect the washers (22) and sleeves (23) in the axle
housing. Loosen the lock nut (5) and remove the housing for wear or damage and replace as necessary.
securing bolt (6). Remove the bolt and the upper To replace sleeves and sealing rings, refer to the proce-
swinging arm (9) from the axle. Remove the 'O' ring dure for reassembly on page 28.
(10) from the bolt (8) and dispose of it.
67(3
Remove the circlip (11), the washer (12), the hydraulic
cylinder (13) and the thrust washer (14) from the bolt
(15).

5002-27

66%
1. SECURING BOLT 10. ’O’ RING 18. CIRCLIP

2. POTENTIOMETER 11. CIRCLIP 19. SLEEVE
3. WASHER 12. WASHER 20. LOWER SWINGING ARM
4. RUBBER DISK 13. HYDRAULIC CYLINDER 21. SLEEVE
5. LOCK NUT 14. THRUST WASHER 22. WASHER
6. SECURING BOLT 15. BOLT 23. SLEEVE
8. BOLT 16. SEALING RING
9. UPPER SWINGING ARM 17. SLEEVE

5002-28
$VVHPEO\
67(3 67(3

&$6 &$6
'3. '3)
Fit new bearing sleeves (23) (both sides), using special Fit the washer (12) and the circlip (11).
tool CAS2716.
67(3
67(3

&$6
&$6

'3.
'3.
Fit new sleeves (17) to the upper and lower swinging
Fit new washers (22). Grease the sleeves (22) and arms, using special tool CAS2717 and the grip
washers (23) with NL GI 2 grease. CAS2555. Fill the sleeves with grease (NL GI 2).
67(3 67(3

'3) '.'
Fit the thrust washer (14), with the chamfered side to- Fit new sealing rings (16) and make sure that the
wards the housing and fit the hydraulic cylinder (13). sealing lips are facing towards the axle housing.

5002-29
67(3 67(3

&$6

&$6
'3. '.'
Fit the circlips (18) and make sure that they are seated
$ correctly in the grooves.
67(3

',(
Fit new sleeves (19) in the upper and lower swinging
arms, using special tool CAS2718. Make sure that the
graduated surface of the sleeve faces the sleeve (17). '3)
127( 7KH VOHHYHV PXVW EH ILWWHG DW D GHSWK $ RI Fit new ’O’ rings at both ends of the bolt (8). Grease the
PPIRUWKHLQQHUEROWDQGPPIRUWKHRXWHUEROW bolt with grease (NL GI 2) and fit it into the upper swin-
0DNH VXUH WKDW WKH FRUUHFW VLGH RI WKH VSHFLDO WRRO ging arm. Make sure that the alignment markings on the
&$6LVXVHGIRUUHDVVHPEO\ bolt (8) and the housing coincide. Fit the securing bolt
(6) with lock nut (5) and tighten to a torque of 135 Nm.
Tighten the locking nut (5) to a torque of 70 Nm.

5002-30
67(3 67(3
%

'3) '.'
Fit the rubber disk (4). Make sure that the tab (B) he Fit new ‘O’ rings (item 36, page 15) in the lower seat of
rubber disk meshes into the bolt and that the marking the swinging arm. Fit new sealing rings (item 37,
"OUTSIDE" is facing outwards. page 15) and make sure that the sealing lips are facing
towards the swinging arm.
67(3
67(3
&$6
&$6

'3)
Fit the washer (3) and the potentiometer (2). Make sure '5.
that the flat side of the potentiometer is seated correctly in Fit new sleeves (21) to the lower securing arm, using a
the rubber disk and that the alignemt marking is correctly
hydraulic press and special tool CAS2719. Fill the
aligned to the swinging arm.
sleeves with grease (NL GI 2).
67(3
'3)
Fit the securing screws and tighten them to a torque of

3 Nm.

5002-31
67(3
$
%
&
'3.
Grease the shaft (C) with grease (NL GI 2). Fit the
swinging arm and the shaft (C). Make sure that the
groves (A) in the shaft (C) are aligned vertically and are
on the same side as the pinion shaft (B).
127( ,Q RUGHU WR ILW WKH SLYRW EHDULQJ KRXVLQJ WKH
ZKHHO KXE DQG WKH SODQHWDU\ JHDU XQLW FDUU\ RXW
67(3 WR67(3 SDJH LQWKHUHYHUVHRUGHU
67(3
Fit the torsion bars and adjust them, refer to "Adjusting
the Torsion Bars" on page 32.

5002-32
$GMXVWLQJWKH7RUVLRQ%DUV
67(3 67(3

6'% '.'
Clean the flange surfaces and place a continuous line Insert the pins (4) and sealing rings (5) into the housing
of LOCTITE 518 around the hole in the lower swinging (7) Ensure that the sealing lip is towards the swinging
arm. arm.
67(3 67(3
6; ';
6'% 6'%
Fit the housing (1) with the centring sleeves. Lightly Connect a suitable lifting device to the pivot bearing
coat the securing screws (2) with LOCTITE 543 and housing and raise the suspension to the upper limit.
tighten the securing screws to a torque of 95 Nm. Support the suspension in the raised position, using
suitable support trestles.
Fit the torsion bar (6). Make sure, that the end of the
torsion bar with the punched marking is at the same
side as the pinion shaft. To differentiate between torsion
bars for the left and right-hand side of the axle, they are
punch marked as follows:
SX .............................................. Left-hand torsion bar
DX ........................................... Right-hand torsion bar

5002-33
67(3 67(3

'3. 6'%
Fit the housing (7). Align the pins in the housing (7) to Fit the circlip (10). Fit the torsion bar (6) completely.
the grooves in the shaft of the lower securing arm Fit
127( ,IQHFHVVDU\ORZHUWKHVXVSHQVLRQLQRUGHUWR
the sleeves (8) and securing bolts (9) loosely, using
DOLJQ WKH WHHWK RQ WKH WRUVLRQ EDU ZLWK WKH JURRYHV LQ
LOCTITE 543.
WKHKRXVLQJ
67(3 67(3

'3.
'3.
Turn the left-hand housing in an anti-clockwise
Turn the adjusting screw (11) in, till it seats on the axle
direction, so that the securing bolts (9) can be aligned
housing. Turn the adjusting screw in 6 turns, in order to
to the right-hand side of the slit.
achieve the correct pre-tension of the torsion bar.
Turn the left-hand housing in a clockwise direction, so
127( 'XULQJWKLVSURFHGXUHWKHKRXVLQJ WXUQVWR
that the securing bolts (9) can be aligned to the right-
SUHWHQVLRQ WKH WRUVLRQ EDU ,I WKH DGMXVWLQJ VFUHZ
hand side of the slit.
LVGLIILFXOWWRWXUQPDNHVXUHWKDWWKHVFUHZV
ZKLFK ZHUH ILWWHG GXULQJ 67(3 DUH QRW RYHU
WLJKWHQHG

5002-34
67(3 67(3
Repeat STEP 1 to STEP 10 to fit the other torsion bar.

67(3
Fit the 4-wheel axle in the reverse sequence to that
used to remove it (see page 22).

67(3
Adjust the potentiometer and calibrate the axle. See
"Adjusting the Potentiometer" and "Axle Calibration" in
chapter 5 – FUNCTIONAL DESCRIPTION; ADJUST-
MENTS AND TROUBLESHOOTING INDEPENDENT-
'3. LY SUSPENDED FRONT AXLE.
Tighten the locking nut (12) to a torque of 45 Nm.
Tighten the securing screws (9) to a torque of 169 Nm.
67(3

'3.
Fit the circlip (13) and the cover (14) (both ends).

5002-35
$;/(+286,1*
'LVDVVHPEO\ 67(3
127( 7KHSDUWVDUHQXPEHUHGLQRUGHURIGLVDVVHP
EO\ :KHQ UHDVVHPEOLQJ WKH SRVLWLRQ RI WKH SLQLRQ
VKDIWPXVWEHVHWSUHFLVHO\6HH$GMXVWLQJWKH3LQLRQ
6KDIWRQSDJH
67(3

6'%

6'%

Remove the securing screws (1) and remove the front
housing cover (2).
67(3
6'%
Remove the piston (5) from the cylinder using a

compressed air gun. Remove the ‘O’ rings (6) and (7)
and dispose of them.

:$51,1*:KHQUHPRYLQJWKHSLVWRQXVLQJFRP
SUHVVHGDLUFDWFKLWLQDFORWK
67(3
6'%
Remove the securing screws (3) and remove the

differential operating cylinder (4).

6'%
Remove the circlip (8), spacer ring (9) and the spring
(10).

5002-36
67(3 67(3
&$6

6'% '3)
Remove the clamping rings using special tool

CAS2714. Remove the ‘O’ rings (21) and dispose of
them. Remove the sealing rings (22) and sleeves (23)
from the clamping rings (20).
67(3

Mark the position of the differential unit (24) with
respect to the axle housing (A) for later alignment.
Remove the screws (19) and bearing cover (16).
Remove the differential unit (24) from the differential
housing.
127( 0DNH PDUNV RQ WKH GLIIHUHQWLDO XQLW DQG WKH
D[OHKRXVLQJIRUFRUUHFWDOLJQPHQWGXULQJUHDVVHPEO\
6'%
Remove the circlip (11). Remove the shaft (12), the shift 67(3
fork (13), the spring (15), the washer (14) and the
circlip (11).
67(3

$

6'%
Remove the shift ring (25) and the four locking pins (26)
from the differential unit.
6'% 67(3
Make alignment markings on both the bearing cover Remove the securing screws (27) and remove the
(16) and the differential housing (A). Remove the flange (28) from the pinion shaft. Remove the sealing
locking screws (17). Loosen the screw (19). cover (29). Remove the shaft sealing ring (31) and
'O' ring (30) from the sealing cover (29) and dispose of
them.

5002-37

$

66%
1. SECURING BOLT 11. CIRCLIP 22. SEALING RING 32. SLOTTED ROUND NUT
2. HOUSING COVER 12. SHAFT 23. SLEEVE 33. WASHER
3. SECURING BOLT 13. SHIFT FORK 24. DIFFERENTIAL UNIT 34. PINION SHAFT
4. CYLINDER 14. WASHER 25. SHIFT RING 35. BEARING
5. PISTON 15. SPRING 26. LOCKING PINS 36. WASHER
6. ‘O’ RING 16. BEARING COVER 27. SECURING BOLT 37. SPRING COLLET
7. ‘O’ RING 17. LOCKING SCREW 28. FLANGE 38. BEARING
8. CIRCLIP 19. SECURING BOLT 29. SEALING COVER 39. PACKING RING
9. SPACER RING 20. CLAMPING RING 30. ‘O’ RING
10. SPRING 21. ‘O’ RING 31. SHAFT SEAL

5002-38
67(3 67(3
Unlock the slotted round nut (32) and put the socket
wrench CAS1885A on it. Fit the rod CAS2483 to the
input flange (28), using 2 bolts, in order to block the
pinion shaft. Remove the union nut (32) and locking
washer (33) and dispose of them.
67(3

6'%
Remove the bearing (35). Remove the bearing (38)

from the pinion shaft, using a bearing puller. Remove
the packing ring (39).
6'%
Press the pinion shaft (34) out of the axle housing, 127( :KHQUHDVVHPEOLQJWKHSRVLWLRQRIWKHSLQLRQ
using a hydraulic press. Support the pinion shaft during VKDIWPXVWEHVHWSUHFLVHO\6HH$GMXVWLQJWKH3LQLRQ
removal. Do not re-use the washers (36) and spring 6KDIWRQSDJH
collet (37).

5002-39

$

66%
1. SECURING BOLT 11. CIRCLIP 22. SEALING RING 32. SLOTTED ROUND NUT
2. HOUSING COVER 12. SHAFT 23. SLEEVE 33. WASHER
3. SECURING BOLT 13. SHIFT FORK 24. DIFFERENTIAL UNIT 34. PINION SHAFT
4. CYLINDER 14. WASHER 25. SHIFT RING 35. BEARING
5. PISTON 15. SPRING 26. LOCKING PINS 36. WASHER
6. ‘O’ RING 16. BEARING COVER 27. SECURING BOLT 37. SPRING COLLET
7. ‘O’ RING 17. LOCKING SCREW 28. FLANGE 38. BEARING
8. CIRCLIP 19. SECURING BOLT 29. SEALING COVER 39. PACKING RING
9. SPACER RING 20. CLAMPING RING 30. 'O' RING
10. SPRING 21. ‘O’ RING 31. SHAFT SEAL

5002-40
',))(5(17,$/81,7
'LVDVVHPEO\ 67(3
127( 0DNH DOLJQPHQW PDUNLQJV RQ WKH KRXVLQJ
VHFWLRQVIRUODWHUUHDVVHPEO\

67(3
Remove the securing bolts (3) and differential master
gear (4).
67(3
Remove the bearing (5) from the differential housing.
67(3
6'%
Remove the differential unit housing section (R).
Fit the thrust washer (7) and the axle bevel gear (9) into
Remove the thrust washer (7) and the axle bevel
the housing section (R).
gear (8).
67(3
67(3
Remove the balancing shaft (12), compensating gears
(11) and thrust washers (10) as a complete unit.
Remove the axle bevel gear (9) and the thrust
washer (7).
67(3
$VVHPEO\ 6'%
Fit the balancing shaft (12), compensating gears (11)

67(3 and thrust washers (10).
Heat the bearings (5) to 90° C in a bearing heater and
fit them to the housing sections. Make sure that the
67(3
needle bearing seats correctly against the shoulder.

:$51,1* $OZD\V ZHDU SURWHFWLYH JORYHV
WRSUHYHQWEXUQVZKHQKDQGOLQJSDUWVZKLFK
KDYHEHHQKHDWHG SM121A

6'%
Fit the axle bevel gear (8) and the thrust washer (7).

5002-41

5
7LJKWHQLQJWRUTXH 1P

/2&7,7(

/

66%
1. SHIFT RING 6. DIFFERENTIAL HOUSING 11. DIFFERENTIAL BEVEL GEAR (4)

2. LOCKING PIN (4) 7. THRUST WASHER (2) 12. BALANCING SHAFT (2)
3. SECURING BOLT (12) 8. AXLE BEVEL GEAR L LEFT-HAND HOUSING SECTION
4. DIFFERENTIAL MASTER GEAR 9. AXLE BEVEL GEAR (LOCKING SIDE) R RIGHT-HAND HOUSING SECTION
5. BEARING (2) 10. THRUST WASHER (4)
67(3 67(3

6'% 6'%
Position housing section (L) on housing section (R) and Fit the locking pin (2) into the differential housing and
align them to the markings. Fit the differential master push the shift ring (1) on.
gear (4). Fit the securing bolts (3) with LOCTITE 270
127( 7RILWWKHGLIIHUHQWLDOXQLWVHHSDJH
and tighten them to a torque of 78 Nm.

5002-42
$GMXVWLQJWKH3LQLRQ6KDIW
67(3 67(3
Fit the outer bearing rings (1) and (2) into the axle
housing (3). Make sure that the bearing rings seat %
correctly against the shoulders.
67(3
Assemble the alignment adapter CAS2489-4 (4) and the
measurement cylinder CAS2489-2 (5) with the screw
CAS1596A-7 (6).
67(3

'3)
Measure the gap (B) between the measuring cylinder (5)

and the gauging tube (10) with a feeler gauge. Make a
note of dimension (B).
67(3
To determine the shim thickness for correct adjustment
of the pinion shaft, proceed as follows:
$ % &
& ± ' ; (shim thickness required)
'3)
$ = Measurement constant PP – calculated
Fit the inner bearing ring (8), using the special tool from:
assembled in STEP 2. Fit the inner bearing ring (7) and fit ³U´ differential bearing (45,00 mm) + length of the
the grip (9) CAS1596A-4. Hand tighten the grip (9) until measurement cylinder (5) (65.04 mm)
the bearings (7) and (8) can only be turned with difficulty.
% = dimension measured in STEP 5
127( 7XUQWKHJULSVRWKDWWKHEHDULQJVDUHDOLJQHG & = Housing dimension (measured with pinion shaft
WRWKHEHDULQJULQJV bearing)
' = Pinion dimension (etched into the end of the pinion
67(3 shaft)
;= Shim
Example:
$ ............................................................ 110.04 mm
% ............................................................ +0.25 mm
& ............................................................ 110.29 mm
& ............................................................ 110.29 mm
' ........................................................... -107.25 mm
; ............................................................ 3.04 mm
Shim thickness required = PP

,03257$17 6KLPVDUHDYDLODEOHLQDWKLFNQHVVRI
'3)
PPWRPP LQLQFUHPHQWVRIPP ,IWKHFDO
Fit the gauging tube CAS1839/1 (10), in place of the FXODWHGWKLFNQHVVRIWKHVKLPLVOHVVWKDQPPRU
differential unit, with the bearing covers (11). Fit the PRUHWKDQPPUHSHDW67(3WR67(3LQRUGHUWR
screws (12) and tighten evenly to a torque of 266 Nm. HOLPLQDWHDPHDVXUHPHQWHUURU
127( 0DNHVXUHWKDWWKHDOLJQPHQWPDUNLQJVPDGH
GXULQJ GLVDVVHPEO\ DUH DOLJQHG FRUUHFWO\ WR RQH
DQRWKHU

5002-43
1P

&$6

&$6
&$6$

&$6
66%
&$6$
1. OUTER BEARING RING 7. NEEDLE BEARING INNER RING

2. OUTER BEARING RING 8. NEEDLE BEARING INNER RING
3. DIFFERENTIAL HOUSING 9. GRIP
4. ALIGNMENT ADAPTER 10. GAUGING TUBE
5. MEASURING CYLINDER 11. BEARING COVER
6. SCREW 12. SECURING BOLT

5002-44
3LQLRQ6KDIW8QLW
67(3 67(3
Remove the pinion adjustment tools and the needle
bearings from the axle housing.
67(3
Fit the shim (1), the size which was calculated in
STEP 6 to the pinion shaft (6), making sure that the
chamfered side of the shim faces the pinion wheel.
67(3
Heat the bearing (2) to 90° C in a bearing heater and fit
it to the pinion shaft.

127( 0DNH VXUH WKDW WKH EHDULQJ LV LQ FRQWDFW ZLWK
6'%
WKHVKLP
Tie a piece of string to the pinion shaft (6) and wind the
string, without overlapping it, around the pinion shaft.
:$51,1* $OZD\V ZHDU SURWHFWLYH JORYHV
Tie a spring balance to the end of the string and mea-
WRSUHYHQWEXUQVZKHQKDQGOLQJSDUWVZKLFK
KDYHEHHQKHDWHG SM121A
sure the rolling resistance.
Tighten the slotted round nut, until the rolling resistance
67(3 is between and 1.
Fit a new washer (3), a new spring collet (4) and a new 127( ,I WKH VORWWHG URXQG QXW LV RYHUWLJKWHQHG DQG
washer (5) to the pinion shaft (6). Fit the pinion shaft (6) WKHUROOLQJUHVLVWDQFHLVVWLOORXWRIWROHUDQFHWKHVSULQJ
into the axle housing. FROOHW PXVW EH UHSODFHG UHIHU WR 67(3 DQG
67(3RQSDJH
67(3
Heat the bearing (7) to 90° C in a bearing heater and fit 67(3
it to the pinion shaft or into the axle housing repsective- Lock the slotted round nut (9) with a suitable pin in the
ly. Fir a new washer (8) and a new slotted round nut (9) groove in the pinion shaft (6).
to the pinion shaft (6).
67(3
&
%
$
6'%
Fit the socket wrench CAS1885A to the slotted round

nut (9). Fit the rod CAS2483 (B) to the input flange (A),
using 2 bolts, in order to block the pinion shaft. Tighten
the slotted round nut until the pinion shaft in the axle
housing is free of play.

5002-45

$ 66%
1. SHIM 7. BEARING
2. BEARING 8. WASHER
3. WASHER 9. SLOTTED ROUND NUT
4. SPRING COLLET A. FLANGE
5. WASHER
6. PINION SHAFT

5002-46
)LWWLQJWKH'LIIHUHQWLDO8QLW
67(3 67(3
$ &$6

&$6
%
'3. 6'&
Fit the sleeve CAS2714-1 to the wrench CAS2714. Fit the bearing cover (5) and make sure to align the
Press the new sleeves (1) into the clamping ring (7) markings.
using a hydraulic press.
67(3
127( :KHQSUHVVLQJWKHVOHHYHVLQPDNHVXUHWKDW
WKHSLQV $ RQWKHZUHQFK&$6DUHDOLJQHGFRU Hand tighten the bolts (6) evenly.
UHFWO\WRWKHKROHV % LQWKHFODPSLQJULQJ ,03257$17 %HIRUHILQDOO\WLJKWHQLQJWKHEROWV
PDNHVXUHWKDWWKHUHLVIUHHGRPRIWUDYHOEHWZHHQWKH
67(3 GLIIHUHQWLDOPDVWHUJHDUDQGWKHSLQLRQ
67(3
$ &$6 &$6
%
'3.
Remove the sleeve CAS2714-1 from the wrench. Press

6'&
the new sealing ring (2) into the clamping ring (7) using
a hydraulic press and wrench CAS2714. Fit new Fit the clamping rings (7) using the wrench CAS2714.
’O’ rings on the clamping ring (7). Grease the ’O’ ring (3)
and sealing ring (2) with NL GI 2 grease.
127( :KHQSUHVVLQJWKHVOHHYHVLQPDNHVXUHWKDW
WKHSLQV $ RQWKHZUHQFK&$6DUHDOLJQHGFRU
UHFWO\WRWKHKROHV % LQWKHFODPSLQJULQJ
67(3
Fit the differential unit (4) into the axle housing (A) and
make sure that the alignment markings coincide.

5002-47
1P

$

',*
1. SLEEVE 5. BEARING COVER

2. SEALING RING 6. BOLT
3. ’O’ RING 7. CLAMPING RING
4. DIFFERENTIAL UNIT A. AXLE HOUSING

5002-48
$GMXVWLQJWKH&URZQ:KHHO7RRWK)ODQN3OD\
67(3 67(3
In order to reduce the tooth flank play, the clamping ring
on the crown wheel side of the differential must be
&$6 turned in a clockwise direction and the clamping ring on
the opposite side of the crown wheel is turned by the
same amount in an anti-clockwise direction.
In order to increase the tooth flank play, the clamping
ring on the crown wheel side of the differential must be
turned in an anti-clockwise direction and the clamping
ring on the opposite side of the crown wheel is turned
by the same amount in a clockwise direction.
Check the tooth flank play and repeat the procedure if
6'&
necessary, until the tooth flank play has been adjusted
to within tolerance.
Turn the clamping ring on the crown wheel side of the
differential, using the wrench CAS2714, in a clockwise 67(3
direction, until the crown wheel makes contact with the
pinion. Simultaneously tap the bearing covers with a Tighten the bolts (6) to a torque of 266 Nm. Check that
soft-faced hammer, to align the bearings. the tooth flank play is still within tolerance.
67(3
Turn the clamping ring at the opposite side of the crown
wheel in a clockwise direction, until there is no play in
the bearings. Simultaneously tap the bearing covers
with a soft-faced hammer, to align the bearings. Play
has been eliminated, when the clamping ring can only
be turned with difficulty.
67(3
6'&
Place a dial test indicator on one tooth of the crown

wheel and measure the tooth flank play between crown
wheel and pinion. The tooth flank play must be measu-
red at three equidistant points around the circumfe-
rence of the crown wheel. The tooth flank play must lie
within the following tolerances:
20.25S axle .................................... 0.18 to 0.23 mm

5002-49
$GMXVWLQJWKH'LIIHUHQWLDO%HDULQJ3UH7HQVLRQ
67(3 67(3
Make sure that the tooth flank play between crown
wheel and pinion is within tolerance and that the bea-
ring cover bolts are tightened to a torque of 266 Nm.

67(3
When the crown wheel and pinion are meshed correctly
and the tooth flank play has been adjusted to within
tolerance, the differential bearing pre-tension is
adjusted as follows:
6'&
When the pre-tension has been correctly adjusted, fit

the locking screw (8) with LOCTITE 543 and tighten it
to a torque of 13 Nm.
127( :KHQILWWLQJWKHORFNLQJVFUHZ PDNHVXUH
WKDW WKH VFUHZ HQJDJHV LQ WKH WHHWK RI WKH FODPSLQJ
ULQJ ,I QHFHVVDU\ URWDWH WKH FODPSLQJ ULQJ
VOLJKWO\
67(3
6'%
Tie a piece of string to the pinion shaft and wind the
string, without overlapping it, around the pinion shaft.
Tie a spring balance to the end of the string and mea-
sure the rolling resistance of the pinion wheel.
The rolling resistance must be 20 N to 30 N above the
bearing pre-tension, which was measured during
STEP 13 on page 44.
If the rolling resistance exceeds the prescribed value,
both clamping rings must be turned, in an anti-
clockwise direction, by the same amount.
If the rolling resistance is below the prescribed value,
both clamping rings must be turned, in a clockwise 6'&
direction, by the same amount. Clean the surfaces on the cover (9) and on the axle
127( ,I WKH FODPSLQJ ULQJV UHTXLUH DGMXVWPHQW housing. Apply a continuous line of LOCTITE 518 to the
67(3WRFKHFNWKHWRRWKIODQNSOD\PXVWEHVXEVH sealing surfaces. Fit the cover and make sure that the
TXHQWO\UHSHDWHG,IWKHWRRWK IODQNSOD\LVQRZ RXW RI shift fork (10) engages in the shift ring. Fit the securing
WROHUDQFHORRVHQWKHEROWV DQGUHSHDW67(3WR bolts with LOCTITE 543 and tighten them to a torque of
67(3 169 Nm.

5002-50
67(3
Press a new sealing ring (12) into the sealing cover
(14). Fit the sealing cover, with a new ’O’ ring (13) into
the axle housing. Fit the flange (15) to the pinion shaft,
using the bolts (16).

66%

5002-51
75$&.$/,*10(17
Ä$³
'ULYLQJGLUHFWLRQ
$[OHLQORZHVWSRVLWLRQ
Ä%³ 66*
127( %HIRUHDOLJQLQJWKHWUDFNFKHFNWKDWW\UHSUHVVXUHVDUHFRUUHFW VHH2SHUDWLQJ0DQXDO
67(3 67(3
Lower the suspended front axle to the lowest (totally
crashed into) mechanical limit.
127( &HQWUHWKHIURQWZKHHOV VWUDLJKWDKHDG
67(3
Make marks on the back inside of the wheel rim (rim
flange), at the same height as the centre of the wheel
hub.
67(3
Measure the distance B between these marks and make
66&
a note of it.
Loosen the locking nuts (1). Extend or shorten the track
67(3 rods by turning the knuckle joints (2). Repeat STEP 1 to
Drive the tractor forwards, until the markings are at the STEP 5.
front of the wheels, at the same height as the centre of When the track has been aligned correctly, tighten the
the wheel hub. locking nuts to a torque of 250 Nm.
67(3
Measure the distance A between these marks and make
a note of it. The toe has to be fitted in a way, that A is 11
to 16 mm bigger than B.
6HWWLQJ:
Axle fully lowered ................. -11 mm to -16 mm toe-out
127( 7KLVVHWWLQJUHVXOWVLQDWRH]HUR PP LQWKH
PLGSRVLWLRQ GULYLQJSRVLWLRQ
127( ,IWKHYDOXHGHWHUPLQHGLVRXWVLGHWKHSUHVFULEHG
VHWWLQJ WKH WUDFN DOLJQPHQW PXVW EH FRUUHFWHG LQ
DFFRUGDQFHZLWK67(3

Section
6
6
HOW IT WORKS
TRANSMISSION T 7200 L
9105a, 9115a, 9125a, 9145a,

CS110, CS120, CS130, CS150
CASE STEYR Landmaschinentechnik GmbH Sva 7-95450 EN © 1999 Case Steyr Landmaschinentechnik GmbH
Technische Dokumentation/Training Center Mai, 1999
Contents
Pages
6.01 GEARBOX – Assembly 3 - 15
6.02 OIL SYSTEM 1 - 15
6.03 MAIN CLUTCH 1 - 19
6.04 GEARBOX – Section 1 - 8
6.05 POWER SHIFT Gearbox – Operation 1 - 36
6.06 Hydr. POWER SHIFT Control Block 1 - 36
6.07 6 Speed SYNCHRONOUS GEARBOX 1 - 23
6.08 REAR AXLE, BRAKES 1 - 24
6.09 POWER TAKE OFF (PTO) Gearbox 1 - 3
6.01 Training Center St.Valentin 1

6.01
GEARBOX – Assembly
GENERAL DESCRIPTION
LOCATION OF AGGREGATES
COMPONENT LAYOUT
VIBRATION DAMPER

General Description
The gearbox is available in three versions, covering a power range of 105 to 150 HP.
T-7224 L → Tractor 9105a CS 110

T-7226 L → Tractor 9115a and 9125a CS 120 and CS 130
T-7228 L → Tractor 9145a CS 150
All gearboxes are fitted with:
∗ 4 stage Power Shift/Reverse Gearbox, hydro-electric gear change with multiple disk clutch.
∗ Fully synchronised 6 speed main gearbox, mechanical gear change.
∗ 24 forward and 24 reverse gears
∗ Additional 16 forward/reverse crawler gears (optional extra)
∗ Forced lubrication in the gearbox by the gearbox hydraulic pump,18 bar (32 cm³, 78 l/min at 2300 rpm engine speed)
∗ Integrated, oil-cooled wet driving clutch – hydro-statically operated, engaged by disk spring and servo-assisted with
booster.
∗ Power shift front wheel drive, integrated into the gearbox
∗ Rear wheel differential with multi-disk lock, hydro-electrically operated.
∗ Wet multi-disc driving and hand brakes.
∗ Final drive with simple planetary gearbox
∗ Two or four-stage power take off (PTO) shaft, with wet PTO shaft clutch, hydro-electrically operated and mechanical
PTO shaft speed change.
∗ Working hydraulics of modular construction with EHR D
∗ There is an opto-acoustic display in the cabin, to indicate gearbox functions, plus an additional indicator lamp on the instrument
panel for forward/reverse pre-selection.
∗ Working hydraulic pump 180 bar (32 cm³, 78 l/min at 2300 engine rpm)
IMPORTANT: The power unit type plate is located beneath the gear shift column. When making inquiries or placing orders, it
is necessary to state the complete aggregate and parts list number as details of the gearbox configuration are
contained in these numbers. Example: Aggregate No. T 7226 L 865
Parts list No. 2093 005 037

Aggregate layout (power unit module)
1 Vibration damper
2 Power shift gearbox
3 Crawler gear range (optional extra or national standard)
4 Main clutch
5 6 Speed synchronous gearbox
6 Rear axle – Differential
Planetary gear unit
Brakes
7 4-Wheel drive (MFD)
8 4-Wheel drive shaft
9 APL – 4-Wheel Planetary Steering Axle
10 PTO shaft gear unit
11 Rear power take off (PTO) shaft
12 PTO shaft clutch
13 Front PTO shaft (optional extra)

Power Unit – Type Plate
Type – Type allocation Aggregate No. – Serial No.
T 7226 L 2015
2093 500 037
second last
digit
Parts list
number 9 → 40 km/h version
3
or → 50 km/h version
6

Component Layout
1 PTO shaft solenoid valve
2 PTO shaft control unit
3 Central rear axle lubrication connection (working hydraulics oil circulation)
4 Working hydraulic pump
5 Suction filter vent hole (M10 x 1)
6 Gear lever, 6-speed main gearbox
7 Speed sensor, working speed – power shift output
8 4-speed power shift control module
9 Forward/reverse shift module
10 Leakage oil return feed line from the booster clutch
11 Pressure line to the booster clutch
12 Clutch master cylinder (booster) → ......
13 Connection to the heat exchanger (M22 x 1.5)
14 Pressure line from the booster to the driving clutch
15 Gearbox oil temperature sensor
16 Measuring point 18 bar (shift pressure not modulated)
17 Solenoid valve for engaging front-wheel drive
18 Suction filter
19 Steering feedback
20 Working hydraulics suction line
21 Rpm sensor, driving speed (6-speed main gearbox drive shaft)
22 PTO shaft
23 PTO shaft gear lever
24 Measuring point for PTO shaft and differential lock 18 bar
25 Steering priority valve → ......
26 Motor speed sensor
27 Gearbox hydraulic pump
28 Gearbox oil pressure switch (18 bar)

1 2 3 4 5 26 6 27 7 8 28 9 10
24
23
22
25 21 20 19 18 17 16 15 14 13 12 11

COMPONENT LAYOUT
1 Brake actuation with bleed point

2 Inhibitor pin for 30 km/h version
3 Driving clutch bleed line
4 Pressure connection, driving clutch from the clutch master cylinder (booster)
5 Connection from the heat exchanger (M26 x 1.5)
6 Leakage oil return line from the clutch master cylinder (booster)
7 Clutch master cylinder (booster) → ......
8 Start inhibitor switch
9 Neutral switch – gearbox control
10 Speed sensor, initial speed / motor speed
11 PTO shaft pressure line / differential lock
12 Central rear axle lubrication connection (working hydraulics oil circulation)
13 PTO shaft control unit with solenoid valve
14 Differential lock control unit with solenoid valve
15 Differential lock pressure measuring point 18 bar
16 PTO shaft
17 Brake booster → ......
18 PTO shaft speed sensor

1 2 3 4 5 6
17
18
16
15
14
13
12 11 10 9 8 7

"Hydrodamp" Vibration Damper System
With the 9100 series, the torsional vibration damper is fitted to the motor flywheel instead of to the driving clutch. It has two damping
systems:
The spring-mass system shifts offsets critical resonance at speeds below the operating speed range.
An individual idling stage (idling damper springs) is matched to customer specific requirements.
The hydraulic damping system reduces the amplitude of vibrations, which occur when passing through resonance (starting and stopping
the engine) or are caused by load impact. When increased vibration amplitudes occur, the highly viscosity stable damping medium is
forced, through precisely defined slits, from one damping chamber to the other, as a result of the relative motion
Main Characteristics of the Hydrodamp System:

– The hydraulic damping fluid is tightly encapsulated. An external supply is therefore not necessary.
– There are no adhesion phases with breakaway and thus no vibration stimulation.
– Damping is proportional to speed, this means that high frequencies or amplitudes lead to greater damping.
– The damping operates free of wear.
Heat build-up is dissipated through the large surface area of the housing.
Important: The secondary part can only move about the primary part by a certain fixed degree.
The Hydrodamp must not be mistaken for a fluid clutch.

6.02
OIL SYSTEM
P1 OIL SUPPLY HYDRAULIC SCHEME

CAPACITIES – SUPPLY QUANTITIES –
TYPES OF OIL – QUALITY OF OIL
FILTER CONFIGURATION – SERVICE INTERVALS
TOWING PROCEDURES
Hydraulic Scheme P1 (18 bar) and P2 (10 bar) circuits
1 Gear housing (tank)
2 Micro-filter β10 = 15 β30 = 20
3 By-pass valve
4 Coarse filter 200 µm
5 Gear pump V = 32 cm³ Q = 78 l/min at nMotor = 2300 rpm
6 Cold starting valve pmax = 25 bar (safety valve)
7 P1 – connection for external consumer, M10 x 1 thread
8 Power shift control block comprising:
P1 System pressure control 18 bar Channel plate
P2 Pilot pressure control 10 bar Control channels to the power shift clutches A, B, C, D, F, G
Solenoid valves Y21 to Y27 S21 Oil pressure control switch (breaker) switching point p = > 15 bar
Valve housing with hydraulic control sliders B32 Gearbox oil temperature sensor (PTC)
R at 20 °C approx. 1000 Ω , signal voltage approx. 2.5 VDC
R at 45 °C approx. 1150 Ω signal voltage 2.3 VDC
9 By-pass control valve thermo-controlled
Gearbox oil temperature < 55 °C 100 % oil cooler by-pass
Gearbox oil temperature > 70 °C 100 % through the oil cooler
10 Gearbox oil cooler
11 Lube-oil channels to: Power shift gearbox
6-speed synchronous gearbox
Driving clutch (main clutch)
Lube pressure at 80 °C oil temperature 1.2 to 1.5 bar
12 Lube pressure limiting valve pmax = 4 bar
13 Clutch operation master cylinder, circuit 1
14 Booster for clutch operation
Y1 4-wheel drive solenoid valve R = 10,3 Ω ± 10 %
Y5 Rear PTO solenoid valve R = 8,5 Ω ± 10 %
Y10 Differential lock(s) solenoid valve R = 8,5 Ω ± 10 %

P1 Pressure – Supply (18 bar)
1 Return feed connection – steering

2 Filter bowl
3 Micro-filter (main-stream filter) β10 = 15 β30 = 20
4 Filter – by-pass valve
5 Coarse filter
6 Bleed screw (open during filter change)
7 Suction pipe
8 Gear pump V = 32 cm³ Q = 78 l/min at nMotor = 2300 rpm
9 Pressure pipe
10 Cold starting valve pmax = 25 bar (safety valve for low pressure circuit)
11 Additional connection option for P1 pressure (M10 x 1 thread)
12 Pressure pipe
13 Hydraulic power shift control unit with P1 (18 bar) – and P2 (10 bar) pressure control
14 Hydr. control valve for forward and reverse driving
15 Oil feed run for gearbox lubrication – through the gearbox oil cooler M22 x 1.5 at above 70 °C
16 High pressure suction connection – hydraulic pump

Component Layout
1 3-way thermo-control valve

2 Oil cooler – short circuit line
3 Oil line to the oil cooler
4 Gearbox oil cooler
5 Oil line from the oil cooler to the power shift gearbox
6 Lube-oil connection M26 x 1.5 and lube pressure limiting valve (max. 4 bar)
7 Clutch booster – bleed line
8 P1 pressure line 18 bar to the booster
9 Slave cylinder, operating circuit Ι
10 Master cylinder, operating circuit ΙΙ
11 Pressure line to the slave cylinder ΙΙ
12 Slave cylinder ΙΙbleed point
13 Lube-oil connection for the rear axle
14 Lube pressure limiting valve (3 bar)
15 Return feed plate – hydraulics
16 Rear power take off (PTO) shaft
17 Pressure oil feed line P1 = 18 bar to Y5 and Y10
18 Lube-oil feed line to the PTO clutch and PTO gearbox
19 Pressure line from the PTO shaft control unit to the PTO clutch
20 Oil level viewing glass
21 Input shaft
S17 Neutral switch (motor start) colour green

S19 Neutral switch (gearbox electronics) colour red
S21 P1 oil pressure switch (closed at p = < 15 bar)
B12 Motor speed or power shift input speed Hall sensor
B7 PTO shaft speed Hall sensor

Gearbox oil cooling – circuit
1 3-way thermo-control valve

2 Short circuit line to the gearbox lubrication (path 2)
3 Oil line to the oil cooler (path 3)
4 The oil cooler is located behind the radiator grill
5 Line from the oil cooler to the gearbox lubrication
6 Lube-oil distribution
7 Lube pressure limiting valve pmax = 4 bar
Function:
– The total leakage losses in the power shift gearbox at an operating (oil) temperature of approx. 80 °C are nominally 5 - 6 l/min,
max. 10 l/min (provided that the mechanical condition is good).
– The remaining oil (QPump minus Qleakage losses) leaves the P1 control valve in the power shift control block in the direction of the 3-way
thermo-control valve.
– The thermo-control valve divides the oil flow as follows:
at a gearbox oil temperature of
a < 55 °C the total oil flow is fed through line 2.
b 55 °C to 70 °C an increasing amount of oil flows through the oil cooler as the temperature increases.
c > 70 °C the total oil flow is fed through the oil cooler
The lubrication pressure at pos. 6 is 1.2 - 1.5 bar at a gearbox oil temperature of 80 °C (acc. to the manufacturer).
With cold gearbox oil and high engine speed, the lube pressure limiting valve limits the lube pressure to max. 4 bar.

Oil supply, capacity, type, quality
Common oil supply (excluding planet gearing in the rear axle) for power shift gearbox, 6-speed synchronous gearbox, main clutch and
high pressure hydraulics, including steering.
Capacity 76 l – at normal oil level, lower marking
increased oil level for increased supply – see explanation
Oil supply (for external cylinders)
a at normal oil level, vehicle stationary on level ground max. 32 l
b at normal oil level, vehicle in motion and (or) max. 14° longitudinal or transversal slope max. 20 l
Only when the oil level is filled to the upper marking, is the amount available for supply increased by 8 litres.
Note: For normal operations, only fill to the normal oil level! (lower marking)
Type of oil E, E2 (STOU multi-purpose oil as gearbox oil)
Oil quality GL 4 or MIL-L-2104C/D or -E, or MIL-L-2105
in accordance with the ZF lubricants list TE-ML 06, edition 05.95
See approved oils, page 10
Planet gearing (rear axle)

Capacity 10 l each
Type of oil G2 (G-SAE 90)
Oil quality GL5 or MIL-L-2105 C/D
for further information, see lubricants – Operating Manual

Approved oils for Gearbox TW 7200, extract from the TF lubricant list TE-ML06, edition 05.95
Manufacturer Product
Agip Petroli SPA Agip Supertractor Universal
Agip Lubrication Technology Autol super – Tractor-Oil Univ.
Baywa AG Baywa Super 2000 CD-MC
German Shell AG Mac Tractor oil Universal TU
Elf Lubricants Tractorelf ST3
Elf Lubricants Antar Agria Super FM
Elf Lubricants Renault Diesel Agrimat oil
Fuchs Mineralölwerke Titan Hydramot 1030 MC
Klöckner Energiehandel GmbH Deutz Oil EHM-Universal 10W30
Klöckner Energiehandel GmbH Deutz Tractor Oil 1030 HC
Mobil Oil Mobil Agri Super
Shell International Shell Harvella T
Shell International Shell Harvella TX
Veba Oel AG Logenta Schlepper-Universal Oil

Oil and Filter change intervals
Gearbox (change both oil and the two filters cartridges at the same time)
initial change after 500 operating hours
second change: after 1000 operating hours
all subsequent changes: each after 1000 operating hours or at least once a year, check and top-up – see maintenance schedule.
Rear axle planetary gearing
initial change after 50 operating hours

second change: after 500 operating hours
third change: after 1000 operating hours
all subsequent changes: every 1000 operating hours or at least 1 x per year, check and top-up – see maintenance schedule.
To Figure – Oil filter and oil level viewing glass
1 Oil drainage plugs (3 off) – open all to change oil

2 Filler plug
3 Oil level viewing glass a Normal oil level
b increased oil level for increased external consumer supply
4 Gearbox bleed point
5 Hydraulic micro-filter
6 Gearbox micro-filter

Maintenance and Inspection Schedule
Operating 50 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000
hours
GEARBOX, HYDRAULIC SYSTEM
Check gearbox oil level, if necessary X X X X X X X X X X X X
top up (viewing glass)
Gearbox oil change (at least 1 x per year) X X X X X
Gearbox: replace both filter cartridges X X X X X
REAR AXLE PLANETARY GEARING

Rear axle planetary gearing (left and right) X X X X X X X X X X X
Check the oil level
Rear axle planetary gearing (left and right) X X X X X X
Oil change
FRONT AXLE
Check oil level (centre section) X X X X
Drive oil change (centre section) X X X X X
Planetary gearing oil change (left and right) X X X X X X X X X
Check wheel bearing play X X X X X X X X
POWER ASSISTED STEERING

Common Oil supply for transmission and
hydraulic systems

Maintenance and Inspection Schedule
Operating 50 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000
hours
BRAKES
Check brake system function X X X X X X X X X X
(see inspection booklet)
Change brake fluid (at least every 2 years) X X
Check compressed air system sealing X X X X X X X X X X
(pressure gauge)
GENERAL INFORMATION
Check for operational safety and X X To be checked by the vehicle owner
roadworthiness, repair as necessary
Check tighten all accessible securing X X X X X X X X X X
screws/bolts and flange connections
Check tighten connections for fuel, cooling,
water, intake, exhaust, hydraulic, steering and X X X X X X X X X X
brake lines
Check the function of all control elements X X X X X X X X X X
Lubricate all pressure lubrication points X X every 50 hours of operation or weekly
Check all control levers for freedom and ease X X
of movement
Check tighten wheel nuts X X X X X X X X X X
Electrical system functional check, battery X X X X X X X X X X
acid level
1. Mandatory check at 50 operating hours
2. Mandatory check at 250 operating hours
Minor inspection every 500 operating hours
(at least 1 x per year)
Major inspection every 1000 operating hours
(at least every 2 years)

Towing procedure
The following lever positions are an absolute must:
– Crawler gear lever to the "Normal" position

– 6-speed main gear lever to the "Neutral" position
Towing when the engine is running:
Gearbox system pressure 18 bar must be available, (gearbox oil pressure warning lamp on the instrument panel is OFF) working
hydraulic pump must be in operation (otherwise there is no rear axle lubrication).
Engine speed: 1200 - 1300 rpm

Towing speed: max. 30 km/h
Towing time: max. 2 hours
Towing when the engine is at a standstill:
Towing speed: max. 10 km/h

Towing time: max. 2 hours
Non-observance can lead to damage being caused to the gearbox!!

The gearbox oil level is 55 mm below the main gearbox shaft.No splash lubrication takes place.

6.03
MAIN CLUTCH
(DRIVING CLUTCH)
LAYOUT – DESIGN
DESIGN CHARACTERISTICS
LUBRICATION
OPERATION – first version
OPERATION – second version
FUNCTION – disengaging
FUNCTION – engaging
CLUTCH BOOSTER
WET DRIVING CLUTCH (main clutch)
Position: The driving clutch is located after the power shift gearbox and after the crawler gear shift (optional extra), at the
input to the 6-speed synchronised gearbox.
This greatly reduces the masses, which need to be accelerated or decelerated when shifting gear in the 6-speed
gearbox.
Version: Wet multiple disk clutch, 8 lining disks, 7 steel disks. Disk spring operated, is hydro-statically disengaged with
servo assistance (booster).
Adjustment (lining wear compensation): automatic
Special design features:
The steel disks are pressed to a sinusoidal shape. This prevents the disks from "clinging" to the oil film when
disengaging and guarantees, together with the special disk spring configuration (third, smaller
only takes effect during the first phase when engaging) a gentle, smooth engagement.
Lubrication: The clutch is not immersed in an oil bath. Lubrication pressure is supplied from within. The axial position of the
pressure piece controls the flow of oil. The cooling and lubrication oil is applied to the disks, from the centre, by
means of centrifugal force. Holes in the disk carrier and in the clutch bell housing allow sufficient oil to flow.
Grooves pressed into the clutch lining allow the entry of oil even when the clutch is engaged.
– The adequate cooling and lubrication during the engagement phase (dissipation of heat caused by friction)
guarantees a long life if operated correctly.
– In a disengaged condition, the oil feed is almost totally cut of by shifting the pressure ring.
This guarantees that the clutch fully disengages.
Permissible wear: The grooves in the clutch lining must remain visible.

Operation – Driving Clutch
Version, booster bottom right-hand side → ...
upper transverse ... →
Components:
1 Master cylinder, circuit 1 S46 Push rod switch (enable – reversing)

2 Expansion chamber B17 Angle of rotation sensor (enable – reversing)
3 Control line to the slave cylinder, circuit 1
4 Slave cylinder
5 Bleeding point, master cylinder, circuit 1
6 Bleeding point, slave cylinder, circuit 1
7 Master cylinder, circuit 2
8 Control line to the slave cylinder, circuit 2
9 Slave cylinder, circuit 2
10 Bleeding point, master cylinder, circuit 2
11 Bleeding point, slave cylinder, circuit 2
12 Driving clutch (main clutch)
13 Booster
14 P1 line (18 bar) to the booster
15 Bleeding point, booster (permanent)

Function
– The driving clutch is hydro-statically disengaged (assisted by the booster when the engine is running).
– The booster circuit is connected to circuit P1 (gearbox oil).
– Circuits Ιand ΙΙare factory filled with mineral brake fluid.
Note: Only top up the expansion chamber (2) with LHM (green in colour).
SLAVE CYLINDER 2 adjusts automatically.
Bleeding sequence:
Bleed circuit Ιby first opening bleed screw (5) and then bleed screw (6) with the engine at a standstill.
Bleed circuit ΙΙby first opening bleed screw (10) and then bleed screw (11), when doing so, pinch off line (15) and
run the engine at 1200 RPM. Do not operate the pedal.
Attention: The booster circuit is bled automatically when the engine is running.

Components:
1 Clutch shaft 15 Axial roller bearing

2 Pressure plate 16 Pressure spring
3 Disk carrier 17 Piston
4 Pressure piece 18 Pressure channel
5 End plate 19 Needle bearing
6 Packing ring – available from 2.6 mm to 5.3 mm 20 Axial roller bearing
/ in steps of 0.5 mm 21 Thrust washer
7 Outer disks – with lining, 8 off 22 Needle bearing 2 off
8 Inner disks – steel, sinusoidal, 7 off 23 Packing ring for axial play
9 Clutch bell housing 24 Slave cylinder, circuit ΙΙ
10 Circlip 25 ‘O’rings 2 off
11 Spacer rings 2 off 26 Lube-oil channel
12 Main disk springs 2 off 27 Lubrication hole
13 Auxiliary disk spring
14.1 Piston cup ∅ differing
14.2 Piston cup
Note: All types of tractor have the same number of disks in the driving clutch.

Note:
– When fitting new parts, the width of the packing ring (6) must be determined by measurement (seeWorkshop Manual).
– When replacing the clutch shaft (1) or adjacent, size relevant parts, the packing ring (23) must be determined by measurement
(see Workshop Manual). Clutch shaft axial play 0.2 + 0.1 mm.
Fitting instructions: New lining disks must be soaked in gearbox oil for a period of time prior to fitting.
Important: If in an exceptional case, the driving clutch is subjected to extreme loading several times in succession, cooling down
periods must be allowed for.
How: Gearshift to the neutral position

Engage the clutch (otherwise no cooling oil feed)
Increased engine speed
Note: In the course of a clutch repair, the disengager piston sealing gaiters and the ‘O’rings for the oil feed to the disengager
piston must be renewed and the surface of the piston and its freedom of movement must be checked.
Bleed the secondary clutch operating circuit.

a Clutch disengaged
– Hydraulic pressure from clutch operating circuit ΙΙmoves the piston in the clutch’s slave cylinder.
– This movement is transferred to the rotating pressure piece via the axial roller bearing, which presses the pressure plate against the
disk springs.
In doing so, the auxiliary spring is also tensioned.
– The clutch disks are now free. The torque transfer is interrupted.
– The sinusoidal shape of the steel disks assists the clutch in disengaging.
– The lube-oil feed to the disks is interrupted due to the pressure piece being moved on the clutch shaft.
b Clutch engaged
– As can be seen in the Illustration part a, in the disengaged state, both main spring disks are flattened and do not have their full
spring force in this condition.
– Engaging the clutch is therefore supported by the auxiliary disk spring. During the course of engagement, the main disk springs
become increasingly effective. The auxiliary disk spring, is on the other hand, released (see Illustration part b).
– The lube-oil feed is also reinstated during engagement – to lubricate and cool the disks.
(dissipation of heat caused by friction during engagement.)
– The helical spring causes the parts involved in disengagement to be advanced, this compensates for lining wear (clutch adjustment
is thus rendered superfluous).

Clutch booster – components
1 Booster housing
2 Booster piston
3 Retractor spring
4 Piston cup
5 Control slide
6 Slide spring
7 Inlet hole
8 Drain hole
9 Slave cylinder, circuit Ι
10 Piston – slave cylinder
11 Stop
12 Piston cup
13 Master cylinder, circuit Π
14 ‘O’ring
15 Piston cup
16 Filler disk
17 Filling hole
18 Pressure connection (from master cylinder, circuit Ι)
19 Bleeding point
20 Pressure connection to slave cylinder, circuit Π
21 P1 18 bar supply
22 Booster bleeding (automatic)
23 Bleeding point, slave cylinder, circuit Π

Clutch booster
Construction and function
– The slave cylinder from circuit Ιis also integrated into booster housing 1. The master cylinder from circuit ΙΙis flanged on opposite.
– The left-hand end of booster piston 2 is shaped to form the piston for the master cylinderΠ. It is returned to its original position by
means of the spring (3).
– Control slide 5 is located in booster cylinder 2 and can be shifted axially. This is kept permanently at its limit, with respect to the slave
cylinder 9, by the slide spring 6.
– The control slide 5 controls the in or outflow of pressure oil from circuit P1 for booster piston 2 by means of its control edges, together
with the control holes 7 and 8.
– The booster is bled automatically through bleed connection 22, when the engine is running.

Initial position
– Booster piston 2, the slave cylinder 10 piston and control slide 5 are all at their right-hand limits.
– The P1 pressure of 18 bar is present at the piston cup 4 and across the control hole 7 in control slide 5.
– Any leakage oil occurring can return to the gearbox oil via hole 8 and connection 22.
– Connections 18 and 20 are pressure free.
Clutch pedal depressed – disengaging

– Slave cylinder piston 10 is controlled by circuit Ιmaster cylinder (pedal) and moves the control slide (5) to the left. The control edge
allows the inflow of pressure oil through hole 7. P1 pressure takes effect on the ring area of the booster piston and moves this to the
left until hole 7 is covered once again.
– The master cylinder 13 displaces mineral medium to the slave cylinder Π directly at the driving clutch. This will be released.
Clutch pedal released – engaging

– Pistons 2 and 10 and control slide 5 return to their original positions. Pressure oil is released from the ring area to the right of booster
piston 2 through hole 7 If circuit Π needs replenishing with hydraulic fluid, this can be sucked in through hole 17 and the slightly raised
filler disk 16.

Service and maintenance work
Check for leaks and correct function in accordance with the customer service book or operating instructions.
Replace the mineral fluid LHM (green in colour) every 2000 operating hours or every 2 years at the latest.
Bleeding
Bleed circuit Ιusing the bleeding device or by pumping the pedal. (bleed nipples on the master and slave cylinders, only top up using
green coloured LHM).
Bleed circuit Π without pumping the pedal, squeeze the booster bleed hose instead. Allow the engine to run at 1300 RPM and bleed
circuit Π at the bleed nipples on the circuit Π master and slave cylinders (in doing so, Pentosin LHM will be replaced by gearbox oil).
Upon completion, check for correct function.
Must be completely disengaged at a min. of 75 % pedal travel.

6.04
GEARBOX – SECTIONAL DRAWING
LUBRICATION
SUPER CRAWLER GEAR
4-WHEEL DRIVE (MFD)
DIFFERENTIAL LOCK
POWER TAKE-OFF (PTO)
Gearbox lubrication
– All shafts in the power shift and synchronous gearboxes (with the exception of shaft 8) are pressure lubricated when the engine is
running (force fed lubrication).
– As well as all idler wheels, clutch disk and drive gearing bearing points.
– The main clutch is provided with additional cooling oil during engagement, to dissipate heat caused by friction.
Pressure oil feed
– From the power-shift gearbox bearing cover into drive shaft 1.
– From the power-shift bearing cover, through a lubrication pipe into countershaft 6, clutch shaft 5 and drive shaft 2.
– From the power-shift gearbox front housing into intermediate shaft 3, through the double gearwheel (crawler gear) or connection
pipe 11 (without crawler gear) into the main shaft 7 (bevel pinion).
– Shaft 8 runs in an oil bath. The lube-oil is fed to the parts to be lubricated by centrifugal force.
Lubrication pressure at an oil temperature of 80 °C at the gearbox inlet 1.2 - 1.5 bar, max 4 bar with colder oil.
GEARBOX – LONGITUDINAL CROSS SECTION – design
1 Drive shaft – with the power-shift clutches A and C

2 Drive shaft – with the power-shift clutches B and D Power-shift gearbox
3 Intermediate shaft – with the power-shift clutches F and G
4 Primary shaft
5 Clutch shaft (main clutch)
6 Countershaft
7 Main shaft (bevel pinion)
8 4-wheel drive shaft
9 Intermediate shaft to the hydro-pump drive
10 Intermediate shaft to the PTO shaft clutch
11 Crawler gear countershaft (double gearwheel)

Super crawler gear – see gearbox sectional drawing, page 2
– Versions fitted with a super crawler gear have a further 16 forward and reverse gear speeds available, for work requiring extremely
slow driving speeds.
– The following speeds are achieved at nominal engine speed:
Crawler gear engaged, 1st gear in the 6-speed gearbox and 1st power-shift stage v = 0.3 km/h
Crawler gear engaged, 4th gear in the 6-speed gearbox and 4th power-shift stage v = 2.6 km/h
Note: When the crawler gear is engaged, 5th and 6th gears in the synchronous gearbox are blocked by a pin between the shift
shafts.
– The crawler gear is fitted between the power shift gearbox and the main clutch. Shifting is synchronised and has 2 positions.
N = normal (forward)
Direct transmission from power shift drive shaft 2 to the main clutch.
SCG = Shift position Super Crawler Gear
The power train is from the power shift drive shaft 2 to crawler gear countershaft 11. From there to a gearwheel, which, in the
SCG shift position, transmits power to the main clutch.
The speed is reduced twice.
Attention: The power unit must not be subject to full load conditions with the gearshift in the SCG position!
Configuration in the gearbox

The gearshift N - SCG is located after the power shift gearbox but
before the main clutch and thus
ahead of the 6-speed synchronised gearbox
See gearbox sectional illustration, page 2.

4-wheel drive – see gearbox sectional illustration, page 2
General information
The 4-wheel drive is a multiple disk clutch.
It is engaged by means of a disk spring and electro-hydraulically disengaged.
The 4-wheel drive is situated under the main clutch and runs in an oil bath. It is encapsulated to prevent oil frothing.
Transmission is made via a helical spur gearwheel pair from the front-end of the gearbox main shaft (bevel pinion).
There is only one ratio per tractor type. This can differ between 40 km/h and 50 km/h versions
(see overview pages – Differences in Ratio).
The 4-wheel drive shaft is borne by a cylindrical roller bearing at the rear and a grooved ball bearing at the front (version C 3).
Pressure Oil Feed:
From the pressure oil channel in the gearbox housing, through two square profile rings in the 4-wheel drive shaft. The 18 bar
control pressure gains access to the piston and cylinder through two further square profile rings.
Clutch Slip Torque: 1700 - 2100 Nm

Differential lock – rear axle
Assembly
– Multi-disk lock with 100% locking value, electro-hydraulically controlled.

– The outer disks engage into the profile in a master gear, the inner disks can not turn with respect to the axle bevel gear.
– The disk piston carries 2 quad-rings as seals and a choke hole for quick disengagement of the lock when switched OFF.
– The differential housing cover is in the form of a cylinder.
Control:
P1 pressure (18 bar) is fed from solenoid valve Y10 via a pressure line to the differential bearing adjusting screw, which is sealed off
from the rear axle housing by 2 ‘O’rings (see Illustration on page 6).
– The adjusting screw has two metal square profile rings on a stepped extension (hidden in the illustration). This effects sealing to the
rotating differential housing.
– The piston has a pressure of 18 bar applied to it through a hole.
This compresses the disk package.

PTO shaft assembly
The standard version comprises a multi-disk clutch, which is switched by means of an electro-hydraulically operated control device. 4
different speeds can be selected 540 - 750 - 1000 - 1400 rpm.
These gears are shifted mechanically by a dog-clutch engagement, whereby one lever is for 540 – Neutral – 1000 and the second lever
shifts these speeds to fast – Economy 750 - 1400 rpm.
The standard PTO shaft stub is fitted with a 6-spline Ø 13/8 inch profile
Further options:
21 spline involute profile Ø 1 3/8 inch
or
20 spline involute profile Ø 1 ¾ inch
Attention: The maximum permissible power output for the 6-spline profile at 540 rpm is 58 kW (80 HP)
Note: Only operate the PTO shaft shift lever with the PTO shaft clutch disengaged

6.05
GEAR BOX – POWER FLOW
POWER SHIFT GEAR BOX – CONTROL

ARRANGEMENT – 3 SHAFTS
DIFFERENCES IN RATIO
OPERATION and ACTIVATION for
DRIVING, 4-WD, DIFFERENTIAL LOCK(S), PTO SHAFT
Power-shift gearbox
General information
The 4 stage power-shift unit including F/R is in exploded construction form, carried out according to the so-called 3 shaft principle.
The advantages of this construction are higher degree of efficiency, stable and compact design.
1 Drive shaft – with the power-shift clutches A and C
2 Drive shaft – with the power-shift clutches B and D
3 Intermediate shaft – with the power-shift clutches F and G
Basic function
The engine torque is fed to the power-shift unit drive shaft via the vibration absorber and the input shaft.
In the case of forwards motion, only the drive shaft and output shaft (1 and 2) and their power-shift clutches are involved in torque gear
box. The intermediate shaft (3) runs torque-free.
To reverse, the power flow is effected via the intermediate shaft (3) before it reaches the rear axle, via the drive shaft (2), crawler gear
group (optional equipment) main clutch and the 6-speed synchronous gearbox.
2 power-shift clutches must always be engaged, in order to transfer torque to the drive shaft!
The power-shift is in neutral after starting the engine and only clutch C is engaged. Furthermore, the FORWARDS direction was given
priority in the A88 electronics box (green "forwards" arrow flashing on the display), even if the engine was switched OFF after reversing.
The power-shift clutch is engaged by a P1 pressure of 18 bar (modulated pressure build-up).
The pressure oil feed to the rotating shafts or clutches is sealed by metallic square-profile rings.
The bearings and disk package are pressure lubricated with cooled oil.
A short intermediate shaft transfers the driving torque from the drive shaft to the hydraulic pump (P1 and high-pressure).
A profile in the hydraulic pump drive gear wheel transfers the driving torque to the rear PTO shaft clutch via a further intermediate shaft.
The disengaging power-shift clutch cylinders are emptied by the drain valves integrated into the pistons.

Gear box section – Power flow Forwards – Power-shift stage 1 - 6th gear, crawler gear shift in N position
– The engine torque is transferred to input shaft 4 via the vibration absorber with zero-loss. This is connected to drive shaft 1 via a
profile, which can not turn in respect to it.
– Drive shaft 1 drives the left-hand gear wheel via the profile, which at the same time serves as disk carrier for the internal disks of
clutch C.
– Clutch C is closed (engaged). Its external disks grip into the piston carrier which transfers the torque on to the external disk of clutch
A.
– Clutch A is also engaged. Its internal disks reach into the disk carrier, which represents a mutual component with the l gear wheel to
the right.
– The gear wheel meshes into the mating gear which is securely seated on drive shaft 2 to prevent it turning with respect to this.
– The sliding sleeve on the crawler gear shift is moved to the left, to the N position. A direct drive transfer occurs and drive shaft 2 drives
the main clutch (driving clutch) via the gear shift parts of the clutch housing.
– The main clutch is engaged through the force of the belleville springs.
– Clutch shaft 5 is driven by the disk carrier, it is fitted in intermediate shaft 6 over a profile to prevent it turning with respect to this.
– The 6th gear is engaged. The synchro-member fitted against turning with intermediate shaft 6, drives the 6th gear via the loose wheel
sliding sleeve. This meshes with the double gear wheel, which is fitted onto main shaft 7 so that it cannot turn with respect to it.
– The driving torque is transferred from the pinion to the rear axle.
4-wheel drive
– A drive gear is mounted at the front end of main shaft 7 to prevent turning. It drives the mating gear on the 4-wheel drive clutch.
This is engaged through the force of the belleville springs and drives the front axle via 4-wheel shaft 8 and the universal drive shaft.

Power-shift gear box power flow Forwards – stages 1 - 4
General information
P1 pressure (18 bar) is applied to clutch C when the engine is started, it is engaged. There is no drive and the drive shaft is stationary,
as no further action occurs without operating the driving clutch.
The power-shift gearbox is in neutral (at the same time, an N is shown on the display).
Stage I
Clutch C and A on the drive shaft are engaged.
After clutch A, a tooth meshing occurs up to the output shaft.
Ratio 1 : 0.6 and reversal of rotation.
Stage II
Clutches A and D are engaged
Power flow from the drive shaft via the first meshing to clutch D. Tooth meshing from its piston carrier to the piston carrier for clutch A.
Then to the drive shaft via a third meshing.
Ratio 1 : 0,8 and reversal of rotation.
Stage III
Clutches C and B are engaged
Power flow from the drive shaft via clutch C. Meshing to clutch B piston carrier.
Further via the drive shaft.
1 tooth meshing to the output drive shaft.
Ratio 1 : 1 and reversal of rotation.
Stage IV
Clutches D and B are engaged
Power flow from the drive shaft via meshing to clutch D piston carrier. From clutch B to the output drive shaft.
1 tooth meshing to the output drive shaft and reversal of rotation
Ratio 1 : 1.2 and reversal of rotation
Note: In the case of forward travel, no power flow occurs via the intermediate shaft

Power-shift gear box power flow Reverse – stages 1 - 4
Stage I
Clutches C and F are engaged.
Power flow from the drive shaft via clutch C piston carrier to clutch F piston carrier of (one tooth meshing). One tooth meshing from
clutch F to the output drive shaft.
Ratio 1 : 0.6
2 meshings – between the input and output drive shafts – no reversal of rotation .
Stage II
Clutches D and F are engaged.
Power flow from the drive shaft via tooth meshing to clutch D piston carrier. From there, tooth meshing to clutch C and clutch A piston
carriers, but neither of the clutches are engaged. From there, tooth meshing to clutch F piston carrier. Further via tooth meshing to the
output drive shaft.
Ratio 1 : 0.8 – no reversal of rotation.
4 meshings
Stage III
Clutches C and G are engaged.
Power flow from the drive shaft via clutch C and its piston carrier to meshing with the piston carrier from clutch G. Via the clutch to the
intermediate shaft. From there to the output drive shaft via meshing.
Ratio 1 : 1 – no reversal of rotation.
2 meshings
Stage IV
Clutches D and G are engaged.
Power flow from the drive shaft to clutch D via meshing. Meshing occurs from its piston carrier to the piston carriers of clutches C and A.
Clutches C and A are not engaged. From here, tooth meshing onto the piston carrier of clutch G. Via clutch G to the intermediate shaft.
Further with meshing onto the output drive shaft.
Ratio 1 : 1.2 – no reversal of rotation
4 meshings

Ratio differences in the drive unit according to type
STEYR and CASE 9105 / CS 110 9115 / CS 120 9125 / CS 130 9145 / CS 150
40 km/h T7224L T7226L T7226L T7228L
Power-shift gearbox
incl. F / R
No. of lining disks 7 8 9

PS clutch
Super crawler gear
6 speed gearbox 6th gear i = 1 : 2,07
MD i = 5.25 : 1
Pinion / spur bevel gear
MD
Planetary gear unit i = 8.25 : 1 i = 9.56 : 1
4-wheel drive i=2:1 i = 2.06 :1 i = 2.41 : 1

Ratio differences in the drive unit according to type
STEYR and CASE 9105 / CS 110 9115 / CS 120 9125 / CS 130 9145 / CS 150
50 km/h T7224L T7226L T7226L T7228L
Power-shift gearbox
incl. F / R
No. of PS clutch lining 7 8 9

disks
Super crawler gear
6 speed gearbox 6th gear i = 1 : 2,19
MD i = 5.25 : 1 i = 4.82 : 1
Pinion / spur bevel gear
MD i = 8.25 : 1 i = 9.56 : 1
Planetary gear unit
4-wheel drive i=2:1 i = 2.06 :1 i = 2.2 : 1

Control of the 4-speed power-shift and reversing gearbox
The 4 power-shift gearbox speeds and F/R are electro-hydraulically shifted via the Multicontroller. Its own electronics system is
responsible for the implementation of the required shift and reverse sequences.
According to the driving situation, the electronics system also has the task of building up the pressure in the gear shift clutch in such a
way that gear shifting is always smooth.
FIELD CHARACTERISTIC CURVE: Extremely quick gear shifts are realised for field operation (heavy pulling work under 15 km/h)
via the field characteristic curve, which means that no pulling power interruptions and speed
reductions can arise.
ROAD CHARACTERISTIC CURVE: Smooth gear shifts are realised for transportation work (over 15 km/h) via the road
characteristic curve, so that jerky gear shifting is prevented.
The electronics system selects the correct shift time dependant on the oil temperature and driving speed.
Reversing is possible up to a max. travel speed of 10 km/h. If, at a higher travel speed, the opposite direction should be preselected and
triggered by pressing the clutch pedal, the electronic system automatically switches the gearbox to neutral for safety reasons, at the
same time a warning peep is emitted and Neutral is shown on the display. The electronics system is provided with a self diagnosis facility
and can display an error code in the case of a fault.
The electronics system is also able to monitor the rotational speed variations between power-shift input and output in each stage. The
correct transmission of stages 1 to 4 is stored in the software. If a deviating speed variation now occurs, this is a sign that the clutch is
slipping. Solenoid valves Y21 / Y22 and Y26 / Y27 are now toggled. That means that the solenoid valves which are ON, are switched
OFF and those which are switched OFF are switched ON for a period of 100 ms. If the clutch still slips, the relevant valve Y21 or Y22 is
switched OFF, the power-shift is blocked and an error code is shown. The same applies for Forward / Reverse Y26 / Y27, except that
switching these valves OFF leads to a "Neutral" setting. A fault is also indicated.

Tape end programming: Codes for gearbox variants
Type Type Veh. No. Imp./rev.• Electronic Software Veh. vmax Gearbox
CS Steyr ndrive nON/nOFF Control Configuration km/h variants
T-7224 L
110 HP 105 HP
T-7226 L
120 HP 115 HP 46/53 40 04
T-7226 L
130 HP 125 HP
T-7228 L 46/43 02
150 HP 145 HP 31 F2
T-7224 L 02
110 HP 105 HP
T-7226 L 46/53 50 04
120 HP 115 HP
T-7226 L
130 HP 125 HP
T-7228 L 46/43 02
150 HP 145 HP

DRIVING – Operating and control elements
MC Multi-Controller Pre-select direction of travel and select power-shift level

and
Gear shift lever engage gear with the lever
N-SKG gear shift lever Pre-select position N or SKG
Clutch pedal disengage and engage (main clutch)
S46 push-rod switch enables the power-shift clutch to be engaged
B17 angle of rotation sensor
S19 checks whether in gear or not
B32 influences pressure modulation during power shift
B12 speed sensor feeds speed signals – power-shift input on power-shift box A88
B5 speed sensor feeds speed signals – power-shift output on power-shift box A88
Attention: Use spacer block s = 2.5 mm when assembling sensor B5 for the following versions, otherwise it will be destroyed
by the transmitter wheel (gear wheel)
T7228L Types 9145 and CS150, 40 km/h and 50 km/h version
T7224L Types 9105 and CS110, 50 km/h version
B6 speed sensor feeds speed signal – speed of travel
1 hydr. power-shift control unit Y21 - Y27 triggered by A88
Y21 - Y27 control hydraulic valves
hydraulic valves (sliders) control the power-shift clutches

MULTICONTROLLER "Driving" operating elements
General information
A 3-way function is mounted on the Multi-controller gear lever, in order to initiate drive commands in the drive unit.
a) Handle Operation of the gear lever, in order to select gears 1 - 6 (1 - 4 with crawler gear switched
ON) in the synchronous gearbox, when the clutch pedal is operated
b) Pre-select direction of travel is actived when the clutch pedal is operated
c) Select the power-shift levels shift up (1 - 4) or down. The power-shift commands are immediately effective.
Note: a) Place your hand against the handle to shift the gears
b) Put the gear lever in neutral to start the engine.

4-wheel drive (MFD) – Operation
4-wheel drive switched OFF
– Switch S2/59 in position 0 = OFF

– Solenoid valve Y1 is charged.
– P1 (18 bar) forces piston 4 against belleville spring 8 until it engages (s = 2.0 ± 0.3 mm).
– The disks are released, the power flow is interrupted. The gear wheel is borne on shaft 1. It can now turn freely against the shaft.
Lubrication: Shaft 1 is below the gearbox oil level. Oil is fed by centrifugal force.
– Stationary metal encapsulation 10 prevents oil frothing.
– 2 metal square profile rings are used as the gearbox housing pressure oil seal to shaft 1 and from shaft 1 to cylinder 2
(in gear wheel F).
Note: Position the open side of the piston ring towards cylinder 2 when assembling.
Optistop: The 4-wheel drive is automatically switched ON by operating both brake pedals.
4-wheel switched ON
1 Switch S2/59 in position I = "permanently on"

2 Switch S2/59 in Auto position = management
2a v = < 14 km/h
2b v = > 14 km/h simultaneous brake operation (Optistop)
– Solenoid valve Y1 is not charged.
– P1 (18 bar) is blocked by Y1.
– Belleville spring 8 presses the disk package together via piston 4, thrust bolt 5 and adjustment wheel 9.
The 4-wheel clutch is engaged.
The 4-wheel clutch simultaneously serves as an overload protection device
Slip torque = 1700 - 2100 Nm

Differential lock – rear axle
Control
S2/56 Switch – Operation of differential lock(s)

Y10 Solenoid valve – Differential lock(s)
1 P1 pressure line 18 bar – to Y10 and Y5
2 Control line to the front differential lock
3 Test connection to rear differential lock M14 x 1.5
4 Control line to rear differential lock (inner)
5 Disk differential lock
Switch-on sequence
– P1 pressure (18 bar) is applied to solenoid valve Y10 when the engine is running (Test possibility M10 x 1 on the PTO shaft control
unit).
– For versions with differential lock(s) management, the "lower" function must be selected on the power lift operating panel on the Multi-
controller.
– Select switch S2/56 to the Auto or I (permanent) position.
– Y10 is controlled via relay connection with 12 VDC.
– P1 (18 bar) pressure is applied to the piston in the differential housing. The differential lock disks are engaged.
If the management facility is fitted, the differential lock is automatically switched OFF by 3 functions.
a) Steering brake automatically back ON
b) "Transport" power lift automatically back ON
c) v = > 14 km/h (must be switched on manually for v = < 14 km/h).
Test facility (hydraulic): Item 3 (M14 x 1.5)
Y10 R = 8.5 Ω ± 10 % Ι= approx. 1.5 amp (cold)

PTO shaft – Operating and control elements
Switch-on sequence
P1 (18 bar) is present as far as Y5 when the engine is running.
540 - 1000
the speed can be pre-selected when S2/70/2 is OFF (touch once):
N - ECO
Oil can Lubricating pressure is always present if the engine is running.
S2/70/2 press at intervals in the "ON" position:
Y5 (hydr. control valve) is pulse-controlled
S2/70/2 hold in the "ON" position for at least 3 sec:
Y5 remains activated
6 Continuous pressure build-up in the control line (modulated by Y5) up to 18 bar
PTO modulated controlled start-up
B7 delivers speed signals from the PTO to the instrument
S2/71 activating the management function
Note: a The generator charging indicator should be out after starting the engine, in order to be able to switch the PTO ON.
b In addition, for versions with PTO management, the power lift must be selected to the "Lower" function on the Multi-
controller.
c The PTO shaft management can only be activated with S2/71, when the PTO has been switched ON with S2/70/2.

PTO - activation
1 PTO shaft gearbox – mounted from the rear into the rear axle housing
2 PTO flange stub – 3 versions are possible:
Type 1 6 spline Profile ∅ 1 3/8 inch Poff = 58 kW (80 HP) at 540 rpm
Type 2 21 teeth Involute profile ∅ 1 3/8 inch
Type 3 20 teeth Involute profile ∅ 1 3/4 inch
Dry changeover possible, screw tightening torque (M12 - 10.9) 110 Nm
3 Shifting from Normal – ECO
4 Shifting 540 - 1000
5 Pressure lubrication
6 Control line – PTO ON p = 18 bar
7 Control valve – Clutch lubrication
a PTO switched OFF = low quantity of lubricating oil
b PTO switched ON = large quantity of lubricating oil plus cooling and lubrication of the clutch disks
Y5 Solenoid valve for PTO (electronically activated)
Y10 Solenoid valve for differential lock(s)
B7 Speed sensor (passive), PTO speed signal fed to A1 (armature) according to Hall principle
Signal: Square wave signal, 20 pulses per revolution

Description of PTO shaft control unit
1 The solenoid valve is supplied with 12 VDC for PTO ON.

2 The ball controls the start-up pressure.
3 The compression spring acts upon the ball.
4 The piston is a variable stop for the compression spring.
5 The pin is fitted in the control channel as choke for the piston.
6 The stop screw limits the pin’s travel.

PTO shaft control unit function
1. PTO shaft OFF

– 0 V at the solenoid (not supplied)
– Connection A is attached to connection T via the solenoid valve control slide.
– Connection P is blocked, a system pressure of 18 bar is applied here when the engine is running.
2. Starting up the PTO

– The solenoid valve is supplied with 12 VDC.
– The control slide in the solenoid valve opens the link from connection P to connection A.
– The system pressure travels from connection P over the tranverse hole to the upper side of the ball, which is opens at approx.
2 bar.
The link to connection T is then opened. Only 2 bar is present in connection A at this time.
– This pressure acts on the underside of the piston, across the defined gap between the hole and pin 5.
– In this way, the piston is driven upwards and pre-tensions the pressure spring in doing so.
– The ball is moved in the direction of its seat and the opening cross-section reduces through the increased pre-tension on the
spring.
– The pressure in connection A increases, due to the continuous reduction in size of the opening’s cross-section.
3. PTO shaft ON
– The ball is pressed into the seat, the link between connections A and T is closed.
– The full system pressure of 18 bar now acts in connection A, and thus in the PTO shaft multiple disk clutch.

6.06
HYDR. POWER SHIFT CONTROL BLOCK
TASKS, CONSTRUCTION
REMOVING AND FITTING the CONTROL BLOCK
CONTROL OF P1 (18 bar) SYSTEM PRESSURE and
P2 (10 bar) PILOT CONTROL PRESSURE
SHIFT SEQUENCE
PRESSURE MODULATION
POWER-SHIFT TROUBLESHOOTING
Tasks of the hydr. power-shift control
– P1 pressure control (System pressure 18 bar)

– P2 pressure control (Pilot control pressure 10 bar)
– Activation of the hydraulic control elements (slider, piston) through the pilot control - solenoid valve Y21 - 28 for each of the selected
transmission ranges (1-4), forward or reverse
– Activation of the corresponding power-shift clutches
– Pressure modulation for closing clutches
– Pressure build-up corresponding to the control command from electronics box A88, dependant on
a driving speed
b gearbox oil temperature field or road travel mode
c whether shifting up or down
– Closing of more than 2 clutches is prevented
– Emergency driving option for electrical or electronics failures
– Message for fault display and warning via S21 at a system pressure drop of p < 15 bar.

VH Valve housing
V / RH Forward / reverse housing
S Stop
SP Stop plate
X6 6-pole plug for Y21 - Y25
Components for control pressure regulation
P1 Control valve for P1 system pressure 18 bar

P2 Control valve for pilot control pressure 10 bar
Components for F / R control
Y26 Solenoid valve for forward

Y27 Solenoid valve for reverse
1 F / R control valve activated by Y26 or Y27
2 Reset valves for F / R control slide – neutral position
3 Piston
X3 3-pole plug for Y26 and Y27 (on F / R housing), not visible in the diagram.
Components for shifting stages 1 - 4
Y21 Solenoid valve to activate G1

G1 Gear valve 1 (clutches A / B and F / G)
Y24 Solenoid valve to activate H1 retaining valve 1
Y22 Solenoid valve to activate G2 gear valve 2 (clutches C / D)
Y23 Solenoid valve to activate H2 retaining valve 2

Pressure modulation components
M Modulation valve
B Bleed valve
R Reset valve
Components for field-road travel mode changeover
Y25 Solenoid valve to activate reversing valve U

R Reversing valve
T Two stages - piston
PR Push rod
Safety shift components
S1 Safety valve 1
S2 Safety valve 2 (in F / R valve housing)
S Shuttle valve (see hydraulics scheme for function) positioned in the channel plate (see workshop manual)

Hydraulic power-shift control
Connection flange on the power-shift gearbox
A
B
C Pressure channels to power-shift clutches A to G
D
F
G
K Housing hole closed by ball
M8 M8 thread for 40 fastening screws.
Observe the different lengths
Tightening torque 23 Nm
Tightening sequence from right to left
R (T) the remaining holes (differing diameters) enable return to the sump (tank)
Note: Use new seals every time the control unit is fitted.

Fitting – Arrangement (Sandwich) of the hydr. control block
1 Flange surface on the power-shift gearbox housing (right)

↓
2 Seal
↓
3 Shim
↓
4 Seal
↓
5 Ball and spring -----------------
↓
6 Channel plate
↓ ↓
7 Seal Seal 11
↓ ↓
8 Shim Shim 12
↓ ↓
9 Seal Seal 13
---------------------- SP stop plate
↓ ↓
10 F / R housing Valve housing 14
Note: NEVER replace the original seals with liquid sealing compound.
Consequences: Malfunction due to chokes being blocked and danger of control slides jamming.

Removing and fitting the hydr. Control block / see workshop manual 8.01 - 8.05
Important notes must be observed
Removal
– When removing the fastening screws, do not lose the special washers and pay attention the differing screw lengths.
– Stop plate SP can fall out when removing the valve housing (see "component arrangement" diagram, page 4).
– Only remove the channel plate together with the shim. Otherwise, the ball and spring of one of thereset valves will fall out.
– When removing the control unit, do not tear the seals in the course of troubleshooting, in order to easily determine leaks (tearsduring
operation).
Fitting
– Check the surface of the connection flanges on the gearbox housing and holes (also thread) for cleanliness.
– Correctly position the centering pins (4) as per the workshop manual (special tool).
– Do not mix up the seals. The grooves and holes in the seals are different in front of and behind the shims.
– Before fitting the channel plate, insert the ball and spring (non-return valve) from the rear side with a minimum amount of oil soluble
grease.
– If removed, fit the speed sensor (power-shift output speed) BEFORE the valve housing, otherwise fitting is no longer possible
– Likewise, check the front side of the channel plate BEFORE assembly, to see whether the component parts of shuttle valve W are
present and fitted in the correct order:
1 Plastic ball
2 Disk – with collar to the outside see workshop manual
3 ‘O’ring
– Choke 2 must also be present and fixed with Loctite 242 (new number 243) (see workshop manual).
Note: When removing or fitting rotational speed sensor B5, the switch housing (rear of valve housing) must be removed if the
valve housing is fitted. Only proceed according to the workshop manual and use centering pins (special tools).
Attention: The force of pressure on the switch housing is from the slider return springs. Sliders and springs could fall out.
Clean the vicinity prior to this.

Control P1 18 bar – and P2 10 bar
P1 18 bar system pressure for power-shift unit

P2 10 bar pilot control pressure (parallel supply of solenoid valves Y21 - Y27)
Components:
1 Cold start valve Pmax = 25 bar (integrated in pump drive housing)
P1 Governor slide valve, pressure 18 bar
P2 Governor slide valve pressure 10 bar (pilot control pressure)
2 Adjuster wheel for P1 pressure
P1 pressure regulation function

– The pump oil flow enters the control housing from below when the motor is running.
– Pressure reaches the left-hand front surface through a control hole in slide valve 2.
– The force if the return spring is overcome at a pressure of 18 bar and the control slider is moved so far towards the right thatits
control edge opens the cross-section partially.
– The sum of the leakage loss in power-shift section 5 amounts to up to 6 l / min at working temperature.
– The remaining oil flow, i.e. the larger portion of the total flow, now flows out of the control housing and eitherdirectly – or through the
gearbox oil cooler to the gearbox lubrication.
P2 pressure regulation function

– Supplied by P1 pressure, the slider regulates the P2 pilot control pressure of 10 bar. This is applied in parallel to the solenoid valves
Y21 to Y27.
Safety
– The cold start valve opens as soon as P1 pressure achieves 25 bar for the following reasons:
a P1 regulator slider, stiff
b Control hole in P1 regulator slider is blocked
c Gear oil viscosity too high (extremely low temperatures)
d Slider in the lubricaton pressure control valve is stiff (pressure accumulation)
Oil flows directly back into the sump if the cold start valve is open.

Shift example: Power-shift level 2 – forwards active shift elements
Y26 supplied
1 regulator slider F / R from Y26 with P2 (10 bar) activated by piston 3.
Y21 supplied
G1 gear valve 1 from Y21 activated by P2
Y24 energised for a short period (t < 2 sec)
H1 activated by Y24 with P2 for a short time and is hydraulically reset by S1 and S2 to the "field" mode.
Y22 supplied
G2 gear valve 2 from Y22 activated by P2
Y23 energised for a short period (t < 2 sec)
H2 activated by Y23 with P2 for a short time and hydraulically reset by S1 and S2 in the "field" mode.
Safety circuit
Should Y23 or Y24 (or both) not be switched OFF – depending on whether the fault is in the electric or electronic system – or should the
control slider of one of these valves not return to its starting position due to dirt or any other reason, at least one retaining valve (H1 or
H2) would remain active.
Subsequently, at least one of the power-shift clutches would be under too much pressure. The power-shift gearbox would block itself
and slow down the engine.
In order to prevent this, the retaining valves are reset via S1 and S2 when a modulation pressure of 9 bar (pressure in the
clutches which are engaging) has been achieved in the "field" or "road" mode.
Note: The modulated pressure build-up follows a set characteristic line (see modulation)

Hydraulic scheme – Power-shift control block
– The shift sequences of the individual levels can be re-enacted in the hydraulic schema.
– The situation which is represented is "neutral" in the power-shift gearbox. (Situation after engine start, only clutch C is closed).
– In the upper left-hand box, you can see
a which gear valve is shifted in which driving stage
b which retaining valve is activated for a short time
c which power-shift clutches are closed and when
d on which measuring points and in which shift stages pressure is applied.
Attention:
Pressure modulation is described in greater detail later on in this chapter.
Legend:
continous red line P1 system pressure 18 bar
broken red line modulated pressure (18 bar after shift sequence)
violet P2 pilot control pressure 10 bar
green lubrication pressure
yellow return (tank)

Pressure modulation – components
M Modulation valve
M1 Control slide
M2 Cocking slider
B Bleed valve
R Reset valve
T Two stage-piston hydraulically activated by P1 in the "field" mode
PR Push rod
R Reversing valve hydraulically activated by Y25 and with P2 in "road" mode
Y25 Solenoid valve
Note: Control slider M1

Bleeder valve E are in motion during each shift sequence, regardless of the mode
Return slider R

Power-shift and F / R
Pressure modulation – general
Pressure modulation has the task of controlling one of the constructive, layout-appropriate pressure build-up in each of the power-
shift clutches to be engaged, for each newly initiated shift sequence in the 4 stage power-shift or forwards / reverse shift, triggered by
operating the corresponding button on the Multi-controller.
The pressure gradient is adapted to the current driving conditions through the targeted influence of further control elements arranged
outside the pressure modulation.
The pressure gradient is the pressure increase per unit of time

It should not exceed 10 bar per second
The pressure modulation recongises 2 different modes:
"field" mode – also known as hard shift

Conditions: v = < 15 km/h or (and) the gear oil temperature is < 45 degrees centigrade.
The pressure modulation follows a steeper characteristic line in this shift mode, in this way, pressure builds up in a short period of
time (t = < 1 sec.).
"road" mode – also known as soft shift

Conditions: v = < 15 km/h and the gear oil temperature is < 45 degrees centigrade
PRESSURE MODULATION IS INFLUENCED BY DRIVING SPEED AND

BY THE GEARBOX OIL TEMPERATURE.
Solenoid valve Y25 is activated by the gearbox electronics in order to change from the "field" to the "road" mode.
It always remains energised in the "road" mode.

PRESSURE MODULATION VALVE
Starting pressure (see pressure diagram)
– The control cross-section is completely open until the starting pressure is achieved. The air play of the clutch(es) is raised quickly and
the disks are applied lightly.
– Pressure modulation is applied after achieving the starting pressure.
– The starting pressure should be 3.5 bar ± 0.2 bar in the "road" mode. The starting pressure is substantially higher in the "field" mode
(approx. 8 - 9 bar).
– Starting pressure is determined by the length of the piston in the 2 stage valve.
– The piston carries the ZF spare part number on its inner face as identification.
– 5 different piston lengths are available.
ZF piston SP-No.: 2093 352 087 fitted in production.

CASE STEYR SP-No.:
Starting pressure too HIGH: Fit shorter piston

ZF SP-No.: 2093 352 086 Starting pressure sinks by 0.3 bar
CASE STEYR SP-No.:
ZF SP-No.: 2093 352 085 Starting pressure sinks by 0,6 bar
CASE STEYR SP-No.:
ZF SP-No.: 2093 352 084 Starting pressure sinks by 0.9 bar
CASE STEYR SP-No.:
Starting pressure too LOW: Fit longer piston

ZF SP-No.: 2093 352 088 Starting pressure increases by 0.3 bar
CASE STEYR SP-No.:
ZF SP-No.: 2093 352 089 Starting pressure increases by 0.6 bar
CASE STEYR SP-No.:
Important: Using a pressure recorder, a pressure characteristic line must be recorded and analysed for both the
"field" and "road" gear shift before another piston is fitted.

Pressure control ramp "Road" and "field" characteristic curve
– The C2 shutter determines the pressure gradient of the pressure control ramp for the "road" and "field" characteristic curve.
– The pressure gradient is the pressure increase per unit of time during pressure modulation (see diagram).
The permitted value is 10 ± 1 bar / sec.
– The pressure gradient is determined with 2 measuring points which are recorded within a specific time interval.
– 4 C2 shutters with differing hole diameters are available.
– The shutters can be identified by a series of grooves or notches.
If the pressure ramp is too flat, use the next larger C2 shutter.
C2 shutter ∅ SP-No. Designation
Series 0.65 mm ZF 2093 352 070 1 width Groove
CASE STEYR
0.70 mm ZF 2093 352 046 3 Notches
CASE STEYR
0.75 mm ZF 2093 352 047 2 Notches
CASE STEYR
0.80 mm ZF 2093 352 049 1 Notch
Important: Using a pressure recorder, a pressure characteristic line must be recorded and analysed for both the "field" and
"road" gear shift before another piston is fitted.

Pressure modulation – Starting position
An operating status between two power-shift sequences serves as starting position, in order to better understand the automatic
introduction of pressure modulation.
– An oil pressure of 18 bar is constantly applied on shutter C1.

– Only a small volume flows to the pressurised clutches (compensation for the leakage loss on the square profile rings of the
compressed oil feed to the LS clutches).
– For this reason, no pressure drop worth mentioning arises at shutter C1 and an 18 bar pressure remains on the engaged clutches.
– As a pressure of > 14 bar acts on the return slider, the hydraulic force from the left predominates the mechanical force of the spring.
– The full control pressure has a connection on the return valve and supports the tension force of the tension springs.
The control valve remains to the left at its limit and the control opening is completely open.
– 18 bar pressure also acts on both faces of the bleed valve. The hydraulic forces on it are balanced as a result.
In addition, the spring resistance also has an effect. The position of the slider holds the chamber vent open.
– The tensioning slider remains in the right-hand limit position and holds the piston of the 2 stage valve to the right, against the 18 bar
pressure, via the push rod.

Pressure modulation – Initiating a power shift
– A corresponding key is pressed on the Multi-controller.

– Subsequently, at least one slider changes a gear valve or a F / R slider (dependant on the shift stage).
– The hydraulic connection is produced between the pressure modulation output and at least one released, depressurised
power-shift clutch.
– A larger volume could flow at the point when the clutch fills up, as the piston in the clutch must first overcome an air play ofapprox.
4 mm before the clutch disks are pressed together.
– The C1 shutter which is arranged in front of the pressure modulation only releases a limited volume of flow.
– As a result, the pressure in the pressure modulation collapses except for a residual value and return valve slider returns to the
left into its starting position. The chamber between the pressure control valve slider is bled.
The pressure modulation is only automatically initiated through this sequences.
– The entire pressure build-up is made up of 3 sections:
a Clutch filling – is ended when the starting pressure is achieved.
b Pressure modulation – more linear, controlled pressure increase between p = starting pressure and p = 14 bar.
c More rapid pressure increase from 14 bar to 18 bar (see pressure diagram).
The starting pressure in the "road" mode should be 3.5 bar ± 0.2 bar (constructive stipulation).
The starting pressure is substantially higher in the "field" mode, between 8 and 9 bar.
– The control slider is positioned to the far left and the control cross section is completely open, until the starting pressure is
achieved.

Pressure modulation – more linear pressure build-up after achieving the starting pressure
– Starting pressure filling time is achieved after approx. 0.2 sec in the "road" and "field" modes.
– The hydraulic force overcomes the force of the tension springs and moves the control slider to the right. The control cross-
section is substantially reduced.
The pressure characteristic line bends and now runs less steeply.
– Meanwhile, the modulation pressure builds up further linearly. A permanent connection to the front of the slider in thebleed valve is
made through the C2 shutter.
– The ventilation slider is moved against the spring as soon as the modulation pressure is p > 7 bar. The current modulation pressure
acts on the tension slider from the right. This pre-tensions the tension springs to an equilibrium of forces.
– As the increasing modulation pressure now acts on both sliders in the pressure control valve at the same time, the control
cross section is not completely cut off.
– The full engine torque can be transmitted from a pressure of approx. 14 bar in the power-shift clutch.
– The return slider is moved against the spring as soon as p > 14 bar. The modulation pressure supports the expanding force of the
tension springs.
– Both pressure control valve sliders are moved instantly to the outside. The control cross-section is completely open.
– From this moment on, the full system pressure of 18 bar acts on the power-shift clutch which just engaged.
(Look at the kink in the characteristic line again, this time in steep ascent).

Power-shift and F/R
Pressure modulation – differences in sequences for "road" and "field" modes.
"Road" mode – soft shifting – slower pressure build-up, course of the characteristic curve is flatter.
– Solenoid valve Y25 ("field"– "road" valve) is energised by the gearbox electronic system.
– In this way, the 10 bar pilot control pressure reaches the reverse valve and moves the slider against its spring.
– The 18 bar channel in the reverse valve is cut off and chamber is bled of air.
– The tension springs press the tension sliders and with that, also the push rod and the 2 stage piston to the right.
– The end position of the tension slider is determined by the length of the 2 stage piston.
– In general, the result is a low spring pre-tension between the springs in pressure control valve A.
– The control slider is moved to the right and pressure modulation is applied after achieving p = 3.5 bar (starting pressure in "road"
mode).
– A small control cross-section appears during pressure modulation as the tension springs are less pre-tensioned.
Pressure build-up occurs more slowly.
"Field" mode – hard shifting – more rapid pressure build-up, course of the characteristic curve is steeper.
– Solenoid valve Y25 is not energised.

– The reverse valve steers 18 bar into chamber i.
– The 2 stage piston pushes the tension slider to the left via the push rod.
– Pre-tension on the tension springs is increased. A starting pressure of 8 to 9 bar must be achieved so that the control slider
moves to the right.
– The control cross-section is reduced by less than in "road" mode.
– Pressure increase occurs more quickly, this is why the characteristic line is steeper.
– After modulation pressure has achieved 9 bar, the hydraulic retaining valves are reset after the safety valves have reached a
system pressure of 18 bar. The clutches to be disengaged are instantly relieved of pressure.
– Solenoid retaining valves Y23 and Y24 are switched OFF several tenths of a second later by the gearbox electronics system.

"Road" mode
Function
– Y25 is energised by gearbox electronic system A88.

– Pressure P2 (10 bar) moves the reverse valve (U) slider against the return spring.
– Pressure P1 (18 bar) is cut off and the chamber to the left of the two-stage piston (Z) can be bled of air.
– The tension springs in the pressure modulation valve move the tension slider, push rod and 2 stage piston to the left.
– Due to the low pre-tension force of the tension springs, the modulation pressure which is building up moves during the next power-
shift (At the same time, pressure in the engaging power-shift clutch) moves the control slider slightly to the left at 3.5 bar (starting
pressure).
– The control slider reduces the control cross-section. A more linear pressure build-up with flatter characteristic curve results.
Note: In the case or the failure of Y25, or for specific faults in the electrics or electronics of the power-shift
control system, the hydraulic control system returns to the ”field”mode.

Gearshift forward from 3rd to 4th ratio in the "field" mode (curves recorded in the practical example with a printer)
compare
a Increase – pressure build-up in the clutch D
b Stop period for the clutch C
c Total shift time until characteristic line kink
d Starting pressure – pressure at the start of modulation
e Pressure gradient – pressure increase in bar per sec.
with the curve in "road" mode
Conditions for the "field" mode

Driving speed < 15 km/h or
Gearbox oil temperature < 45 °C or
both
Function
– Y25 is NOT energised. The P2 pilot control pressure of 10 bar does not reach the reverse valve slider.
– The reverse valve return spring pushes the slider into the starting position.
– P1 18 bar reaches the left-hand side of the 2 stage piston and moves it to the right, to the limit.
– The tension slider in the modulation valve is also moved to the right via the push rod.
– Due to the larger pre-tension force of the tension springs, the control slider first moves from its starting position at a starting pressure
of approx. 9 bar

6.07
6 SPEED SYNCHRONOUS GEARBOX
DESIGN, FUNCTION
DUOCONE – SYNCHRONISATION
GEAR SHIFT ADJUSTMENT
DIFFERENCES IN RATIO
ADJUSTMENTS in the synchronous and power shift gearboxes
Bevel pinion ADJUSTMENT – Differential master gear
Assembly
– The synchronous gearbox is designed in the traditional two-shafted way (countershaft and main shaft)
– Since the change of the direction of rotation for reversing was moved into the power shift gearbox, a simple design was possible.
Shaft bearing
Tapered roller bearings for both shafts
X bearing for the countershaft
O bearing for the main shaft
Adjusting the bearings see Adjustments on pages 9 and 10
Bearing of the movable wheels on the shafts
– movable wheels 1. and 2. gear needle bearing
– movable wheels 3., 4. and 5. gear as friction bearing on the countershaft
– movable wheel 6. gear as friction bearing on the steel bushing
For more information on Adjusting the Bearings and Other Settings, see pages 9 and 10.
Lubrication
Forced oil lubrication from the neutral circulation of circuit P1.

Lubricating oil feed: Countershaft – from the back through a lubrication pipe
Main shaft – from the front from the power shift gear
Lubrication pressure at the lubricating oil entry (power shift gear) at
gearbox oil temperature cold max. 4 bar (valve)
≥ 80 °C 1.2 - 1.5 bar
Maximum gearbox oil temperature
a when driving on public highways max. 100 °C
b when performing other work long-term max. 80 °C
short-term max. 90 °C

Arrangement of the gears
1st and 2nd gears at the rear, shift control on main shaft
3rd and 4th gears at the front, shift control on countershaft
5th and 6th gears in the centre, shift control on countershaft
Synchronisation
1st and 2nd gear duocone
blocking synchronisation
3rd to 6th gear single cone
Friction lining sintered bronze alloy
Function
The driving torque is delivered by the main clutch to the countershaft. From there, via the pair of wheels of the gear selected (helical
gearing) to the main shaft, which is formed as a bevel pinion at its rear end.
4-Wheel drive (MFD)

At the front end of the main shaft a spur gear (helical gearing) drives a mating gear in the four-wheel drive clutch.
Attention: For each tractor type there is only one final speed ratio (40 km/h or 50 km/h) assigned.
All shift forks are fitted with sliding shoes made from bronze alloy. Their bearings can pivot. The advantages are:
a adaptation to the sliding sleeve
b noise reduction
c long life due to ideal material matching
Shifting the gears

– Gearshift engages flexibly with ball in lever of rotating shaft.
– Shift finger on rotating shaft engages in carrier of the chosen gear’s shift shaft.

Duocone synchronisation 1st and 2nd gears
Components:
1 Synchromesh body 7 Inner ring (2 off) with outer cone

2 Sliding sleeve 8 Intermediate ring (2 off) with sinter bronze lining on outer and inner cone
3 Pressure piece (3 off) 9 Outer ring (2 off) with inner cone
4 Pressure spring (3 off) 10 Gear wheel 1st gear
5 Clutch piece (3 off) 11 Gear wheel 2nd gear
6 Clutch disk (2 off) 12 Needle bearing
Function
– When the sliding sleeve is moved, the spring-loaded pressure piece exerts axial pressure on the outer ring. Since the inner ring can
not deviate, the outer ring is pushed onto the intermediate ring and the intermediate ring onto the inner ring (see function of cone in
figure).
– The intermediate ring engages the clutch disk with its drive tabs in such a way that it cannot turn.
– Inner and outer ring engage the 3 clutch pieces with their drive tabs.
– Thus, the two rings are can not twist because of the clutch pieces and the synchromesh body which is located on a profile on the shaft
(bevel pinion).
– The previously mentioned parts are synchronized by work of friction.
– The radial torsional force lessens and the sliding sleeve can be moved by the outer ring shifting claws and finally engages with the
shifting claws of the clutch disk.
Advantages: Lesser specific loading and therefore longer life

Shift positions
– Adjust all shifting forks with grub screws to the same shift travel (measure with a dial test indicator).
– Adjust all shift shaft carriers with grub screws so that their gaps are flush.
– Adjust the shift finger on the rotating shaft so that it engages centrally (not offset) with its carrier in 3rd and 4th gear.
– In the "Super crawler gear" version, adjust the shift travel (symmetrical) from outside, through the opening to the left in the area of the
crawler gear, also with grub screw in the shift fork.
The gear latches for all shift shafts can be accessed from the top outside.
Latches to avoid wrong gear-shifting

– Prevention – shifting 2 gears at the same time: inhibitor pins between the shift shafts (observe the varying lengths)
– When the crawler gear is engaged, an inhibitor pin blocks the shift rod for the 5th and the 6th gears.
– In the 30 km/h version, an inhibitor pin mounted vertically across the 5th and 6th gear shift fork prevents shifting to 6th gear.
Important: Observe the sequence of the shift positions

a Shift forks: always after mounting a shift shaft (otherwise they can no longer be accessed).
b Carrier – gears 1-6 and shift fingers on rotating shaft:
After adjusting all shift forks, but before fitting the main clutch
c crawler gear shift fork:
After assembling the power shift gearbox and the 6-speed gearbox.

Differences in ratio
When ordering spare parts for repair, observe the following:

T7224L (CS110, 9105) power shift ratio differs between 40 km/h and 50 km/h versions.
T7226L (CS120, CS130, 9115 and 9125)

Ratio (number of teeth) of pair of 6th gear wheels differs between 40 km/h and 50 km/h versions.
T7228L (CS150, 9145)

Bevel pinion ratio – different differential master gear in 40 km/h and 50 km/h versions.
T7224L
T7226L Four-wheel drive ratio dependent upon tractor type or 40 km/h or 50 km/h versions.
T7228L

6-speed power shift gearbox
Countershaft Axial play 0.05 - 0.12 mm
Packing ring at the back of the bearing cover
Loose wheel 6th gear Axial play of the bearing bushing 0 - 0.15 mm
Adjustment: flange bushing in various lengths
Main shaft (bevel pinion) Bearing pre-tension rolling moment 4 - 5 Nm

Packing ring between castellated nut and four-wheel drive wheel
Attention:Determine packing ring S for position of bevel pinion before adjusting the bearings (see pages 11 and 12).
Movable parts on main shaft Axial play 0.05 - 0.20 mm

Collar ring behind the front tapered roller bearing in various lengths
Clutch shaft (main clutch) Axial clearance 0.2 - 0.1 mm

Packing ring at the rear end of the clutch shaft
Hydro-pump drive – Adjustments
Spur gear bearing – pump drive shaft

Axial clearance max. 0.4 mm
Packing ring between ball bearing and P1-hydraulic pump (front pump)
Intermediate wheel bearing (tapered roller bearing) Axial play 0.03 - 0.07 mm
Packing ring between bearing and circlip

Gearbox adjustments
Power-shift gearbox
Drive shaft 1
Drive shaft 2 Axial play 0.03 - 0.07 mm
Intermediate shaft 3
Packing rings in the back of the bearing cover
Attention:
– Rotate the shafts or the loose wheels respectively before measuring

– To verify the adjustment, fit only 1 shaft at a time
Movable wheels on the 0.03 mm Axial play
power shift shafts up to 0.7 Nm rolling moment
Packing ring between bearing and circlip
Air play of the power shift clutches 3.8 - 4.3 mm
Adjustment with retaining rings of different widths in the piston carrier.

Adjustment – bevel pinion (position)
Meshing adjustment part 1
1 Tooth of the differential master gear

Meshing to the left: Thrust flank at 15 Nm braking moment on the bevel pinion
Meshing to the right: Towing flank
2 Bevel pinion (main shaft)
3 Inner bearing ring (tapered roller bearing)
4 Gearbox casing
S Packing ring
K Test measurement of the end face – gearbox casing on the inner ring of the tapered roller bearing after bearing adjustment
(pre-tension) when deviation of bevel pinion = 0 (see Workshop manual)
Observe the test sequence in workshop manual
For the adjustment part 2, see pages 13 and 14 and the workshop manual.

Meshing adjustment part 2 rear axle components or marking in the area of the rear axle housing
1 Use "thicker seal" coding (see coding on seal).

2 Use "thinner seal" coding (see coding on seal).
3 Differential
4 Differential master gear
5 Differential master gear screws
6 Lubricating oil distributor (when fitting, put throttles in the correct position, see workshop manual)
7 Lubrication pressure limiting valve pmax = 3 bar
8 Control line to the differential lock
9 Lube-oil line to wet disk brake
E(84) theoretical adjustment dimension
Adjustment procedure
to 1 or 2 respectively:
– Use correct seal according to the marking punched into the flange surface of the rear axle (one - or two zeroes).
– Adjust differential bearing with the help of the adjusting screws to 5 to 7 Nm rolling moment.
– Measure dimension E and, if necessary, pre-set adjusting screws by turning them at the same angle to 84 mm.
– Screw gear box casing to rear axle housing but insert correct seal beforehand.
Tighten screws M14 / 10.9 to 185 Nm.
– Check the tooth flank play and, if necessary, correct it to 0.15 - 0.20 mm.

Version "crawler gear group"
Crawler gear shifting area adjustment
– When repairing or replacing parts in transmission versions with crawler gear, the dimension in this area must be set to 14.5 +0.1 mm
once again.
– For this purpose, the thrust ring "S" for the axial needle bearing or the clutch bell housing respectively is available in steps of 0.1 mm
or 0.05 mm respectively and 6.3 mm to 7.4 mm.
– The purpose of this dimension is to ensure that, despite the production tolerances, the whole crawler gear group has sufficient room
on the one hand and not too much play on the other hand.
Note: Whenever repairs are carried out in this area, the axial play of the clutch shaft (0.2 +0.1 mm) must be checked using the
adjustment procedure described previously. If necessary, change packing ring at the rear end of the clutch shaft; see workshop
manual T7200L, page 3.10 to 3.13.
When measuring the axial play of the clutch shaft, the drive shaft 2 must be pressed to the rear (in direction of the main clutch; the drive
shaft is adjusted with play) using an appropriate tool (screwdriver etc.), otherwise the measurement will be incorrect.

Version without "crawler gear group"
– Instead of the gear shift parts for N or SKG, a coupling sleeve (see figure above) transfers the driving torque from the power shift drive
shaft 2 to the clutch bell of the driving clutch.
(Fit the coupling sleeve with the bevel towards the front).
– In the version without crawler gear group, the thrust ring S towards the front axial roller bearing on the clutch shaft is used only in the
standard measurement of S = 6.7 mm.
Attention: As the version without crawler gear does not have the longitudinally bored double gear wheel 11 between the power shift
intermediate shaft 3 and the gearbox main shaft (bevel pinion) 7, a lubrication pipe is inserted there.If it is forgotten during
fitting, all bearing points on the main shaft will run dry.
Note: Standard transmission fluid level is 55 mm below the main shaft.

Adjustments – 4-wheel drive
Bearing: cylindrical roller bearing to the rear

ball bearing to the front
Packing ring 12 between roller bearing and circlip
Four-wheel clutch air play adjustment
– Press four-wheel clutch together according to workshop manual and measure clearance. If necessary, adjust with appropriate packing
ring 9 to 2.0 ± 0.3 mm.
Shaft 1 axial play adjustment
– Fit ball bearing 11 according to workshop manual with special tool until shaft is free of play.
– Fit old packing ring 12 and circlip 13.
– Pull or push shaft 1 to its front limit and measure the axial play with a dial test indicator.
– Correct the packing ring dimension as necessary until there is an axial play of 0.1 - 0.3 mm.
– Slightly grease sealing lips, then fit sealing ring 14 and metal fleeting ring 15 with special tool, according to workshop manual.

Tightening torques for bolts
Ma safety type
Power-shift gearbox
Housing flange PS gearbox, 6-speed gearbox M14 / 10.9 185 Nm

Bearing cover for power shift shafts M10 / 8.8 46 Nm
Grub screws – sealing of power shift shaft oil access holes 18 Nm Loctite 270
Power shift control – hydraulic section
Channel plate M8 23 Nm
Valve housing V / R M8 23 Nm
4-speed control module M8 23 Nm
Speed sensor PS-outlet M8 / 8.8 23 Nm

Ma safety type
Housing flange 6-speed gearbox – rear axle M14 / 10.9 185 Nm

gearbox main shaft – castellated nut 650 Nm hammered in
Countershaft
Piston carrier M8 / 8.8 23 Nm

Rear bearing cover M10 / 8.8 46 Nm
Lubrication pipe – banjo bolt 50 Nm
Grub screws in shift forks and carriers 34 Nm Loctite 243
Grub screws – four-wheel drive clutch shaft 18 Nm Loctite 270
Shift housing M12 / 10.9 117 Nm
Drive housing – hydraulic pumps M10 / 8.8 46 Nm
Pressure oil feed – four-wheel drive clutch
Swiveling screw fitting 90 Nm

Screw-in plug 80 Nm
Screw – oil filter head 40 Nm

Ma safety type
Solenoid valve – four-wheel drive clutch
Valve insert 30 Nm
Hexagonal nut 9 Nm
Temperature transmitter 20 Nm
Engine speed sensor = power shift input M8 23 Nm
Driving speed M8 23 Nm
Rear axle
Differential housing – master bevel pinion M12 / 10.9 110 Nm Loctite 243
Brake plate M12 / 8.8 80 Nm
Axle stub M12 / 8.8 80 Nm
Axle stub fastening – tightening torque and number of screws, modification see CS note.

6.08
REAR AXLE
DESIGN, FUNCTION
PRESSURE LUBRICATION
BRAKES – Adjustments
AXLE STUB – Adjustments
BRAKE BOOSTER
Rear axle
Assembly
– The rear axle is flanged to the 6-speed synchronous gearbox.

– Bevel pinion – differential master gear with Gleason-teeth – the transmission differs depending upon type and speed.
– Bevel gearwheel differential (4 differential wheels) with 100 % multiple disc differential lock, controlled by P1. Pressure oil feed
through square profile rings.
– Wet multiple disk brake, fast running (5 lining disks), hydrostatically controlled (push-key version with booster – 1st variant, draw-key
version without booster – 2nd variant).
– Mineral brake fluid Pentosin LHM – green in color.
– Parking brake acts mechanically on working brake.
– Planetary gearbox final drive with own oil supply, transmission depending on type.
– Version of axle stub depending on type, see following pages.
– Tapered roller bearings for differential and axle shafts.
Cartridge sealing rings on the wheel hubs.
– PTO shaft gear unit with PTO shaft clutch mounted from the rear into the rear axle.

Pressure lubrication
– Pressure oil feed – from the neutral circulation or pressure-free return of the high-pressure hydraulic system
– Lubricating pressure limiting valve pmax = 3 bar (see figure ”gearbox bird’s-eye view”)
– Pressure lubrication is made to
– Tooth meshing bevel pinion – differential master gear
– Differential
– Differential bearing
– Pressure oil feed to disc brakes running in oil bath for continuous oil exchange (dissipation of heat caused by friction)
Important: Fit the chokes in the correct position when fitting the lubricating oil distribution pipes (see workshop manual).
Attention: Fitting instructions for differential, differential lock, tooth flank play, bearing adjustment, brakes and axle stub, see workshop
manual and info’s (see service-bulletin).

Rear axle – Section
Rear view Brake operation 1st version
1 Rear axle housing 13 Actuating cylinder

2 Differential 14 push-key
3 Differential master gear 15 differential piston
4 Adjusting screw (for differential bearing) 16 Hand-brake lever
5 Safety plate 17 Adjusting screw and lock nut
6 Disk – differential lock
7 Piston (Sealing 2 quad-rings)
8 Control pressure connection (18 bar when differential lock is ON)
9 Pressure lubrication connection for differential and bearings
10 Pinion shaft
11 Brake operation (expander)
12 Lining disks (2 + 3)

Axle stub – construction and adjustments
1 Rear axle housing (modification 4 additional threads, see info’s)

2 Internal geared wheel (modification 4 additional holes, see info’s)
3 Internal geared wheel thread (modification 4 additional screws, see info’s)
4 Axle stub
5 Planet carrier
6 Brake plate
7 Threads for brake plate
8 Pinion shaft
9 Shaft sealing ring
10 Thrust ring
11 ‘O’ring
12 Sprung dowel pin
13 Planet wheel
14 Oil drainage plug
15 Axle shaft
16 Tapered roller bearing
17 Cartridge sealing ring (for fitting instructions, see workshop manual)
18 Grub screw and ball
19 Castellated nut

Adjustments
Axle shaft bearing

– Tighten castellated nut to bearing pre-tension
– Slightly loosen castellated nut
– Tap axle shaft until there is freedom of movement and bearing play
– Tighten castellated nut until bearing no longer has play (0 - 0.01 mm bearing pre-tension)
Planet carrier axial play

– Adjust to 0.15 - 0.25 mm axial play using the grub screw.
– Treat the thread and grub screw with Loctite Activator and secure using Loctite 243.

Brake system
Assembly
– The working and parking brake is as a multi-disc brake, which runs in an oil bath and is integrated into the rear axle.
– The parking brake acts mechanically on the working brake.
– The 5 lining disks on either side act on the planetary gear pinion shaft.
– With the motor running, the oil is continuously exchanged thus dissipating the heat caused by friction.
– The service brake is operated hydrostatically, in the first generation, as push-key brake – assisted by a brake booster.
– The second generation – as a draw-key brake does not require a booster.
– The brake boosters are supplied with 18 bar from the circuit P1.
– The operating circuits 1 (from the pedal to the booster) and 2, from the booster to the brake actuator operate with mineral brake fluid,
green in color (LHM, Pentosin).
Attention: Never mix with other brake fluids!
– Depending on national standards or optional equipment the tractor can be fitted with Optistop-four-wheel brake or a wet multi-disk
brake in the front wheel hubs. The latter is controlled by a hydraulic brake valve.

Brake diagram with brake booster (first generation)
1 Brake pedal
2 Master cylinder, circuit 1
3 Expansion chamber circuit 1 and clutch operating circuit 1
4 Brake line
5 Slave cylinder, circuit 1
6 Bleeding point
7 Brake booster
8 P1 supply 18 bar (gearbox oil)
9 Bleeding point (booster)
10 Main brake cylinder circuit 2 with compensating valve and compensating line
11 Expansion chamber, circuit 2
12 Compensating line
13 Brake line
14 Actuator with differential piston and brake adjustment
15 Bleeding point
16 Hand-brake lever
17 Brake expander (brake plate)

Brake booster with main brake cylinder circuit II
Components:
1 Booster housing 17 Pull rod

2 Booster piston 18 Brake compensating valve
3 Retractor spring 19 Packing ring
4 Stop (with ‘O’Ring and piston rod sealing) 20 Piston rod
5 Circlip 21 Feed from expansion tank
6 Slave cylinder, circuit 1 22 Pressure connection from master cylinder circuit 1
7 Piston - slave cylinder 23 Bleeding point circuit 1
8 Piston spring 24 Pressure connection to working brake
9 Circlip 25 Compensating line
10 Quad-rings (sealing rings) 26 Connection P1 18 bar
11 Main brake cylinder, circuit 2 27 Booster bleeding (automatic)
12 Piston main brake cylinder 28 Inlet – control hole
13 Retractor spring 29 Outlet – control hole
14 Circlip 30 Bleeding point
15 Piston cup 31 Plastic tag (green in color) on slave and
16 Feeder valve main brake cylinder

Brake booster initial position
Construction and function
– The slave cylinder of circuit 1 is integrated into the booster housing. The main brake cylinder is flanged on.
– The left-hand side of piston 7 controls the booster (power assistance).
– The booster medium (gearbox oil) is separated from the brake medium (Pentosin) by the sealed off stop 4.In the same way, quad-
ring 10/1 separates the two media.
Braking when engine is at a standstill
– Pressure from the master cylinder (brake pedal) operates piston 7 of slave cylinder 6. The left-hand surface of piston 7 moves piston
rod 20 across booster piston 2 the and in doing so, moves piston 12 of the main brake cylinder 11.
– Pistons 2, 7 and 12 are at the right-hand stop in their initial position.
– Adjusting valve 16 is held open by pull rod 17. Mineral brake fluid can enter from the expansion chamber.
– The position of piston 7 in relation to control holes 28 and 29 causes the pressure of P1 to be shut off at 28 and
at 29 a possible oil leakage can return via 27 so that there is no hydraulic actuating power on booster piston 2.
– Connections 22, 24 and 25 are pressure free.

Partial braking (brake end position)
a both pedals operated
– Pressure from the master cylinder of the pedal acts via connection 22 on the slave cylinder 6 and moves control piston 7 to the left
against spring 8.
– Inlet hole 28 is opened and P1 starts to act on the ring area of booster piston 2.This pushes it to the left. Piston 12 of the main brake
cylinder 11 is moved to the left by piston rod 20.
– The feeder valve closes inlet 21. The pressure generated reaches the brake actuator via connection 24 and partial braking sets in.
– There is a pressure compensation with the second main brake cylinder over the mechanically opened compensating valve 18.
– The partial pressure of p < 18 bar acting on booster piston 2 also acts on the left-hand surface of piston 7.The latter assumes a mid-
position. Control holes 28 and 29 are closed.
This state is known as the brake end position.
b single-wheel brake (steering brake)
– When the main brake cylinder is not operated, compensating valve 18 remains closed. The brake pressure of the other main brake
cylinder supports itself on the closed compensating valve 18.
General information
– The booster circuit bleeds automatically when the engine is running.

– Leakage in the slave cylinder circuit 1 returns to the gearbox oil through booster bleeding point 27.
– A visible sign is the decreasing fluid level in the expansion chamber.
– Leakages at piston cup 15 of the main brake cylinder or on the piston rod sealing of stop 4 reach the open air through bleeding
point 30.

Full braking
– With the help of increased pedal power – and thus a higher pressure in circuit Ι, piston 7 of the slave cylinder is kept at its limit at the
left-hand side of booster piston 2.
– The outlet control hole 29 remains ineffective. The P1 pressure of 18 bar gets through the inlet control valve 28 unhindered to the ring
area of booster piston 2 so that the booster power is added to the increased pedal power. The main brake cylinder now generates a
high brake pressure.
Braking when engine is at a standstill
– The mechanical state is the same as with full braking with the engine running.
– Since there is no pressure, there is no booster effect.
The brake pressure is reduced or the pedal power must be increased respectively.
Service and maintenance work requirements
– Check brake system for correct function and leak-tightness and adjust working and parking brake / for maintenance intervals see CS-
booklet and operating manual).
– Replace mineral brake fluid LHM (green in colour) in brake operating circuits Ιand Π every 2,000 service hours or every 2 years.

Brake bleeding (version with booster)
– Top up expansion chamber of circuits 1 and 2 with LHM-Pentosin.

– Bleed circuit 1 at the bleeding point of slave cylinder with bleeding device or by pumping the brake pedal.
– Bleed circuit 2 at the bleeding point of the actuator (brake cylinder) with bleeding device or by pumping the brake pedal.
Note: The brake booster is bled automatically when the engine is running.
Adjusting the working brake
– Remove bleeder valve 1 and fit a damped pressure gauge (up to 16 bar).
– Remove screw-on cover 2.
– Bleed actuation cylinder.
– Pressurise actuation cylinder to 9 bar (+ 1 bar).
– Screw in the adjusting screw 3 by hand. (Adjustment piston 4 rests on the upper circlip 5.)
– Pressure inside actuation cylinder is at 0 bar.
– Turn adjustment screw 3 out by two revolutions and counter with hexagonal nut 6.
– Replace screw-on cover 2.
– Remove pressure gauge, fit bleeder valve 1 and bleed actuation cylinder.
Note: A defective actuation cylinder must be replaced (do not repair).
Adjusting the parking brake:
Adjust parking brake by turning the yoke end on the hand-brake lever so that the hand-brake lever returns to its initial position on the
actuator.

Adjusting the brake without booster
– Unhook hand-brake cable and check that the hand-brake lever on actuator moves freely.
– Loosen lock nut.
– Tighten adjusting nut to 50 - 60 Nm.
– Loosen adjusting nut again and then tighten it to 10 Nm.
– Turn adjusting nut back 1.5 revolutions and counter.
– Re-fit the hand-brake cable.
Adjusting the parking brake:
Adjust hand-brake linkage rod to the hand-brake lever at the actuator so that the hand-brake lever returns to its initial position.

6.09
POWER TAKE OFF (PTO) – Gearbox
CONSTRUCTION
ADJUSTMENTS
PTO shaft gearbox
Assembly
1 Housing 12 Packing ring for bearing of flange shaft

2 Clutch bell Adjustment 0 to 0.05 mm clearance
3 Clutch shaft 13 Axles for intermediate wheels
4 Flange shaft 14 Adjusting nuts for bearing adjustment
5 Screw flange – PTO shaft 0 to 0.05 mm clearance
6 gearshift 540 /1100 RPM 15 Lube-oil channel
7 gear shift N – ECO 16 PTO-shaft
8 Bearing flange with pressure and lubricating oil connection and 17 Pressure channel (18 bar if PTO shaft is ON)
changeover amount of lubricating oil 18 Main lubrication (if PTO shaft is ON)
9 Hall generator for PTO shaft speed 19 Sealing ring flange shaft
10 Transmitter wheel for hall generator z = 20 20 ‘O’rings (axle sealing)
11 Packing ring for clutch shaft bearing
Adjustment 0 to 0.05 mm clearance

Bearing adjustment (summary) and tightening torques
All 4 tapered roller bearings Means of adjustment

Clutch shaft Pos. 11 packing ring
Intermediate shaft Pos. 13 nut
Intermediate shaft Pos. 14 nut
Flange shaft Pos. 12 packing ring
are to be adjusted to an axial clearance of 0 - 0.05 mm.
Tightening torque Ma safety type
PTO shaft gearbox

Rear axle housing – PTO shaft gearbox M10 / 8.8 46 Nm
Grub screws – PTO shaft clutch shaft 18 Nm Loctite 243
Oil inlet cover – PTO shaft M8 / 8.8 23 Nm
Sealing cover – PTO shaft flange shaft M8 / 8.8 23 Nm
PTO shaft stub M12 / 10.9 110 Nm
Flange bearing – shifting

PTO shaft 540 / 1000 and normal / economy M8 / 8.8 23 Nm
PTO shaft speed sensor M8 23 Nm

Section
6A
6A
HOW IT WORKS
POWER SHUTTLE
(Supplement to section 6)
9105a, 9115a, 9125a, 9145a,

CS110, CS120, CS130, CS150
Contents
Page Page
3-4 Characteristics
25 Reversing characteristic (pressure - time
5 Modifications - Mechanics, Hydraulics
diagram)
6 Modifications - Electrics, Electronics
26 Current - pressure characteristic diagram
7-8 Position of the components on the vehicle
27 Pedal travel comparison values
9 - 10 P1 and P2 hydraulics layout
28 Pedal characteristic (travel - pressure)
11 - 12 Lubricating circuit - components
29 Technical data
13 - 14 Operating and control elements for driving
30 Fault code - general
15 - 16 Installation position of the main clutch
31 Driving programmes
17 - 18 Main clutch components
32 Electrics - fusing / electric welding
19 - 20 Main clutch - fundamental characteristics
33 Equipment for programming and fault code read-out
21 - 22 Power Shuttle control - components
34 Codes for end-of-tape programming
23 Power Shuttle control - basic function
35 Abbreviations used in the fault code list
24 Control circuit to main clutch
36 - 42 Fault codes
43 - 44 Miscellaneous information
POWER SHUTTLE Training Center St.Valentin 2

POWER SHUTTLE
CHARACTERISTICS
• Starting, reversing and stopping possible without operating the clutch pedal
• 2 operating possibilities for starting and reversing:

a Via lever keys (operated with the left hand)
b Via keys on the multi-controller
• Stopping by activating function N (neutral) via the lever key
• Reversing possible up to 12.5 km/h
• Smooth, gentle frictional connection of the main clutch through modulated, sensor-controlled rotational
speed and speed monitoring
• Starting safety through driver's seat switch, safety pushbutton - rear side of multi-controller, for starting via the multi-controller
• The main clutch can be controlled via the clutch pedal for particularly smooth starting and driving
• Low pedal force through electrical signal transmission from the clutch pedal to the electronic control unit
(hydrostatic clutch operation no longer necessary)
Activation of the main clutch via an electrohydraulic proportional valve
• The clutch control system does not have to be bled after assembly or repair work
(The system bleeds itself after operating the clutch a few times)

forward
forward
neutral
Ç
reverse É reverse
power
shuttle

MODIFICATIONS - Mechanics, Hydraulics
• Modified construction of the main clutch:

Opened by spring tension and
closed electrohydraulically. Pressure oil supply via circuit P1, 18 bar
• Modified countershaft in the area of the main clutch
• Hydrostatic clutch control mechanism including clutch booster has been dropped
• Modified 6-speed transmission housing:

Inclusion of rotational speed sensor B4 - rotational speed at clutch output
(The gear wheel for the 2nd gear on the transmission main shaft is used as the pick up)
Inclusion of proportional pressure control valve Y3
• Integrated pressure oil channel and M16x1.5 test connection
• Bigger hydraulic pump for circuit P1, 18 bar

V = 36 ccm, Q = 88 l/min
• Lubrication system of the rear wheel differential and PTO shaft clutch connected to the transmission lubrication system.
Volume of lubricating oil regulated by throttles
3 bar lubricating pressure limiting valve in the rear axle housing has been dropped
• Pedal force for fine dosing is attained by means of a matched return spring
• The clutch pedal only operates the angular sensor (B17) and, the plunger-operated switch (S46), on reaching a pedal travel of 75%

MODIFICATIONS - Electrics, electronics
• A68 New electronics box for activating the main clutch and power-shift transmission
• New software
• PC application (laptop or notebook) for the following procedures:
• End of tape - programming of the electronics box
• Reading out the stored fault codes
• Deleting the fault code memory
• Data display and
• Menu-prompted troubleshooting
• S4/4 lever keys with 3 key functions (F, R and N)
• B4 Rotational speed sensor for rotational speed at the clutch output (hall generator)
• S46 Plunger-operated switch (plunger-operated Reed switch) is operated directly via the clutch pedal at a travel of 75%
Safety-relevant components
• Starting safety through:
• S8 seat switch
Guard for lever key S4/4
Neutral position for lever key S4/4
Safety key S11/13 on the rear side of the multi-controller
Attention:the following operating functions are only active when seat switch S8 has been activated
(Driver is sitting in the driving seat)
S4/4 lever key functions Forwards and Reverse
S11/7 multi-controller key Forwards
S11/8 multi-controller key Reverse
(With safety key S11/13 depressed at the same time)

POSITION OF COMPONENTS on the vehicle
1 Hydr. control block for power-shift and field/road characteristic curves S4/4 Lever key
2 Hydr. control block F/R S8 Seat switch
P6 Display on the A-column
A68 E-box for power-shift and Power Shuttle control
MC Multi-controller Power-shift, Power Shuttle F/R
B17 Angular sensor Clutch pedal
S46 Plunger-operated switch Clutch pedal, black
Y3 Proportional pressure control valve for main clutch
B4 Rotational speed sensor Main clutch, rotational speed at output
B5 Rotational speed sensor Power-shift output
B6 Rotational speed sensor Driving speed
B12 Rotational speed sensor Power-shift input (engine speed)
B34 Temperature sensor Transmission oil
S19 Neutral switch 6-speed transmission and starting interlock, green (break contact)
S21 Oil pressure switch P1 circuit (make contact)
Y1 Solenoid valve Four-wheel (MFD)
Y4 Solenoid valve Front PTO shaft
Y5 Solenoid valve Rear PTO shaft
Y10 Solenoid valve Differential lock front and rear

P1 HYDRAULICS LAYOUT (18 BAR) AND P2 (10 BAR)
1 Transmission housing (tank) 13 Main clutch
2 Fine filter β10 = 15 β30 = 20 14 Lubrication of differential
3 By-pass valve 15 Lubrication of PTO clutch
4 Coarse filter 200 µm 16 5.5 mm throttle
5 Gear pump V = 36ccm Q = 88 l/min 17 2.6 mm throttle
6 Cold start valve pmax = 25 bar (safety valve) 18 M16x1.5 test connection for
7 P1 connection for ext. users, M10x1 thread Control pressure to main clutch
8 Power-shift control block consisting of: B34 Temperature sensor for transmission oil
P1 System pressure control 18 bar S21 Oil pressure switch (make contact) p=14.5 bar
P2 Pilot pressure control 10 bar Y1 Four-wheel solenoid valve
Channel plate R = 10.3 ohms +10%
Solenoid valves Y21 to Y27 R = 28 ohms Y3 Proportional pressure control valve
Valve housing with hydr. control valves R = 5.3 ohms +10%
Control channels to the power-shift clutches Y4 Front PTO (not serial)
9 By-pass control valve thermally controlled R = 8.5 ohms +10%
Transmission oil temperature < 55°C 100% oil cooler by-pass Y5 Solenoid valve for rear PTO
Transmission oil temperature > 70°C 100% through oil cooler R = 8.5 ohms +10%
10 Transmission oil cooler Y10 Solenoid valve for diff. locks
R = 8.5 ohms +10%
11 Lubricating oil channels to: Power-shift transmission, main clutch
6-speed synchronous transmission
12 Pressure control valve for lubricating pressure pmax = 4 bar Pressure at 80 °C oil temperature 1.2 to 1.5 bar

LUBRICATING CIRCUIT - components
1 3-way thermal control valve

2 Short-circuit line to transmission lubrication (path 2)
3 Line to oil cooler (path 3)
4 Oil cooler (located behind radiator grill)
5 Line from oil cooler to transmission lubrication
6 Lubricating oil distribution and pressure control valve for lubrication pressure pmax = 4 bar
7 Lubricating line to main drive differential and PTO clutch
8 Lubricating line to PTO clutch
9 Test connection for pressure test (activation of main clutch), M16x1.5

DRIVING - Operating and control elements
N - SKG Gear shift lever for selecting super crawling gear or normal
MC Multi-controller with gear shift handle grip For controlling the Power Shuttle, selecting the power-shift stages and engaging
the gear S11/7 (V) S11/8 (R) S11/13 (safety key for Power Shuttle and electronic lifting gear control)
S4/4 Lever key for controlling RS and Neural
Clutch pedal For engaging and disengaging the main clutch
(only if particularly gentle starting and driving is necessary)
B17 Angular sensor For transmitting the pedal position to the electronic control unit (A68)
S46 Plunger-operated switch (colour: black) For releasing the power-shift at a pedal travel of 75%
Y3 Proportional pressure valve Controls the closing pressure for the main clutch (modulated)
B12 Rotational speed sensor Rotational speed at power-shift transmission input (engine speed)
B5 Rotational speed sensor* Rotational speed at power-shift transmission output
B4 Rotational speed sensor Rotational speed at main clutch output
B6 Rotational speed sensor Driving speed
B34 Temperature sensor Transmission oil temperature
S21 Pressure switch (make contact) For monitoring the transmission oil pressure switching point p = < 14.5 bar
S19 Neutral switch (colour: green) Signal for neutral position of the 6-speed transmission for Power Shuttle and
engine start
S8 Seat switch (Safety)
Y1 Solenoid valve Four-wheel (MFD)
1 Hydr. power-shift control unit Y21 - 27 activated by A68
Y21 - 27 control hydr. control valve (pilot control)
Control valves control power-shift clutches
2 Pressure line P1 18 bar supply to proportional valve Y3
3 M16x1.5 test connection Modulated control pressure for closing the main clutch
* Use a 2.5 mm spacer for: CS150 and 9145 40 km/h and 50 km/h and for CS110 and 9105 50 km/h

INSTALLATION POSITION OF THE MAIN CLUTCH
1 Vibration damper 13 6th and 5th gear synchronizer
2 Intermediate housing 14 Countershaft
3 Input shaft 15 PTO shaft drive
4 Power-shift group 16 2nd and 1st gear synchronizer
5 Clutch "C“ 17 Main shaft
6 Clutch "A“ 18 Front axle drive
7 Crawling gear group 19 Crawling gear drive
8 Crawling gear group synchronizer 20 Clutch "F“
9 Drive clutch 21 Clutch "G“
10 6-speed main transmission (counter and main shafts) 22 Clutch "D“
11 Spur wheel for hydraulic pump drive 23 Clutch "B“
12 4th and 3rd gear synchronizer

MAIN CLUTCH COMPONENTS
1 Output shaft (power-shift transmission)

2 Normal gear - crawling gear synchronizer
3 Clutch casing
4 Disk pack
5 Disk carrier
6 Adjusting ring for play
7 Piston
8 Sealing rings for sealing the piston (flexible moulded sealing rings)
9 Release springs
10 Rotary pressure compensator (consisting of: screening plate, 2 O-rings, ring-shaped oil chamber and compensation channel)
11 Clutch shaft
12 Control pressure supply (sealing between shaft and bearing flange by means of 2 rectangular rings (metal)
13 Pressure lubricating channel
14 Pressure control channel
15 Adjusting ring for axial play of the clutch shaft
16 Pressure spring
17 Countershaft (6-speed synchronized transmission)

MAIN CLUTCH - fundamental characteristics
A few important constructional characteristics of the main clutch were retained for the Power Shuttle version. They are:
• Wet multi-disk clutch with 16 friction surfaces with a diameter of 200 mm
• Positioning of the main clutch between the power-shift transmission and synchronized transmission
• Sinusoidal formation of the steel disks for smooth clutch engagement and perfect release
• Supply of large cooling oil flow when engaging the clutch but the oil supply is cut off when in a declutched state
• Fixed dimension between the toothing on the output shaft (power-shift) and stop disk (axial roller bearing) 14.5 + 0.1 mm
Stop disk is available in various dimensions as a spare part
• Axial play of the clutch shaft 0.2 + 0.1 mm
Adjusting disk available in various dimensions as a spare part
Modifications for the Power Shuttle version
• Opening of the clutch through spring force
• Closing through characteristic modulated control pressure
• Pressure oil supply to the rotating clutch shaft (sealed by means of rectangular metal rings), sealing between the shaft and piston by
means of flexible moulded sealing rings. (The open side must face towards the pressure oil side after assembly).
• The integrated rotary pressure compensator ensures troublefree opening of the clutch even at high rotational speeds
• Clutch play 6.0 - 0.4 mm
• Play adjustment by measuring and selecting the correct adjusting rings in accordance with the workshop manual
• Wear limit of the clutch lining is reached when recesses on the clutch lining disappear
• Lay new lining disks in transmission oil before assembly

POWER SHUTTLE control components
1 Motor P1 18-bar supply from lower pressure circuit
2 Vibration damper S8 Seat switch (safety)
3 Hydr. control block for power-shift and F/R
4 Main clutch
5 6-speed synchronized transmission
6 Clutch pedal
Y3 Proportional pressure control valve
Y26 u. 27 Solenoid valves F/R
Y21 - 25 Solenoid valves, 4 stages, power-shift and field - road characteristic
A68 Electronic control unit
P6 Display unit
B12 Rotational speed sensor Power-shift Input (engine speed) Rectangular signal
B5 Rotational speed sensor Power-shift Output Rectangular signal
B4 Rotational speed sensor Main clutch Output Rectangular signal
B6 Rotational speed sensor Driving speed Rectangular signal
B17 Angular sensor Position of clutch pedal Analog signal (VDC)
S4/4 Lever key F/R and Neutral key functions
S19 Neutral switch Neutral position of 6-speed transmission and starting interlock (break contact)
S21 Oil pressure switch Monitoring of transmission oil pressure (make contact) switching point p< 14.5 bar
B34 Temperature sensor Transmission oil
S46 Plunger-operated switch "High“ signal (+12 Volt) gets at 75% clutch pedal travel interrupted

POWER SHUTTLE CONTROL - basic function
General information
• The electronics box (A68) forms the central control unit (hardware) for the Power Shuttle and power-shift control
• The software is entered and programmed type and speed-related by means of a PC or laptop
• Characteristic curves are stored in the software. The closing of the main clutch and power-shift clutches is thus activated
by modulated pressure.
INPUTS
Switches
The lever key (S4/4), the keys on the multi-controller, the plunger-operated switch (S46) on the clutch pedal, the neutral switch (S19)
and the oil pressure switch (S21) supply individual digital impulses as a signal to A68.
Sensors
Sensors B17 and B32 supply a continuous analog D.C. signal to A68
Sensors B4, B5, B6 and B12 supply a continuous rectangular signal to A68. The frequency is decoded as the signal.
OUTPUTS
Actuators
• Upon activation A68 feeds the proportional pressure control valve (Y3) with a variable direct current which
a follows a preprogrammed characteristic curve when starting without the clutch pedal
b has a level corresponding to the position of the clutch pedal upon starting with the clutch pedal
c if certain rotational speed signals fail, then A68 activates a so-called default characteristic to engage the main clutch
• The direct current for Y3 is varied infinitely by pulse-width modulation
• Solenoid valves Y21 to Y27 are activated digitally by A68. This activation is effected by a "low" signal at the respective output
• A digital output supplies all information to the display (P6)
• Additional connections are used to transmit data from and to the test/programming unit via an interface using digital signals
• Faults which occur in the system are signalled to the driver in the form of a 2-digit code number on the display and are written into the
fault memory. This can be read out and deleted.

CONTROL CIRCUIT TO THE MAIN CLUTCH FOR SHUTTLE OPERATION as well as starting with and without
the clutch pedal
General information
• The software has 4 reversing characteristic curves for starting or reversing without the clutch pedal. Their pressure level depends on
the gear selected in the 6-speed synchronized transmission (pressure level increases when a higher gear is selected), whereby the
characteristic curves for the 1st and 2nd gear are almost identical. There is only one characteristic curve for the 5th and 6th gear.
If certain rotational speed signals fail, the A68 activates the proportional valve (Y3) according to a "default characteristic
curve" whose pressure curve corresponds to the characteristic curve for the 5th and 6th gear.
• If the clutch pedal is used to start, then activation of the proportional valve (Y3), and thus the main clutch, is not effected in
accordance with a characteristic curve but according to the current position of the clutch pedal.
Signal characteristic when "engaging the clutch without using the clutch pedal"
• The driver's command to start or reverse is carried out by operating keys. This sends
"high" digital signals (+12 VDC) to the E-box (A68).
• A68 immediately activates a variable direct current with the characteristic of a selected characteristic curve in the range of
400 to 1060 mA for control valve Y3.
The infinite variation of the control current is effected by pulse-width modulation.
• At the same time Y3 activates a variable hydraulic control pressure of 2 to 18 bar to close the main clutch.
The increase in the control pressure is effected proportionally to the current rise - see characteristic curves on page 26.
Signal characteristic when "engaging the clutch using the clutch pedal"
• The angular sensor (B17) for the clutch pedal supplies a variable direct voltage (VDC) of 1 to 4 volts (the signal voltage increases
when the clutch pedal is fully depressed)
• The signal voltage of B17 is transmitted to the E-box (A68)
• A68 activates the control current for Y3 according to the signal voltage of B17
• Y3 activates the hydraulic control pressure for the main clutch
• The signal voltage of sensor B17 and the control current for Y3 bear a ratio to each other - refer to page 27.
On reaching a pedal travel of 75%, the plunger-operated switch (S46) interrupts the "high“ signal (+12 VDC) to A68. 2 clutches are
then actuated in the power-shift transmission and there is a power transfer from the engine to the main clutch.
• The power-shift transmission is actuated the moment the main clutch starts to close.
Attention: If it is discovered that the values of the control voltage and control current do not match when taking a comparison
measurement whilst troubleshooting, then it must also be checked whether the programming and code input has been carried in
accordance with the tractor type and final speed.

COMPARISION VALUES PEDAL TRAVEL - B17 SIGNAL VOLTAGE - CONTROL CURRENT TO Y3
Pedal travel B17 VDC (in volts) Y3 ADC (in mA)
Idle position 1.00 1060
1/6 1.50 920
1/3 2.00 760
1/2 2.50 670
2/3 3.00 610
3/4 (75%)* 3.25 585
5/6 3.50 560
Fully depressed 4.00 400
* The plunger-operated switch (S46) is also activated by the clutch pedal at a pedal travel of 75%.
The "high“ signal of +12VDC to E-box A68 (pin 44) gets interrupted.

TECHNICAL DATA
Hydraulic pump for P1 circuit (18 bar) V = 36 ccm Q = 88l/min
Main clutch
Type Wet multi-disk clutch
Number of friction surfaces 16
Outside diameter 200 mm
Play 6.0 - 0.4 mm
Axial play of the clutch shaft 0.2 + 0.1 mm
Hydr. control pressure modulated 1.5 - 18 bar
Closing time for auto. clutch engagement Approx. 3.5 sec
Y3 Proportional pressure valve
Position on vehicle Behind gear lever for the 6-speed transmission
Type Proportional pressure valve
Control pressure 1.5 - 18 bar
Qmax 30 l/min (at Dp » 4 bar)
Control current (from A68) 400 - 1060 mA direct current (ADC)
Type of current control Pulse-width modulation
Ohmic resistance R = 5.3 ohms + 10%
Voltage 8 - 15 volts
Current Up to 1.2 amps (ADC)
Tightening torques:
Valve insert Ma = 10 + 2 Nm Spanner size 28 mm
Nut for fastening the magnet Ma = 5 + 3 Nm
B17 Angular sensor (cl. pedal) Supply pin 2 = 5 VDC stabilised
Ground pin 1
Signal pin 3 = 1 - 4 VDC
S4/4 lever key Control pulses (key) + 12 VDC
S46 plunger-operated switch (cl. pedal) Control signal (at pedal travel of 75%) + 12 VDC gets interrupted

FAULT CODES
General information
If there is a fault, only the fault code with the highest fault number is displayed (depending on the driving programme).
The "spanner“ fault symbol also lights up on the display.
WARNING: The acoustic and optical displays/signals (alert tone, continuous alert tone, fault codes, "N“lights up)
must always be observed. Safety-relevant driving situations can arise if these alert signals are not taken notice of !
Independent of this, faults which have been determined are stored in the A68 fault memory (fuse F19 must be OK).
An acoustic alert tone sounds:
•a When the direction of travel is changed at a driving speed of >12.5 km/h
•b After a misoperation when changing the direction of travel if the speed is still >12.5 km/h and the direction cannot be shifted
from NEUTRAL.
(In these two cases there is a continuous tone at intervals)
The continuous tone is switched off by shifting the transmission to NEUTRAL and reducing the driving speed to <12.5 km/h.
• Excessive transmission oil temperature (tone sounds 5 times, then at 2-minute intervals as long as the transmission oil temperature is
too high.)
The number of the fault code indicates the seriousness of the fault
The control automatically switches to another driving programme depending on the seriousness of the fault
NOTE: When shifted to NEUTRAL, the vehicle coasts without being powered by the engine

DRIVING PROGRAMMES
Normal Driving Fault code 10 - 22
Minor faults, the tractor continues to operate normally. Starting/change of direction possible delayed or jerkily.
Eliminate the fault the next time the tractor is taken to the garage. Delete the fault memory!
Fault code 22 Transmission oil temperature too high
Reduce the load until the fault code goes out. If the fault cannot be eliminated by reducing the load, then the tractor must be taken to the
garage!
Restricted driving Fault code 27 - 41
Power-shifts are locked
Work can be continued. However, it is advisable to go to the garage as soon as possible!
Stand-by driving programme (Limp Home) Fault code 47 - 58
Power-shifts are locked.
Preconditions for starting and changing direction:
• The transmission must be in the neutral position for at least 1 second with the tractor standing still
WARNING: In the event of a failure of rotational speed sensor B6 for the driving speed (fault code 47, 48, 49), it is also
possible
to change the direction of travel at driving speeds exceeding 12.5 km/h - DANGER OF ACCIDENT!
Work which has been started can be finished. The tractor must then be taken to the garage!
Emergency driving programme Fault code 64 - 70
Power-shifts are locked. No function of the main clutch (driving clutch) - Driving only possible via lever keys.
Preconditions for starting and changing the direction of travel:
The transmission must be in the neutral position for at least 1 second with the tractor standing still.
WARNÍNG: When using the emergency driving programme for driving, the power transfer cannot be interrupted by operating
the
clutch pedal. This is only possible via the lever key (S4/4) - danger of accident!
Fault must be eliminated at the garage without delay.
You are not allowed to continue working when using the emergency driving programme!
It is only for driving to the next garage!
It is no longer possible to drive Fault code 76 - 99
IMPORTANT: Call Customer Service/vehicle has to be towed (refer to towing instructions - operating instructions, page 106

ELECTRICS - fusing and welding instructions
Fuses for the power supply:

F 19 3 amps +30 supply potential to A68 fault memory
F 24 10 amps +15/2 supply potential to A68 for operating the Power Shuttle and power-shift control
Both fuses are located on the central printed board (A12)
Electric welding on the tractor or on mounted/connected implements

• Switch off the ignition
Earth for welding must be as close as possible to the welding point

Equipment for programming and fault code read-out
Laptop or PC
With Pentium at least 100 MHz clock frequency
32 MB RAM memory
500 MB hard disk memory
12“colour screen (min.)
CD-ROM drive
Windows 95 operating system Obtainable at specialised dealers
The following programming and software equipment is obtainable at CASE STEYR.

Diagnose Software 1TSW 605
Diagnose Software EST-45 in german 1TSW 611 Diagnose Software EST-38 in german 1TSW 606
for version with in english 1TSW 612 for version in english 1TSW 607
Power Shuttle in france 1TSW 613 without Power Shuttle in france 1TSW 608
in spain 1TSW 614 in spain 1TSW 609
in italian 1TSW 615 in italian 1TSW 610
DPA - 03 interface adapter 1TSW 616
Adapter cabel 1TSW 617

Vehicle Electronic Soft- Vehicle Max. Transmission Identification code
type control ware configuration speed versions Case Steyr
T 7224
9105
CS 110
T 7226 04
9115 40 km / h
CS 120
9125
CS 130
T 7228
9145
CS 150 33 03 1
T 7224
9105
CS 110
T 7226
9115 50 km / h
CS 120 04
9125
CS 130
T 7228
9145 03
CS 150

ABBREVIATIONS
LI Line interruption GV Gear valve
SE Short circuit against earth HV Holding valve
S+ Short circuit against vehicle network plus, general SV Solenoid valve
nPSI Rotational speed at power-shift transmission input Term Terminal
nPSO Rotational speed at power-shift transmission output
nDCO Rotational speed at driving clutch output
nPTO Rotational speed at PTO, driving speed
MC Main clutch
MCped Main clutch pedal
ID Input, digital
IU Analog input voltage (U)
IR Analog input resistance (R)
IF Input frequency (F)
OU Output voltage (U) (supply plus sensor system)
SES Supply earth sensor (sensor system)
SESA Supply earth sensor, analog (sensor system)
ODE Output digital earth
OIP Output current (I) proportional
SPS Supply Plus (actuator system)

11 EEPROM end-of-tape data - NORMAL operating mode - Carry out/repeat
invalid (contact pressure) - Default contact pressure MC adjustment
12 Temperature sensor LI, S+ - Default value: cold - Check cabling
(MCped holding time, splitter holding times, - Check temperature sensor
slip times) - Check sensor supply
- Same operating mode - Check vehicle network voltage
13 Temperature sensor SE - Default value: - Check cabling
(MCped holding times, splitter holding times, - Check temperature sensor
slip times) - Check sensor supply
- Same operating mode - Check vehicle network voltage
14 Synchronous neutral switch - Same operating mode - Check cabling
plausibility - Check neutral switch
- Check rot. speed sensor/cabling
nPTO, nMC
15 Warning lamp LI - Same operating mode - Check cabling
(oil pressure / MC excessive - Check lamp
rot. speed) - Check supply to warning lamp
16 Warning lamp SE - Same operating mode - Check cabling
(oil pressure / MC excessive - Check supply to warning lamp
rot. speed)
17 Warning lamp S+ - Same operating mode - Check cabling
(oil pressure / MC excessive - Check supply to warning lamp
rot. speed)
18 System pressure plausibility - Warning lamp lights up - Check oil pressure switch
- Same operating mode - Check cabling
- Check system pressure
- Check rot. speed sensor for nPSI
19 Signal line display SE - "EE" on display, continuous beep - Check cabling
- Same operating mode - Check display
20 Signal line display S+ - "EE" on display, continuous beep - Check cabling
- Same operating mode - Check display
21 Limit speed exceeded - Continuous beep as long as rot. speed is - Reduce driving speed
excessive- Same operating mode

22 Excess temperature - Signalled by 5x beep, then 1x every 2 min. - Reduce load
- Same operating mode - Switch off engine
27 Characteristic valve LI - ALTERNATIVE STRATEGY operating mode - Check cabling
(power-shifts locked) - Check valve
- Check valve supply (SPS2)
28 Characteristic valve SE - ALTERNATIVE STRATEGY operating mode - Check cabling
29 Characteristic valve S+ - ALTERNATIVE STRATEGY operating mode - Check cabling
30 Holding valve 2 LI - ALTERNATIVE STRATEGY operating mode - Check cabling
31 Holding valve 2 SE - ALTERNATIVE STRATEGY operating mode - Check cabling
32 Holding valve 2 S+ - ALTERNATIVE STRATEGY operating mode - Check cabling
33 Holding valve 1 LI - ALTERNATIVE STRATEGY operating mode - Check cabling
34 Holding valve 1 SE - ALTERNATIVE STRATEGY operating mode - Check cabling
35 Holding valve 1 S+ - ALTERNATIVE STRATEGY operating mode - Check cabling

36 Gear valve 2 LI - ALTERNATIVE STRATEGY operating mode - Check cabling
37 Gear valve 2 SE - ALTERNATIVE STRATEGY operating mode - Check cabling
38 Gear valve 2 S+ - ALTERNATIVE STRATEGY operating mode - Check cabling
39 Gear valve 1 LI - ALTERNATIVE STRATEGY operating mode - Check cabling
40 Gear valve 1 SE - ALTERNATIVE STRATEGY operating mode - Check cabling
41 Gear valve 1 S+ - ALTERNATIVE STRATEGY operating mode - Check cabling
47 nPTO rot. speed sensor LI, - LIMP-HOME operating mode - Check cabling
S+ - Check rot. speed sensor
48 nPTO rot. speed sensor SE - LIMP-HOME operating mode - Check cabling
- Check rot. speed sensor
49 nPTO rot. speed sensor - LIMP-HOME operating mode - Ignition off/on
gradient - Check cabling
(plausibility) - Check rot. speed sensor
50 nMC rot. speed sensor LI, S+ - LIMP-HOME operating mode - Check cabling
51 nMC rot. speed sensor SE - LIMP-HOME operating mode - Check cabling
52 nMC rot. speed sensor - LIMP-HOME operating mode - Ignition off/on
53 nPSO rot. speed sensor LI, - LIMP-HOME operating mode - Check cabling
S+ - Check rot. speed sensor
54 nPSO rot. speed sensor SE - LIMP-HOME operating mode - Check cabling
55 nPSO rot. speed sensor - LIMP-HOME operating mode - Ignition off/on
56 nPSI rot. speed sensor LI, S+ - LIMP-HOME operating mode - Check cabling
57 nPSI rot. speed sensor SE - LIMP-HOME operating mode - Check cabling
58 nPSI rot. speed sensor - LIMP-HOME operating mode - Ignition off/on
64 Clutch pedal sensor system - Shift to neutral, EMERGENCY DRIVING - Ignition OFF/ON.
plausibility operating mode - End-of-tape programming
sensor/switch Make/repeat MCped adjustment
- Check/adjust mechanical tolerance
of the MCped sensor system
- Check cabling
- Check MC switch
- Check MC sensor
- Check sensor supply
- Check sensor/switch for LI,SE,S+
65 Clutch pedal sensor system - Shift to neutral, EMERGENCY DRIVING - Check cabling
LI, SE operating mode - Check sensor installation
- Check sensor
66 Clutch pedal sensor system - Shift to neutral, EMERGENCY DRIVING - Check cabling
S+ operating mode - Check sensor installation
- Check sensor

67 Sensor supply undervoltage - Shift to neutral, EMERGENCY DRIVING - Check cabling
operating mode - Check cabling at temperature
sensor/ clutch sensor
68 Sensor supply - Shift to neutral, EMERGENCY DRIVING - Check cabling
Overvoltage operating mode - Check cabling at temperature
sensor/ clutch sensor
69 Clutch pedal sensor system - Shift to neutral, EMERGENCY DRIVING - Ignition OFF/ON.
Plausibility end-of-tape data operating mode - End-of-tape programming
Make/repeat MCped adjustment
70 EEPROM end-of-tape data - Shift to neutral, EMERGENCY DRIVING - Ignition OFF/ON.
invalid (clutch pedal sensory operating mode - End-of-tape programming
system) Make/repeat MCped adjustment
76 Proportional valve LI - Shift to neutral, - Check cabling
IMMOBILISE VEHICLE operating mode - Check valve
77 Proportional valve SE - Shift to neutral, - Check cabling
79 Direction valve forward LI - Shift to neutral, - Check cabling
80 Direction valve forward SE - Shift to neutral, - Check cabling
82 Direction valve backward LI - Shift to neutral, - Check cabling
83 Direction valve backward SE - Shift to neutral, - Check cabling

85 Combinatorial - Shift to neutral, - Check cabling
driving switch fault (LI, SE, IMMOBILISE VEHICLE operating mode - Check driving switch
S+)
87 Pin coding does not match - CONTINUOUS-NEUTRAL operating mode - Check pin coding
vehicle type - Ignition off/on
(T7100/T7200) - Check end-of-tape data
Carry out end-of-tape programming
- Check cabling
89 SPS1 plausibility (SE,S+) - Shift to neutral, - Check cabling (SE, S+)
IMMOBILISE VEHICLE operating mode - Check voltage at SPS1
- Check voltage at Term.30
- Check forward/reverse valves (S+)
90 SPS2 plausibility (SE, S+) - CONTINUOUS-NEUTRAL operating mode - Check cabling (SE, S+)
- Check voltage at SPS 2
- Check voltage at Term.30
- Check cabling at GV/HV/SVterm.
(S+)
91 MC plausibility circuit - Shift to neutral, - Switch on/off crawling gear lever
IMMOBILISE VEHICLE operating mode - Plugs mixed up on rot. speed
sensors: Nmc/Npto
- Check cabling at proportional valve
(S+)
- Check prop. valve
- Check MC
- Check rot. speed sensors nPSO,
nMC
- Check hydraulic system
92 Vehicle network overvoltage - Shift to neutral, - Ignition off/on
IMMOBILISE VEHICLE operating mode - Check vehicle network
- Check cabling
93 Vehicle network undervoltage - Shift to neutral, - Ignition off/on
IMMOBILISE VEHICLE operating mode - Check vehicle network
- Check cabling
94 Proportional valve S+ - Shift to neutral, - Check cabling

IMMOBILISE VEHICLE operating mode -Check valve
95 Direction valve forward S+ - Shift to neutral, -Check cabling
96 Direction valve backward S+ - Shift to neutral, -Check cabling
97 Application fault - CONTINUOUS-NEUTRAL operating mode -Check application data
98 Configuration fault - CONTINUOUS-NEUTRAL operating mode -Ignition OFF/ON
(End-of-tape customer - Check/carry out end-of-tape
programming) programming (customer, variant)
99 EEPROM end-of-tape data - CONTINUOUS-NEUTRAL operating mode - Ignition OFF/ON
incorrect (vehicle config.) - Repeat end-of-tape programming.

Miscellaneous information
Fault - effect/reaction of system Possible cause of fault Possible remedy

No display activation/"EE" display - EST45 "does not run up" - Check supply paths, LI, SE
- Communication line defective - Check fuse F24 (term.15, term.30)
- Voltage supply defective - Check communication line (LI)
Diagnosis tool cannot set up a - EST45 "does not run up" - Ignition off/on, repeat
connection - Communication line defective - Check supply paths, LI, SE
- Voltage supply defective - Check fuse (term.15, term.30)
- Check communication line (LI)
Power-shift transmission switches to - Wrong vehicle variant selected for end-of- - Check/correct vehicle variant
neutral when starting/reversing (jolt tape programming programmed for end of tape
discernible). - nPSI and nPSO rot. speed sensors defective - Check cabling for rot. speed sensors for
Display: "N", forward/reverse arrows - Defect in hydraulic system nPSI and nPSO
flash, no fault code, continuous beep - (Neutral through reversing monitor) - Check rot. speed sensors for nPSI and
nPSO
Automatic changing up/down in splitter, - Wrong vehicle variant selected for end-of- - Check/correct vehicle variant
shift noises approx. every 1-2 sec. tape programming programmed for end of tape
- Rot. speed sensor for nPSI and nPSO - Check cabling for rot. speed sensors for
defective, mixed up nPSI and nPSO
- Gear valves GV1/GV2 mixed up - Check cabling for gear valves GV1/Gv2
- Defect in hydraulic system - Check rot. speed sensors for nPSI and
(pressure modulation by GV toggling) nPSO
Short interruption in the tractive power - Wrong vehicle variant selected for end-of- - Check/correct vehicle variant
whilst driving with closed drive train tape programming programmed for end of tape
(power-shift pressure modulation) - Rot. speed sensor for nPSI and nPSO - Check cabling for rot. speed sensors for
defective nPSI and nPSO
- Defect in hydraulic system - Check rot. speed sensors for nPSI and
(pressure modulation by GV toggling) nPSO

Automatic starting not possible, vehicle - No starting lock signal - Check starting lock signal (LI, SE, S+)
remains in neutral

Chapter
6D
ECCU Functional Description
Electronic Central Control Unit
9105a, 9115a, 9125a, 9145a

CS 110, CS 120, CS 130, CS 150

6D
Technische Dokumentation/Training Center April 1999
2
&217(176
GENERAL INFORMATION ............................................................................................................. 3

ELECTRICAL FITTINGS ................................................................................................................ 4
VIEW OF THE ECCU Box .............................................................................................................. 5
OPERATING REGULATIONS, SAFETY DEVICES AND PROTECTIVE MEASURES ................. 6
EXPLANATION of the Functional Schematic Diagram ................................................................... 7
FUNCTIONAL SCHEMATIC DIAGRAM ......................................................................................... 8
ECCU – supply ............................................................................................................................... 9
STARTING .................................................................................................................................... 10
ACTIVATION of the A68 'E' box
for power shift and power shuttle, by means of the lever switch S4/4 or Multicontroller S11 ....... 11
EHR ACTIVATION "Transport" ..................................................................................................... 12
EHR ACTIVATION "Control" (lower) ............................................................................................. 13
EHR ACTIVATION "Fast Retract".................................................................................................. 14
PTO SHAFT front and rear ............................................................................................................ 15
PTO SHAFT (rear): Switching ON and OFF .................................................................................. 16
PTO SHAFT (rear): Management .................................................................................................. 17
PTO SHAFT (front) ....................................................................................................................... 18
AUXILIARY CONTROL UNIT – dual-action, freedom of movement and inhibit block
Operation: Multicontroller
Function: Pressure in connection “A” ............................................................................................ 19
Operation: Multicontroller or joystick
Function: Pressure in connection “B” ............................................................................................ 20
Operation: Multicontroller or joystick
Function: Freedom of movement (floating position) ...................................................................... 21
Operation: Lever switch
Function: Pressure in connection “A” ............................................................................................ 22
Function: Pressure in connection “B” ............................................................................................ 23
Function: Freedom of movement (floating position) ...................................................................... 24
4-WHEEL DRIVE (MFD) “ON” Version without Management and without Optistop ..................... 25
4-WHEEL DRIVE (MFD) “OFF” Version without Management and without Optistop ................... 26
4-WHEEL DRIVE (MFD) “ON” Version with Management and with Optistop ............................... 27
4-WHEEL DRIVE (MFD) “OFF” Version with Management and with Optistop.............................. 28
DIFFERENTIAL LOCK(S): EHR Management in the “Control” function........................................ 29
DIFFERENTIAL LOCK(S): EHR Management in the “Transport” function ................................... 30
Sva 7-97110 EN Ausgabe 05/99

3
GENERAL INFORMATION
Use: Series 9100 – post Power Shuttle versions
Types of tractor CS110 CS120 CS130 CS150 / 9105 9115 9125 9145
Location: In the cab - driver's right-hand side, behind the synchronous shift, under
the black interior covering.
Purpose: The ECCU partially carries out control and regulating functions
automatically.
It also carries out the auxiliary functions necessary for control and
regulation units, which are fitted with their own electronic box.
Main functions:
1) Operation of 2 independent electrical auxiliary control units, e.g. single-
action, double-action, floating position
2) Run-up control for front and rear PTO shafts (with run-up monitoring)
3) Rear PTO shaft management function
Auxiliary functions:
4) Safety circuit, start enable only with the synchronous gearbox gear shift
in the neutral position
5) Neutral position recognition for synchronous gearbox for power shift and
power shuttle control
6) Power shift and power shuttle control, including F/R, Drive inhibitor and
neutral-latching circuit
7) EHR-D switchover-control voltage for the transport, control and fast
retract functions
8) EHR-D latching circuit for the transport and control functions
9) Differential locks management ground for control (intermediate link
between EHR Box and ADM control unit A10)
10) 4-wheel drive indicator lamp activation (MFD)
IMPORTANT for function and troubleshooting:

The ECCU is made up of several electronic circuits.
For this it requires:
A supply of 12 VDC and ground (see Circuit Diagram -41-577-500, Page 35
Section B).
Fuse F34 25 A to A12 on the central print. Supply potential +15/1

4
ELECTRICAL FITTINGS
Number of plug pins and pin layout
PLUG:
The ECCU has 6 Molex system plugs (see Layout, page 3), which, in conjunction
with circuit diagram -41-577-500, carry the following designation and are
connections for the following functions:
X18/3 Supply, 4-wheel drive (MFD), Diff. lock MM, EHR (transport, control and fast
retract
X 6/7 Starting and neutral signal to A68
X10/7 Electrical auxiliary control unit (green)
X10/7 Electrical auxiliary control unit (yellow)
X24/4 Front and rear PTO shaft control and A68 activation (F/R, neutral and drive
inhibitor)
X14/7 Front and rear PTO shaft control and A68 activation (F/R, neutral and drive
inhibitor)
Pin layout:
If an ECCU plug is viewed in the horizontal position and the securing latch is at the
bottom, pin 1 is at the top left-hand side. Count through the rows horizontally.
Abbreviations for electrical components:
A60 ECCU
A55 EHR-Box
A10 ADM (4-wheel drive and differential lock management control unit)
A1 Print
A12 Central print
F Fuse
H Indicator lamp
K Relay
L Indicator lamp
R Resistor
S Switch, spring loaded (contacts)
Y Solenoid coil (e.g. of electrically controlled hydraulic valves)
X.. Plug-in connection
⊥ Ground potential

Sva 7-97110 EN
FUNCTIONS
– Start inhibitor
– Pulse width modulation for rear PTO run-up
– Pulse width modulation for front PTO run-up
– Transmission control from the Multicontroller
lever switch: START INHIBITOR
FORWARD
NEUTRAL
REVERSE
– EHR operation from the Multicontroller
– Signal processing for PTO (rear) and
Lock management (lifting gear, raise lower)
– 4-wheel drive indicator lamp control
– Control for electrical auxiliary control unit 1
– Control for electrical auxiliary control unit 2
VIEW OF THE ECCU Box
SS99D207
5
Edition 05/99
6
OPERATING REGULATIONS, SAFETY DEVICES AND PROTECTIVE
MEASURES
Operating voltage:
12 Volt DC nominal (voltage peaks must not exceed 16 Volts).
Take care when using jumper cables for starting:
– Only connect in parallel to another 12 Volt source (battery or vehicle).
– Take care when using starting aid devices: avoid excess voltage.
– Do not reverse connect the poles.
– Never remove jumper cables during the starting procedure and ensure that the cable clips
can not inadvertently fall off:
This can result in voltage peaks of several hundred Volts – danger of damage to the
ECCU.
Arc-welding on the tractor or implements attached:
– Connect the welding equipment ground to the part to be welded.
– Switch the engine OFF and turn the ignition switch S1 to the 0 position.
– Leave the battery connected.
Protection to the inputs to the ECCU Box:
The inputs are of high resistance, hence no risk of overloading through a short circuit.
Protection to the outputs:
– The outputs to actuators like solenoid valves (PTO, auxiliary control units) are fitted with
special output stages with built-in overload protection against short circuit, short circuit in
coil on solenoids etc. They switch OFF if subject to excess current.
– Outputs to the display – and indicator lamps are on the other hand “Open Collector”
outputs.
They switch these lamps through to ground. During operation in the vehicle, the current is
limited by the load resistance (Lamp resistance).
– When testing, a dummy load (e.g. a lamp of the same but not greater power (Wattage)
must be used to limit the test current, otherwise it will result in an electrical short circuit.
This will destroy the output stage (transistor) immediately.

7
EXPLANATION of the Functional Schematic Diagram
1) Potential (supply to a switch or pushbutton) or input value Sensor (physical).
– For supplies with a permanent ground potential, the number of the grounding point is
given in brackets.
– For positive supplies, e.g. 12 VDC, the potential is stated (+30, +15/1, D+) or non-
electrical input values like e.g. speed, temperature etc.
2) Switch, pushbutton or sensor function, and its designation according to the circuit
diagram.
3) and 4) Input function:
Measurement value (bold letters) in input lines to the ECCU (DC voltage, AC voltage,
frequency) for the function stated previously (input activated).
5) and 6) Input function:
Measurement value in input lines, when the input is not activated.
7) Plug and pin assignment of the corresponding input to the ECCU.
8) Plug and pin assignment of the corresponding output to the ECCU.
9) Output value for the corresponding function.
10) An electrical load activated by the output e.g. solenoid valve, indicator lamp or an input
into another control unit e.g. EHR box or Power Shift-box.
11) Permanently supplied loads, either ground (in this case the number of the grounding
point is given, or a positive supply, in which case the potential is given.

8
FUNCTIONAL SCHEMATIC DIAGRAM
Example: Function STARTING Circuit diagram number and page
e.g. -41-577-500 Pages 1 and 2
INPUTS OUTPUTS
A60 ECCU
1 2 3 4 5 6 7 8 9 10 11
S19 Position neutral Position not K8/1

⊥ Neutral neutral 12 VDC Relay ⊥
(4) switch ⊥ 0.1 VDC 10 VDC X6/7-5 X6/7-1 0 VDC "start" (5)
S1 Position start Position not

Ignition start
+3 switch 12 VDC 0 VDC X6/7-4
0
Example with other Inputs / Outputs
Speed B7 PTO turns PTO does not turn

Rear Speed n/PTO
PTO
shaft
Sensor V in VDC
f in Hz V in VDC
⊥ 0 VDC H3
PTO MM Indicatio 12 VDC
active n +15/1
PTO MM

9
ECCU – supply
-41-577-500 Page 35
Conditions: Ignition switch S1 to position 1
INPUTS
A60 ECCU
Print Fuse
A12 F34 X18/3
+15/1 25A 12 VDC Pin 1
X18/3
12 VDC Pin 2
⊥ X18/3
(22) 0 VDC Pin 3
⊥ X18/3
(22) 0 VDC Pin 4
Note: If fuse F34 is blown, this can be immediately recognised by the various
characteristics, e.g.:
– Will not start, because the ECCU does not make the starting relay K8/1.
– Fault code no. 85 appears on the display on the A Column (gearbox control).
– The EHR diagnosis LED does not light up, because the supply potential +15
through fuse F33 to the EHR is missing.
Fuse F34 supplies F33 in series.

10
STARTING
-41-577-500 Pages 1 and 2
INPUTS OUTPUTS
A60/3 ECU
S19 Position Position not

Neutral neutral neutral K8/1 ⊥
⊥ switch ⊥ X6/7 X6/7 12 Relay (5)
(4) 0.1 VDC 10 VDC Pin 5 Pin 1 VDC "start"
0 VDC
S1 Position not
Ignition Position start
switch start 0 VDC X6/7
+30 12 VDC Pin 4
Requirements for starting:
– Power supply to the ECCU must be available.

– Gear shiftf or the 6 speed synchronous gearbox must be in the neutral position.

11
Activation of the A68 ’E’ box
for power shift and power shuttle, by means of the lever switch S4/4 or
Multicontroller S11
41-577-50 Page 33
INPUTS OUTPUTS
A60/5 ECCU A68
+15/2 Pushbutton After an impulse

form v Pushbutton Pushbutton not from Pushbutton V
S8 Terminal 5 pressed pressed the 12 VDC
Seat remain until
conta S4/4 X14/7 X24/4 another
ct S11/7 0 VDC Pin 7 Pin 20 pushbutton is Pin 63
12 VDC pressed
(then 0 VDC)
+15/2 Pushbutton After an impulse

form R Pushbutton Pushbutton not from Pushbutton R
S8 Terminal 6 pressed pressed the 12 VDC
Seat remain until
conta S4/4 X14/7 X24/4 another
ct S11/8 0 VDC Pin 5 Pin 12 pushbutton is Pin 20
12 VDC pressed
(then 0 VDC)
12VDC after
turning S1 to
Pushbutton Pushbutton Pushbutton not position 1 or if
N pressed pressed pushbutton N was
Terminal 3 pressed.
S4/4 0 VDC if another
X14/7 X24/4 pushbutton is
+15/2 0 VDC Pin 3 Pin 21 pressed Pin 65
12 VDC
Drive
inhibitor Pushbutton Pushbutton not
Terminal 2 pressed pressed
S4/4 X24/4
+15/2 S11/13 0 VDC Pin 3
12 VDC
12VDC 0 VDC Pin 30
Prerequisite for the function of pushbutton N and the drive inhibitor and safety pushbutton
S11/13 on the Multicontroller:
– Power supply +15/2 from fuse S24 must be available.
Prerequisite for the function of pushbuttons V and R:
– Power supply +15/2 to the seat contact S8 must be available.
– The driver must be seated, so that the seat contact S8 feeds potential +15/2 to
pushbuttons V and R (not only to lever switch S4/4 but also to the Multicontroller S11).

12
EHR ACTIVATION "Transport"
-41-577-500 Pages 29 and 30
Note:
– To activate the “Transport” function, Multicontroller pushbutton S11/1 must be
pressed.
– Once activated by a trigger impulse, this function is maintained (ECCU latching circuit)
until another function is selected.
– After the engine has been stopped or whenever it is re-started, the EHR automatically
goes to the "control" function.
INPUTS OUTPUTS
A60/4 ECCU A55
MC Pushbutton "Transport" the "transport" function EHR

S11/1 pressed 6.4 VDC box
Pushbutton 12 VDC X18/3 X18/3 2
or /3 of 9.5 VDC stab. Pin 21
+15Si Transport not pressed Pin 9 Pin 6
0 VDC
R3/4 the "transport" function S2/72

9.5 to Conta
VDC print A16 6.4 VDC X18/3 X18/3 cts
stab. Pin 5 Pin 7 0 VDC open
Requirements in the EHR-D box for the "Transport" function:

– Supply +15/2 to the EHR box
ECCU must be available.
– Power supply +15Si to Multicontroller switch S11/1 must be available.
– S2/11 (switch +15Si) must be switched to the "ON" position.
Note: After the engine has been started, the pushbutton function "Transport" is also used
to activate the EHR!

13
EHR ACTIVATION "Control" (lower)
-41-577-500 Pages 29 and 30
Note:
– To activate the “Control” function, 2 buttons on the Multicontroller must always
be pressed simultaneously: Button S11/2 and button S11/13 (Safety button).
– The signal from the button is fed in SERIES through the "made" safety switch S2/11.
– Once activated by a trigger impulse, this function is maintained (ECCU latching circuit)
until another function is selected.
– After the engine has been stopped or whenever it is re-started, the EHR automatically
goes to the "control" function.
INPUTS OUTPUTS
A60/4 ECCU A55
Pushbutton S11/2
MC "Control"and EHR
S11/13 safety pushbutton S11/13 Box
pressed
12 VDC "Control" function.
and 1 or both pushbuttons
not pressed
0 VDC 4.8 VDC
+15/2 S11/2
to Pushbutton Note:
S11/ "Control" The signal is fed in X18/3 X18/3 or 1/3 of 9.5 VDC stab.
13 SERIES through Pin 8 Pin 6 Pin 21
the "made" safety switch
S2/11
"Control" function. S2/72

9.5 R3/4 Conta
VDC to X18/3 X18/3 cts
stab. print A16 9.5 VDC Pin 5 Pin 7 4.8 VDC open
Requirements in the EHR-D box for the "Control" function:

– Power supply +15/2 to Multicontroller switch S11/13 must be available.
– S2/11 (switch +15Si) must be switched to the "ON" position.

14
EHR ACTIVATION "Fast Retract"
-41-577-500 Pages 29 and 30
Note:
The "Fast Retract" function is only active as long as the pushbutton S2/72 is pressed.
The ECCU does not provide latching in this function.
INPUTS OUTPUTS
A60/4 ECCU A55
indirectly S2/72 Pushbutton "Fast Retract" "Fast Retract" function EHR

grounded
through Pushbutto pressed Box
R3/5 n 3.3 VDC 3.3 VDC
"Fast Pushbutton not pressed X18/3 X18/3
Retract" 4.8 VDC Pin 7 Pin 6 or 1/3 of 9.5 VDC stab. Pin 21
R3/4 "Fast Retract" function

9,5 to
VDC print A16 9.5 VDC X18/3
stab. Pin 5
Requirements in the EHR-D box for the "Fast Retract" function:

– The connection to ground, via resistor R 3/5 to the "Fast Retract pushbutton" (S2/72)
must be made.

15
PTO SHAFT front and rear
Flow diagram Switching the PTO shaft ON, OFF, Monitoring and Management (only for
the rear PTO shaft)
Briefly turn PTO shaft Preparation

Press one of the Use the PTO shaft lever to Use switch S2/57
"ON" buttons select a speed of 540 or 1000 to select display of the
briefly several times and N or ECO rear PTO shaft
(rear PTO shaft only) or front PTO shaft speed
Switching "ON"
Speed signal from PTO shaft rotates slowly Press one of the "ON"
sensor B7 and comes to a standstill buttons for at least
rear PTO shaft or
from sensor B8 Modulated PTO shaft run-up for 1.5 sec’s.
front PTO shaft and continues running Indicator L7 lights up
available
PTO 10 sec’s. after switching ON

PTO shaft Managemt. comes to a no speed signal
standstill available at the ECCU or
speed too low
Unlatch pushbutton S2/71 and
press once EHR in the
"Control" function PTO sh. continues running
Ind. L7 (PTO shaft) lights up
Indicator H3 (MM) lights up
Tractor can be driven and the PTO shaft comes to a Tractor can not be driven the
EHR will be operated in the standstill after 1.5 sec’s. EHR will be operated in the
"Transport" function Indicator L7 doesn’t light up "Transport" function
Indicator H3 blinks
Tractor can be driven and the PTO shaft runs-up once Tractor can not be driven and
EHR will operate in the again the EHR will operate in the
"Control" function within Indicator L7 lights up "Control" function within
120 sec's. Indicator H3 lights up 120 sec's.
Tractor can be driven and the PTO shaft – Standby Tractor can not be driven and
EHR is operated only after function has expired. the EHR is operated only
120 sec's in the "Control" PTO shaft will be autom. after 10 sec's in the "Control"
function. shut down completely function.
Indicator L7 doesn’t light up

Indicator H3 doesn’t light up
To run the PTO shaft again,
press an “ON” button
PTO shaft management active PTO shaft remains at a A button

An external EHR button standstill “PTO OFF”
is pressed PTO shaft remains OFF is pressed
(switch ON by pressing the
“ON” button)

16
PTO SHAFT (rear)
-41-577-500 Page 34
Switching ON and OFF

INPUTS OUTPUTS
A60/1 ECCU
S2/70/2 Y5
Pushbutton PTO ON Pushbutton not Solenoid
PTO shaft Pushbutton pressed valve
ON, PTO pressed X24/4 X24/4 Rear ⊥
D+ shaft OFF 0 VDC Pin 4 Pin 8 12 VDC PTO (4)
12 VDC shaft
S17/1 Pushbutton Pushbutton not L7 ⊥

Rear pressed pressed Indicator A1
pushbutton X24/4 X24/4 12 VDC lamp print
D+ PTO ON 12 VDC 0 VDC Pin 6 Pin 10 0 VDC PTO ON
S17/2 Pushbutton Pushbutton not

Rear pressed pressed
pushbutton X24/4
D+ PTO ON 12 VDC 0 VDC Pin 5
S2/70/2 PTO OFF Pushbutton not

PTO shaft Pushbutton pressed
ON, PTO pressed X24/4
D+ shaft OFF 0 VDC Pin 22
12 VDC

pushbutton X24/4
D+ PTO OFF 12 VDC 0 VDC Pin 24

pushbutton X24/4
D+ PTO OFF 12 VDC 0 VDC Pin 23
S14/1 EHR contacts are At least 1 rear

S14/2 normally closed EHR
S15/1 no pushbutton pushbutton
S15/2 pressed pressed
⊥ Rear EHRH ⊥ X14/7
(17) pushbutton 0 VDC Pin 4
approx. 3.8 VDC
B7 Rear PTO turns Ignition ON

Speed Rear PTO  3.5 VDC PTO does not turn
PTO shaft speed 180 Hz Level
rear sensor 540 rpm “high” 6.2 VDC X14/7
end “low” 1.5 VDC Pin 14
Requirements for the rear PTO shaft to run and remain ON after switching ON
– Power supply to the ECCU and to sensor B7 must be available; 12 VDC, Potential +15
– Ground potential, through all 4 rear EHR buttons must be available at the ECCU
– Power supply to the PTO “ON” buttons must be available; 12 VDC, Potential D+
– The digital signal must be present, when the PTO shaft turns

17
PTO SHAFT (rear)
-41-577-500 Page 34
Management
INPUTS OUTPUTS
A60/1 ECCU
S2/71 Pushbutton Pushbutton EHR Y5

pushbutto PTO MM PTO MM Control Solenoid
n pressed not 12 VDC valve
pressed Transp Rear PTO
PTO X24/4 X24/4 ort shaft ⊥
+15/ SHAFT 12 VDC 0 VDC Pin 17 Pin 8 0 VDC (4)
MM
“active”
PTO A55 EHR EHR H3

runs EHR Function Function ⊥ Red
under Box Control Transport 0.7 indicator
Control ⊥ X14/7 X24/4 VDC lamp
Pin 15 0 VDC 12 VDC Pin 2 Pin 19 12 VDC PTO +15/
SHAFT
MM
“active”
Speed A1 Tractor Tractor can not

print can be driven be driven X14/7
 6.6 VDC 0 Hz Pin 12
Requirements for PTO shaft management:

– The PTO shaft must already be switched ON.
– Power supply +15/ to button S2/71 PTO MM must be available.
– Ground potential from A55 EHR box must be available at the ECCU in the “Control”
function in order to run the PTO shaft in the Management mode.
Note:
– With the tractor at a standstill, EHR in the “Transport” function and PTO shaft
Management active, the PTO shaft will switch OFF after only 10 sec’s.
– As long as the tractor is in motion, the latching time for the PTO Management is
2 minutes.
– Red indicator lamp H3 blinks during the latching period.

18
PTO SHAFT (front)
-41-577-500 Page 34
Switching ON and OFF
INPUTS OUTPUTS
A60/1 ECCU
S2/70/1 Pushbutton PTO shaft “ON” pressed Y4

pushbutto 12 VDC Solenoi
n d valve
PTO shaft Pushbutton not pressed X24/4 X24/4 12 VDC PTO ⊥
D+ ON, PTO 0 VDC Pin 15 Pin 11 0 VDC front (4)
shaft OFF end
S2/70/1 Pushbutton PTO shaft “OFF” pressed L7

pushbutto 12 VDC Indicato ⊥
n r lamp A1
PTO shaft Pushbutton not pressed X24/4 X24/4 12 VDC PTO print
D+ ON, PTO 0 VDC Pin 13 Pin 10 0 VDC ON
shaft OFF
Front PTO shaft “turns”:

Speed B8 Square wave signal 3.5 VDC constant
PTO Sensor 483 Hz at 1000 rpm
shaft Speed Front PTO shaft does not turn:
(front) front PTO Level “high” 6.2 VDC X14/7
shaft Level “low” 1.5 VDC Pin 13
Requirements for the front PTO shaft to run and remain ON after switching ON
– Power supply to the ECCU and to sensor B8 must be available: 12 VDC, Potential +15
– Power supply to the PTO “ON” button must be available; 12 VDC, Potential D+
– The digital signal must be present, when the PTO shaft turns

19
AUXILIARY CONTROL UNIT – dual-action, freedom of movement and inhibit
block
-41-577-500 Page 26
Function: Pressure in connection "A":

Operating:
By means of the Multicontroller (S 11/5 green) or button (S36) on the joystick or
external pushbutton (S14/3) for the front end lifting gear.
Note:
If one of the buttons is pressed, all 3 outputs (solenoid coils Y2/1, Y2/3 and Y2/4) will
be energised simultaneously.
– The function “pressure in A” is only then active for as long as a button is pressed (no
latching).
– The power supply to buttons (+15 safety) via fuse F14 must be available, as a result:
switch S2/11 must be in the “ON” position.
INPUTS OUTPUTS
A60/6 ECCU
S11/5 1 of the 3 buttons pressed

S36 12 VDC energised Y2/1
S14/3 12 VDC
pushbutto
n No pushbutton pressed X10/7 X10/7 not energised ⊥
+15Si Pressure 0 VDC Pin 5 Pin 2 0 VDC (22)
in “A”
energised
12 VDC Y2/3
X10/7 not energised ⊥

Pin 4 0 VDC (22)
energised
12 VDC Y2/4

Pin 1 0 VDC (22)
Requirements for “pressure in connection A”

– Power supply to the pushbuttons (+15Si) must be available.

20
AUXILIARY CONTROL UNIT – dual-action, freedom of movement and inhibit
block
-41-577-500 Page 26
Function: Pressure in connection "B":

Operating:
By means of the Multicontroller (S 11/4 green) or button (S36) on the joystick or
external pushbutton (S14/3) for the front end lifting gear.
Note:
If one of the buttons is pressed, both outputs (solenoid coils Y2/1 and Y2/2) will be
energised simultaneously.
– The function “pressure in A” is only then active for as long as a button is pressed (no
latching).
INPUTS OUTPUTS
A60/6 ECCU
S11/4 1 of the 3 buttons pressed

S36 12 VDC supplied Y2/1
S15/3 12 VDC
pushbutton
Pressure in No pushbutton pressed X10/7 X10/7 not energised ⊥
+15Si “B” 0 VDC Pin 10 Pin 2 0 VDC (22)
supplied
12 VDC Y2/2

Pin 3 0 VDC (22)
Requirements for “pressure in connection B”


21
-41-577-500 Page 26
Function: Freedom of movement (floating position)

Operating:
By means of the Multicontroller (S 11/11 green)
Note:
If pushutton S11/11 is pressed, both outputs (solenoid coils Y2/3 and Y2/4) will be
energised simultaneously.
– The “Freedom of movement” function remains active, due to the latching circuit in the
ECCU, until another function is selected or the ignition switch is turned to the “0”
position.
INPUTS OUTPUTS
A60/6 ECCU
Pushbutton S11/11 pressed supplied

S11/11 12 VDC 12 VDC Y2/3
Latching
pushbutto
n No pushbutton pressed X10/7 X10/7 not energised ⊥
+15Si Freedom 0 VDC Pin 7 Pin 4 0 VDC (22)
of
Movement
supplied
12 VDC Y2/4
Latching
X10/7
Pin 1 not energised ⊥
0 VDC (22)
Requirements for “Freedom of movement” (floating position)

– Power supply to button S11/11 (+15Si) must be available.

22
-41-577-500 Page 26
Function: Pressure in connection "A":

Operating:
with lever switch S16
Note:
If the lever switch S16 is moved to the 1 position, all 3 outputs (solenoid valves Y2/1,
Y2/3 and Y2/4) will be energised simultaneously.
– The switch position 1 is a pushbutton function, for this reason: – The function “pressure
in B” is only then active for as long as a lever switch is held in the 1 position (no
latching).
– The power supply to the lever switch (+15 safety) via fuse F14 must be available, as a
result: switch S2/11 must be in the “ON” position.
INPUTS OUTPUTS
A60/6 ECCU
S16 Lever switch held in the “1”

Lever position supplied Y2/1
switch 12 VDC 12 VDC
position 1
Pressure Lever switch held in the “0” X10/7 X10/7 not energised ⊥
+15Si in “A” 0 VDC Pin 6 Pin 2 0 VDC (22)
supplied
12 VDC Y2/3
X10/7 X10/7 not energised ⊥

Pin 8 Pin 4 0 VDC (22)
supplied
12 VDC Y2/4

Pin 1 0 VDC (22)
Requirements for “pressure in connection A”

– Power supply to lever switch S16 (+15Si) must be available.

23
-41-577-500 Page 26
Function: Pressure in connection "B":

Operating:
Note:
If the lever switch S16 is moved to the 3 position, both outputs (solenoid valves Y2/1,
Y2/2) will be energised. simultaneously.
– The switch position 3 is a pushbutton function, for this reason: The function “pressure
in B” is only then active for as long as a lever switch is held in the 3 position (no
latching).
Operating a HYDROMOTOR
– If the lever switch S16 is moved further to position 4, the output function Pressure in
connection "B" is maintained:
– The lever switch can be latched in position 4 by turning the knob on the lever.
INPUTS OUTPUTS
A60/6 ECCU
S16 Toggle switch held in the “3”

Toggle position: 12 VDC supplied Y2/1
switch Toggle switch held in the “4” 12 VDC
position 3 position: 12 VDC
Pressure Toggle switch held in the “0” X10/7 X10/7 not energised ⊥
+15Si in “B” 0 VDC Pin 10 Pin 2 0 VDC (22)
supplied
12 VDC Y2/2
X10/7 X10/7 not energised ⊥

Pin 8 Pin 3 0 VDC (22)
Requirements for “pressure in connection B”


24
-41-577-500 Page 26
Function: Freedom of movement (floating position)

Operating:
Note:
– If the lever switch S16 is moved to position 2, both outputs (solenoid coils Y2/3 and
Y2/4) will be energised simultaneously.
– The switch position 2 is a pushbutton function, for this reason:
the “Freedom of movement” function is maintained until the switch is released.
– The lever switch can be latched in position “2” by turning the knob on the lever.
INPUTS OUTPUTS
A60/6 ECCU
Lever switch
S16 in position “2” energised Y2/3
Toggle 12 VDC 12 VDC
switch Lever switch Latching
latched in position “2” ⊥
+15Si Position 2 12 VDC (22)
Freedom Lever switch
of in position “0” X10/7 X10/7 not energised
Movement 0 VDC Pin 6 Pin 4 0 VDC
energised
12 VDC Y2/4
Latching
⊥
X10/7 not energised (22)
Pin 1 0 VDC
Requirements for “Freedom of movement” (floating position)

– Power supply to lever switch S16 (+15Si) must be available.

25
4-WHEEL DRIVE (MFD) “ON”
-41-577-500 Page 6
Version without Management and without Optistop

Requirements for 4-wheel drive “ON”:
Solenoid valve Y1 must not be energised. Due to this, the 4-wheel drive clutch is not
hydraulically activated (0 bar in the 4-wheel drive clutch).
The Belleville spring is effective, thus the 4-wheel drive clutch is engaged.
INPUTS OUTPUTS
A60 ECCU
S2/27 4-wheel drive “ON” Function Y1

Switch contacts open 4-wheel drive Solenoi
Switch “ON” d valve
F13 “4-wheel X18/3 X18/3 Solenoid valve 4-wheel ⊥
+15/1 drive” 0 VDC Pin 16 Pin 17 not energised drive (4)
0 VDC
Indicator lamp L13 potenti

L13 lights up Indicato al pos.
X18/3 ⊥ r 58D
Pin 18 0 VDC lamp
4-wheel
drive
Potential 58D:
The letter D stands for “Dimmer”.
The 4-wheel drive indicator lamp L13 is supplied with various voltages in the print A1,
independent of whether the tractor’s lights are ON or OFF.
58 D with “Lights OFF”: approx. 8 VDC (indicator lamp not very bright).
58 D with “Lights OFF”: approx. 3.5 VDC (indicator lamp even less bright) to avoid
impeding night vision.

26
4-WHEEL DRIVE (MFD) “OFF”
-41-577-500 Page 6
Version without Management and without Optistop

Requirements for 4-wheel drive “OFF”:
Solenoid valve Y1 is energised. Due to this, the 4-wheel drive clutch is hydraulically
activated (18 bar in the 4-wheel drive clutch).
The force of the Belleville spring is counteracted and the 4-wheel drive clutch is
disengaged.
INPUTS OUTPUTS
A60 ECCU
S2/27 4-wheel drive “OFF” Function Y1

The switch contacts 4-wheel drive Solenoi
Switch are closed “OFF” d
F13 “4-wheel X18/3 X18/3 Solenoid valve valve ⊥
+15/1 drive” 12 VDC Pin 16 Pin 17 is energised 4-wheel (4)
12 VDC drive
Indicator lamp L13

L13 does not Indicato potenti
light up r al pos.
X18/3 Lights OFF: 8 lamp 58D
Pin 18 VDC 4-wheel
Lights ON 3.5 drive
VDC:

27
4-WHEEL DRIVE (MFD) “ON”
-41-577-500 Page 5
Version with Management and with Optistop

Requirements for 4-wheel drive “ON”:
Solenoid valve Y1 must not be energised. Due to this, the 4-wheel drive clutch is not
hydraulically activated (0 bar in the 4-wheel drive clutch).
The Belleville spring is effective, thus the 4-wheel drive clutch is engaged.
INPUTS OUTPUTS
A60 ECCU
Switch position Function Y1

A10 when not S2/59 4-wheel drive 4-wheel drive Solenoi
ADM braking Switch “permanently “ON” d
4- ON” X18/3 X18/3 Solenoid valve valve ⊥
12 VDC wheel Pin 16 Pin 17 not energised 4-wheel (4)
drive 0 VDC 0 VDC drive
with MM S2/59 Management Indicator lamp L13 potenti

A10 and F = Switch 4-wheel drive L13 lights up Indicato al pos.
ADM < 14 km/h 4- “ON” X18/3 X18/3 ⊥ r 58D
wheel 0 VDC Pin 17 Pin 18 0 VDC lamp
drive 4-wheel
drive

28
4-WHEEL DRIVE (MFD) “OFF”
-41-577-500 Page 5

Conditions for 4-wheel drive “OFF”:
Solenoid valve Y1 is energised. Due to this, the 4-wheel drive clutch is hydraulically
activated (18 bar in the 4-wheel drive clutch).
The force of the Belleville spring is counteracted and the 4-wheel drive clutch is
disengaged.
INPUTS OUTPUTS
A60 ECCU
Switch position Function Y1

A10 when S2/59 4-wheel drive 4-wheel drive Solenoi
ADM not Switch “OFF” “OFF” d
braking 4- and X18/3 X18/3 Solenoid valve valve ⊥
wheel no braking Pin 16 Pin 17 is energised 4-wheel (4)
12 VDC drive 12 VDC 12 VDC drive
Indicator lamp L13 potenti

L13 does not light Indicato al pos.
X18/3 up r 58D
Pin 18 Lights OFF: 8 VDC lamp
Lights ON: 3.5VDC 4-wheel
drive

29
DIFFERENTIAL LOCK(S) – Management
-41-577-500 Page 29
EHR in the “Control” function

INPUTS OUTPUTS
A60/4 ECCU
EHR “Control” function ⊥

A55 grounded A10
EHR box no ground ADM
Terminal (12 VDC) X18/3 X18/3 0.6 VDC Pin
34 Pin 11 Pin 10 8

30
DIFFERENTIAL LOCK(S) – Management
-41-577-500 Page 29
EHR in the “Transport” function

INPUTS OUTPUTS
A60/4 ECCU
EHR “Transport” function light up

A55 ⊥ grounded A10
EHR box grounded ADM
Terminal 0.2 VDC X18/3 X18/3 4.4 VDC Pin
34 Pin 11 Pin 10 8

Section
6002
6002
TROUBLESHOOTING
TRANSMISSIONCONTROL - electric and

electronic T7200 L
(post Power-Shuttle)
9105, 9115, 9125 und 9145

CS110, CS120, CS130 und CS150
Training Center April, 1999
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Chapter
6003
TROUBLESHOOTING
4-Wheel Drive – Differential lock –

Management
6003
(post Power Shuttle versions)
9105, 9115, 9125 and 9145

CS110, CS120, CS130 and CS150
Training Center April 1999
EMPTY PAGE

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127(
– All values measured with the Digital Multimeter.
– Tractors 9105 - 9145 and CS 110 - 150 are series 91.
– FA is the abbreviation for Front Axle.
– OPTI - STOP means that 4-wheel drive is automatically switched ON when braking with both pedals.
(GLWLRQ
6008
Chapter
6008
DISASSEMBLY AND RE-ASSEMBLY
POWER SHUTTLE CLUTCH

(Supplement to Chapter 6006)
9105a, 9115a, 9125a, 9145a

CS110, CS120, CS130, CS150
Technische Dokumentation/Training Center July, 1999
6008-2
Index
Disassembly....................................................................................................................... 3
Re-assembly ...................................................................................................................... 7
Power shuttle – driving clutch ............................................................................................ 7
Pre-assembling the inner disk carrier ................................................................................ 7
Adjusting the disk assembly air gap................................................................................... 8
Adjusting the Clutch Shaft and Crawler gear Synchronisation .......................................... 16
Special Tools, Category 1

Clamping device Socket wrench
SS99J066 SS99J067
1 x 1W5870654031 1 x 1TSW 621

6008-3
Disassembly
STEP 1 STEP 4
Parting the power shift transmission from the main
transmission:
To part the power shift transmission from the main
transmission, see Basic Workshop Manual 7-70690
(CASE) or TS 261/96 (STEYR) Section 1.1 / Page
1.01 / Fig. 1 to Page 1.02 / Fig. 5.
Power shuttle – driving clutch:
127( The disassembly power shuttle – driving
clutch illustrated here is based on a transmission
version "without crawler gear". Further steps
regarding versions "with crawler gear" can be found sd99g025
in the Basic Workshop Manual.
Loosen the screwed connection and pull the oil feed
out of the borehole in the housing.
STEP 2
STEP 5
sd99g023
Remove the complete driving clutch from the main sd99g026

transmission.
Remove the packing ring and both rectangular rings
127(The packing ring exposed by this can remain (arrows).
on the clutch shaft (see Fig. Step 5) or in the
countershaft borehole.
STEP 6
STEP 3
sd99g027
sd99g024
Remove the axial roller bearing and washer.
Remove the pressure spring.

6008-4
STEP 7 STEP 10
sd99g028 sd99g031
Remove the clutch bell housing and both halves of Remove the lip sealing ring.
the pin ring.
STEP 11
STEP 8
sd99g032
sd99g029
Lever the inner disk carrier out.
Pre-tension the inner disk carrier (pressure springs),
127( Disassembly made more difficult by ’O’-ring
using a press and thrusting bush, and remove the
expansion – see Fig. Step 13!
circlip.
STEP 12
STEP 9
sd99g033
sd99g030
Remove the packing ring and all component parts of
Pull the clutch shaft out.
the disk assembly.

6008-5
STEP 13 STEP 16
sd99g034 sd99g037
Remove the pressure springs (8 x 2 items) and the If necessary, drive the inner shielding plate (’O’-ring
’O’-ring (arrow) from the piston. locator) evenly out through the oil borehole.
STEP 14 STEP 17
sd99g035 sd99g038
Release the cirlip and pressure plate. Remove the ’O’-ring (shielding plate locator) from the
piston.
STEP 15
STEP 18
sd99g036
sd99g039
Remove the lip sealing ring from the piston.
Proportional valve ("Y3" driving clutch):
Remove the oil feed pipe.
127(Pay attention to the exposed seal (arrow)!

6008-6
STEP 19 STEP 22
sd99g040 sd99g043
Screw the filter (sieve) insert out of the borehole. Unscrew the valve.
(use a socket wrench 1TSW 621)
STEP 20
STEP 23
sd99g041
sd99g044
Remove the nut (screw-on plug).
Speed transmitter – output speed/driving clutch:
127(Pay attention to the exposed ’O’-ring
Loosen the screw and pull off the speed transmitter
with 'O'-ring.
STEP 21
sd99g042
Remove the coil.

6008-7
Re-assembly
127( The re-assembly power shuttle – driving clutch illustrated here is based on a transmission version
"without crawler gear". Further steps regarding versions "with crawler gear" can be found in the Basic Workshop
Manual.
Power shuttle – driving clutch
),*85(
Legend to Figure 1
1 = Clutch shaft
2 = Piston
3 = Pressure plate
4 = Disk assembly
5 = Inner disk carrier
6 = Clutch bell housing
VVJ
),*85(
Legend to Figure 2
2 = Sealing cap
3 = ’O’-Ring
4 = Shielding plate
VVJ
Pre-assembling the inner disk carrier

STEP 1 STEP 2
sd99g045 sd99g046
Drive the sealing cap (item 2, Figure 2) flush into the Insert the ’O’-ring (Item 3, see arrow) and oil it.
oil feed borehole access holes.
127(Only required if new parts are fitted.

6008-8
STEP 3 STEP 4
sd99g047 sd99g048
Insert the shielding plate (Item 4). Press the shielding plate in, till it seats.
:$51,1* Ensure it is fitted correctly – see also
Figure 2!
Adjusting the disk assembly air gap:
),*85(
Legend to Figure 3

2 = Packing ring ("S" optional)
3 = End ring
4 = Spring disk
5 = Outer disk
6 = Inner disk
7 = Pressure plate
8 = Piston
9 = Lip sealing ring
10 = 'O'-Ring
11 = Pressure spring
12 = Pressure spring
13 = Circlip
14 = Clutch shaft
15 = Lip sealing ring
16 = Locking ring
* = Seating ⇒ no play
X = Air gap (play) ⇒ 6.0 – 0.4 mm when
the disk assembly is compressed
(outer disk corrugation is flattened)
VVJ F = Axial force 8000 ± 300 Nm
A = Support (support – front side/piston)

6008-9
STEP 5 STEP 8
sd99g049 sd99g052
Measure dimension "I" – see also Figure 3: Slide the end ring (item 3), without packing ring
(item 2), onto the inner disk carrier (item 1).
Slide the piston (item 8) without lip sealing rings (item
9/15) and 'O'-ring (item 10) onto the clutch shaft. 127(Fitted position – see Figure 3.
STEP 6 STEP 9
sd99g050 sd99g053
Slide the pressure plate (item 7) on. Hold the end ring in position and slide on together
with the inner disk carrier.
STEP 7
STEP 10
sd99g051
sd99g054
Place 3 of the pressure springs (item 11) onto the
pressure plate at intervals of 120°. Slide the locking ring (item 16) on loosely.
Pre-tension the pressure springs, using a press and
thrusting bush. In doing so, guide the inner disk
carrier into the pressure plate teeth and insert the
locking ring.

6008-10
STEP 11 STEP 13
sd99g055 sd99g057
Ensure that the fitted parts are seated correctly (see ,03257$17 Immerse the lining disks in an oil bath
also – Item*, Figure 3). for 30 minutes before fitting. Use oil in accordance
with the lubricants list TE-ML 06!
Measure dimension "I" – (see also Figure 3). Thickness of the individual outer lining disks (Item 5)
Dimension "I" e.g.............................48.95 mm e.g. = 2.55 mm
Total sum of all lining disks
STEP 12 e.g. = 20.40 mm
EXAMPLE CALCULATION:
e.g. Outer disk assembly..................... 20.40 mm
e.g. Inner disk assembly.....................+19.65 mm
Result ⇒ dimension "II" e.g............. 40.05 mm
STEP 14
sd99g056
Measure dimension "II"

(thickness of the disk assembly):
Measure dimension "A", inner disk thickness (Item 6)
(inner disks are corrugated and can thus not be
measured as a complete assembly)!
Thickness of the individual disks
sd99g058
e.g. = 2.81 mm
Total sum of all inner disks 127( As an alternative to measuring the individual
e.g. = 19.65 mm disks, the thickness of the disk assembly can be
determined using a press and load cell.
Load the disk assembly (without spring disks) with an
axial force of F = 8000 ±300 N and measure dimen-
sion "II" (thickness of the complete disk assembly)
Dimension "II" e.g..............................40.05 mm
(S) Load cell 5870 700 001
EXAMPLE CALCULATION:
Dimension "I" e.g. ...................................... 48.95mm
Dimension "II" e.g. ..................................- 40.05 mm
result e.g. .................................................... 8.90 mm
Air gap (6.0 - 0.4) ⇒ ..................................- 5.80 mm
Result ⇒ Packing ring "S" = 3.10 mm

6008-11
STEP 15 STEP 18
sd99g059 sd99g062
Remove the circlip and remove the parts fitted to Slide the end ring (Item 3) on.
determine dimension "I".
:$51,1* Ensure it is fitted correctly – see also
Figure 3!
STEP 16
STEP 19
sd99g060
Insert the inner disk carrier (Item 1, Figure 3) into the sd99g063
tensioning device (Part I).
Fit the spring disk (Item 4).
(S) Tensioning device 1W5870654031
127( Fit the individual parts of the disk assembly
alternately, as shown in steps 19 to 22 (see also
STEP 17 Figure 3), onto the inner disk carrier.
STEP 20
sd99g061
Slide on a packing ring (Item 2, Figure 3) "S" of the

sd99g064
required size = e.g. 3.10 mm.
Position the outer disk (Item 5) (spring disk on the
inside).
127( Outer disks (lining disks) must be soaked in
oil prior to fitting! Use oil in accordance with the
lubricants list TE-ML 06!

6008-12
STEP 21 STEP 24
sd99g065 sd99g068
Slide the inner disk (item 6) on. Fit the clamping device (Part II) and align the disks.
Evenly pre-tension the disk assembly by tightening
:$51,1* The assembly instruction, shown in
the wing nuts, until the teeth of the pressure plate
Step 22, must be observed when sliding the
corrugated inner disks on! engage in the teeth of the inner disk carrier.
STEP 22 STEP 25
D E

E

D
sd99g069
sd99g066
:$51,1* The inner disks must be fitted into the Oil the lip sealing ring (see arrow 1) and the ’O’-ring
disk assembly "hill to hill", i.e. missing tooth (whole (see arrow 2) and fit them.
tooth missing) to missing tooth (see pos. a). How- :$51,1* Ensure that the lip sealing ring is fitted
ever, the shortened teeth (half tooth) must be posi- into the piston correctly. The groove must face
tioned alternately to the left and right (pos. b) of the towards the pressure chamber (to the top in the
missing teeth (pos. a). Figure).
STEP 23 STEP 26
sd99g067 sd99g070
Fit the pressure plate (Item 7, Figure 3). Place the pre-assembled piston onto the support
(arrow). Insert the pressure springs (Items 11
and 12).

6008-13
STEP 27 STEP 30
sd99g071 sd99g074
Fit the pre-assembled clutch assembly onto the Fit the lip sealing ring (Item 15, Figure 3) into the
piston. groove in the clutch shaft (Item 14).
:$51,1*Ensure that the lip sealing ring is fitted to
STEP 28 the clutch shaft correctly – groove towards the pres-
sure chamber (direction of arrow)!
STEP 31
sd99g072
Align the piston radially, until the teeth on the piston

coincide with the teeth on the pressure plate. Pre-
tension the pressure springs so that the circlip sd99g075
(Item 13, figure 2) can be fitted. Fit the pre-assembled clutch assembly onto the
clutch shaft.
STEP 29
STEP 32
sd99g073
127( Step 25 is only required if new parts have sd99g076

been fitted. Fit the circlip (Item 16, Figure 3).
Close off the access openings of both oil feed
boreholes (arrow) with grub screws.
127(Use locking fluid (Loctite 262) when inserting
the grub screws!
Tightening torque (M8/10.9) ........ MA = 6 Nm

6008-14
STEP 33 STEP 35
sd99g077 sd99g079
Pre-tension the clutch assembly using a pressure Fit and snap in both rectangular rings (arrow).
piece and remove the fixing device.
STEP 36
STEP 34
sd99g080
sd99g078
Screw in two adjustment screws (M8) and slide the
Check the clutch assembly air gap (play): oil feed ring on till it seats.
Air gap (play).................. Nom. = 6.0 - 0.4 mm.
Support the pre-assembled clutch on the piston STEP 37
(see Item A, Figure 3) and load the clutch shaft with
an axial force of F = 8000N ± 300N.
:$51,1* If the required air gap can not be
achieved, an error was made in determining the
thickness of the packing ring (Item 2, Figure 3). This
must be corrected!
sd99g081
Secure the oil feed ring.

Tightening torque (M8 – 8.8)............... MA = 23 Nm

6008-15
STEP 38
sd99g082
Slide a packing ring on (s = optional, empiric value

e.g. S = 3.30 mm).
STEP 39
sd99g083
Fit the pre-assembled clutch with packing ring but

without pressure spring.
:$51,1* Adjust the axial play or crawler gear
synchronisation adjustment in accordance with the
procedure in the Basic Workshop Manual! (See also
Figure 4).

6008-16
Adjusting the Clutch Shaft and Crawler Gear Synchronisation
Version "I" = View – Transmission unit "without crawler gear"
Version "II" = View – Transmission unit "with crawler gear"
),*85(
9(56,21,
9(56,21,,
VVJ
Legend to Figure 4:
1 = Clutch shaft "A" = Flange surface / main gearbox housing up to the end
2 = Countershaft face / countershaft
3 = Drive shaft "B" = End face / clutch shaft up to the seating / packing ring
4 = Axial roller bearing "C" = Flange surface / power shift gearbox housing up to the
5 = Packing ring seating surface / packing ring
(Version "I" thickness = 6.9 mm / constant) "D" = 0.20 mm + 0.10 mm play (in completely assembled
(Version "II" thickness = optional) gearbox = with gasket fitted)
6 = Profiled bush "F" = 14.50 mm + 0.10 mm (adjustment dimension)
7 = Cover "S" = Packing ring thickness
8 = Cover seating (Versions "I" and "II" thickness = optional)
9 = Power shift gearbox housing "a" = Packing ring thickness
10 = Main gearbox housing (Version "I" = 6.9 mm / constant)
11 = Seal (thickness exaggerated) (Version "II" = optional)
12 = Pressure spring "b" = Seating / clutch body to the seating / packing ring
13 = Crawler gear synchronisation "c" = Seating / clutch body / crawler gear pinion
14 = Crawler gear pinion "d" = Seating – no play
Y = Roller bearing
X = Roller bearing

6008-17
Clutch shaft – adjustment:
– adjustment dimension = 0.2 +0.10 mm (play).
– Measure dimension "A", from the flange surface / main gearbox housing (without seal) to the seating surface /
seat countershaft in bearing Y. With bearing play = 0 (or allow for bearing play).
– Measure dimension "B", at the end face / clutch shaft (but not however on the offset segment – as this is reset).
– Measure dimension "C", from the flange surface / main gearbox housing (without seal) to the seating surface /
packing ring, whereby the drive shaft must be seated in bearing X. With bearing play = 0 (or allow for bearing
play).
– Determine the thickness "S" of the packing ring: S = A – B – C.
– Select the next smallest ring thickness (S = optional – see details in the relevant spare parts list).
Crawler gear synchronisation adjustment (Version "II"):

– Adjustment dimension = 14.50 mm +0.10 mm.
– Measure dimension "b", with the crawler gear pinion on the drive shaft collar seated (no play).
– Determine the thickness "a" of the packing ring: a = 14.50 mm + 0.10 mm.
– Select the next largest ring thickness (S = optional – see details in the relevant spare parts list).

6008-18
STEP 40 STEP 43
sd99g084 sd99g087
After successfully completing adjustment, remove Re-fit the complete clutch (with packing ring).
the clutch from the main gearbox.
:$51,1* Carry out further assembly sequence in
Slide on the inner pin ring segment (arrow) and
accordance with the Basic Workshop Manual!
clutch bell housing. (Version "I" = Section 4.2 / Page 4.04)
(Version "II" = Section 3.2.1 / Page 3.09)
STEP 41
STEP 44

sd99g085
Fit the second pin ring segment. sd99g088
Proportional valve ("Y8" driving clutch):

STEP 42 1 = Nut (screw-on plug)
2 = ’O’-Ring
3 = Coil
4 = Valve
5 = ’O’-Rings
sd99g086
Fit the pressure spring into the countershaft.

6008-19
STEP 45 STEP 48
sd99g089 sd99g092
Fit the valve (Item 4) with ’O’-rings (Item 5). Screw the filter (sieve) insert into the borehole.
(use a socket wrench 1TSW 621)
Tightening torque (M24 x 1.5)............. MA = 10 Nm STEP 49
:$51,1*The tightening torque
(MA = 10 Nm) must not be exceeded (malfunction)!
STEP 46
sd99g093
Fit the seal.
STEP 50
sd99g090
Slide on the coil (Item 3) with ’O’-rings (Item 2).

127(Ensure that the coil is fitted correctly!
STEP 47
sd99g094
Fit the pipeline.

Tightening torque (M8/8.8)............... MA = 23 Nm
sd99g091
Secure the coil (Item 1) with the nut.

Tightening torque................... MA = 5 +3 Nm

6008-20
STEP 51
sd99g095
Speed transmitter (driving clutch):

Fit the speed transmitter (with ’O’-Ring).
127( Grease the contact surface (with e.g.
Glisando 283 EP 2 LF) of the speed transmitter!
STEP 52
sd99g096
Secure the speed transmitter with a cylinder screw.

Tightening torque (M8/8.8).............. MA = 23 Nm

Section
8
8
HOW IT WORKS
OC-LS HYDRAULIC SYSTEM

(Open Center - Load Sensing with Constant Displacement Pump)
9105a, 9115a, 9125a, 9145a,

CS110, CS120, CS130, CS150
Contents
LS Hydraulics – Technical Data Page 8–3 – 8–5

LS Hydraulics – Introduction Page 8–6
LS Hydraulics – Auxiliary Control Unit Variants Page 8–7 – 8–8
LS Hydraulics Scheme – Components List Page 8–9
LS Hydraulics Schematic Diagrams Page 8 – 10 – 8 – 13
Pipe Layout Plan Page 8 – 14 – 8 – 16
Functional Description Page 8 – 17 – 8 – 24
Connection Plate Page 8 – 25 – 8 – 28
SB 23-LS-Q4 Auxiliary Control Unit Page 8 – 29 – 8 – 36
SB 23-LS-Q3 Auxiliary Control Unit without Latches Page 8 – 37 – 8 – 42
SB 23-LS-Q3 Auxiliary Control Unit with Latches Page 8 – 43 – 8 – 44
Electrical Auxiliary Control Unit Page 8 – 45 – 8 – 48
SB 23 LS EHR Control Unit Page 8 – 49 – 8 – 54
Fitting Instructions for LS Blocks Page 8 – 55 – 8 – 56
OC Directional Control Valve Connection Page 8 – 57 – 8 – 58
LS Directional Control Valve Connection Page 8 – 59 – 8 – 60
LS Hydraulics High Pressure Circuit – Technical Data
LS-Hydr./K. Training Center St. Valentin 8–2

Oil System: – Common (Transmission, Steering, Hydraulics)
Oil Quantity / Quality: – 721 / STOU according to ZF lubrication list TE-ML06
Oil quantity available: – with the tractor at a standstill on level ground, the normal oil level is 32 l.
– with the tractor in motion at a longitudinal or lateral angle of tilt of max. 14°, the normal oil level is 20 l.
– at an increased oil level, the above values increase by approx. 8 l.
Oil change: – after 500, 1000, and every further 1000 operating hours – at least once a year
Oil filter: – 130 l/min suction filter cartridge, filter density β18 = 75, by-pass valve opens at 0.3 bar +/- 10 %
HD Gear pump: – 32 cm³ single pump = 78 l/min at 2300 rpm – engine;

– tandem pump – 1st pump 32 cm³ = 78 l/min at 2300 rpm
2nd pump 16 cm³ = 39 l/min at 2300 rpm – engine
Connection plate: – with pressure scale, DBV is 175 bar (pilot valve) ∆p = 4 - 6 bar
∆p changeover to ∆p = 11 bar
– p max. at N = 30 bar
SB 23 Q4 (priority): – double action

– mechanical operation
– latch in positions B and F
– pressure point in position A
– freedom of movement - position
– automatic latching at approx. 150 bar (from 1. January 1999, at approx. 165 bar)
– shut-off valve in B channel
– individual pressure scale (3-way flow regulator) with setting range of 0-45 l/min
– 1st priority after steering
– leakages A → R = 18 cm³/min B → R = 1 cm³/min = at 125 bar
T = 50 °C, ν = 33 mm²/s.

SB 23 Q3 without
latches and freedom of movement
– double-action
– individual pressure scale (2-way flow regulator) with setting range of 0 - 80 l/min
– leakages A → R = 18 cm³/min B → R = 1 cm³/min = at 125 bar
T = 50 °C, ν = 33 mm²/s
SB 23-LS-Q3 with latches

and freedom of movement:
– double-action
– latch in positions B and F
– pressure point in position A
– automatic latching at approx. 150 bar (from 1. January 1999, at 165 bar)
– individual pressure scale (2-way flow regulator) with setting range of 0 - 80 l/min
– leakages A -> R = 18 cm³/min B -> R = 1 cm³/min = at 125 bar
T = 50 °C, ν = 33 mm²/s
ACU EL./LS: – double-action

– electro-magnetic operation
– voltage of magnets = 12 VDC
– power consumption of each magnet = 32.7 W
– resistance of magnets = 2.7 Ω ± 10 %
– continuous duty (100 %)
– max. oil flow is 50 l/min (output A)
– Tightening torque for locking block Y2/4 = 25 Nm
2/4 and 3/4 directional control valves M 5x45 = 9 Nm

SB 23 EHR-LS: – proportional, single-action, LS sublevel construction
– permissible max. pressure p = 250 bar, R1 = 30 bar
– rated pressure flow is 80 l/min
– leakages A -> R = 4 cm³/min at 125 bar, ν = 35 mm²/s
– direct slider operation through 12 V proportional magnet
– coil: R = 1.7 Ω /max. = 3.5 A
– safety valve: 220 + 20 bar
Steering servostat: – Manufacturer: Danfoss OSPQ LSR

– absorption volume of rotor pump is 80 cm³/R
– oil flow with the amplifier slide opened to the maximum is 160 cm³/R
– amplification starts at 10 rpm of the steering wheel
– PLV in the LS connection is 150 bar (from 1st June 1998, it will be 170-175 bar)
Tightening torque for block control units: see page 55.

LS Hydraulics – Introduction
With CASE-STEYR tractors, different hydraulic systems are used for the various tractor series and sizes. Before the Load Sensing
System with fixed displacement pump (LS System) was introduced, CASE-STEYR had exclusively been using the constant flow system.
Since the performance of the hydraulics system is improving continuously and fuel consumption is becoming an issue of increasing
importance, the use of a more advanced hydraulics system is required. The most important improvements of the LS System are as
follows:
• very low neutral circulation pressure (e.g. on long road-journeys) keeps power consumption and oil heating to a minimum
• pressure scale in the connection plate reduces choke losses in the partial power range
• oil flow regulators in the mechanical control units enable operation of several consumers in parallel
• priority control in the first auxiliary control unit (Q4) keeps the hydraulic motor at a constant speed

LS Hydraulics – Auxiliary Control Unit Variants
• The LS System is available with 2 pump variants.

Variant 1: 32 cm³ gear pump = 78 l/min at 2300 rpm engine speed
Variant 2: 32 cm³ tandem gear pump = 78 l/min and 16 cm³ tandem gear pump = 39 l/min
with a total volume flow of 117 l/min at 2300 rpm engine speed
• Front-end and rear-end lifting gear are usually available as single-action but may be ordered as double-action if required.
Variants of auxiliary control units are available in the form of four blocks:
Block 1: 1st position from left, double-action (Q3), freedom of movement, shut-off valve in plug-in connection B,
continuouslyadjustable oil quantity of 0 - 80 l/min, kick-out, mechanical operation;
2nd position double-action with freedom of movement and shut-off valve in plug-in connection B, electromagnetic operation
Block 2: 1st position from left, double-action (Q4) with freedom of movement, shut-off valve in plug-in connection B, continuously
adjustable oil quantity of 0 - 45 l/min, kick-out, mechanical joystick operation in fore and aft direction and priority over other
control units;
2nd position double-action (Q3) without freedom of movement, shut-off valve in plug-in connection B, continuously
adjustable oil quantity of 0 - 80 l/min, mechanical operation through joystick in lateral directions.
3rd position double-action with freedom of movement and shut-off valve in plug-in connection B, electromagnetic operation
Block 3: 1st position from left, double-action (Q4) with freedom of movement, shut-off valve in plug-in connection B, continuously
adjustable oil quantity of 0 - 45 l/min, kick-out, mechanical operation and priority over other control units.
2nd position is the same as for block 2, pos. 2;
3rd position is the same as for block 2, pos. 3;
4th position is the same as for the 3rd position;
Block 4: positions 1, 2, and 4 are the same as for block 3.

3rd position double-action with freedom of movement (Q3), shut-off valve in plug-in connection B, continuously adjustable oil
quantity of 0 - 80 l/min, kick-out, mechanical operation;

Note: From the technical point of view, retrofitting of electrical and mechanical auxiliary control units at a later date is
possible. When ordering the tractor, however, the higher costs of retrofitting should be considered.
Plug-in connections: The plug-in connections used can be connected up under pressure. When connecting, the plug and the
connection can be under pressure. However, the connection must be depressurised. To enable smooth
connecting-up, it is recommended to switch the control unit to the freedom-of-movement position. In the same
way, the plug-in connections are provided with a pull-out protection and an oil tray.

LS Hydraulics Scheme – Components List
1 Suction filter (with by-pass valve) 20 Pressure-free oil return (plug-in connection)
2 32 cm³ gear pump = 78 l/min at 2300 rpm engine speed 21 0.35 bar non-return valve
3 32 cm³ + 16 cm³ tandem pump = 120 l/min at 2300 rpm engine speed 22 1.5 bar non-return valve
4 LS steering priority valve 23 Return plate
5 Four-wheel brake control unit 24 Lubrication for rear PTO shaft
6 Line to the front axle brake 25 3 bar PLV rear axle lubrication
7 Control line from service brake 26 Lubrication of rear axle
8 Control unit – hydraulic trailer brake 27 Splash buffle
9 Plug-in connection – hydraulic trailer brake 28 Steering servostat with 150 bar PLV
10 Control line from working brake 29 Steering cylinder
11 Connection plate with pressure scale and 175 bar PLV 30 Lifting gear cylinder
12 Mechanical auxiliary control unit (depending on block variant) 31 Three-way valve for lifting/pressure
changeover
13 Mechanical auxiliary control unit (depending on block variant) 32 Double-action lifting gear cylinder
14 EHR control unit with 220+20 bar shock valve 33 p line sprung front axle
15 Spacer 96 Cooling for rear axle brake
16 Electrical or mechanical auxiliary control unit (depending on block variant) N Neutral circulation
17 Electrical Auxiliary Control Unit X Insertion plate (divides N/R channel)
18 End plate up to May 1998 p Pressure connection from the pump
19 End plate from May 1998 with LS connection for sprung front axle, R or T Return to the sump
without sprung front axle connected to the return plate LS Signal line
19 A End plate will be implemented as standard (Power Beyond) by the end of 1998 A, B Connection for consumer
55 D+ interrupter (EHR box)
EF Transfer to the connection plate
CF Transfer steering servostat

LS-Hydr./K. Training Center St. Valentin 8 – 10
PIPING PLAN – POWER SHUTTLE


11 12 13 14 15 16 17 18/19
20
30 30

Functional Description
Neutral circulation:
The oil taken in by the gear pump (2) is fed via a pipeline to the priority valve (4). The priority valve has not been included in this scheme
because it is not required for the direct function of the auxiliary control units. The oil flows from the priority valve (4) to the connection
plate (11). The connection plate (11) contains the pressure scale (35) which enables neutral circulation (37) due to the increasing oil
pressure applied to the spring (36). Since no consumer is operated in the neutral circulation, the pressure applied to the closed sliders
(38 + 39) of the individual consumers is very low. The neutral circulation pressure results exclusively from the force of the spring (36)
because signal line (40) merges into the return (41) and is therefore pressure-free.

One consumer in operation:
Once the consumer (I) is activated via the control slider (38) of the first control unit (12), a connection to the signalling shuttle valve (44)
leading into the signalling line is established via the hole (43). Then, the neutral circulation pressure and the spring (36) both act on the
pressure scale (35). Thus, the cross section to the neutral circulation (37) is reduced. The pressure in the pump pipeline (45) rises and
the consumer (I) is in operation. The working pressure applied to the consumer (I) results from the working resistance and the adjusted
oil quantity passing through the oil flow regulator (46) and the adjustable choke on the control unit (12). The working pressure also acts
on the pressure scale (46 = oil flow regulator) via the connection (48). Thus, the speed of the consumer (I) remains constant even with
varying work loads. The first control unit (12) of this equipment contains a three-way oil flow regulator (46), i.e. this control unit has
priority over all other control units. The surplus oil flow is passed by the three-way oil flow regulator (46) via the connection (49) to the
other consumers which are all connected in parallel. Since the consumer (I) does not use all of the oil delivered by the pump (2), the
remaining oil flows back to the neutral circulation (37) passing pressure scale (36).

Two consumers in operation:
In this scheme, the consumer (II) has been activated by the second control unit (13). The slider (39) has established the connection to
the consumer (II) via the connection (49) to the two-way oil flow regulator (20), leading to the adjustable choke (21). The working
pressure of the second consumer (II) results from the load to be moved and the working speed selected. The working speed can be
determined by means of the two-way oil flow regulator (52) and/or the adjustable choke (53). The scheme shows that the working
pressure of consumer (I) is higher than the working pressure of consumer (II) because only the highest pressure of all consumers being
operated is transmitted via the shuttle valves (44 + 45) to the pressure scale (35) in the connection plate (11). Then, the pressure scale
(35) in the connection plate (11) supplies the pressure of consumer (I) and the oil quantity of both the consumers. The excess oil flow
produced by the pump (2) flows from the pressure scale (35) into the neutral circulation (37). Only two consumers are shown in the
scheme. However, up to 4 ACU’s and the EHR control unit can be fitted to the vehicle, i.e. theoretically and practically all consumers can
work with different quantities and working pressures simultaneously, as long as the total oil flow being currently delivered by the pump is
not exceeded.

Maximum working pressure:
The cylinder (II) has run against the stopper, the second control unit (13) remains switched on. The working pressure of consumer (II)
exceeds the working pressure of consumer (I). Therefore, the signalling shuttle valve (44) switches over. Then, the working pressure of
consumer (II) acts on the pressure scale (35) in the connection plate (11). The pump pressure and/or the working pressure of consumer
(II) rises to the maximum working pressure. The choke (56) and the PLV (55) prevent the pressure from rising any further. The slider in
the pressure scale (35) opens the neutral circulation connection (37) until the forces are balanced. The pump (2) works at maximum
working pressure until consumer (II) switches off. Consumer (I) is not affected by the pressure and the varying oil quantities, i.e. the oil
flow set remains constant and the speed of the oil motor does not change.

Connection Plate
In addition to the inlet connection (45) and the neutral circulation connection (N), the connection plate (11) also has a pressure scale (35)
for operating the fixed displacement pump and an adjustable pressure limiting valve (55).
The pressure scale (35) fulfils the following functions:
• In conjunction with the current choke cross sections on the directional control valves – control slider (38) and/or adjustable choke (47)
– the connection plate works as a three-way flow regulator. The load pressure acts, via the (LS) control line (40), on the spring side of
the pressure scale (35). (Spring (36) plus ∆p = 11 bar.)
• When the pressure has been removed from the control line (LS) (40) (all control units are in the neutral position), the inlet pressure
(45) acts on the pressure scale (35) and causes it to open, whereby a ∆p of 4 bar is applied to the spring (36) of the neutral circulation
(N).
• The pressure scale (35) and the adjustable 175 bar PLV (55) make up the main stage of a pilot-operated pressure limiting valve which
is used to restrict the maximum working pressure.
• Test connection (76) for testing the pump pressure (from 1. January 1999, M10x1)
• Test connection (77) for testing the signal pressure (from 1. January 1999, LS M10x1)
• The sectional drawing does not show test connection (77) which is situated opposite the flange face and merges into the LS channel.

Connection Plate – ∆p Changeover
The volume flow passing through a choke depends on the pressure head (∆p), i.e. the greater ∆p the larger the volume flow passing
through the directional control valve. The pressure head (∆p = 4 bar) is determined by the spring (36), resulting in a volume flow which is
actually too low. By reinforcing the spring (36), larger volume flows can be obtained but when the directional control valves are in the
neutral position, the neutral circulation pressure also increases. To realise a large volume flow of 80 l/min and a low neutral circulation
pressure, a pilot valve (34) is integrated in the pressure scale (35). This valve opens, as soon as the pressure in the LS connection (40)
activates one of the directional control valves. Thus, the higher pressure from connection P (45) can be fed through the choke (57) into
the hole (58) and through the open valve (34) and be applied to the spring side of the pressure scale (35). Spring = ∆p 4 bar + ∆p of
changeover = ∆p 11 bar on the choke → resulting in a volume flow of at least 80 l/min (Q3 directional valves).

SB 23-LS-Q4 Auxiliary Control Unit
This directional control valve is a double-action control unit with shut-off valve in connection B, freedom-of-movement position,
mechanical lock in position B and freedom-of-movement position, pressure centre in position A, kick-out and a three-way flow regulator
which gives priority to the control unit. The flow regulator can be adjusted within a setting range of 0 - 45 l/min via a rotary knob outside
the rear window. (This Q4 control unit with priority must be fitted directly after the connection plate, otherwise the priority will be lost.
Operation via joystick in fore/aft direction.)
Neutral Position:
The oil flow is fed from the pump via the connection plate through connection (P) to the control unit (12). From there, it is fed through the
hollow slider of the three-way flow regulator (46) via the adjustable choke (47) to the closed control slider (38). The pressure being
applied presses the slider (46) against the spring (59) and opens connection (P1), which supplies all the other consumers. The spring
(51) holds the control slider (38) in the neutral position. Thus, outputs A and B are closed. In addition, B has a shut-off valve (conical
slide valve 60) which seals the output to 100 %.

Pressure in "B":
The slider (38) is pulled out of the control unit (12) against the spring (51); the balls (61) are latched in this position. The neutral
circulation pressure can act on the pressure scale (35) of the connection plate (11) via the connection released by the slider, the shuttle
valve (44) and the LS connection (40). In the same way, the pressure can act on the spring side of the three-way flow regulator through
the hole (62). The working pressure being produced opens the non-return valve (63) and can be fed through the open shut-off valve (60)
to output B. The oil returning from connection A can flow through the open slider (38) into the connection R. The working speed of the
relevant consumer can be adjusted by means of the displacement of the control slider (38). In the same way, the maximum flow of
0 - 45 l/min can be adjusted using the adjustable choke (47).
Kick-Out:
The automatic shutdown of the control unit shortly before reaching the maximum working pressure is referred to as "kick-out". Upon
reaching the set latching pressure of approx. 150 bar (from 1. January 1999, 165 bar), the oil pressure acts through a hole in the slider
(38) on the latching valve (66) and the piston (67). The piston, on the other hand, exerts pressure on the coned tappet (68). Then, the
balls (61) can give way and the spring (51) can shift the slider (38) to the neutral position. Using the packing rings (69), the latching
pressure can be altered. Inserting packing rings will cause the latching pressure to rise. The pressure set should never be to near the
maximum working pressure in order to ensure a safe shutdown (the temperature of the oil rises).

SB23-LS-Q4 Auxiliary Control Unit
Pressure in "A":
The slider (38) is pushed against the spring (51) into the control unit (12). The balls (61) sense the path and transmit the max. path via
the pressure point (no latch). The neutral circulation pressure can act on the pressure scale (35) of the connection plate (11) via the
connection released by the slider (38), the shuttle valve (44) and the LS connection (40). In the same way, the pressure can act on the
spring side of the three-way flow regulator (46) through the hole (62). Then, the working pressure being produced opens the non-return
valve (63) and can be fed through the open slider (38) to output A. The returning oil flows from connection (B) via the mechanically
opened shut-off valve (60) into the return (R).
Shut-Off Valve:
Under high load pressure, the shut-off valve (60) can only be opened via the pilot valve (64). When the slider (38) is moved, the tappet
(65) exerts pressure on the ball (64), causing the oil to flow into the chamber below the shut-off valve. The slider (38) has not yet opened
the return connection; thus, the pressure produced is the same as in output B (pressure compensation). Due to the pressure
compensation the shut-off valve (60) can be opened without the use of force. The returning oil flow can be adjusted via the fine-control
edges.

Freedom of Movement:
Pushing the slider (38) over the pressure point in position (A) causes the balls (61) to latch into the freedom-of-movement position. The
shut-off valve (60) is completely open, slider (38) has connected channels A, B and R with one another. A consumer, e.g. a cylinder, can
now be freely operated. Thanks to the UPC couplings, devices under pressure can be connected up in the freedom-of-movement
position without the use of force.

SB 23-LS-Q3 Auxiliary Control Unit without Latches
This double-action auxiliary control unit comprises a shut-off valve in output B, and is parallel to the p connection. An oil flow of setting of
0 - 80 l/min is made possible, pressure independent of the two-way flow regulator and the control slider (39). A max. flow of 0 - 80 l/min
can be set through the adjustable choke by means of the adjusting knob outside the rear window. The control unit is mounted in the
second position as seen from the connection plate. It is operated by means of the joystick in a lateral direction without latches.
NEUTRAL POSITION:
The control slider (39) is in the neutral position due to spring (70). The slider of the two-way flow regulator (52) is opened completely by
spring (71). The oil under neutral circulation pressure can flow through the p connection, the slider (52), and the adjustable choke (53) to
the control slider which will then stop the oil flow. Due to the neutral position of the slider (39), the LS connection is linked to the return
(R). Thus, the pressure scale (35) in the connection plate remains in neutral circulation. Outputs A and B are kept closed by the slider
(39). Connection B contains a shut-off valve (74) in order to obtain 100 % sealing.

Pressure in "B":
The slider (39) is pulled out of the control unit (13) against the spring (70) (without latching). The neutral circulation pressure can flow
through the connection (P) via the slider (52), the choke (53), the open control slider (39), the shuttle valve (54) into the LS channel and
act on the pressure scale (35). In the same way, the pressure can pass through the hole (72) and act on the spring side of the two-way
flow regulator. The working pressure now being produced opens the non-return valve (73) and can be passed through the open shut-off
valve (74) to output B. The oil returning from connection (A) can flow via the slider (39) into the R connection. The working speed of the
relevant consumer can be adjusted via the travel of control slider (39). The maximum flow of 0-45 l/min can also be adjusted using the
adjustable choke (53) and remains constant even with changing working pressure.

Pressure in "A":
The slider (39) is pushed against the spring (70) into the control unit (13). The neutral circulation pressure can act on the pressure scale
of the connection plate (11) via the connection enabled by the slider (39), the shuttle valve (54) and the LS channel (40). In the same
way, the pressure can pass through the hole (72) and act on the spring side of the two-way flow regulator. The working pressure now
being produced opens the non-return valve (73) and can be fed through the open slider (39) to output (A). The returning oil flows from
connection (B) via the mechanically opened shut-off valve (74) into the return (R).
Shut-Off Valve: For the functional description, see SB 23-LS-Q4 Auxiliary Control Unit, chapter Pressure in "A" (page 33).

SB 23-LS-Q3 Auxiliary Control Unit with Latches
• Double-action directional control valve,

• Shut-off valve in "B"
• Freedom-of-movement position
• Latch in position "B" and freedom-of-movement position
• Kick-out (150 bar)
• Pressure point in position "A"
• Two-way flow regulator with adjustment range of 0 - 80 l/min
• In block variant 4, mounted in third position
In all positions, this control unit works the same way as the SB 23-LS-Q3 control unit without latch. Thus, the same functional description
applies with the exception of the lock and the freedom of movement. For lock and freedom of movement, see SB 23-LS-Q4.

Electrical Auxiliary Control Unit
The double-action electrically operated auxiliary control unit is always fitted after the mechanical control units. Depending on the block
variant, up to 2 control units may be fitted. The directional control valves used by the control unit are so-called "black/white valves". Due
to the electrical operation, the control unit can be operated in many different ways, e.g. by means of pushbuttons on the multi controller
or joystick or via the remote control in the front grill for the front lifting gear. Electrical control units can also be operated by means of the
lever switch on the right-hand wheel cladding. The control unit can also be equipped with all three operating facilities. The locking block
Y2/4 maintains a pressure seal on output B. The freedom-of-movement position can be selected using the multi controller or the lever
switch. (With electrical control units, the amount of oil flow cannot be regulated.)
Technical data: Tightening torques:
Duty cycle: DC 100 % Securing screws M5x45 = 9 Nm
Voltage: 12 VDC Locking block Y2/4 = 25 Nm
Power consumption: 32.7 W
Oil temperature: -20 to + 100 °C
Max. operating pressure: 320 bar
Max. oil flow: 45 l/min at 50 bar

Electrical Auxiliary Control Unit
I Neutral position:
All solenoid valves are de-energised. Springs keep all three directional control valves in position (see drawing 1). Directional control
valve 2/4 links channel P with A. Channel A is closed. The directional control valve 2/4 links the LS channel with the return. Thus, the
pressures scale (35) in the connection plate (11) remains in neutral circulation. Control valve 4/3 keeps outputs A and B closed. In
addition, the locking block Y2/4 maintains a pressure seal on output B.
II Pressure A:
The solenoid valves Y2/1, Y2/3, and Y2/4 are energised. On the one hand, the neutral circulation pressure is fed through the 2/4
directional control valve to the shuttle valve (75) into the (LS) channel and can act on the pressure scale (35), and on the other hand,
it is fed through the 4/3 directional control valve to output (A). The oil returning from connection (B) can flow through the open Y2/4
locking block and the 4/3 directional control valve into the return.
III Pressure B:
The solenoid valves Y2/1 and Y2/2 are energised. On the one hand, the neutral circulation pressure is fed through the 2/4 directional
control valve to the shuttle valve (75) into the (LS) channel and can act on the pressure scale (35), and on the other hand, it is fed
through the 4/3 directional control valve and the Y2/4 locking block – which acts in this flow direction like a non-return valve – to output
(B). The returning oil flows through the 4/3 directional control valve into the return (R).
IV Freedom-of-movement position:
The solenoid valves Y2/2 and Y2/4 are energised. The oil can flow from output (B) via the open Y2/4 locking block through the 3/4 and
the 2/4 directional control valves into the return connection (R). At the same time, output (A) is also connected to the return via the 4/3
directional control valve. In this position, the hydraulic oil passing the outputs (A) and (B) can flow in both directions. This example
shows, that the piston in the cylinder can move freely.

SB 23-LS EHR Control Unit
General information:
The EHR control unit is mounted in the third position after the connection plate. It is an electro-magnetic proportional control unit of plate
construction with an integrated two-way flow regulator in parallel to the P channel. The magnets are controlled via the A55 E-box by
means of pulse-bandwidth modulation.
Neutral Position:
The magnets (H) and (S) are de-energised. The slider (79) of the two-way flow regulator has been shifted by the spring (75) against the
neutral circulation pressure to a balanced position. The pressure can be fed from connection (P) to the closed slider (80). The (LS)
channel is also connected via slider (80) for lifting, with connection (R). The load pressure from output (A) acts on the conical slide valve
(81), the load safety valve (82), the pilot cone (83), and the main conical slide valve for lowering.
Emergency Operation:
In case of an electrical or electronic failure the slider can be operated manually to raise or lower the lifting gear. The relevant magnet
must6 be pushed onto the rubber cap by means of a pin. (it is not necessary to run the engine to lower)
WARNING: In case the control unit has to be disassembled for cleaning or repair (see maintenance manual), care should be taken not
to remove the positioning screws (92) and (94). Otherwise, the adjustment of the control unit will be altered. If the control
unit has been misaligned, it must be replaced (replacement unit).

RAISING:
The E-box (A 55) energises magnet (H). The current supplied is proportional to the control deviation. The slider (80) is pushed against
the spring (85) of the magnet (H). The pressurised oil from connection (P) can, on the one hand, now flow via the open slider (80)
through the hole (86) and act on the spring side of the two-way flow regulator (79), and on the other hand, flow via the shuttle valve (90)
into the LS channel and act on the pressure scale (35) of the connection plate (11). At the same time, the oil flowing to output (A) causes
the conical slide valve (81) to open. The working pressure being produced results from the implement load and the lifting speed. The
lifting speed depends on the electrical current, which flows through magnet (H) and causes slider (80) to open. Slider (80) acts as an
adjustable choke for the two-way flow regulator (79).
This results in the following options:

1. A lifting speed which does not depend on the load or the pump flow
2. Parallel operation of several auxiliary control units, steering and EHR which work with different flow rates and pressures until such
time as the current pump flow is achieved.

LOWERING:
Depending on the adjustment of the potentiometer for the lowering speed (nominal value), the EHR box supplies the magnet (S) with a
defined current. The position sensor transmits the actual lowering speed value to the EHR box, which continuously compares the
nominal and actual values and adjusts the current supply to the magnet (S) accordingly. This results in a lowering speed independent of
load.
By supplying the magnet (S) with current, the pilot cone (83) opens and the load pressure on the rear side (89) of the main cone (84) is
passed into the return. Then, the pressure acting on the front side opens the main cone (84). Thus, the travel of the main cone (84) is
determined by the travel of the magnet (S) and the pilot cone (83). Opening the main cone (84) causes the pilot cone (83) to close.
When the pilot cone (83) is closed, the load pressure on the rear side (89) can act on the main cone. The returning oil can flow through
an external line (R1) into the sump.

Fitting Instructions for LS Blocks
• When fitting the individual blocks, care should be taken that in certain points between the control units which have been marked in the
drawing with the letter (Z) (very thin intermediate disks), one intermediate disk must be mounted per securing screw. The intermediate
disks (Z) must be fitted to obtain a contact point and to avoid distortion of the control units.
• In the drawing, the securing screws are listed in sequence:
Tighten A -> B -> C using the specified tightening torque
A and B = 25 + 8 Nm
C = 14 + 5 Nm
The property class of the screws and nuts is 10.9
• The insertion plate (X) separates the return from the neutral circulation channel.
To avoid the insertion plate to falling out, grease should be used when fitting it in the connection plate (11).

OC Directional Control Valve Connection
It is possible to integrate OC directional control valves, for the front loader or other consumers, into the hydraulics circuit. The connection
must be established as described in the following scheme (broken lines). Under no circumstances must a consumer be fitted between
the pump and the priority valve, otherwise the priority of the steering would be lost. Care should also be taken that the max. oil flow of
the directional control valve equals or exceeds 80 l. In the directional control valve, a 175 bar pressure limiting valve must be integrated
in order to protect the hydraulic pump.

LS Directional Control Valve Connection
If the factory fitted equipment is insufficient, it is possible connect LS directional control valves and harvesting machines as described in
the following scheme.
There are two possible variants:
1. For tractors without a sprung front axle, the LS line must be connected to the return plate and linked to the directional control valve by
means of the LS connection. Tractors with end plate (18 + 19) must be modified to end plate (19 A).
2. For tractors with sprung front axle, the LS line must be connected to the end plate and fitted with an external shuttle valve as
described in the following scheme (item 98). This shuttle valve is commercially available and can be ordered from Messrs. Parker
under the designation ERMETO WV8-PL (M14 x 1,5). Production of the end plate (19A) will start by the end of 1998. Until then, this
hole in the P channel must be drilled in the workshop.

Section
8A
8A
HOW IT WORKS AND
TROUBLESHOOTING
OC HYDRAULIC SYSTEM
(Open Center)
9105a, 9115a, 9125a, 9145a,

CS110, CS120, CS130, CS150
CASE STEYRLandmaschinentechnik AG Training Center St. Valentin
9105 - 9145 / CS110 - 150 hydraulics St.Valentin, November 1997

1st edition L-LAS / Ad / Schw
CONTENTS
1 - 5 High pressure circuit, 2-circuit hydraulics

6 - 15 Mechanical auxiliary control units
16 - 17 Function of the auxiliary control units
18 - 19 Function of the hydraulic release
20 - 21 Oil flow controller
22 - 25 Electrical auxiliary control units, single-action
26 - 29 Electrical auxiliary control units, double-action + check valve
30 - 31 Hydraulics circuit diagram - control units
32 - 33 Hydraulic steering - non-reaction
34 - 35 Hydraulic steering - reaction
36 - 47 Trailer brake valve + functional description
48 - 56 Test instructions
Hydr. 9105-9145 / Schw

9100 high pressure hydraulics
The working hydraulic system is an open system to which the hydraulic steering is connected via a priority valve. The necessary oil
flow for the steering is metered with priority and load-dependent (LOAD SENSING) by the priority valve. The high pressure circuit
can be equipped with up to four auxiliary control units depending on how it is ordered. The variation possibilities range from three
mechanical auxiliary control units and one electrical unit up to three electrical units and one mechanical unit.
A hydraulic trailer brake valve or a four-wheel brake valve is possible if desired.
Hydr. 9105-9145 / Schw 1

Hydraulics high pressure circuit
1 0.95 η suction filter 16 Free oil return

2 Gear pump 32 cm³ = 78 l/min at 17 3 bar pressure control valve for lubricating oil
2576 rpm (when mot.N = 2300) 18 Transmission lubrication
3 Priority valve 19 Hydraulic trailer brake valve
4 Surge tank 20 Quick coupler for trailer brake
5 Steering servostat (150 bar pressure control valve) 21 Brake valve for 4-wheel brake
6 Steering cylinder 22 Line to front axle
7 Connection plate with 175 +12 bar pressure control valve
8 EHR (electronic lifting gear) control unit 23 OC
(with 220 +20 bar shock valve) P = Pressure line
9 Auxiliary control units, electrical or mechanical CF = to steering
10 Intermediate piece EF = to hydraulics
11 End plate N = Neutral
12 Lifting gear cylinder T = Tank (return)
13 Return plate Y1 = Control line - service brake, right
14 1.5 bar check valve Y2 = Control line from 2 +3 bar emergency valve
15 0.35 bar check valve
Hydr. 9105-9145 / Schw 2

Hydr. 9105-9145 / Schw 3

2 - circuit hydraulics
23 2nd gear pump 16 cm³ = 39 l/min at 2300 rpm (motor)

24 2nd connection plate with 175 +12 bar pressure control valve
25 Auxiliary control unit, electrical or mechanical
Hydr. 9105-9145 / Schw 4

Hydr. 9105-9145 / Schw 5

B 410 ... auxiliary control unit, single-action
Construction: Slide valve seat construction with mechanically unlocking check valve and hydraulic release (kickout).
Lock and circuit controller
Nominal flow: 70 l/min
Max. permissible operating pressures: P 250 bar

T 20 bar
N 250 bar
B 250 bar
Max. leakage from B to T 1 cm³/min at 125 bar and an oil temperature of 50°C.
Fields of application: Single-action working cylinders which are restored by dead load or external load and oil motors with a direct
return to the oil tank.
Hydr. 9105-9145 / Schw 6

Hydr. 9105-9145 / Schw 7

B 414 ... auxiliary control unit, double-action - pressure sealed in B
Construction: Slide valve seat construction with mechanically unlocking check valve in B with free floating and hydraulic
release (kickout). Outlet A = Parallel connection
B = Blocking circuit

T 20 bar
N 250 bar
A, B 250 bar
Max. leakage from A to T 18 cm³/min and from B to T 1 cm³/min at 125 bar and an oil temperature of 50°C.
Field of application: Control of single and double-action working cylinders plus free floating as well as oil motors with supply and
return lines.
Hydr. 9105-9145 / Schw 8

Hydr. 9105-9145 / Schw 9

B 414 … auxiliary control unit, double-action - pressure sealed in A and B
Construction: Slide valve seat construction with mechanically unlocking check valve in A and B with free floating and
hydraulic release (kickout). Outlet Lock and circuit controller
Max. permissible operating pressures:

P 250 bar
T 20 bar
N 250 bar
A, B 250 bar
Max. leakage from A and B to T 1 cm³/min at 125 bar and an oil temperature of 50°C.
Field of application: Control of single and double-action working cylinders plus free floating as well as oil motors with supply and
return lines.
Hydr. 9105-9145 / Schw 10

Hydr. 9105-9145 / Schw 11

B 414 … auxiliary control unit, double-action - pressure sealed in A and B
Construction: Slide valve seat construction with mechanically unlocking check valve in B without locating and free floating
Outlet A = Parallel connection
B = Blocking circuit
Max. permissible operating pressures:

P 250 bar
T 20 bar
N 250 bar
A, B 250 bar
Max. leakage from A to T 18 cm³/min and from B to T 1 cm³/min at 125 bar and an oil temperature of 50°C.
Fields of application: Operating implements on front loaders.
Hydr. 9105-9145 / Schw 12

Hydr. 9105-9145 / Schw 13

Auxiliary control unit, double-action, with integrated changeover to single-action and oil flow controller
Construction: Slide valve construction with hydraulic release (kickout).

T 20 bar
N 250 bar
A, B 250 bar
Max. leakage from A / B to T 20 cm³/min at 125 bar and an oil temperature of 50°C.
Important: If free floating is required for double-action working cylinders, then the control unit has to be converted to single-action.
Connection B is thus permanentely connected to T. Connection A can now be operated in all functional positions like a
single-action device.
Hydr. 9105-9145 / Schw 14

Function of the auxiliary control units
Hydr. 9105-9145 / Schw 15

The individual valves are arranged in a row. The valves can have a parallel connection or blocking circuit or a mixture of both.
The control channels in the housing have a symmetrical layout for all versions. However, the control valve is always shaped
according to the application.
The oil supply as well as the volume flow to the respective working connection is determined by the position of the control valve.
The version shown corresponds to the B 414 double-action auxiliary control unit. Connection A is not pressure sealed, connection
B is pressure sealed by a shut-off valve.
Switch positions: 1. Neutral, as long as the control valve remains in this position, the oil can flow from the two
outer channels into the middle one and from there into the neutral circulation.
2. Pressure in B
3. Pressure in A
The middle channel is closed by shifting the control valve. Channel
B or A is supplied with pressure oil depending on the movement of the slide valve and
the opposite side is connected to the return line.
4. Float position, both outlets A and B are connected to the return line.
5. Check valve for pressure oil supply via non-pressure sealed connections (parallel connection).
6. Shut-off valve for pressure sealed connections (blocking circuit).
Hydr. 9105-9145 / Schw 16

Hydr. 9105-9145 / Schw 17

Function of the hydraulic release Mechanical unlockable check valve
The hydraulic release ("kickout") disengages a The pilot-operated sealing cone is released via a
latched slide valve position as soon as the user attains a bevel on the control valve and a push rod.
response pressure of approx. 150 - 160 bar. If, for
example, a cylinder moves against a limit stop, the
slide valve which was latched in a working position
beforehand automatically goes back to its initial
position with neutral circulation. 1 Sealing cone
2 Push rod
1 Pull-back spring
2 Stop only for single-action control units or control units without float position
3 Notch for switch position pressure in B
4 Notch for switch position pressure in A
5 Notch for free floating
6 Pressure channel to release valve
7 Adjusting disks for release pressure
Hydr. 9105-9145 / Schw 18

Hydr. 9105-9145 / Schw 19

Oil flow controller
3 way flow control valve

Adjustable constant flow 2 - 40 l/min
The residual flow is fed to the downstream valves via the neutral circulation.
IMPORTANT: In the event of malfunctions, adjust the basic setting of the oil flow controller to the value given
above.
Changeover from double to single-action:
Channel T is connected directly to the working connection which is not in use by turning the handwheel. The double-action control
unit can then be operated as a single-action unit. Field of application, for example, single-action cylinders or tippers.
Hydr. 9105-9145 / Schw 20

Hydr. 9105-9145 / Schw 21

B 410 ... - electrical auxiliary control unit, single-action
Operating time: OT 100%

Voltage: 12 V direct voltage
Power supply: Jet plug-in connection
Power consumption: 30 W
Make time: 110 ms
Break time: 150 ms
Op. pressure: up to 250 bar
Oil temperature: -20° to +80°C
P - Supply from pump

N - Continuation of supply to next control unit
R (T) - Return to tank
A - Connection for user (pressure sealed)
S - Through fastening bores (tightening moment for M8 - 10.9 = 22 - 27 Nm)
Y2/1 - LOWER solenoid valve
Y2/2 - RAISE solenoid valve
Hydr. 9105-9145 / Schw 22

Hydr. 9105-9145 / Schw 23

B 410 ... Switch positions of the single-action auxiliary control unit
A = Neutral
B = RAISE
C = LOWER
Y2/1 Y2/2
RAISE m l single-
action
Neutral m m
LOWER l m
m Magnet deenergized
l Magnet excited
Hydr. 9105-9145 / Schw 24

B 414 ... electrical auxiliary control unit - double-action + shut-off valve
Hydr. 9105-9145 / Schw 25

Operating time: OT 100%

Voltage: 12 V direct voltage
Power supply: Jet plug-in connection
Power consumption: 30 W
Make time: 110 ms
Break time: 150 ms
Op. pressure: up to 250 bar
Oil temperature: -20° to +80°C
P - Supply from pump

N - Continued supply to next control unit
R (T) - Return to tank
A (B) - Connection for user (pressure sealed)
S - Through fastening bores (tightening moment for M8 - 10.9 = 22 - 27 Nm)
Y2/1 - Neutral circulation solenoid valve
Y2/2 - Pressure in B solenoid valve
Y2/3 - Pressure in A solenoid valve
Y2/4 - Shut-off valve in B
Hydr. 9105-9145 / Schw 26

Hydr. 9105-9145 / Schw 27

B 414 ... - four switch positions of the double-action auxiliary control unit
A = Neutral
B = Pressure in "B"
C = Pressure in "A"
D = Float positions
Y2/1 Y2/2 Y2/3 Y2/4
Pressure in B l l m m double-
action
Neutral m m m
Pressure in A l m l l
Float position off m m m m
Float position on m m l l
m Magnet deenergized
l Magnet excited
Hydr. 9105-9145 / Schw 28

Hydraulics circuit diagram - control units
Hydr. 9105-9145 / Schw 29

1 Connection plate with 175 +12 bar pressure control valve

2 EHR (electronic lifting gear) control unit SB 23 OC (functional description: refer to document "EHR D 9105-9145")
3 Double-action auxiliary control unit, float position and shut-off valve in B
4 Double-action auxiliary control unit without float position and locking, with shut-off valve in B, for implement operation on front
loaders.
5 Double-action auxiliary control unit with float position (free floating) and shut-off valves in A and B.
6 Electrical double-action auxiliary control unit with shut-off valve in B
7 End plate
Hydr. 9105-9145 / Schw 30

Hydr. 9105-9145 / Schw 31

Hydraulic steering
The 9100 series was equipped with a DANFOSS OSPQ 80 / 160 LS steering servostat when series production was taken up.
OSPQ is a LOAD-SENSING steering unit with an integrated The boost factor can lie between 1.2 and 2.
oil flow booster which meters an oil flow to L or R via the gear cluster There is no oil flow boost at steering
proportional to the rotational speed of the steering and depending wheel speeds of under 10 rpm.
on the boost factor. The oil flow boost function is fully active at steering speeds
above 20 rpm.
The pressure control valve is located outside the servostat in a rectangular block. It has a setting of 150 bar.
The priority valve is integrated in the pump housing. The OSPQ 80/160 LSR servostat was used from vehicle No. ... → upwards.
This servostat has the following differences compared to the earlier servostats: The pressure control valve is integrated in the
servostat housing and this servostat is a reaction version. The priority valve is not integrated in pump.
OSPQ 80/160 LS diagram (non-reaction)
1 150 bar pressure control valve (external) P = Pump

2 Booster slide valve (Q slide valve) T = Tank
3 205 - 225 bar hose safety valves CF = Connection to steering P
4 Priority valve (on pump) EF = Connection to hydraulics
LS = Sensor connection
L-R = left - right
V = Connection for boost oil flow
Hydr. 9105-9145 / Schw 32

OSPQ LSR diagram (reaction)
Hydr. 9105-9145 / Schw 33

Functional description of OSPQ steering:
The servostat steering for Steyr tractors is not a new feature and a functional description will therefore be dispensed with. The "Q"
version is new and will be described in the following.
When steering, the connection from LS to T is blocked. The pressure in the LS connection increases and moves the slide in the
priority valve (OLS). The oil flow thus reaches the P connection in the servostat (OSPQ) via CF. The pressure in the P connection
then increases and makes the booster slide valve (Q slide valve) build up the boost oil flow and also the pilot oil flow. First of all the
pilot flow flows to the gear cluster (used to steer). The boost oil flow (used to support the steering process) is then carried directly to
the cylinder line via the steering. However, this boost can only has an effect on the steering wheel at 10 rpm.
The reason for this version: A high volume flow at a low rotational speed at the steering through an additional oil flow via a booster
slide valve. Realisable steering forces in emergency steering mode through small absorption volume at the rotor pump (80 cm³/
revolution of the steering wheel).
1 150 bar pressure control valve (integrated) P = Pump

2 Booster slide valve (Q slide valve) T = Tank
3 Priority valve CF = Connection to steering P
EF = Connection to hydraulics
LS = Sensor connection
L-R = left - right
V = Connection for boost oil flow
Hydr. 9105-9145 / Schw 34

Hydraulic trailer brake valve / 4-wheel brake valve
Hydr. 9105-9145 / Schw 35

The hydraulic trailer brake valve / 4-wheel brake valve is available as optional equipment.
It is mounted on the right-hand side of the rear axle in series between the priority valve and the connection for the auxiliary control
units.
Make: BOSCH
Oil supply: via 175 bar high pressure pump
max. brake pressure:150 bar
max. oil flow: 15 l/min
Control piston: ∅ 20 mm as a trailer brake valve and ∅ 14 mm when used for the 4-wheel brake
P = Pump connection
N = Connection for downstream auxiliary control units
B = Connection for the trailer brake
T = Tank (connection for oil sump)
Y1 = Connection for the control line from the tractor's service brake (wheel brake cylinder, right)
Y2 = Connection for the control line from the tractor's service brake (2 +3 bar emergency valve)
Hydr. 9105-9145 / Schw 36

Hydr. 9105-9145 / Schw 37

Construction and function of the trailer brake valve / 4-wheel brake valve
The trailer brake valve consists of the following elements:
- Flow control valve 1

(with throttle (9) and screen (11)) to control the delivery flow Qp and the flow of hydraulic fluid for the trailer brake.
- Control valve 2
(with piston area 13) to control flow control valve 1 and the pressure of the trailer brake.
- Pressure control element 4
(with pretensioned springs 8) to restrict the pressure of the trailer brake
- Drive head 5
(with piston 6 and bleed valve 7) to control the trailer brake valve via the tractor's service brake.
Hydr. 9105-9145 / Schw 38

Hydr. 9105-9145 / Schw 39

Trailer brake - released
The control line Y is pressureless. The brake line is relieved via control valve 2 and connection T to the tank. The delivery flow (Qp)
from the pump flows from connection P past flow control valve 1 and then further with Qp - Qx to the hydraulics via connection N.
A small control oil flow (Qx) of approx. 0.6 l/min flows from connection P via screen 11, throttle 9, bore 10, control valve 2 and
connection T to the tank. The pressure drop at throttle 9 thus keeps flow control valve 1 in the free through position a.
Flow control valve 1 does not have a control function.
Hydr. 9105-9145 / Schw 40

Hydr. 9105-9145 / Schw 41

Partial braking of the trailer brake - initiation
Pressure is applied to piston 6 of drive head 5 via control line Y from the tractor's service brake. Control valve 2 is then pushed to
the left and first disconnects brake line B and then bore 10 from the tank. Control valve 2 is shifted from position c to position e.
The control oil flow is blocked whereby flow control valve 1 is controlled in position B (control function).
A constant flow Qr (e.g. 15 l/min.) flows from connection P to the trailer brake via screen 11, bore 12 and connection B.
Screen 11 is designed for the constant flow Qk.
A residual flow Qr flows past flow control valve 1 and then to the tractor's hydraulics via connection N. Pressure is built up in trailer
brake line B and reacts on area 13 on control valve 2 against the pressure on piston 6.
Hydr. 9105-9145 / Schw 42

Hydr. 9105-9145 / Schw 43

Partial braking of the trailer brake
The trailer brake pressure pb (acts on area 13 of control valve 2) is equal to the tractor brake pressure py (acting on piston 6).
Brake line B remains disconnected from the tank thus enclosing the oil in the trailer brake. On reaching the pressure balance,
control valve 2 is shifted to the right and opens bore 10 via connector R to the tank. Control valve 2 is in position d. Flow control
valve 1 is thus controlled in position a and does not have a control function.
As in the case of the released trailer brake, the delivery flow Qp from the pump flows to the tractor's hydraulics via connection N
with Qp - Qx and the control oil flow Qx flows to the tank via control valve 2.
Hydr. 9105-9145 / Schw 44

Hydr. 9105-9145 / Schw 45

Maximum braking of the trailer brake - limited brake pressure
Flow control valve 1 and control valve 2 have the same slide positions (a and b) as in the case of partial braking.
The flows of hydraulic fluid Qp and Qx flow in the same way as for partial braking.
The maximum permissible trailer brake pressure pb (e.g. 150 bar) has been attained. A further increase in the trailer brake pressure
is prevented even if the tractor's brake pressure continues to increase. Pressure control valve 4 is shifted to the left in this case.
The springs (8), pretensioned to the maximum permissible trailer brake pressure pb, are depressed. If the trailer brake pressure pb
increases, e.g., through external influences, then control valve 2 opens brake line B to the tank for a short while whilst preventing
the brake pressure from increasing any further.
The tractor's hydraulic system can be used as desired and can be subjected to a pressure load via connection N in every functional
position of the trailer brake valve. There is no appreciable reaction on the trailer brake. The trailer brake has priority over the
tractor's hydraulics. The maximum pressure of the tractor's hydraulics can be higher than the maximum trailer brake pressure.
Hydr. 9105-9145 / Schw 46

Hydr. 9105-9145 / Schw 47

Test instructions for the high pressure hydraulics
The following test values were measured at an oil temperature of 60°C and should be seen as guide values.
Attention: Equipment variants, component tolerances or a different oil viscosity can cause deviations from the specified values.
Attention must be paid that adapter pieces made to test oil flows have a sufficient cross section. One should also bear in mind that
the pressure control valve does not provide any protection when tests are being carried out upstream from it and that pressures
exceeding 250 bar can cause damage or destroy pumps or other components.
Tools: - TSW 515-1 hydraulics tester

- 2 high pressure hoses with quick couplers
- Additional connection parts have to be made
Hydr. 9105-9145 / Schw 48

Test 1
Hydr. 9105-9145 / Schw 49

Motor Oil temp. Q P measured at possible faults

rpm °C l/min bar notes
mechanical double-action, → 175 +12 bar pressure control
A or B → free return valve→ auxiliary control units
→ hydr. trailer brake valve → hydr. front axle
brake valve → priority valve → pump
1000 60 34 -
2300 60 76 -
1000 60 26 150
2300 60 68 150
2300 60 0 190
Kickout at approx.
135
Test 2
To pump → pump line to priority valve → Pump / pump drive → pump speed
1000 60 36 15 Neutral circulation
2300 60 78 45
1000 60 36 150
2300 60 72 150
2300 60 69 175
Hydr. 9105-9145 / Schw 50

Test 3
Motor Oil temp. Q P measured at possible faults

rpm °C l/min bar notes
Priority valve (EF) → pipeline to aux. control unit → Priority valve → Pump
connection plate without steering
1000 60 36 11 Neutral circulation
2300 60 76 37
1000 60 25 175
2300 60 67 175
Test 4
Motor Oil temp. Q P/CF P/LS measured at possible faults

rpm °C l/min bar bar
CF connection at priority valve → hose
line to surge tank
1000 60 0 14 1 without steering
2300 60 0 14 1
Q and P depending on axle load
1000 60 - 114 100
and
steering speed
1000 60 0 164 150 Steering cylinder at limit
Hydr. 9105-9145 / Schw 51

Test 4a
Motor Oil temp. Q P/CF P/LS measured at possible faults

rpm °C l/min bar bar
CF connection at priority valve → free → Priority valve → steering servostat →
return pump
1000 60 37 not under
load
2300 60 56
Test 5
Motor Oil Q P measured at possible faults

rpm temperat l/min bar notes
ure
°C
Electrical auxiliary control unit outlet A or B →
free return
1000 60 28 not
under
load
2300 60 70
1000 60 27 150
2300 60 55 150
Hydr. 9105-9145 / Schw 52

Test 6 EHR (electronic lifting gear) control unit
U
Motor Oil temp. Q P U measured at possible faults
rpm terminal 28-35
°C l/min bar MGV on X55 notes
EHR control unit outlet A → free return
Slowly turn the target value pot
towards "Raise" until the "Raise" arrow
lights up and the mixed pot to
1000 60 7 - 2.3 VDC 0.13 VDC "Position". (The E-box switches off
after a certain time as no movement of
the lifting arms is signalled → ignition
OFF/ON → activate).
Target value pot on max. raise (E box
2300 60 77 - 6.8 VDC 0.38 VDC switches off again after a certain time)
Test 7 Electrical auxiliary control unit
Electrical aux. control outlet A/B → → EHR control unit (e.g. slide
EHR control unit outlet A (flow valve jams) → electrical (e.g.
direction elect. aux. contr. unit → EHR) magnetic coil, plug oxidated etc.)
Slowly turn the target value pot
1000 60 3 - 2.5 VDC 0.14 VDC towards "Lower" until the "Lower"
arrow lights up.
2300 60 70 - 6.6 VDC 0.36 VDC Target value pot on max. lower
Hydr. 9105-9145 / Schw 53

Test 8 EHR (electronic lifting gear) control unit
Put the EHR control unit under pressure by means of a hand pump at connection A until the load safety valve opens (220 +20 bar).
Then check for leakage. The pressure must not drop noticeably. Possible faults: Safety valve → Lowering or check valve.
Hydr. 9105-9145 / Schw 54

Test 9 Hydraulic trailer brake

Motor Oil temp. P1 in bar P2 in bar measured at possible faults
rpm °C Service brake Hydr . brake notes
P1 pressure gauge on service brake "Y"
(Knott and Sirmac brake
∅ 20 mm control piston)
P2 pressure gauge on quick coupler of trailer
brake
1000 60 1 10
2 20
3 30
4 40
5 50
6 60
7 75
8 85
9 95
10 110
11 120
12 130
13 135
50 135
Test 10 4-wheel brake
Hydr. 9105-9145 / Schw 55

Motor Oil temp. P1 in bar P2 in bar measured at possible faults

rpm °C Service brake Hydr.-brake notes
P1 pressure gauge on service brake
(bleeding of wheel brake cylinder)
P2 pressure gauge on 4-wheel brake line
(Knott and Sirmac brake ∅ 14 mm control
piston)
1000 60 <2-5 0
6 5
7 8
8 13
9 20
10 24
15 55
20 81
25 108
30 135
35 140
40 140
Hydr. 9105-9145 / Schw 56

Chapter
8C
HOW IT WORKS
CC-LS HYDRAULIC SYSTEM

(Closed Center-Load Sensing)
9105, 9115, 9125 and 9145

CS110, CS120, CS130 and CS150
8C
Training Center September, 1999

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&RPPRQ.............................................................................................. oil supply (transmission, steering, hydraulics)
2LOTXDQWLW\TXDOLW\............................. 175 l / STOU corresponding ZF list of lubricants TE-ML06 (see Chapter 6)
2LOTXDQWLW\DYDLODEOH
Tractor stationary, level ground and normal oil level .............................................................................................. 32 l
With the tractor in motion and max 14° longitudinal or lateral angle of tilt 14° ....................................................... 20 l
With increased oil level, the above values increase by ............................................................................... approx. 8 l
2LOFKDQJH........................................... at 500, 1000, and every further 1000 operating hours – at least once a year
2LOILOWHUFKDQJHe .............................................................................................................................. every oil change
6XFWLRQILOWHUFDUWULGJH......................................................... ∆p = 0.1 bar at 30 cst and 130 l/min, filter gauge 160 µ
3UHVVXUHILOWHU ...................... ∆p = 0,15 bar at 30 cst and 120 l/min, β16 = 75, service switch opens p > 1.0 + 0.2 bar
PFC Pump unit

Supply pump .......................................................................................................... 57 cm³ 140 l/min 2300 rpm motor;
PFC axial piston pump ............................................................................................ 45 cm³ 110 l/min 2300 rpm motor
Ratio ............................................................................................................................. i = 1:1.12 l motor / PFC pump
Turbo-pump pressure .................................................................................................................... min. 0.8 max. 5 bar
Nominal working pressure ....................................................................................................................... 205 +/- 5 bar
Control ∆p (Standby, without steering) ...................................................................................................... 20 +/- 1 bar
Control ∆p (Standby, with steering) ................................................................................................ approx.25 - 26 bar
Safety valve ..................................................................................................................................................... 235 bar
3ULRULW\YDOYH/7+$(standard fitting)
Priority 1 ............................................................................................................................................... Steering circuit
Priority 2 ..................................................................................................................... EHR and Auxiliary control units
7UDLOHUEUDNHYDOYH/7+3 (optional extra)

Priority 2 .................................................................................................................................................. Trailer brake
Hydraulic transmission ..................................................................................... Piston diameter D = 20 mm d = 6 mm
Brake pressure ........................................................................................................................................ max. 150 bar
ZKHHOEUDNHYDOYH/7+3 (optional extra)

Priority 2 ................................................................................................................................................ 4-wheel brake
Hydraulic transmission ............................................................................... 1:4 piston diameter D = 12 mm d = 6 mm
Brake pressure ................................................................................................................................ max. 90 - 105 bar
ZKHHOEUDNHYDOYH/7 (optional extra)

Application ................................................................................................... together with hydraulic trailer brake LT43
Hydraulic transmission ............................................................................... 1:4 piston diameter D = 18 mm d = 9 mm
Brake pressure ................................................................................................................................ max. 90 - 105 bar
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Actuation .......................................................................................................................... Mechanical – double-action
Latch ............................................................................................................................................ in positions B and F
Pressure point .......................................................................................................................................... in position A
Floating position ....................................................................................................................................... in position F
Automatic unlatching ...................................................................................................................... at approx. 165 bar
Shut-off valve ........................................................................................................................................... in B channel
Individual pressure scale .................................................................. (3-way flow regulator) setting range 0 - 80 l/min
Leakages ..................................................... A to R 18 cm³/min, B to R 1 cm³/min at 125 bar, 50 °C, viscosity 33 cst.

4
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Actuation .......................................................................................................................... mechanical – double-action
Leakages .................................................... A to R 18 cm³/min, B to R 1 cm³/min at 125 bar, 50 °C, viscosity 33 cst.
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Actuation .......................................................................................................................... mechanical – double-action
Latch ............................................................................................................................................. in positions B and F
Pressure point .......................................................................................................................................... in position A
Automatic unlatching ...................................................................................................................... at approx. 165 bar
Floating position ....................................................................................................................................... in position F
Leakages ..................................................... A to R 18 cm³/min, B to R 1 cm³/min at 125 bar, 50 °C, viscosity 33 cst.
(OHFWULFDODX[LOLDU\FRQWUROXQLW/6
Actuation .................................................................................................................. electro-magnetic – double-action
Floating position ........................................................................................................ on Multi-controller / lever switch
Rated voltage ....................................................................................................................... of the solenoids 12 VDC
Power consumption ............................................................................................................. of each magnet = 32.7 W
Resistance .......................................................................................................... of the solenoid coils 2,7 Ohm ±10%
Continuous duty .................................................................................................................................................. 100%
Oil flow ............................................................................................................................. max. 50 l/min (outlet A or B)
(+5FRQWUROXQLW6%(+5/6
Actuation ..............................................................single-action, direct slider actuation by proportional solenoids 12 V
Permissible max. pressure .............................................................................................. p = 250 bar, R1 max. 30 bar
Rated pressure flow ......................................................................................................................................... 80 l/min
Leakages .................................................................................... A to R 4 cm³/min at 125 bar, 50 °C, viscosity 35 cst.
Resistance of coils .......................................................................................................... R = 1.7 Ohm, I max. = 3.5 A
Safety valve ............................................................................................................................................. 220 + 20 bar
6WHHULQJVHUYRVWDW
Manufacturer ............................................................................................................................ Mannesmann Rexroth
Aggregate designation .................................................................................... LAGU 160/80-11/ LDR-175 M40-000S
Rotor pump absorption volume in servo mode ........................................................................................... 160 cm³/U
Rotor pump absorption volume in emergency mode ...................................................... 80 cm³/U (chamber shut-off)
DBV ............................................................................................................................ 175 +/- 5 bar in the LD-channel
7LJKWHQLQJ7RUTXHV
Anchor bolts for auxiliary control unit blocks ............................................................. double, triple, quadruple blocks
Tightening sequence ...................................................................................................................... from bottom to top
Bottom and centre bolts ................................................................................................................................ 25+8 Nm
Upper bolt ..................................................................................................................................................... 14+5 Nm

5
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Differing hydraulic system are used on the various CASE-STEYR tractor series/sizes. Prior to the
introduction of the load compensated system with constant flow pump, abbreviation OC LS-
System (2pen &enter /oad 6ensing), only the OC constant flow system was used at CASE
STEYR. Because the power requirements placed on hydraulic systems is constantly increasing
and with fuel consumption playing an increasingly important role, it is necessary to use a more
modern hydraulic system. A further step in this direction is the introduction of the CC LS system
(&losed-&enter-/oad-6ensing). The most important advantages of the CC-LS system are listed
below:
1 Low power requirements and little oil heating – through zero flow when no consumers are
being operated, e.g. on longer road journeys.
2 No throttle losses in the partial power range – through use of a PFC pump (variable
displacement pump).
3 Parallel operation of several consumers – through oil flow dividers in the mechanical control
units.
4 Constant hydraulic motor speed – through priority control in the first auxiliary control unit.

6
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ILYH EORFNV
%ORFN 1st position from the left – double-action (Q3), floating position, shut-off valve in output
B, continually adjustable oil flow from 0 - 80 l/min, kick out, mechanically operated
2nd position – double-action (Q3) no floating position, shut-off valve in output B, conti-
nually adjustable oil flow from 0 - 80 l/min, mechanically operated using the joystick
in the left-to-right direction.
%ORFN 1st position from the left, double-action (Q3), floating position, shut-off valve in output
2nd position – double-action with floating position and shut-off valve in output B, electro-
magnetic operation
using the joystick in a fore-and-aft direction, priority over the following control units;
2nd position – double-action (Q3) no floating position, shut-off valve in output B, conti-
nually adjustable oil flow from 0 - 80 l/min, mechanically operated using the joystick
in the left-to-right direction.
3rd position – double-action with floating position and shut-off valve in output B, electro-
magnetic operation
B, continually adjustable oil flow from 0 - 80 l/min, kick out, mechanically operated,
priority over the following control units.
2nd position is the same as for block 2, 2nd position
3rd position is the same as for block 2, 3rd position
4th position is the same as for the 3rd position;
%ORFN positions 1,2, and 4 are the same as for block 4.
3rd position – double-action (Q3), floating position, shut-off valve in output B, continu-
ally adjustable oil flow from 0 - 80l/min, kick out, mechanically operated
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7
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Sva 7-95320 EN
Return feed
Feed pressure
Low standby
pressure
Working pressure

ss99h177
Edition 09/99
9
)XQFWLRQ/RZ6WDQGE\3UHVVXUH
No particular value is placed on the actual configuration in this schematic diagram. This will make
it easier to understand the CC-LS hydraulic system. The technical details of the individual com-
ponents will be discussed in the course of this document. The oil taken in by the feed pump (2) is
pressurised slightly and fed to the inlet side of the PFC pump (5).
Because all consumers are in the neutral position, in low standby pressure, the PFC pump (5) has
only assumed a small angle of pivot and compensates for any leakage. The low standby pressure
originates on the one hand through the spring (7) pressure (adjustable) and on the other hand,
through the hydraulic pressure, which is takes effect on the front of the slider (8).
The slider (8) thus controls the pressure to the variable piston (9), which applies pressure to the
pivot plate (10). On the opposite side of the pivot plate, the control spring (11) counteracts this.
This results in stable position of the pivot plate. With closed sliders, the low standby pressure is
available to the individual consumers.

21(&21680(5,123(5$7,21 10
Sva 7-95320 EN

Return feed
Feed pressure
Low Standby
Pressure
Working pressure

ss99h178
Edition 09/99
11
)XQFWLRQ2QHFRQVXPHULQRSHUDWLRQ
As soon as the consumer (II) is set into operation, via the slider (13) in the second auxiliary control
unit, a connection is set up to the pump controller (6) via the hole (14), the signalling shuttle
valve (15) and the signal line. The low standby pressure now takes effect on the slider (8) via the
signal line together with the spring (7). This opens the pressure chamber of the variable piston (9)
to the tank. Thus, the spring (11) can move the pivot plate (10) against the variable piston (9).
The pressure in the pump line increases and the consumer (II) operates. The working pressure at
the consumer (II) is dependent upon the working resistance. The working speed is dependent
upon the oil flow rate set at the oil flow regulator (16) or by the position of the control slide (13) in
the auxiliary control unit respectively.
The working pressure also takes effect, via a channel, on the pressure scale of the oil flow regula-
tor (16). This maintains the consumer (II) at a constant working speed, even if the working resi-
stance fluctuates

7:2&21680(56,123(5$7,21 12
Sva 7-95320 EN
Return feed
Feed pressure
Working pressure
Pump pressure

ss99h179
Edition 09/99
13
)XQFWLRQ7ZRFRQVXPHUVLQRSHUDWLRQ
In this schematic diagram, the consumer (I) is also set into operation via the 2nd control unit. The
slider (17) has opened the path to the consumer (I) via the two-way oil flow regulator (18). The
working pressure of the 2nd consumer (I) depends directly upon the working resistance and the
speed setting.
The speed of the hydraulic motor is maintained constant by the two-way oil flow regulator (18).
The quantity of flow is controlled by the choke (19) or the movement of the slider (17) respectively.
As one can see in the schematic diagram, the working pressure of the consumer (I) is higher than
that of the 1st consumer (II). In this case, only the highest working pressure of all consumers in
operation will be registered by the pump compensator (6), via the shuttle valve (20).
The swivel plate is moved via the pump compensator sufficiently far, that the extra working pres-
sure or oil flow rate required is supplied by the PFC pump.
The pump compensator and the PFC pump are now in balance. A balance of forces is produced
at the slider (8), this is the result of the working pressure felt on the one side and the signal and
spring pressure (7) felt on the other.
The working speed (oil flow) of the consumer (II) can be kept constant, in spite of the increased
pump pressure, by the two-way oil flow regulator (16). Only two consumers are shown in the sche-
matic diagram. A maximum of 4 auxiliary control units can be fitted to the tractor with the EHR
control unit. Additional, external consumers can be connected via the power-beyond plate. Under
normal operating conditions, all consumers can operate simultaneously at differing flow rates and
working pressures, providing that the total oil flow rate being supplied by the pump at that time, is
not exceeded.

0$;,080:25.,1*35(6685( 14
Sva 7-95320 EN
Return feed
Feed pressure
Working pressure
Max. working
pressure

ss99h180
Edition 09/99
15
)XQFWLRQ0D[LPXPZRUNLQJSUHVVXUH
The cylinder (II) is driven against its limit, the second control unit remains activated (driver keeps
hold of the operating lever). The working pressure of consumer (II) rises above the working pres-
sure of consumer (I), causing the signalling shuttle valve (15) to switch over The pressure from
consumer (II) now takes effect on the slider (8) and spring (7) in the pump compensator (6), via
the signal line.
Because there is no oil flow to the consumer (II), there is also no drop of pressure in the consu-
mer’s (II) control unit. Thus the same pressure is in effect in the signal line as is in effect at the
consumer (II), which would lead to an infinite increase in pressure. There is an additional
slider (2) in the pump compensator (6), which is connected to the PFC pump pressure. The
PFC pump pressure can increase until the slider (21) is pressed against the spring (22), which
causes a connection to the variable piston (9) to be set-up. The maximum working pressure is
now reached and can increase no further.
An additional safety measure is provided in the form of a pressure relief valve (PRV), which limits
the system pressure to 235 bar (PRV not shown in the schematic diagram). The PFC pump ope-
rates at maximum pressure, until the consumer (II) switches OFF. The consumer (II) is not affec-
ted by the pressure and the alteration in the flow rate, i.e. the flow rate set for the consumer (I)
remains constant and thus no change in the speed of the hydraulic motor is experienced.

35,25,7<%/2&./76&+(0$7,&',$*5$0 16
Sva 7-95320 EN

ss99j003
Edition 09/99
17
/LVWRIFRPSRQHQWV3ULRULW\EORFN/7VFKHPDWLFGLDJUDP
1 Suction filter 160µ

2 Pump unit
3 Pressure filter 10µ
4 Priority block LT41 (steering priority valve)
5 Steering servostat with 175 bar PRV
6 Return feed plate (rear axle)
7 Rear axle brake cooling line
8 Connection Plate
9 Auxiliary control unit, mechanical, double-action with floating position and priority over other
control units
10 Auxiliary control unit, mechanical, double-action
11 EHR control unit with safety valve 220 +20 bar
12 Spacer plate
13 Auxiliary control unit, electrical, double-action with floating position
14 Power-beyond plate (connections for other consumers e.g.: front loader, harvesting
machines)
16 Plug-in connection, pressure-free return

6&+(0$7,&',$*5$035,25,7<%/2&./7±K\GUDXOLFWUDLOHUEUDNH 18
Sva 7-95320 EN

ss99j004
Edition 09/99
19
/LVWRIFRPSRQHQWV6FKHPDWLFGLDJSULRULW\EORFN/7
K\GU WUDLOHU EUDNH

2 Pump unit
4 Priority block LT43 (steering priority valve, trailer brake priority valve and trailer brake
proportional valve)
8 Connection Plate
control units
12 Spacer plate
machines)
17 Working brake
18 Plug-in connection, hydraulic trailer brake

6&+(0$7,&',$*5$035,25,7<%/2&./7K\GUDXOLFZKHHOEUDNH 20
Sva 7-95320 EN

ss99j005
Edition 09/99
21
/LVWRIFRPSRQHQWV6FKHPDWLFGLDJSULRULW\EORFN/7
K\GU ZKHHO EUDNH

2 Pump unit
4 Priority block LT44 (steering priority valve, brake priority valve and 4-wheel brake
proportional valve)
8 Connection Plate
control units
12 Spacer plate
machines)
17 Working brake
18 Braked front axle
20 Emergency valve (Messr's. ATE)

6&+(0$7,&',$*5$035,25,7<%/2&./7K\GUDXOLFWUDLOHUZKHHOEUDNH/7ZKHHOEUDNH 22
Sva 7-95320 EN

ss99j006
Edition 09/99
23
/LVWRIFRPSRQHQWV6FKHPDWLFGLDJUDPSULRULW\EORFN/7
K\GUDXOLFWUDLOHUEUDNHZLWK/7ZKHHOEUDNH

2 Pump unit
4 Priority block LT43 (steering priority valve, priority valve, trailer brake and trailer brake
proportional valve)
8 Connection Plate
control units
12 Spacer plate
machines)
17 Working brake
18 Braked front axle
19 Plug-in connection, hydraulic trailer brake
20 Emergency valve (Messr's. ATE)
21 LT03 control unit, 4-wheel brake with hydraulic trailer brake
22 Valve cluster, sprung front axle
23 Cylinder, sprung front axle

3LSHOD\RXWWRSYLHZ 24
1 PFC Pump unit

2 LT 41 Priority block, steering
Sva 7-95320 EN
3 Connection plate / Auxiliary control unit block
4 Power-beyond plate
5 Return plate
Return feed line 6 Plug-in connection, pressure-free return
7 Hydraulic block, sprung front axle and electronics
Working line

8 Steering servostat:
P line 9 LT 43 priority block, steering / hydr. trailer brake,
LT 44 priority block, steering / 4-wheel brake

LS line

10 P-IN line
11 P-IN line, steering
12 X-ST LS line, steering
13 X-ST LS line, PFC pump
14 TB line, trailer brake
15 X-AUX LS line, auxiliary control units
16 P-AUX P line, auxiliary control units
17 Working brake line
Edition 09/99
ss99j036
3LSHOD\RXWVLGHYLHZ
1 PFC Pump unit
Sva 7-95320 EN
Lubrication line
4 LT41Priority block, steering
Return feed line 5 Power-beyond plate
6 R, return feed for other consumers
Working line 7 LS connection for other consumers
8 P connection for other consumers
P line 9 LT 43 priority block, steering / hydr. trailer brake,
LT44 priority block, steering / 4-wheel brake
LS line 10 P-IN line

11 X-LS LS line, PFC pump
12 P-IN line, steering
13 X-ST LS line, steering
14 LT03 proportional valve for 4-wheel brake and
hydr. trailer brake
15 Emergency valve, 4-wheel brake (Messr's. ATE)

Edition 09/99
25
ss99j037

3LSHOD\RXWUHDUYLHZ 26
Sva 7-95320 EN
1 Plug-in connection, pressure-free oil return

2 Plug-in connection, trailer brake
3 R1, return feed line, EHR control unit
4 LS line, auxiliary control units
5 R return feed line, auxiliary control units
6 P line, auxiliary control units / EHR

Lubrication line 7 Auxiliary control unit Q4 mechanical, priority,
double-action
Return feed line 8 Auxiliary control unit Q3 mechanical,
double-action
Working line
9 EHR control unit
10 Auxiliary control unit, electrical, double-action
P1 line
Edition 09/99
ss99j038
27
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ss99j039


29
1 Input, feed pump

2 Feed pump 57cm3 (rotor pump)
3 Non-return valve 5 bar (short circuit valve)
4 Output, feed pump /input, pressure filter
5 Output, pressure filter / input, high pressure pump
6 Non-return valve, 1 bar Qmax. 30l/min (pump cooling in stand-by mode)
7 R line (tank)
8 Input, high pressure pump (feed pressure, min 0.8 bar, max. 5 bar)
9 Pivot plate
10 Drive shaft
11 L outlet hole, leakage oil
12 LS line from priority block (LT41/43/44)
13 P channel connected to HD pump output
14 Control pressure channel (connected to control piston / pivot plate)
15 Return feed channel
16 Feed flow slider
17 Maximum pressure slider
18 Adjusting screw, feed flow (low standby pressure 25 - 26 bar, with steering)
19 Adjusting screw, maximum pressure 205 ± 5 bar
20 Output, PFC pump
21 Safety valve 235 bar

30
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ss99j041
5 3 /6

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ss99j040

31

2 Feed pump 57 cm3 (rotor pump)
3 Non-return valve 5 bar (short circuit valve)
4 M2, measuring point for feed pressure in front of pressure filter (M 10x1)
5 Pressure filter ß16 = 75, p max. 8 bar
6 Non-return valve, 1 bar, Qmax. 30 l/min (pump cooling in the standby mode)
7 R line (tank)
8 Output, high pressure pump
9 LS line from priority block (LT41/43/44)
10 L outlet hole, leakage oil
11 Filter control switch (opens at > 1,0 + 0,2 bar) M1 measuring point for feed pressure after the
pressure filter, min. 0.8 bar, max. 5 bar (M10x1)
12 Axial piston pump 45 cm3 110 l/min, at 2300 engine rpm
13 Control piston / control spring
14 Safety valve 235 bar
15 Pump controller DFR1/52R (pump compensator)
16 Feed flow slider (low stand-by pressure 25 - 26 bar)
17 Maximum pressure slider (maximum pressure 205 ± 5 bar)
18 Oil filler plug
)XQFWLRQ2LOIHHGFLUFXLW
Oil sucked in by the feed pump (2) via the suction filter (1) is fed through the pressure filter (5) to
the input of the axial piston pump (12). Because the feed pump (2) has a larger volume than the
axial piston pump (12) and is designed as a constant flow pump, there will be a greater or lesser
excess feed volume at the input to the axial piston pump (12). Due to the situation, the result can
be high engine speed an no oil will be taken by the consumer. In order to reduce power losses in
such a situation, the short circuit valve (3) opens at 5 bar and the excess oil flows back to the
intake side of the feed pump (2). This again will, over a period of time, lead to oil heating in the
feed pump (2). The non-return valve (3) opens at a pressure of 1 bar, thus a max. of 30 l/min can
flow into the return feed. This means that the same amount of cool oil can be taken into the oil
feed circuit.
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The valve is designed for use on the tractor. It works on the Closed Centre Load Sensing principle
and is designed to suit this series of pumps. On the tractor, the steering valve and other high pres-
sure consumers are supplied by this valve.
The output PST to the steering valve has priority over all other consumers. This is guaranteed by
the priority valve (1).
The priority valve (1) is controlled by the pressure drop across the steering valve (between PST
and XST). Whereby the load signal pressure XST from the steering valve acts on the spring side of
the priority piston (2), auf der gegenüberliegenden Seite über die Düse (3) Rückschaltventil (4) –
Kombination der Lenkventilzulaufdruck PST. The nozzle (3) has the task of continually relaying the
pressure but only to allow a low flow rate, in order to dampen the piston movement and have a
stabilising effect. The non-return valve on the other hand allows the piston to move rapidly in the
direction of priority, in order to suffice the dynamic requirements of the steering. If the difference in
pressure between PST and XST is below the value prescribed by the spring (5), feed to the follo-
wing consumers will be reduced, in order to guarantee a minimum pressure drop across the stee-
ring valve. (The threshold (action limit) to reduce the secondary flow rate is matched to the control
pressure difference of the flow rate regulator on the axial piston pump). If the pressure drop at the
steering valve is a above the flow rate regulator's control pressure difference by certain amount
(e.g. through the higher pressure of a connected consumer), the priority valve will decrease the
pump pressure to the PST connection, so that the intended, maximum pressure drop from PST to
XST is not exceeded (compensation mode).
A continuous, low rate of flow, is fed from pressure connection XST into the load signalling line XST
via the nozzle (6) (approx. 3.5 bar). Load signalling will be less dependent upon variations in tem-
perature and a full load signalling line is always guaranteed. Both factors lead to shorter pump
and priority valve reaction times.
The nozzle (6) also has the task of relieving the PST connection if no priority consumers require oil
and the following consumers are operated at high pressure. The load pressures, of the priority
consumer and the following consumers, are compared in the shuttle valve (7) and the resultant
signal is sent to the control pump.
PIN Input from the PFC pump

P1 P connection, sprung front axle
P1 P connection, steering
PAUX P connection, auxiliary control unit / EHR
XAUX LS connection, auxiliary control unit / EHR
XLS LS connection, PFC pump controller
XST LS connection, steering

34
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PIN Input from the PFC pump 39$ 7%

P1 P connection, sprung
front axle (LT44/ LT43) 5
PST P connection, steering
PAUX P connection, ZSG / EHR <
XAUX LS connection, ZSG / EHR
XLS LS connection, PFC pump
controller
TB Connection, hydraulic trailer
brake (LT43)
TB Connection, 4-wheel brake (LT44)
PVA P connection, LT03 (LT43) L 57%
Y Connection, working brake

i Adapter Ø 20 mm LT43
i Adapter Ø 12 mm LT44
RTB Connection, return feed (tank)
R0 Connection, return feed (tank)
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It comprises two valve discs with two piston axes, one on the upper and one on the lower valve
disc. Thus the steering valve and the brake line connection, to the trailer brake system on the trac-
tor, are supplied with priority over the other high pressure consumers (directional control valves,
EHR control unit). Through the flat constructional design of the valves LT41 (priority valve) and
LT 42 (priority and trailer brake valve), they can be unified with the compact block LT43/LT44.
The connection lines to and from the control pump are connected to the tractor-side valve disc.
The priority valve (1) feeds the volume flow to the second disc with the priority valve (2) for the
steering and trailer braking valves (3). When the steering valve and trailer braking system are
adequately supplied, the priority valve (1) diverts the remaining volume flow to the other high-
pressure consumers.
The priority valve is controlled by the pressure drop across the "steering valve" and "trailer braking
valve" consumers. The load signal pressure XST/ XTB, hereby takes effect on the spring side of the
priority piston (4) and the resultant signal is fed to the shuttle valve (5). The feed pressure for this
consumer takes effect on the opposite side via a
nozzle / non-return valve combination. The nozzle has the task of continually forwarding the pres-
sure but only to allow a low flow rate, in order to dampen the piston movement and have a stabili-
sing effect. The non-return valve on the other hand allows the piston to move rapidly in the priority
direction, to meet the dynamic requirements of steering actions.
The pressure drop set through the control spring (6) is "tuned" to the pressure drop at the steering
calve spring (7) and the control pressure difference of the quantity regulator.
The load pressures of the priority consumer and the other consumers are compared in the shuttle
valve and the resultant signal is fed to the control pump.
The priority consumers, steering valve and trailer brake, are controlled by the priority valve (2)
Output PST to the steering valve has priority over the supply to the trailer brake valve. This works
as a pressure reduction valve with a maximum pressure stipulated by law. The priority valve (2) is
controlled by the pressure drop across the steering valve (between PST and XST). Because the
design and function of the priority valve (2) is identical to priority valve (1), there is no need for a
further explanation of its function. If the pressure difference between PST and XST is below the
value set by the spring (7), the flow to the trailer brake valve will be throttled, in order to guarantee
a minimum pressure drop across the steering valve. The intervention limit, to throttle the secon-
dary volume flow, is "tuned" to the control pressure difference of the quantity regulator on the axial
piston pump and the control pressure difference of the priority valve in LT41. If the pressure drop
at the steering valve exceeds the control pressure difference value, stipulated for the valve, by a
certain amount, the pump pressure to connection PST will be throttled by the priority valve, so that
the maximum, foreseen pressure drop from PST to XST is not exceeded (compensation mode). A
small quantity of oil is continuously fed, via nozzle (9), into the load sensing line XST from pressure
connection PST.
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EUDNH/7ZLOOEHGHVFULEHGLQGHWDLOODWHULQWKLVGRFXPHQW

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PIN Input from the PFC pump 39$ 7%

P1 P connection, sprung front axle
(LT44/ LT43) 5
PST P connection, steering
PAUX P connection ACR / EHR <
XAUX LS connection ACR / EHR
XLS LS connection, PFC pump
controller
TB Hydraulic trailer brake
connection (LT43)
TB 4-wheel brake connection (LT44)

PVA P connection LT03 (LT43) 57%

Y Connection, driving brake

RTB Return feed connection (tank)
R0 Return feed connection (tank)
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The hydraulically controlled trailer brake valve (1) works as a proportional pressure reduction
valve. The quantity of oil from priority valve (2) is fed at low-loss to the TB connection and the
height of the pressure p-TB, proportional to the control pressure Y, is held constant. The pressure
requirement of the trailer brake is reported to the control pump, via the dynamic nozzle (3) and
shuttle valve (4) signal chain.
The signal pressure Y is also the tractor braking pressure. This acts on the transmitter piston (5)
and moves the control piston (7), by means of the spring (6), until the force of pressure on both
the transmitter piston and the front face of the opposing control piston are equal.
Legal requirements stipulate a maximum pressure of 100 to 150 bar in the TB connection. The
tractor brake pressures Y are much lower than this, which is why a pressure conversion device is
fitted to the control piston. Maximum pressure limiting at the TB connection must be independent
of the signal pressure Y. This function is carried out by the spring (6), which initially, for small
signal pressures Y, acts as a rigid transmission element and transmits the force directly. Only at
higher signal pressures, is it compressed, so that the force transmitted is limited to the prescribed
maximum.
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LT43 – hydr. trailer brake i = .................................................................................. 1 : 11.1

Large piston Ø ............................................................... 20 mm
Small piston Ø ................................................................. 6 mm
Max. brake pressure ..................................................... 150 bar
LT44... 4-wheel brake i = ....................................................................................... 1 : 4
Large piston Ø ............................................................... 12 mm
Small piston Ø ................................................................. 6 mm
Max. brake pressure ..................................................... 105 bar

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The LT03 4-wheel brake control unit is supplied with oil pressure, parallel to the trailer brake, by
priority valve LT43. The 4-wheel brake without hydraulic trailer brake is fitted with priority block
LT44. Both valves are fitted to the rear axle housing. The PFC pump supplies the oil pressure for
both the trailer brake and 4-wheel brake.
The oil flows from the PFC pump, through a priority slider, which guarantees priority for the stee-
ring. If the steering priority is fulfilled, the priority slider is pushed against its spring and allows a
parallel flow of oil to the trailer brake and 4-wheel brake priority valve LT03 and further on to the
auxiliary control unit block.
The tractor brake lines are connected to the emergency valve (ATE). If both pedals are operated,
the brake pressure can reach the 4-wheel brake valve. If only the right-hand or left-hand brake
pedal is operated, the emergency valve (ATE) will lock and the front axle will not brake. The 4-
wheel brake valve controls the brake pressure to the front axle, proportional to the control pres-
sure (working brake).
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If the brake is not operated, there is no pressure present at connection (Y) and the spring (1)
pushes the main piston (2), together with the control piston (3) to the right. There is no oil feed in
this position and the oil from the 4-wheel brake is fed to the return feed line via the main piston (2).
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When both tractor brake pedals are operated, pressure builds up at connection (Y). This pressure
pushes the control piston (1) and main piston (2) against the spring (3). The flow of oil bypasses
the main piston, through the front axle brake connection (BVA) to the front axle brake. The LS con-
nection is closed off by a screw-on plug. The PFC pump is controlled via the LS line on LT43
(hydraulic trailer brake). Due to the fact that the transmission ratio for the hydr. trailer brake LT43
is 1:11.1 and the 4-wheel brake LT03 is 1:4, it is ensured that excess pressure from the PFC
pump is always available for the hydr. trailer brake priority valve and the 4-wheel brake LT03.
The front axle brake pressure acts in the same way on piston (4), which moves the main piston (2)
to the right, against the force of the control piston (1). The main piston (2) has assumed a position,
in which the oil flow to the front axle brake is limited and the pressure does not rise any further
(end of braking position).
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For excess working brake pressure, the front brake pressure increases to max. 90 - 105 bar. The
control piston’s (2) internal spring (1) will be compressed at this pressure. This causes the main
piston (3) to move to the right, into a position in which the flow of oil to the valve is limited and the
pressure at the front axle brake connection remains stabile.
Hydr. transmission ratio 1:4 control piston (1) Ø 18 mm and piston (4) Ø 9 mm.

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This directional control valve is a double-action control unit with shut-off valve in outlet A, freedom
of movement position, mechanical latching in position B, pressure point in position A, kick-out and
a 3-way flow regulator, which gives the control unit priority. The flow regulator can be set to bet-
ween 0 and 80 l/min. by a rotary knob outside the rear cab window. (this control unit Q4, with prio-
rity must always be fitted in the 1st position after the connection plate, otherwise priority will be
lost. Operated by the joystick, in a fore-and-aft direction)
)XQFWLRQ1HXWUDO
The flow of oil from the pump, through the connection plate, enters the control unit through the
channel (P). Continues through the hollowed slider (1) of the 3-way flow regulator, past the adju-
stable throttle (2), to the closed control slider (3). The pressure now acting moves the slide (1)
against the spring (4) and opens the channel (P), through which the remainder of the consumers
are supplied. The control slider (3) is kept in the neutral position by the spring (5), thus outlets A
and B are shut-off. There is an additional shut-off valve (needle valve 6) in B, which seals the out-
let 100%.

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The slider (1) is pushed into the control unit against the force of the spring (2). The balls (3) sense
the amount of travel and report the max. amount of travel above the pressure point (no latch). The
low standby pressure can now act on the PFC pump regulator, via the channel opened by the
slider (1), the shuttle valve (4), the LS channel (5) and the priority block. The pressure can also act
on the spring side of the 3-way flow regulator (6), through the hole (7). The operating pressure
building up opens the non-return valve (11) and can reach the output (A). The return oil flow tra-
vels from channel (B) via the open shut-off valve (8) to the return feed line (R).
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The shut-off valve (8) can only be opened, under high load pressure, by the pilot control valve (9).
If the slider (1) is moved, the tappet (10) acts on the pilot control valve (9) and oil flows into the
chamber under the shut-off valve. The slider (1) has not yet opened the return flow channel,
through which the same pressure builds up as in outlet B (pressure compensation). Due to the
pressure compensation, the shut-off valve (8) can be opened without the use of force. The return
oil flow can be regulated by the fine control edges.

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The slider (1) is pulled out of the control unit, against the spring (2) pressure and latched in this
position by the balls (3). The low standby pressure can act on the PFC pump compensator, via the
channel opened by the slider, the shuttle valve (4) and LS channel (5). The pressure can also act
on the spring side of the 3-way flow regulator, through the hole (6). The working pressure build-up
opens the non-return valve (7) and oil can flow to output B via the open shut-off valve (8). The oil
returning through channel A can flow into the R channel through the open slider (1) The working
speed of the consumer can be adjusted by the travel of the control slider (1). The max. flow of
0 - 80 l/min can also be set by the adjustable throttle (9).
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"Kick-out" is the term used, when the control unit automatically cuts out, shortly before reaching
the max. working pressure. When the set unlatching pressure of approx. 165 bar is reached, the
oil pressure acts on the unlatching valve (10) and on the piston (11) via a hole in the slider (1).
This in turn operates the tappet (12). The balls (3) can now release and the spring (2) can move
the slider (1) to the neutral position. It is possible to alter the unlatching pressure by means of the
packing rings (13). Fitting additional rings raises the unlatching pressure. In order to ensure that
"kick-out" takes place, never set too close to the max. working pressure(oil warming).

44
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By pushing the slider (1) past the pressure point, to position (F), the freedom of movement posi-
tion is reached and latched by the balls (2). Shut-off valve (3) is completely open and the slider
has interconnected channels A, B and R. One consumer (e.g. a cylinder) can now be moved fre-
ely. Implements, which are under pressure, can be connected without effort, in the freedom of
movement position. This is made possible by the UP (under pressure) connections.

45
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The plug-in connections used, can be connected under pressure (UPC). The implement plug can
be under pressure when connecting but the tractor coupling must be free of pressure. In order to
ensure effortless connection, it is recommended to shift the control unit to freedom of movement.
The plug-in connectors are fitted with pull-out protection and an oil spill collector.
In order to make assignment of control unit operating elements and their plug-in connections visi-
ble, these are provided with colour coding. The connections are also marked with for pressure
sealed andfor non-pressure sealed.

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This is a double-action control unit, with shut-off valve in output B and is connected in parallel to
the P channel. Oil flow regulation independent of pressure, from 0 - 80 l/min, is made possible by
the 2-way flow regulator and the control slider. A max flow setting, of between 0 - 80 l/min, can be
made, using the adjusting knob on the adjustable throttle, outside the rear cab window. This con-
trol unit is fitted in the second position, as seen from the connection plate. It is operated by using
the joystick in a lateral direction (side-to side), without latching.
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The control slider (1) is, due to the spring (2), in the neutral position. The 2-way flow regulator
slider is fully opened by the spring (3). The oil, under low standby pressure, can flow through the P
channel, the slider (4) and the adjustable throttle (5) to the control slider (1), which stops it from
flowing further. The LS channel is connected with the return flow (R) by the neutral position of the
slider (1). Thus no pressure is sensed at the pump regulator and the PFC pump remains at low
standby pressure. Outputs A and B are closed-off by the slider (1). In order to achieve a 100%
seal, there is a shut-off valve (6) in the (B) channel.

48
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The slider (1) is pushed into the control unit against the force of the spring (2). The low standby
pressure can now act on the pump regulator, via the channel opened by the slider (1), the shuttle
valve (3) and the LS channel (4). The pressure can also act on the spring side of the 2-way flow
regulator, through the hole (5). The operating pressure building up opens the non-return valve (6)
and can reach the output (A) through the open slider (1). The return oil flow travels from
channel (B) via the mechanically opened shut-off valve (7) to the return feed line (R).
6KXW2II9DOYH:
For the functional description, see SB 23-LS-Q4 Auxiliary Control Unit, chapter "Pressure in A".

49

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The slider (1) is pulled out of the control unit against the force of the spring (2) (no latch). The low
standby pressure flows through the channel (P), the slider (3), the throttle (4), the opened control
slider (1), the shuttle valve (5) into the LS channel (6) in the pump regulator. The pressure can
also act on the spring side of the 2-way flow regulator, through the hole (7). The operating pres-
sure building up opens the non-return valve (8) and can reach output (B), via the opened shut-off
valve (9). The returning oil from channel (A) flows past the control slider (1) into the R channel.
The working speed of the consumer can be adjusted by the travel of the control slider (1). The
max. flow of 0 - 80l/min, which remains constant under fluctuating working pressure, can also be
set at the adjustable throttle (4).

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l Double-action directional control valve,

l Shut-off valve in "B"
l Freedom-of-movement position
l Latch in position "B" and freedom-of-movement position
l Kick-out (165 bar)
l Pressure point in position "A"
l Two-way flow regulator with adjustment range of 0 - 80 l/min
l In block variant 4, mounted in third position
This control unit functions in exactly the same way, in all positions, as control unit SB 23-LS-Q3
without latch. The functional description, with the exception of latching and freedom of movement,
can be taken from there. For latching and freedom of movement, see SB 23-LS-Q4.

52
ss99j186

53
The double-action electrically operated control unit is always fitted after the mechanically
operated control units. 1 to 2 control units can be fitted, depending upon the block version. The
shuttle valves, used in the control unit, are so called "black / white" valves Because they are
electrically operated, there are a host of operating options. By pushbuttons on the multicontroller
and joystick or external pushbuttons in the radiator grill for the front-end lifting gear. Electrically
operated control units can also be operated from a lever switch on the right-hand wheel cladding.
A control unit can be configured for all three operating options. Output B is pressure sealed by
locking block Y2/4. The freedom of movement position can be selected from the multicontroller or
the lever switch. (Oil flow rate regulation is not possible with electrically operated control units.)
7HFKQLFDO'DWD
Securing screws M5x45 = 9 Nm
Locking block Y2/4: 25 Nm
Duty cycle: DC 100%
Voltage: 12 VDC
Power consumption: 32.7 W
Oil temperature: -20 to + 100 °C
Max. operating pressure: 320 bar

54
3UHVVXUH$ Return flow pressure

1HXWUDO
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No solenoid valves are energised All 3-way valves are held in position by spring pressure (as
shown in drawing I). Directional control valve 4/2 connects channel P with channel A. Channel A
is closed off and the LS channel is connected to the return flow line by the directional control
valve, whereby the PFC pump remains at low standby pressure. Outputs A and B are closed-off
by the directional control valve 4/3. In addition, there is a locking block Y2/4 in output B, which
pressure seals the output.
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Solenoid valves Y2/1, Y2/3 and Y2/4 are energised. This allows the low standby pressure to
flow a) through directional control valve 4/2 to the shuttle valve in the (LS) channel on the pump
controller and b) through directional control valve 4/3 to output (A). The returning oil from
channel (B) can flow into the return line through the open locking block Y2/4 and directional con-
trol valve 4/3.
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Solenoid valves Y2/1 and Y2/2 are energised. This allows the low standby pressure, on the one
hand, to flow through the directional control valve 4/2 to the shuttle valve in the LS channel on the
pump controller and on the other hand, through the directional control valve 4/3 and locking
block Y2/4, which in this direction of flow acts as a non-return valve, to output (B). The return oil
flows through directional control valve 4/3 into the return feed line (R).
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Solenoid valves Y2/2 and Y2/4 are energised. The oil can flow from output (B), via the open lok-
king block Y2/4, through the directional control valves 4/3 and 4/2 into the return feed line (R). At
the same time, output (A) is also connected to the return flow line via directional control valve 4/3.
In this position, the hydraulic oil passing the outputs (A) and (B) can flow in both directions. This
example shows, that the piston in the cylinder can move freely.

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Working pressure

ss99j185
Edition 09/99
57
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The EHR control unit is located in the third position as seen from the connection plate. It is an ele-
tro-magnetic, proportional control unit of plate construction with an integrated 2-way flow regula-
tor, which lies parallel to the P channel. The solenoids are controlled by pulse modulation from E-
box A55.
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Solenoids (H) and (S) are not energised. Spring (1) has brought the slider (2) of the 2-way flow
regulator, against the low standby pressure, into a balanced (neutral) position. The pressure can
flow from channel (P) up to the closed slider (3). The LS channel is connected to the (R) channel.
The load pressure from output (A) acts on the conical slide valve (4), load safety valve (5), pilot
valve (6) and main conical slide valve (7).
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If either the electrics or electronics fail, it is possible to raise or lower the lifting gear by manually
operating the slider. The rubber cap, of the relevant solenoid, must be pressed in with a pin (the
engine must not be running when lowering).
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Working pressure

ss99j188
Edition 09/99
59
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The solenoid (H) is energised by the E-box (A55). Energisation takes place according to the con-
trol deviation. The slider (1) is pushed against the force of the spring (2) by the solenoid (H). The
pressurised oil from channel (P) can now flow, on the one hand, through the open slider (1),
through hole (3) to the spring side of the 2-way flow regulator (4) and on the other hand, through
the shuttle valve (5) in the LS channel to the pump controller. At the same time, the conical
valve (6) is opened by the flow of oil to output (A). The working pressure now builds up, according
to the implement load and the speed at which it is being raised. The raising speed is dependent
upon the electrical current, which flows through solenoid (H) and opens slider (1). The slider (1)
acts as the adjustable throttle for the 2-way flow regulator (4).
This results in the following options:
1. A raising speed which does not depend on the load or the pump flow
2. Parallel operation of several auxiliary control units and lifting gear, which work with different
flow rates and pressures until such time as the current pump flow is achieved.

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By adjusting the lowering speed potentiometer (setpoint), a certain current will be fed to the sole-
noid (S) from the EHR box. The position sensor reports the actual lowering speed value to the
EHR box, where a continuous Nominal/Actual comparison is carried out and the current to the
solenoid is varied accordingly. This results in a lowering speed independent of load.
When the solenoid (S) is energised, the pilot control valve (1) opens and the load pressure behind
the main valve (2) is diverted into the return line. The load pressure acting on the front now opens
the main valve (2). Thus the travel of the main valve (2) is determined by the travel of the
solenoid (S) and the pilot valve (1). When the main valve (2) opens, this causes the pilot valve (1)
to shut off. When the pilot valve (1) shuts off, the load pressure acts on the back of the main
valve (2). The return oil flow can return to the sump via an external line (R1).

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When installing the individual blocks, attention must be paid to the fact that very thin spacers (one
each per tie rod) are fitted, in some places, between the control units (indicated by the letter (Z) in
the drawing). The purpose of the spacers (Z) is to achieve a surface contact, in order to prevent
uneven stress to the control units.
The tie rods must be tightened in the following sequence:

Sequence .................................................................................... 1 -2 -3
Torque – tie rods 1/2 .................................................................... 25+8 Nm
Torque – tie rod 3 ........................................................................ 14+5 Nm
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It has been made possible, by the power-beyond-plate (9), to integrate an external consumer into
the CC-LS hydraulic system. This makes it possible to operate an external consumer (in our
example, a Pöttinger harvester), using the energy saving CC-LS hydraulic system
In order to extend the system, a shuttle valve (10) is fitted in the LS channel on the power-beyond-
plate. This shuttle valve can be obtained through the central spare parts service under the UHWUR
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3 Priority Block LT41
4 Steering servostat
5 Steering cylinder
7 Auxiliary control unit block (EHR valve)
10 Shuttle valve 1GB416.N0109
11 Directional control valve – Pöttinger harvester
12 Changeover valve OC/CC
13 Return flow line, with no sprung front axle
14 Plug-in connection, LS
15 Plug-in connection, P line
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the CC-LS hydraulic system. This makes it possible to operate external consumers (in our
example, a Pöttinger harvester and a front-loader), using the energy saving CC-LS hydraulic
system The chain of consumers can be extended, if necessary.
In order to extend the system, shuttle valves (10) and (16) is fitted in the LS channel on the power-
beyond-plate.
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2 PFC pump unit
3 Priority Block LT41
4 Steering servostat
5 Steering cylinder
7 Auxiliary control unit block (EHR valve)
10 Shuttle valve 1GB416.N0109 (harvester)
11 Directional control valve – Pöttinger harvester
12 Changeover valve OC/CC
13 Shuttle valve 1GB416.N0109 (front-loader)
14 Plug-in connection, LS
15 Plug-in connection, P line
16 Plug-in connection, free return flow
17 Joystick – front-loader control unit
18 Front-loader cylinder
19 Front-loader cylinder tools

8001
Chapter
8001
TROUBLESHOOTING IN THE HIGH-PRESSURE

HYDRAULIC CIRCUIT
with LOAD-SENSING control units
9105, 9115, 9125 and 9145

CS110, CS120, CS130 and CS150
Technical Documentation Oktober, 1999

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8001-5
AN INTRODUCTION TO TROUBLESHOOTING
Read through the FUNCTIONAL DESCRIPTION in the HYDRAULICS and ELECTRICS chapters in the
training manual before starting troubleshooting on a hydraulics problem or even better, before a fault occurs.
You must likewise familiarise yourself with the correct operation and function of the tractor (see operating
instructions).
Before carrying out each inspection, ensure that the hydraulic oil level is correct and the oil temperature for
the system is approx. 60 °C. Check the functionality of the other circuits if a fault occurs in a hydraulic
circuit. Establish whether the fault has only occurred in a circuit or whether a further, or all hydraulics
functions are affected.
The tractor hydraulics circuit is controlled by electro-switches, electronic and mechanical connections. For
this reason, the mechanic must first isolate the fault as an electrical, electronic, hydraulic or mechanical
problem. In the HYDRAULICS - TROUBLESHOOTING chapter, references are made to the fact that specific
electrical tests must be carried out first. In this case, a reference to the ELECTRICS - TROUBLESHOOTING
chapter is given.
Use a multimeter to inspect the electrics. DO NOT use a test lamp as certain types of switches and
components in the electronic control module can be damaged by it.
A good mechanic avoids removing hydraulic parts which prove not to be the cause of the problem. If a fault
has been clearly identified as a hydraulics problem, determine the necessary repairs to the tractor by using
the corresponding troubleshooting procedure and system diagnostics test listed below.
• Neutral circulation pressure test

• Pump test
• Steering test
• Auxiliary control unit test
• ∆P changeover (connection plate) test
• EHR control unit test
If the defective part has been identified and must be removed from the tractor for repair, clean the area
around the part and all screws which have to be removed. Seal all open connections and pipeline/hose
connections with a cap or a plug.

8001-6
GENERAL SYSTEM DESCRIPTION
In this series, the hydraulic circuits are supplied by two or three gear pumps depending on the version.
LOW PRESSURE CIRCUIT

- up to the POWER SHUTTLE version, the system rotary pump (P1) 32 cm3 (78 l/min) supplies the following
circuits:
1. Clutches for power and reverse gear shift (A, B, C, D, F and G)
2. 4-wheel drive
3. Front and rear differential locks
4. Front and rear PTO shafts
5. Main coupling booster
6. Gearbox pressure circulation lubrication
- from the POWER SHUTTLE model onwards, the system rotary pump (P1) 36 cm3 (88 l/min) supplies the
following circuits:
1. Clutches for power and reverse gear shift (A, B, C, D, F and G)
2. 4-wheel drive
3. Front and rear differential locks
4. Front and rear PTO shafts
5. Main coupling proportional feed valve
6. Rear PTO shaft, rear axle and gearbox pressure
circulation lubrication
HIGH-PRESSURE CIRCUIT
The high-pressure circuit can either be fitted with a single pump 32 cm3 (78 l/min) or a tandem pump 32 cm3
(78 l/min) + 16 cm3 (39 l/min). It supplies the following circuits:
1. Steering (via priority valve)
2. Hydraulic trailer brake (if fitted)
3. Braked front axle (if fitted)
4. First auxiliary control unit (priority)
5. Remaining auxiliary control units, EHR valve and sprung front axle
(are connected in parallel)
6. Brake (cooling) and differential master gear (lubrication)

8001-7

8001-8
Neutral Circulation Pressure with LS Pressure Test
1 TSW 5010
77
1 TSW 5025
76
SS98J046
TEST CONNECTIONS
Connect the 25 bar pressure gauge 1TSW 5025 to measuring point 76 (neutral circulation pressure), and
the 10 bar pressure gauge 1TSW 5010 to measuring point 77 (LS pressure).
The mini measuring connections 1TSW 640 and measuring lines 1TSW 635 must be used for this purpose.
TEST REQUIREMENTS
• Move the gearshift lever to the neutral and apply the parking brake.
• Shift all auxiliary control units to neutral.
• Start the motor and allow it to run at a speed of 1000 rpm.
WARNING: No circuit should be activated on the high-pressure circuit (including steering).The working
brake must not be operated if a HYDRAULIC TRAILER BRAKE or BRAKED FRONT AXLE option is
fitted. This will cause damage to the pressure gauge.

8001-9
MEASURED VALUES "UP TO" POWER SHUTTLE
PRESSURES AT MEASURING POINTS 76 AND 77
MOTOR speed OIL TEMPERATURE °C Neutral circulation pressure / bar LS pressure / bar
Measuring point 76 Measuring point 77
1000 60 8 1
1500 60 11 1.5
2300 60 17 2.5
MEASURED VALUES "FROM" POWER SHUTTLE ONWARDS

MOTOR speed OIL TEMPERATURE °C Neutral circulation pressure / bar LS pressure / bar
1000 60 6 0.8
1500 60 7 1.5
2300 60 8 2
NOTE: In practice, these measured values can show slight deviations due to equipment versions and
component tolerances.
SYSTEM RESPONSE POSSIBLE CAUSE
Neutral circulation pressure too high •A defective pressure lubricating valve in the rear
axle
•Pipelines and non-return valves (21) fitted
incorrectly
•A slider (35) is jammed in the connection plate
(11) due to dirt or non-compliance with the
tightening regulations
•Pilot valve (34) for ∆P changeover in slider (35)
does not close due to dirt
Neutral circulation pressure too low •Suction filter blocked

•Pump drive defective
•The pressure balance slider (35) in connection
plate (11) is jammed in the open position due to
dirt or distortion
LS pressure is too high •One or more circuits aren’t in neutral (auxiliary

control unit sliders or EHR valve sliders are
jammed)
•Non-return valve (21) fitted incorrectly
•Pilot valve (34) for ∆P changeover is jammed in
the open position due to dirt

8001-10
High Pressure Pump Test
1TSW 646
1 TSW 515-1
SS98J049

8001-11
TEST CONNECTIONS
The hydraulic tester is connected directly onto the pump in the hydraulic system, in order to test the high-
pressure pump. To do this, loosen the pipeline from the pump to the priority valve, and pivot it to the rear.
Replace the screw-on connector on the pump with a 180327030007 straight thread, and connect the
hydraulic tester 1TSW 515-1 with two high-pressure hoses 1-32-373-010 and the straight reduction piece
1TSW 646.
NOTE: Open the hydraulic tester pressure build-up valve completely before starting the test.
TEST REQUIREMENTS
• Move the gearshift lever to neutral and apply the parking brake.
• Shift all auxiliary control units into neutral.
MEASURED VALUES
Measured values for the single pump or the 1st stage of the tandem pump
MOTOR speed OIL TEMPERATURE °C Oil flow l/min Pressure / bar
2300 60 78 0*
2300 60 72 150
Measured values for the 2nd stage of the tandem pump

MOTOR speed OIL TEMPERATURE °C Oil flow l/min Pressure / bar
2300 60 39 0*
2300 60 36 150
* It is assumed that the hydraulic tester's pressure build-up valve is opened to the maximum with 0 bar.
However, in practice, a neutral circulation pressure of up to 20 bar can build up.
Oil flow or pressure too low •Oil level in the power unit is too low
•Suction filter blocked
•Pump drive defective
•Pump worn out
•Air ingress via the suction line or shaft sealing ring
on the pump
•Axial seal on the pump is leaking

8001-12
Steering test
1 TSW 5250 1 TSW 5250 WARNING: To test the maximum working

pressure, use the 250 bar pressure gauge.
SS98J049
TEST CONNECTIONS
The mini measuring connections 1TSW 636 and 1TSW 638 must be connected to the priority valve on the
LS (load sensing) and CF (control flow) outlets, for the steering test. The neutral position is tested with the
10 bar pressure gauge on the LS outlet, and the 25 bar pressure gauge on the CF outlet.
To test the maximum working pressure, connect a 250 bar pressure gauge to both outlets.
TEST REQUIREMENTS
• Move the gearshift lever to neutral and apply the parking brake.
• Shift all auxiliary control units to neutral.
WARNING: No circuit should be activated on the high-pressure circuit (including steering) during
neutral position testing. The working brake must not be activated if the HYDRAULIC TRAILER BRAKE
or BRAKED FRONT AXLE options are fitted. This will cause damage to the pressure gauge.

8001-13
MEASURED VALUES
Measured variables in neutral.
MOTOR speed OIL TEMPERATURE °C CF pressure / bar LS pressure / bar
1000 60 14 1
2300 60 14 1
Measured values at maximum working pressure (Steering wheel held at full lock)
MOTOR speed OIL TEMPERATURE °C CF pressure / bar LS pressure / bar
1000 60 164 150
2300 60 164 150
Measured value deviations •PRV in the steering control unit is adjusted

incorrectly or dirty
•The slider in the priority valve is jammed / choke
in the priority valve is blocked
•Poor pump performance
•Servostat defective
Measured value correct but steering is heavy •Front axle is overloaded

•Steering column is damaged (bearing)
•Servostat fitted under tension
Correct measured values but too many turns of the •Q slider in the servostat doesn't open
steering wheel are required
•Seals in steering cylinder are leaking
•Leakages in the servostat

8001-14
Auxiliary Control Unit Test
Q4 with latch Q3 without latch Q4 with latch electr. ACU
1 TSW 515-1
SS98J046

8001-15
TEST CONNECTIONS
To test the auxiliary control units, the hydraulic tester must be connected to each unit respectively and to the
free return.
TEST REQUIREMENTS
• Move the gearshift lever to the neutral position and apply the parking brake.
• Shift all auxiliary control units into the neutral position.
• Ensure that the control slides move to the maximum setting when operating the mechanical auxiliary
control units (check the remote-control setting).
MEASURED VALUES
NOTE: The measurements are carried out on both plug-in connectors (A and B) with the oil flow
regulator (mechanical auxiliary control units) open to the maximum.
Measured value at Q4 auxiliary control unit
MOTOR speed OIL TEMPERATURE °C Oil flow l/min Pressure on pressure gauge / bar
2300 60 min. 45 150
Measured values at Q3 auxiliary control unit without latch and free travel
2300 60 min. 80 150
Measured values at Q3 auxiliary control unit with latch and free travel
2300 60 min. 80 150
Electrical auxiliary control unit measured values

2300 60 min. 32 150
Steering is operational but no auxiliary control units •The slider (35) in the connection plate (11) is
(including EHR) are operational jammed
•The slider (46) in the 3-way flow regulator from
auxiliary control unit Q4 is jammed
•The auxiliary control unit is fitted under tension
(refer to chapter 8002 – Control Unit Fitting
Instructions)
•The choke (56) in the connection plate (11) is
blocked
The steering is operational but one or more of the •Shuttle valve leakage (dismantle the control block
auxiliary control units, or the sprung front axle is not and clean all shuttle valves, check the valves and
operational valve seats on both sides for tightness)

8001-16
None of the auxiliary control units achieve the min. oil •Pump performance (see high-pressure pump test)
flow
•The pressure balance (35) in the connection plate
(11) is distorted or jammed due to dirt
•The pilot valve (34) for ∆P changeover is stuck or
the hole or choke in the slider (35) is blocked (see
∆P changeover test)
•Check the priority valve
One mechanical auxiliary control unit does not •The spool valve does not move to the maximum
achieve the min. oil flow setting (check the remote-control setting)
•Adjustable choke 47, 53 or 88 is not at the
maximum setting
•Slider 46, 52 or 91 is jammed
None of the auxiliary control units achieve the •Check the pressure limiting valve (55) setting in
maximum system pressure the connection plate (11)
•Pump output (see high-pressure pump test)
One electrical auxiliary control unit is not operational, •By means of a an emergency procedure, check
or only partially operational the solenoid valves to see whether a mechanical
or electrical fault has occurred (the emergency
procedure is possible for the shut-off valve)
•Check the solenoid valve wiring

8001-17

8001-18
∆P Changeover Test
1 TSW 5250
77
1 TSW 5250
76
1 TSW 515-1
SS98J046

8001-19
TEST CONNECTIONS
Connect the 250 bar pressure gauges 1TSW 5250 to measuring points 76 and 77.
At the same time, connect hydraulic tester 1TSW 515-1 to any auxiliary control unit and to the free return.
TEST REQUIREMENTS
• Set the oil flow regulator of the connected auxiliary control unit to maximum flow rate.
TEST SEQUENCE
Continually close the pressure build-up valve on the hydraulic tester and simultaneously read off the
pressure gauges on measuring points 76 and 77. A difference in pressure of 10-15 bar (=∆P) must always
be displayed on the pressure gauges. Carry out the test on various control units.
∆P pressure difference is less than 10 bar •The pilot valve (34) does not open in the
connection plate (11) slider (35)
•The hole in the slider (35) to the pilot valve (34) is
blocked
•The slider (35) in the connection plate (11) is stiff
(connection plate fitted under tension state)

8001-20
EHR Control Unit Test
1 TSW 5250
77
1 TSW 5250
76
SS98J046

8001-21
TEST CONNECTIONS
Connect the 250 bar pressure gauges 1TSW 5250 to measuring points 76 and 77.
TEST REQUIREMENTS
• Fit a heavy implement to the three-point linkage.
TEST SEQUENCE
Raise the implement and check the EHR system for tightness. If the device can not be raised, the fault can
be narrowed down to either mechanical or electrical, by pressing the emergency actuation (solenoid valve,
raising/lowering). If the fault is electrical – refer to the EHR training documentation.
The hoisting unit can not be raised using the •Oil level is too low, suction filter is dirty, pump
emergency actuation drive is defective
•Auxilliary control unit (Q4) is stuck in setting
A or B
•The 3-way oil flow regulator slider (46) in the
auxiliary control unit (Q4) is jammed
•The slider (35) in the connection plate (11) is
jammed
•The 2-way oil flow regulator slider (79) or the
slider (80) is jammed (EHR control unit)
•The LS pressure is either not effective, or only
partially effective, on the spring side of the slider
(35) in the connection plate (11) (leakages on the
shuttle valves)
The lifting gear lifts too slowly or only at higher motor •The lifting gear is overloaded
speeds
•Oil level is too low, suction filter is dirty
•∆P changeover pressure deviation (see ∆P
changeover test)
•PRV (55) in the connection plate (check the
setting)
•Two-way oil flow regulator (79) jammed due to dirt
or distortion
•The slider (80) in the EHR control unit for raising
does not open sufficiently (elect. or mechanical
fault)
electrical fault: Insufficient current in the magnetic
raising coil (see EHR training data)
mechanical fault: Slider (80) stiff due to dirt or
distortion

8001-22
The lifting gear does not remain in the raised position •Electrical fault – can be checked by pulling the
under load plug out of the RAISE and LOWER magnetic coil
•Non-return valve (81) leakage
•Load safety valve (82) leakage
•Pilot cone in the slider for lowering (84) is leaking
•Main cone (84) for lowering is leaking
•O-rings in the vicinity of the lowering valves are
leaking (4 off)
•The EHR control unit is fitted under tension (see
Chapter 8002 – Control Unit Fitting Instructions)
WARNING: The EHR control unit must be replaced completely if a fault is detected in it and the vehicle
is still under guarantee.

Chapter
8002
8002
LOAD SENSING (LS) - HYDRAULIC VALVES
FOR FIXED DISPLACEMENT PUMP
Mechanical and electrical auxiliary control units,

connecting plate, EHR valve and priority valve
9105, 9115, 9125 and 9145

CS110, CS120, CS130 and CS150
Technical Documentation May, 1999
8002-2
TABLE OF CONTENTS
LOAD SENSING (LS) BLOCK ........................................................................................................... 3

CONNECTING PLATE ...................................................................................................................... 5
ADJUSTING – PRESSURE RELIEF VALVE (Connecting Plate) ........................................................ 7
Q4 MECHANICAL AUXILIARY CONTROL UNIT ............................................................................... 9
Q3 AUXILLIARY CONTROL UNIT WITHOUT CATCH ..................................................................... 15
Q3 AUXILLIARY CONTROL UNIT WITH CATCH ............................................................................ 19
ASSEMBLING THE BEARING BLOCK AND ANGLE LEVER ........................................................... 19
EHR CONTROL UNIT ............................................................................................................... ...... 21
SETTING THE SAFETY VALVE (EHR Control Unit) ........................................................................ 24
ELECTRICAL AUXILLIARY CONTROL UNIT .................................................................................. 25
PRIORITY VALVE................................................................................................................. .......... 27
LOAD SENSING (LS) BLOCK ASSEMBLY DRAWING ................................................Sva 7-96980 EN

8002-3
LOAD SENSING (LS) BLOCK
Dismantling Assembly
STEP 1 STEP 3
NOTE: Check all o-rings, two-way valves and
packing rings for damage, replace if necessary.
STEP 4
Fit the hydraulic valves, connecting plate and end
plate according to the assembly drawing.
NOTE: Use the LS block assembly drawing to
configure the hydraulic valves and packing
rings.
ss98k035
Disconnect all lines from the LS block.
STEP 2
Remove the hexagonal nuts on the connecting
plate and the end plate. Remove the connecting
plate/end plate and the hydraulic valves.
NOTE: Pay attention to the insert plate in the
connecting plate, the two-way valves and
packing rings – see LS block assembly drawing.

8002-4
CONNECTING PLATE
1 Protective cap
1 2 O-Ring
3 Hexagonal screw
2 4 Hexagonal nut
3 5 Valve bushing
6 O-Ring
4 7 Valve piston
8 Pressure spring
5 9 Valve cone
7 10 Valve disk
11 Locking screw
6
8 12 Pressure spring
9 13 Pressure governor
18 14 Stop pin
10 15 Shim ring
16 O-Ring
11 17 Locking screw
12 18 Locking screw
13 19
14 19 Insert plate
15 20 O-Rings
16
17
20
ss98k039
11
18 13
17
ss98k041

8002-5
CONNECTING PLATE
Dismantling STEP 3
STEP 1
18
sd98k003
Loosen the screw-in connector and screw-in

sd98k001 sealing plug (18).
Place the connecting plate on a clean work
surface. STEP 4
STEP 2
5
17
15 sd98k004
Remove the protective cap from the PRV. Remove

sd98k002 and dismantle the pressure relief valve (5). Check
the parts for damage and replace as necessary.
Loosen the locking screw (17) and remove the
pressure governor.
STEP 5
WARNING: The slide valve is under spring
pressure.
NOTE: The quantity and thickness of the shim
ring(s) (15) must not be changed.
NOTE: The complete connecting plate must be
replaced, if the pressure governor is damaged
(striation).
11
sd98k005
Loosen the screw-in sealing plugs (11) for the test

connections and the screw-in connectors.

8002-6
Assembly STEP 8
NOTE: Clean all parts and replace o-rings and
all worn or damaged parts. Oil all individual
parts before assembly.
18
STEP 6
sd98k003
Fit the screw-in sealing plug (18) and tighten to a

torque of von 38 +13 Nm. Fit the screw-in
11 connector.
sd98k005 STEP 9
Fit the locking screw-in sealing plugs (11) for the
test connections and screw-in connections, using
new seals.
17
STEP 7
13 15
sd98k002
Insert the pressure governor (13) with spring, stop

pin and shim rings (15) into the connecting plate.
Fit the screw-in sealing plug (17) with new o-ring
into the connecting plate and tighten to a torque of
67 +22 Nm.
sd98k004
Insert new o-rings and re-assemble the pressure STEP 10

reduction valve (5). Fit the pressure reduction
valve into the connecting plate and tighten to a
torque of 13.5 +4.5 Nm.
NOTE: The pressure relief valve must be 4
adjusted after fitting the connecting plate.
(see Adjustment page 7)
19
sd98k006
Fit new o-rings (4) into the connecting plate.

Lubricate the insert plate (19) and insert into the
return feed channel.
8002-7
ADJUSTING – PRESSURE RELIEF VALVE
Check that all hydraulic lines and screw-on connections on the LS block are fitted correctly before
adjustment is made.
Connections
In order to carry our adjustment, a hydraulic tester 1TSW 515-1 must be connected to the first mechanical
auxiliary control unit and the free return.
NOTE: Open the hydraulic tester pressure build-up valve completely before starting adjustment.
Adjustment conditions
• Start the motor and allow it to run at a speed of 1000 rpm. (Oil temperature must be approx. 60 °C)
• Operate the control unit and set the oil flow regulator on the control unit to a flow rate of approx. 30 l (the
control unit lever must be held in position during adjustment).
ADJUSTMENT:
Close the pressure build-up valve on the hydraulic tester until the pressure relief valve opens and read the
pressure gauge when this happens. The opening pressure has been reached when the pointer on the
pressure gauge does not rise any further.
The opening pressure should be between 175 – 180 bar, whereby there must still be a flow rate of at least
20 l/min. The adjusting screw (3) must be adjusted accordingly if the opening pressure deviates from this
value. Secure the adjusting screw by means of the locknut (4) after the setting has been carried out. Fit the
protective cap (1).
1
3
4
ss98k041

16 25
15 24
8002-8
14 23
13 22
12 21
Sva 7-96960 EN
7 20
6 11
5 19
4 18
3
2
62 1
61 8 9 17
60
59
58 10 31 32
57 33
56 30
55 29
34
28
27 35
54 36
53 37
52 26
38 ss98k042
39
40
41
42 46 O-Ring
43 47 O-Ring
48 Locking screw
49 Spring washer
45 33 Spring washer 50 Cheese head screw
51 46 34 Cap 51 Scraper ring
50 47 35 Locking screw 52 Bearing block
48 44 36 Shim ring
49 53 Supporting plate
37 Spring collar 54 O-Ring
1 Ball 9 O-ring 17 Control slider 25 Hollow screw 38 Pressure spring 55 Thrust bolt
2 Compression spring 10 Two-way valve 18 Valve insert 26 Control slider 39 Spring collar 56 Valve cone
3 O-ring 11 O-ring 19 Ball 27 Circlip 40 Pressure spring 57 Ball
4 Thrust ring 12 Flat sealing ring 20 Thrust bolt 28 Pressure spring 41 Notched shaft 58 Pressure spring
5 Stopper plug 13 Spacer ring 21 Pressure spring 29 Guide bolt 42 Support washer 59 Washer
6 Circlip 14 O-Ring 22 Shim ring 30 O-ring 43 Support ring 60 Pressure spring
7 Protecting cap 15 Thrust ring 23 O-ring 31 Locking screw 44 Notched plate 61 Clamping plate
8 O-Ring 16 Spacer ring 24 O-ring, back-up ring 32 Cheese head screw 45 Throttle screw 62 Circlip
Edition 05/99
8002-9
Q4 MECHANICAL AUXILIARY CONTROL UNIT
ss98k043
Dismantling STEP 2
STEP 1 61 62
10
sd98k008
Dismantling the shut-off valve:

sd98k007 Set the slide valve to neutral. Press the bow (A)
from the circlip (62) upwards. Turn the circlip 90°
Place the auxilliary control unit onto a clean work
to the right. Press the supporting plate (61)
surface. Remove the o-rings and take the two-way
downwards, turn by 90° (turn the circlip at the
valve (10) out of the LS channel.
same time) and pull it out at an angle towards the
top. Remove the valve insert (55-60).

8002-10
STEP 3 STEP 5
52 16
15 25
14
13
12
11
sd98k009 ss98k047
Dismantle the cap (34), angle lever and bearing Loosen the hollow screw (25) and remove the
block (52). “Kick-out”unit (19 – 24) from the slide valve.
Remove item 11 – 16 from the slide valve.
STEP 4 NOTE: There are 2 balls located in each of the
three holes in the hollow screw (25).
STEP 6
38
6
35
ss98k046
Take the slide valve (17) completely out of the

control unit. Loosen the fixing screw (35) for the
spring collar and remove the stop unit (37 – 44). sd98k048
WARNING: The compression spring (38) is Remove the cap (7) for the non-return valve and
under pressure. remove the circlip (6). Remove the non-return
valve.
NOTE: An air pistol (compressed air) can be
used to remove the non-return valve. For this
purpose, admit compressed air to the LS
channel and close P channels at the same time.
WARNING: Catch the non-return valve with a
cleaning cloth.

8002-11
STEP 7 Assembly
NOTE: Clean all parts and replace o-rings and
26 28 29 31 all worn or damaged parts. Oil all individual
parts before assembly.
STEP 9
sd98k010
Loosen the locking screw (31) for the oil flow

regulator. Remove the stop (29), spring (28) and 48 45
slide valve (26).
STEP 8 sd98k011
Fit the throttle screw (45) with the new o-ring into
the locking screw (48). Fit the locking screw with
the new o-ring into the control unit.
STEP 10
26 28 29 31
48 45
sd98k011
Loosen the locking screw (48) and dismantle the

throttle screw (45).
sd98k010
Insert the slide valve (26), spring (28) and

stop (29) into the control unit. Fit the locking screw
(31) with the new o-ring and tighten to a torque of
67 +22 Nm.

8002-12
STEP 11 STEP 13
25
6
5
2
1
7
sd98k048 sd98k013
Fit the ball (1), spring (2) and stopper plug (5) with Insert the ball (19), thrust bolt (20), compression
the new o-ring into the control unit. Attach the ring (21) and shim ring (22) into the spool valve. Fit
circlip (6) and the cap (7). the hollow screw (25) with the new o-rings (23 and
24) onto the spool valve and tighten to a torque of
STEP 12 19 +6.3 Nm.
Use grease to insert two balls into each of three
holes in the hollow screw.
16 STEP 14
40
44
43
sd98k012
Insert the new o-ring (14) (with thrust ring) into the
spacer ring (13). Slide the spacer ring with the new
o-ring (11) and flat packing ring (12) onto the spool
valve. Slide on the spacer ring (16). sd98k014
Fit the stop plates (44) with retaining rings (43)

onto the spool valve. Insert the notched shaft (41)
and spring (40) into the hollow screw.

8002-13
STEP 15 STEP 18
37 38 52
53
39
42
51
sd98k015 sd98k009
Use the locking screw to fit the retaining Insert the supporting plate (53) and scraper
washer (42), spring (38) and spring collars (39, ring (51) into the control unit. Fit the bearing
37). Tighten the locking screw (35) to a torque of block (52) with cheese head screw and tighten to
19 +6.3 Nm. a torque of 5.5 +1.8 Nm. Fit the angle lever
according to the assembly drawing (page 19).
NOTE:
Secure the locking screw with Loctite 243.
STEP 16 STEP 19
54
sd98k008
sd98k016
Fit the shut-off valve in reverse order to step 2.
Insert the new o-ring (54) into the control unit.
Insert the pre-assembled control slider into the
control unit. STEP 20
STEP 17
Fit the cap (34). Tighten the cheese head screw to 10
a torque of 5.5 +1.8 Nm.
sd98k007
Place the two-way valve (10) in the LS channel.

Insert new o-rings.

3
2
1
8002-14
11
Sva 7-96960 EN
7
9 6
8 5
45 4
44
43
42 10
41
40 16
39
38 15
14
37 13
36 12
35
17
18
19
25 20
26 21
27 22
34 28 23
33
32 29 24
30
31
ss98k050
1 Ball 9 O-ring 17 Cheese head screw 25 Supporting plate 33 Spring washer 41 Compression spring
2 Compression spring 10 Two-way valve 18 Spring washer 26 Supporting plate 34 Scraper ring 42 Washer
3 O-ring 11 Control slider 19 Cap 27 O-ring 35 Bearing block 43 Compression spring
4 Thrust ring 12 Control slider 20 Shim ring 28 Throttle screw 36 Supporting plate 44 Clamping plate
5 Stopper plug 13 Circlip 21 Locking screw 29 O-ring 37 O-ring 45 Circlip
6 Circlip 14 Pressure spring 22 Spring collar 30 O-ring 38 Thrust bolt
7 Protecting cap 15 O-ring 23 Pressure spring 31 Locking screw 39 Valve cone
8 O-Ring 16 Locking screw 24 Spring collar 32 Cheese head screw 40 Ball
Edition 05/99
8002-15
Q3 AUXILLIARY CONTROL UNIT WITHOUT CATCH
NOTE: Non-return valve and quantity of adjuster screws – see Q4 auxilliary control unit.
ss98k051
Dismantling STEP 2
STEP 1 44 45
10
sd98k008
Dismantling the shut-off valve:

sd98k017 Set the slide valve to neutral. Press the bow (A)
from the circlip (45) upwards. Turn the circlip 90°
to the right. Press the supporting plate (44)
surface. Remove the o-rings and take the two-way
downwards, turn by 90° (turn the circlip at the
same time) and pull it out at an angle towards the
top.
Remove the valve insert (38-43).

8002-16
STEP 3 STEP 5
35
6
sd98k018 sd98k048
Dismantle the angle lever and bearing block (35). Remove the cap (7) for the non-return valve and
remove the circlip (6). Remove the non-return
STEP 4 valve.
(see “NOTE” and “ATTENTION” page 10)
11 STEP 6
12 14 16
21
19
sd98k019
Remove the cap (19) and and take the slide

valve (11) completely out of the control unit.
sd98k020
Loosen the fixing screw (21) and dismantle the
compression spring (23). Loosen the locking screw (16) for the oil flow
regulator. Take out the spring (14) and slide
NOTE: The compression spring is pressurised.
valve (12).
STEP 7
31 28
sd98k011
Loosen the locking screw (31) and dismantle the

throttle screw (28).

8002-17
Assembly STEP 10
NOTE: Clean all parts and the sealing ring and
replace all worn or damaged parts. Oil all
individual parts before assembly.
6
5
STEP 8
2
1
7
sd98k048
Fit the ball (1), spring (2) and stopper plug (5) with
31 28 the new o-ring into the control unit. Attach the
circlip (6) and the cap (7).
sd98k011 STEP 11
Fit the throttle screw (28) with the new o-ring into
the locking screw (31). Fit the locking screw with 23 25
the new o-ring into the control unit.
STEP 9 27
26
12 14 16
sd98k021
Slide the o-ring (27), thrust ring (26) and suppor-

ting plate (25) onto the control slider. Use the lok-
king screw (21) to fit the compression spring (23)
and spring collars (22,24) onto the control slider.
Tighten the locking screw (21) to a torque of
sd98k020
19 +6.3 Nm.
Insert the slide valve (12) and spring (14) into the
control unit. Fit the locking screw (16) with the new NOTE:
Secure the locking screw with Loctite 243.
o-ring and tighten to a torque of 67 +22 Nm.

8002-18
STEP 12 STEP 15
37
sd98k016 sd98k008
Insert the new o-ring (37) into the control unit. Fit the shut-off valve in reverse order to step 2.
Insert the pre-assembled control slider into the
control unit. STEP 16
STEP 13
Fit the cap (19). Tighten the cheese head screw to 10
a torque of 5.5 +1.8 Nm.
STEP 14
35
36 34
sd98k017

Insert new o-rings.
sd98k018
Insert the supporting plate (36) and scraper

ring (34) into the control unit. Fit the bearing block
(35) with cheese head screw and tighten to a
torque of 5.5 +1.8 Nm. Fit the angle lever according
to the assembly drawing (page 19).

8002-19
Q3 AUXILLIARY CONTROL UNIT WITH CATCH
Instructions on dismantling and assembling this auxilliary control unit can be taken from the Q4 control unit
and Q3 control unit without catch sections.
NOTE: Refer to the Q4 control unitsection for information on removing and fitting the shut-off
valve (1), non-return valve (2) and the control slider (3).
NOTE: Refer to the Q3 control unit without catch section for information on removing and fitting the
oil flow regulator (4).
4
2
ss98k075
ASSEMBLING THE BEARING BLOCK AND ANGLE LEVER

(mechanical LS auxilliary control unit)
NOTE: Various final positions of the bearing blocks (1) and angle levers (2 / 3) result for the
mechanical auxilliary control units, they are displayed as follows.
Assembly for the 1st mech. Assembly for the 2nd mech.
auxilliary control unit (Q4) auxilliary control unit (Q3 without latch)
A1 A2
1 1
2
ss98m006
ss98m005 3
Assembly for the 3rd mech.
auxilliary control unit (Q3 with latch)
A1 A2 A3
2 3 2
A3
ss98m008 ss98m008 ss98m009
1
ss98m007 1 Bearing block 3 Angle lever
2 2 Angle lever

36 3
2
1
8002-20
34 35
Sva 7-96960 EN
33
32
31
30
29 4
28
27 5
18
19
20
21 8
9
22 10
11 26 Protecting cap
27 Locking screw
23 14 12 28 O-ring
24 15 29 Shim ring
25 16 13 ss98k053 30 Compression spring
26 17 31 Valve insert
1 O-ring 6 Two-way valve 11 O-ring 16 O-Ring 21 Pressure pipe 32 Non-return valve
2 Mounting flange 7 O-ring 12 Trip coil 17 Locking screw 22 Trip coil 33 Guide washer
3 Cheese head screw 8 Protecting cap 13 Pressure pipe 18 O-ring 23 O-ring 34 Circlip
4 Locking screw 9 O-ring 14 Control slider 19 Mounting flange 24 Union nut 35 Locking screw
5 O-ring 10 Union nut 15 Compression spring 20 Cheese head screw 25 O-ring 36 Locking screws
Edition 05/99
8002-21
EHR CONTROL UNIT
ss98m002
Dismantling STEP 2
STEP 1
34
6
sd98k023
Remove the circlip (34) and remove the non-return

sd98k022 valve.
Place the EHR control unit onto a clean work
surface. Remove the o-rings and take the two-way STEP 3
valve (6) out of the LS channel. SAFETY VALVE
31
30
29
27
ss98m003
Loosen the locking screw (27) and remove the

shim ring (29) and compression ring (30).
Dismantle the valve insert (31).

8002-22
STEP 4 after dismantling/assembling the “LOWERING”
unit.
STEP 7
36
36
17
4
sd98k024
Loosen the locking screws (4 and 17) and remove

the slide valve with the spring.
(item 36 – see step 6) sd98k027
RAISE the slide valve and remove the spring.

STEP 5
Assembly
NOTE: Clean all parts and the replace the
sealing rings and all worn or damaged parts. Oil
all individual parts before assembly.
STEP 8
sd98k025
Dismantle the solenoids for RAISING and

LOWERING.
STEP 6
sd98k027
Insert the spring and the slide valve for RAISING

into the control unit.
sd98k026
Dismantle the pressure pipes for RAISING and

LOWERING.
WARNING: The locking screws (item 36, step 4)
or the “LOWERING” unit may not be
dismantled. A testing stand setting is required
8002-23
STEP 9 STEP 12
SAFETY VALVE
31
30
29
27
2 19
sd98k026 ss98m003
Fit the pressure pipes for RAISING and Fit the valve insert (31) with the new o-ring and
LOWERING with new sealing rings. Use the tighten to a torque of 15 +4 Nm. Insert the
cheese head screws to fit the mounting flanges (2 compression spring (30) and shim ring (29).
and 19) and tighten to a torque of 2.6 +0.5 Nm. Fit the locking screw (27) with the new o-ring and
tighten to a torque of 65 +10 Nm.
STEP 10 NOTE: The safety valve must be set after
assembly is complete (see setting page 24).
STEP 13
33 34
sd98k025
Fit the trip coils for RAISING and LOWERING.

32
STEP 11 sd98k023
Insert the non-return valve (32) and guide

washer (33) into the EHR valve. Fit the circlip (34).
4 17
14 15
sd98k024
Insert the control slider (14) and compression

spring (15). Fit the locking screws (4 and 17) with
the new o-rings and tighten to a torque of
46 +15 Nm.

8002-24
STEP 14
Insert new o-rings.
6
sd98k022
SETTING THE SAFETY VALVE

Assemble the EHR valve according to instructions before commencing the setting procedure. A
commercially available hydraulic hand pump (equipped with at least one 300 bar pressure gauge),
connected to “A”, is used for setting. The EHR valve must be tested for leaks before the safety valve is set.
ADJUSTMENT:
1. Operate the hydraulic hand pump until a pressure of approx. 125 bar has been achieved (maintain the
pressure by re-pumping). Imperviousness is determined via the leakage from connection “A” to connection
“R1” or channel “R”.
Maximum leakage from “A” to „R1/R“ = 4 cm3/min (at ν = 35 mm2/s)
The EHR valve should be replaced if a leakage of over cm 3/min occurs.
2. Operate the hydraulic hand pump until the safety valve opens and read the pressure on the pressure
gauge. Opening pressure = 220 +20 bar
If the opening pressure is outside the stated value, raise or reduce the thickness of the shim rings (29)
accordingly.
Order numbers for the shim rings
155700730734 0.3 mm
29 155700730735 0.4 mm
1390470706 0.5 mm
155700730736 0.8 mm
ss98m003
ss98m002

8002-25
ELECTRICAL AUXILLIARY CONTROL UNIT
Dismantling STEP 3
STEP 1 2
3
2
sd98k030
Dismantle the directional control valve (2) and the

sd98k028 shut-off valve.
surface. Remove the o-rings and take the two-way STEP 4
5 6 8
STEP 2
7
4
sd98k031
Dismantle the pressure pipes (4) and the locking

screw (8). Remove the springs (6), washers and
sd98k029 control slider (7).
Dismantle the trip coils for the directional control
valve and the shut-off valve. STEP 5
sd98k032
Remove the o-ring and thrust ring from the shut-off

valve.

8002-26
Assembly STEP 8
NOTE: Clean all parts and the replace the 2
sealing rings and all damaged parts. Oil all
individual parts before assembly.
STEP 6
3
2
sd98k030
Fit the shut-off valve (3) into the plate and tighten
with a torque of 25 Nm. Fit the directional control
valve (2) with new sealing rings. Tighten the
cheese head screws to a torque of 8.9 Nm.
sd98k032
STEP 9
Attach the thrust ring and the new o-ring to the
shut-off valve.
STEP 7
5 6 8
7
4
sd98k029
Fit the trip coils to the directional control valve or

the shut-off valve. Tighten the plastic nuts by hand.
sd98k031
STEP 10
Insert the control slide (7), washers (5) and springs
into the directional control valve. Assemble the the
locking screw (8) and the pressure pipes (4) with
new o-rings and tighten with a torque of 30 Nm.
1
sd98k028

Insert new o-rings.

8002-27
PRIORITY VALVE
1
2
3
4
5
6
1 Locking screw 3 Control slider 5 Sealing ring

2 Sealing ring 4 Compression spring 6 Screw-in connector
ss98k076
Removal Dismantling
STEP 1
A
6
1
ss98m001
Disconnect all lines from the priority valve (A).

Loosen the securing screws and take the priority sd98m001
valve from the tractor. Place the priority valve onto a clean work surface.
Loosen the locking screws (1 and 6).

8002-28
STEP 2 Assembly
NOTE: Clean all parts. Oil all individual parts
before assembly.
STEP 3
4
3
sd98m002
Remove the compression spring (4) and the

control slider (3). 4
3
sd98m002
Insert the control slider (3) and compression

spring (4) into the priority valve.
STEP 4
6
1
sd98m001
Fit the locking screws (1 and 6) and tighten to a

torque of von 50 +10 Nm.

Chapter
8003
TROUBLESHOOTING IN THE LOW-

PRESSURE HYDRAULIC CIRCUIT
(P1 – 18 bar)
8003
9105, 9115, 9125 and 9145
CS110, CS120, CS130 and CS150
Technical Documentation/Training Centre June, 1999
8003-2
Contents
AN INTRODUCTION TO TROUBLESHOOTING .............................................................. 5
MEASUREMENT POINTS ON THE POWER SHIFT CONTROL BLOCK....................... 7
SYSTEM PRESSURE TEST P1 (18 bar) and pilot control press. P2 (10 bar) ............... 8
TESTING THE LOW-PRESSURE PUMP OUTPUT FLOW............................................ 11
TESTING THE LUBRICATION PRESSURE ....................................................................13
TESTING THE LUBRICATION FLOW............................................................................. 14
TESTING THE CONTROL PRESSURE FOR THE 6 POWER SHIFT STAGES .......... 16
TESTING THE LATCHING VALVES H1 AND H2........................................................... 18
TESTING THE SAFETY VALVES S1 AND S2 ............................................................... 19
TESTING THE CHANGEOVER FROM FIELD / ROAD MODE ..................................... 20
TESTING THE CONTROL PRESSURE TO THE MAIN CLUTCH

(post Power Shuttle versions) .......................................................................................... 21
TESTING THE CLUTCH BOOSTER

and hydro-static clutch operation (pre Power Shuttle versions) .................................... 22
TESTING THE BRAKE BOOSTER.................................................................................. 22
TESTING THE DIFFERENTIAL LOCK(S)....................................................................... 23
TESTING THE 4-WHEEL DRIVE .................................................................................... 25
TESTING THE REAR PTO SHAFT ................................................................................. 27
Sva 7-97200 EN Ausgabe 06/99

8003-3
SPECIAL TOOLS
Hydraulics tester Pressure gauge 1/4"
SD98J001
SS98J047
[76: EDU
[76: [76: EDU
Straight connection High-pressure hoses
SS99G081
SS99G064
[76: $'
[76: 3/5 /HQJWKFP
&RQQHFWLRQIRUWKHK\GUDXOLFVWHVWHU76: 7\SHRIILWWLQJV&RQLFDOQLSSOHZLWKXQLRQQXW
Tapered reducing connection High-pressure hose
SS99G063 SS99G082
[76: 3/ [ KLJKSUHVVXUHKRVH
[ EDQMREROW

8003-4
Mini measuring line Mini measuring connection
SS98J030
6WN76:
SS98J031
6WN76: 0[
Mini measuring connection
6WN76: 0[
6WN76: 0[
6WN76: 0[
Test connection
QRLOOXVWUDWLRQ
SS98J032
6WN76: /
6WN76: /
6WN76:
Pressure gauge connection
Test hose and reduction
SS98J033
[76: 0´
<DGDSWHU
SD99G018
[76: WHVWKRVH
[76: UHGXFWLRQ
QRLOOXVWUDWLRQ
76:

8003-5
In order to achieve swift, successful results when troubleshooting functions in the Low Pressure
Hydraulics (P1 Circuit, 18 bar), the following important aspects must be observed:
● The individual functions must be understood (see list of functions Page6). If necessary, Chapter 6 of the
Workshop Manual CS110-150/105-9145 can be referred to.
● If the red indicator lamp L27 (transmission oil pressure) lights up when the engine is running, the engine
must be stopped immediately. Top up the transmission oil level to the "Normal" mark on the sight glass,
using oil of the recommended quality and viscosity.
● Re-start the engine and check whether the indicator lamp L27 has gone out. If it has, operate the
function, which appeared defective, once more. If one or more functions still do not react, further P1
functions should be tested. This will give an initial indication as to whether the hydraulic working
pressure is present.
● With the engine running, all functions are supplied in parallel up to their control valves.
● With pre-power shuttle versions, the majority of P1 functions are electrically/electronically
actuated, the remainder are electrically actuated.
● With post-power shuttle versions, all P1 functions are electrically/electronically actuated.
● Not all of these functions are actuated by way of the same electronics unit (box).
Therefore: When carrying out systematic troubleshooting, proceed in the correct sequence!
● If possible, use the emergency controls (e.g. electrically operated auxiliary control units) to test the
hydraulic function and thus isolate the fault.
● If a fault is found in the electrical or electronic actuation, the first step to be taken, is to ensure that the
electrical power supply is available (see circuit diagram).
● Check that the supply potential, required by the corresponding function, is available (e.g. +15/, +15Si,
D+ or ⊥ ground, see circuit diagram)
● With certain functions, the fault can be readily isolated by providing an external supply to an actuator,
e.g. that of a relevant solenoid valve.
,03257$17 In order to prevent damage to the electronic boxes (transmission electronics, ECCU,
PTO shaft management), the connection to the corresponding electronic box must be disconnected
before providing the solenoid valve with an external supply.
● The basis for a satisfactory function, is that the correct P1 pressure of 18 bar is available. The supply
pressure is checked at allocated measurement points. A non-damped pressure gauge of 0 to 25 bar
must preferably be used. The oil temperature must be at least 60 ° Celsius where possible.
● For testing individual functions, the measurement points for pressure and oil flow are also shown, in
graphic form, in the corresponding chapters!

8003-6
FUNCTIONS, which are supplied with P1 pressure (pre power shuttle versions)
Supplied by low pressure pump V = 32 cm3 Q = 78 l/min
● Power shift control, including F/R Y21 – Y27
● Clutch booster Main clutch
● Brake booster (2 off, pre Sirmac brake versions) Working brake
● 4-wheel drive Y1
● Differential lock(s) Y10
● Rear PTO shaft Y5
● Front PTO shaft (option) Y4
FUNCTIONS, which are supplied with P1 pressure (post power shuttle versions)
Supplied by low pressure pump V = 36 cm3 Q = 88 l/min
● Power shift control, including F/R Y21 – Y27
● Main clutch actuation Y3
● 4-wheel drive Y1
● Differential lock(s) Y10
● Rear PTO shaft Y5
● Front PTO shaft Y4
P2 PILOT CONTROL PRESSURE (10 bar)

In the 9100 tractor series, P2 pressure is used, in the power shift control, to actuate the control slides in the
following valves:
Gear valves 1 and 2, stop valves 1 and 2, forwards / reverse valve and changeover valve. A pressure of
10 bar is maintained by way of a spring loaded control slide in the power shift control block. This is supplied
in parallel to the solenoid valves Y21 to Y27. The P2 pilot control pressure is derived from the P1pressure.
MAIN CLUTCH – CONTROL PRESSURE (proportional, 1.5 to 18 bar)

Controlled by the proportional control valve Y3, for characteristic curve-controlled main clutch engagement
(closing).
LUBRICATION PRESSURE
● With cold engine oil and high engine speed, the lubrication pressure can reach 4 to 5 bar (limited by the
lubrication pressure limiting valve).
● A lubrication pressure of 1.2 to 1.5 bar, at the feed-in point to the lubrication oil distributor, is sufficient at
an oil temperature of 80 ° Celsius. (See details in Chapter Testing the Lubrication Oil Pressure.)
OIL COOLING
Above a transmission oil temperature of 55 ° Celsius, part of the lubrication oil flow is diverted through the
oil cooler, above 70 ° Celsius the total lubrication oil flow is diverted through the oil cooler.
127( The smaller the lubrication oil flow, the less heat is dissipated through the transmission oil
cooler!

8003-7
MEASUREMENT POINTS ON THE POWER SHIFT CONTROL BLOCK
The measurement points 1 – 13 (M10 x 1) can be accessed using the test line 1TSW 643.
Exception: The tapered reducing connection 1TSW 644 is required for measurement point 7 (M18x1.5).
M.P. PURPOSE REACTION
5 SYSTEM PRESSURE P1 18 bar P1 pressure with the engine running
3 PILOT CONTROL PRESSURE 10 bar P2 pressure with the engine running, parallel to
the solenoid valves Y21 to Y27
6 LATCHING PRESSURE TO LATCHING VALVE H1 P1 pressure with the engine running
8 LATCHING PRESSURE TO LATCHING VALVE H2 P1 pressure with the engine running
7 CONTROLLED PRESSURE PG P1 pressure between power shift and
modulated pressure during a power shift
1 CONTROL PRESSURE TO CLUTCH D
2 CONTROL PRESSURE TO CLUTCH C
12 CONTROL PRESSURE TO CLUTCHES B/G
13 CONTROL PRESSURE TO CLUTCHES A/F at measurement points 1, 2, 12 and 13:
modulated pressure during a power shift
sequence. P1 pressure minus 0.5 to 1 bar when
the power shift sequence is completed.
11 CONTROL PRESSURE TO SAFETY VALVE S1 P2 pressure (from Y23 or Y24 or from both)
operates the safety valve-S1 at the beginning of
a power shift sequence.
10 CONTROL PRESSURE TO SAFETY VALVE S2 when the modulated pressure reaches a
pressure of 8 to 9 bar during a power shift, the
safety valve S2 is operated.
9 RESET PRESSURE (P1) TO THE
LATCHING VALVES H1 AND H2 reset the slides of latching valves H1 and/or H2,
as soon as safety valve S2 is operated.
10
9
11
12
13
5
7 6
3
2
1
SS99F051

8003-8
SYSTEM PRESSURE TEST P1 (18 bar) and pilot control press. P2 (10 bar)
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SS99F051 SS99F052
TEST CONNECTIONS
● Test connections for all P1 functions with the exception of the rear PTO shaft and differential lock(s):
Disconnect and remove the P1 pressure monitoring switch S21 (measuring point 5, thread M10 x 1).
Connect the 25 bar pressure gauge 1TSW 5025 with test hose 1TSW 643, mini test connection
1TSW 640 and mini test line 1TSW 635.
● Test connection P1 pressure – supply for the rear PTO shaft and differential lock(s):
Remove the upper blanking screw M10x1 on the PTO shaft control unit Y5 and connect the 25 bar
pressure gauge 1TSW 5025 with mini test connection 1TSW 640 and mini test line 1TSW 635.
● In order to test the pilot control pressure, connect the 25 bar pressure gauge 1TSW 5025 with test hose
W0501 206 836, mini test connection 1TSW 640 and mini test line 1TSW 635 .
TEST REQUIREMENTS
● Apply the parking brake and shift the gear lever into the neutral position.
● Start the engine and operate all P1 functions in the corresponding combination, at the engine speeds
given in the table, so that firstly the least possible and secondly the maximum possible leakage losses
prevail, taking normal leakage losses, at the piston rings and pressure oil supply to the rotating units,
into consideration (e.g. switch the PTO shafts and differential lock ON and 4-wheel drive OFF and vice-
versa).
The measured values must correspond to those given in the table that follows!
127(If the P1 pressure at measurement point 5 is not achieved at any one of the stipulated speeds,
temporarily blank the supply lines off in the following sequence and repeat the pressure test.
● pre Power Shuttle versions
Line to the control valves Y5 and Y10, rear PTO shaft and differential lock(s)
Line to the front PTO shaft control valve (only if a front PTO shaft is fitted)
Line to the brake boosters (if fitted)
Line to the clutch booster
● post Power Shuttle versions
Line to the proportional control valve Y3 (operates the main clutch)
Line to the rear PTO shaft and differential lock(s) control valves
Line to the front PTO shaft control valve Y4 (only if a front PTO shaft is fitted)

8003-9
127( If the P1 pressure is OK but the P2 pressure deviates substantially from 10 bar, then remove
the P2 control slide, clean and inspect the housing, slide and slide spring. Refit and check for
freedom of movement. Repeat the P2 pressure test.
P1 PRESSURE AT MEASUREMENT POINT 5 AND AT THE MEASUREMENT POINT OF THE PTO SHAFT
CONTROL VALVE Y5
P2 PRESSURE AT MEASUREMENT POINT 3
MOTOR speed OIL TEMPERATURE P1 pressure in bar P2 pressure in bar

°C
750 80 18 to 19 10 ± 0,5
1500 80 18 to 19 10 ± 0,5
2300 80 18 to 19 10 ± 0,5
P1 pressure too high at all speeds. • Control slide for P1 pressure in the power shift
control block sticking (dirt, scoring).
• Pressure setting incorrect (adjusting washers for
the slide spring).
P1 pressure too high only at higher speeds and low • Lubrication pressure control valve control slide
oil temperature. sluggish, hence pressure accumulates.
P1 pressure too high only at higher speeds and high • Partial blockage in the oil cooler circuit (line
oil temperature. kinked), hence pressure accumulates.
127(P1 pressure can be slightly higher at very low oil temperatures and high engine speeds, due to
the high viscosity of the oil!
P1 pressure too low at both measurement points at • Pressure setting incorrect (adjusting washers for
all engine speeds. the control slide).
P1 pressure too low at both measurement points at • Control slide for P1 pressure sticking (dirt,
low engine speeds. scoring).
• Cold start valve leaking, valve cone sticking (dirt,
scoring), pressure setting too low (set value
27+3 bar).
• Suction – and coarse filters dirty.
• Power shift control block gasket torn.
• Pump worn out
P1 pressure too low at both measurement points at • Extreme leakage at the 4-wheel drive clutch:
low engine speeds (4-wheel drive is switched OFF). Bearings and (or) piston rings worn.
Leakage at the piston or thrust bolt seals.
P1 pressure too low at both measurement points at • Countershaft bearings and/or piston rings worn.
low engine speeds (main clutch is engaged). Piston seal leaking.
127(only valid for post Power Shuttle versions
Low pressure pump noisy. • Suction and coarse filters dirty

• Pump takes in air: Leaking pump shaft sealing
ring. Leakage in the suction side.
• Pump worn out
P1 pressure only too low at the Y5 PTO shaft control • Internal leakage in the PTO shaft and/or
unit measurement point, with the PTO shaft and differential lock control unit ('O' ring between
differential lock switched OFF. channel P and A leaking or missing).

8003-10

P1 pressure only too low at the Y5 PTO shaft control • Loss of pressure through excessive leakage:
unit measurement point, with the PTO shaft and Bearings and/or piston rings on the clutch shaft or
differential lock switched ON. clutch are worn. PTO shaft clutch piston to
cylinder seal leaking. Broken rear piston ring on
the clutch shaft (separation lubrication pressure –
clutch control pressure)
P1 pressure only too low at the Y5 PTO shaft control • Loss of pressure through excessive leakage:
unit measurement point, with the differential lock Differential bearings and/or piston rings on the
switched ON. differential housing are worn.
Piston to cylinder seal leaking (quad-ring).

8003-11
TESTING THE LOW-PRESSURE PUMP OUTPUT FLOW
SS99F053
76:
TEST CONNECTIONS
In order to test the output flow, the U-shaped connection pipe to the power shift block must be removed.
Connect the hydraulics tester 1TSW 515-1 using two high-pressure hoses 1TSW 633 and the reducing
connections 1TSW 634.
127(In order to be able to use the high-pressure hoses 1TSW 633 the straight connections
1TSW 632 must be fitted to the hydraulics tester 1TSW 515-1.
127(Fully open the pressure build-up valve on the hydraulics tester before starting the engine!
TEST REQUIREMENTS
● Check the transmission oil level.
● Apply the parking brake and shift the gear lever to the neutral position.
● Start the engine and allow it to run at the speeds stipulated in the table.
● If the nominal values are not achieved, check the cold start valve (safety valve for the P1 circuit) for ease
of movement, condition of the seal seating and pressure setting, using the pressure build-up valve on
the hydraulics tester. Opening pressure 27 +3 bar.
127(If the nominal value is not achieved, proceed as follows:
A- pre Power Shuttle versions – temporarily blank off the supply line to the control valves for the rear
PTO shaft and differential lock(s) and the supply line to the clutch booster.
B- post Power Shuttle versions – temporarily blank off the supply line to the control valves for the rear
PTO shaft and differential lock(s) and the supply line to the main clutch control valves and temporarily
lock the front PTO shaft.
Check the 4-wheel drive valve insert and switch the 4-wheel drive ON during the subsequent trial run.

8003-12
LOW PRESSURE PUMP OUTPUT FLOW TEST VALUES
MOTOR speed OIL TEMPERATURE Output flow Q in l/min Remarks

°C
750 80 25 pre power shuttle
750 80 28 post power shuttle
127(A deviation in Q of up to 10 % is permissible, due to pump wear.

Output flow too low at high speed and pump is noisy. • Suction filter dirty and (or) leakage in the suction
side. Pump shaft seal leaks.
Output flow too low at all speeds. • Pump worn out.
• Cold start valve leaks or pressure setting too low.
• Casting fault in the cold start valve housing.
• Extreme leakage in one or more of the following
control valves:
front or rear PTO shaft, differential lock(s), main
clutch control valve, clutch booster, brake booster.

8003-13
TESTING THE LUBRICATION PRESSURE
The presence of a minimum lubrication pressure, also at operating temperature, is of the utmost importance
for the T7200L power unit:
● Due to the fact that only the 4-wheel drive shaft and the PTO shaft drive are splash lubricated, pressure
lubrication to all other shafts and rotating parts, including the power shift clutch, is of the utmost
importance.
● In the main clutch and the PTO clutch, the pressure lubrication oil fulfils a second important role of
dissipating heat caused when engaging or by friction.
● In pre power shuttle versions, the rear axle differential, the PTO shaft clutch and their shafts are
lubricated by the neutral circuit and the high pressure hydraulics return feed.
● On post power shuttle versions, the rear axle differential, the PTO clutch and their shafts are provided
with lubrication by the low pressure system.
● The oil supply to the wet brakes in the rear axle (dissipation of heat caused by braking) and lubrication of
the meshing between bevel pinion/differential master gear in all versions, is provided by the neutral
circuit and the high pressure hydraulics return feed.
A 76:
SS99G026
TEST CONNECTIONS
The most important test point for measuring the lubrication pressure is the inlet point to the lubrication oil
distributor on the power shift transmission housing, above the lubrication pressure limiting valve.
127( Further measuring points are the lubrication oil feed to the rear axle differential and 2
measuring points to measure the PTO shaft lubrication pressure.
Remove the mat and floorboard from the cab. Fit the existing T junction (A) as shown in the diagram.
Connect the 10 bar pressure gauge 1TSW 5010 using the test connection 1TSW 637 and mini test line
1TSW 635. Make the connection to the inlet point (lubrication oil distribution) using the high-pressure hose
1TSW 633.
TEST REQUIREMENTS
● Start the engine and read off the lubrication pressure at the speeds and transmission oil temperatures
stipulated in the table.
● Carry out these test steps in all forward and reverse power shift stages and switch the maximum number
of P1 consumers ON once when doing so (switch the 4-wheel drive OFF!).

8003-14
LUBRICATION PRESSURE TEST TABLE; AT THE INLET POINT TO THE POWER SHIFT GEAR BOX
MOTOR speed OIL TEMPERATURE Min. lube pressure Max. lube pressure
°C
750 20 1.5 bar 4 to 5 bar
1500 20 1.5 bar 4 to 5 bar
2300 20 1.5 bar 4 to 5 bar
750 80 1.2 bar 4 to 5 bar
1500 80 1.5 bar 4 to 5 bar
2300 80 1.5 bar 4 to 5 bar

Lubrication pressure too low at low engine speed and/ • Suction filter dirty.
or high oil temperature.
• Pump worn out.
• Cold start valve leaks or sticks.
• Power shift control block gasket torn.
• Incorrect oil viscosity or quality.
Lubrication pressure only too low in one or more P1 • Extreme leakage in individual P1 functions.
functions.
127(The lubrication pressure is dependent upon both the oil temperature and flow!
TESTING THE LUBRICATION FLOW
76:
SS99F054
The manufacturer provides details of the internal construction leakage in the power unit (piston ring sealing,
gaps on cams). This leakage will increase over the course of time, due to normal wear and tear. This has an
immediate influence on the lubrication oil flow.
,03257$17Only a comparison measurement between pump oil flow and lubrication oil flow can give
conclusive evidence as to the overall state of the power unit.
TEST CONNECTIONS
Remove the mat and floorboard from the cab. Fit the existing T junction (A) as shown in the diagram.
Connect the hydraulics tester 1TSW 515-1 using two high-pressure hoses 1TSW 633.
127(In order to be able to use the high-pressure hoses 1TSW 633 the straight connections
1TSW 632 must be fitted to the hydraulics tester 1TSW 515-1.

8003-15
TEST REQUIREMENTS
● Start the engine and read off the lubrication oil flow at the speeds and transmission oil temperatures
stipulated in the table.
127(Fully open the pressure build-up valve on the hydraulics tester before starting the engine!
:$51,1* The engine must not run for longer than two minutes during this test. Rear axle and PTO
shaft lubrication is not provided!
MEASUREMENT VALUES – COMPARISON PUMP OIL FLOW / LUBRICATION OIL FLOW

MOTOR speed OIL Pump oil flow QP Lubrication oil flow Remarks
TEMPERATURE °C in l/min QP in l/min
750 80 25 QP minus 5 to 10 pre power shuttle
750 80 28 QP minus 6 to 12 post power shuttle
PTO shaft switched ON – partial leakage max. 1 l/min
Differential lock switched ON – partial leakage max. 1 l/min
Main clutch engaged – partial leakage max. 2 l/min post power shuttle

The lubrication oil flow is far too low, in relation to the • Internal leakage in the main control block:
pump oil flow, at all speeds and in all power shift Housing gasket torn:
stages (see previous table). Valve housing sealing surface is not flat (level).
Securing screws were tightened to the wrong
torque and/or in the wrong sequence.
• Piston ring seals on all shafts worn due to length
of power shift service.
• Casting flaw or machining fault on the housing.
The lubrication oil flow is far too low, in relation to the • Internal leakage in the F/R control block:
pump oil flow, at all speeds and in particular forward Gasket on a housing web torn:
or reverse power shift stages (see previous table).
• Valve housing sealing surface is not flat (level).
Securing screws were tightened to the wrong
torque and/or in the wrong sequence.
• Piston ring seal on only one shaft badly worn due
to excess bearing play (bearing worn or
incorrectly adjusted).
127(At a transmission oil temperature of > 70 °C and with an operational temperature control valve,
the lubrication oil flow quantity is the same as the oil flow through the transmission oil cooler. As a
consequence, the smaller the lubrication oil flow rate, the smaller the oil flow rate through the
transmission oil cooler. The result is a higher transmission oil temperature.

8003-16
TESTING THE CONTROL PRESSURE FOR THE 6 POWER SHIFT STAGES
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SS99F051
127( In order to have a solid basis for pressure comparison, this test should be preceded by a
measurement of the system pressure at measuring point 5.
TEST CONNECTIONS
Connect a 25 bar pressure gauge 1TSW 5025 to each of the power shift control block measuring points 1, 2,
12 and 13. To do this, use the test hoses 1TSW 643, mini test connections 1TSW 640 and mini test lines
1TSW 635.
RESTING THE POWER SHIFT IN THE NEUTRAL "N" POSITION

Apply the parking brake and shift the gear lever into the neutral position. Start the engine but do not yet
operate any other controls.
A On pre power shuttle versions, the display on the A column will indicate "N" and power shift stage "3".
Only clutch “C” is operated (engaged). The following pressures will be indicated:
• The pressure at measuring point 2 is the pressure to clutch C.
• The pressure at measuring point 12 is the P1 pressure up to the V/R control slide.
Due to the fact that a small amount of leakage is always present at the piston ring seals of activated
clutches, there is a consequent slight loss of pressure (∆p). With perfect piston ring seals, the pressure drop
between measuring point 5 (P1 system pressure) and the measuring point of an activated clutch is not more
than 0.5 to 1 bar (see data in the Measurement Table).
A On post power shuttle versions, the display on the A column will indicate "N" and power shift stage "1".
Only clutch “C” is operated (engaged). The following pressures will be indicated:
• The pressure at measuring point 2 is the pressure to clutch C.
• The pressure at measuring point 13 is the P1 pressure up to the V/R control slide.
127(Measuring points 12 and 13 each serve 2 clutches, independent of whether driving forwards or
reverse, see measuring points in the Power Shift Table.
The pressures taken at measuring points 12 and 13 are only then control pressures to the
power shift clutches, when the FORWARD or REVERSE arrow indicating the direction of travel
lights up constantly: Clutches A / B or F / G are not operated by P1 pressure so long as an arrow
only blinks.

8003-17
CHECKING THE CONTROL PRESSURES IN POWER SHIFT STAGES 1 TO 4, FORWARD AND REVERSE
127( 2 clutches are each operated, thus control pressure must be indicated at 2 measuring points
(see the Table below).
● The pressures must be read off in all power shift stages, forward and reverse, at the stipulated engine
speeds, and compared to the values given in the Table.
● If problems arise in one or more power shift stages, it is an absolute must to test all stages, in order to be
able to make comparisons in pressure.
● Not only the rise in pressure of the clutches which are engaging must be checked, also observe that the
pressure of disengaging clutches falls to 0 bar.
PRESSURES AT MEASURING POINTS 5; 1; 2; 12 AND 13 (TESTING GEAR VALVES G1 AND G2)
Oil temperature 80 °C, engine speed n = 750 – 1500 – 2300 rpm
Stage Stage Stage Stage Stage Stage Stage Stage
4R 3R 2R 1R 1V 2V 3V 4V
P1 pressure (in bar) 18 to 19 18 to 19 18 to 19 18 to 19 18 to 19 18 to 19 18 to 19 18 to 19
at measuring point 5
Clutch D D D D D D D D
Measuring point 1 P1 0 P1 0 0 P1 0 P1
pressure in bar minus minus minus minus
0.5 to 1 0.5 to 1 0.5 to 1 0.5 to 1
Clutch C C C C C C C C
Measuring point 2 0 P1 0 P1 P1 0 P1 0
0.5 to 1 0.5 to 1 0.5 to 1 0.5 to 1
Clutch G G G G B B B B
Measuring point 12 P1 P1 0 0 0 0 P1 P1
0.5 to 1 0.5 to 1 0.5 to 1 0.5 to 1
Clutch F F F F A A A A
Measuring point 13 0 0 P1 P1 P1 P1 0 0
0.5 to 1 0.5 to 1 0.5 to 1 0.5 to 1
127(2 clutches are fitted to each of the 3 shafts in the power shift transmission. A seal between the
fixed housing and the rotating shaft is provided, on all shafts, in the form of piston rings at some point
on the shaft. In addition, there is a piston ring seal between the shaft and the piston carrier. The
pistons themselves are sealed with respect to the piston carriers (cylinders) by 2 ‘O’ rings.
● If the control pressure at measuring point 1, 2, 12 or 13 is much lower than the P1 pressure, a further
pressure measurement must be made at the same measuring point, whereby power shift stages must be
selected, which operate a different clutch, but the same shaft is affected. The following pairs of clutches
are each assigned to a common shaft: A and C, B and D, F and G.
● If the control pressure is far lower than P1 pressure, in all power shift, where the same shaft is involved,
it can be assumed that there is excessive leakage on the piston ring seal. The higher rate of oil flow
caused by this causes an excessive loss of pressure between measuring points 5 and the other
measuring points.
Pressure loss at measuring point 5:

If the pressure drops noticeably in a particular power shift stage, particularly at low engine speed, it must be
checked that the volume flow to the power shift control is sufficient.
Quick test by measuring the lubrication pressure:

A lubrication pressure must be present, in all power shift stages, at engine idling speed and an oil
temperature of 80 °C, with PTO shaft and differential lock switched ON but 4-wheel drive switched OFF. This
is a quick, simple method of getting an indication that the volume flow is sufficient to supply the P1 functions,

8003-18
particularly when no flowmeter and connecting parts required are not on hand (see details in Chapter
Testing the Lubrication Pressure).
127(In order to determine the volume flow reserves more precisely, it is essential to test the pump
output flow prior to this (for details, see the Chapter “Testing the Pump Output Flow”).
TESTING THE LATCHING VALVES H1 AND H2

The latching valves have the job of holding the disengaging clutches engaged for a certain period of time, in
order to create an “overlap” in conjunction with the engaging clutches, when shifting to another power shift
stage.
,03257$17Each of the two gear valves has a latching valve assigned to it.
● When testing the gear valves and simultaneously testing the pressures at the measuring points to the
power shift clutches, a functional test of the latching valves can be carried out.
● Shift up and down through all power shift stages in turn. Observe the pressure drop in the disengaging
clutches when doing so. The pressure gauge pointer must stop briefly at a pressure drop of between 12
and 14 bar (≤ 1 sec) because the clutch to be officially disengaged remains engaged for a short time due
to the latching pressure input (intentional overlapping of clutches).
127( Testing the function of the gear valves and latching valves using pressure gauges is simpler
and more precise if the assigned pilot pressure solenoid valves (Y21 to Y27) are individually operated
in the power shift block.
TEST REQUIREMENTS
● With the engine stopped, disconnect the electrical control plug from the power shift block.
● Connect a “Y” adapter 1TSW 528-56 to both plugs on the power shift block. Do not connect the adapter
to the tractor’s cable harness.
● Make a provisional connection from a fused 12 Volt power supply on the tractor to both red sockets on
the adapter. Also provide a ground connection.
● Start the engine and activate the pilot valves Y21 and Y22 together with Y26 or Y27 in turn with ground
in accordance with the Power Shift Table.
Check the course of pressure increase and drop in the clutches using the pressure gauges.
● Carry on to activate the valves Y21 and Y23 parallel to the assigned pilot valves Y23 and Y24 in turn.
Observe whether the pressure drop in a disengaging clutch occurs in 2 stages (disengaging clutch
must be supplied briefly with P1 pressure).
● Operate the gear valve on its own and together with the relevant latching valve in turn and observe the
difference in pressure drop of the disengaging clutch.

8003-19
TESTING THE SAFETY VALVES S1 AND S2
76: 76:
0HDVXULQJ 0HDVXULQJ
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SS99F051
The safety valves have the following function:

● Resetting latching valve(s) H1 and/or H2, as soon as the modulated pressure in the engaging clutch
reaches between 8 and 9 bar, when the power shift switches to the “field” mode.
● Resetting the latching valve(s) H1 and/or H2 at the previously mentioned pressure – if one or both of the
latching valves remains operated, for longer than the time stipulated in the software by Y23 or Y24, due
to an electrical or mechanical fault (prevents 3 clutches from being engaged simultaneously).
,03257$17 Safety valve S1 is supplied with P2 pressure (10 bar) during every power shift
sequence. Safety valve S2 is supplied with modulated control pressure PG during every power shift
sequence.Safety valveS2 applies P1 pressure, as resetting pressure PR, to the reverse side of the
latching valve control slide during every power shift sequence.
TEST SEQUENCE
● Connect the 25 bar pressure gauge 1TSW 5025 to measuring point 11 on the power shift block.
● Start the engine Operate the pilot control valves Y23 and Y24 via the “Y” adapter1TSW 528-56 several
times one at a time and simultaneously.
● Y23 and/or Y24 now operate safety valve S1 via the shuttle valve.
The pressure gauge at measuring point 11 must immediately indicate 10 bar (P2 pressure).
● Connect an additional 25 bar pressure gauge 1TSW 5025 to measuring point 10 on the power shift
block.
● Start the engine Operate the pilot control valves Y23 and Y24 via the “Y” adapter 1 TSW 528 several
The pressure gauge at measuring point 11 must immediately indicate 10 bar and the pressure
gauge at measuring point 10 must immediately indicate P1 pressure to minus 1 bar.
NOTE: If this pressure test is carried out in the normal way, from the Multicontroller (without energising
externally via the “Y” adapter), the pressure increase at measuring point 10 will be modulated.
● Connect a 25 bar pressure gauge 1TSW 5025 to measuring point 9 on the power shift block.
● Start the engine Operate the pilot control valves Y23 and Y24 via the “Y” adapter1TSW 528-56 several
The pointer of the pressure gauge at measuring point 9 must move from zero and rise instantly to
P1 pressure no later than when the pressure gauge at measuring point 10 indicates a pressure of
9 bar.
Note: If this pressure test is carried out in the normal way, from the Multicontroller (without energising
externally via the “Y” adapter), the pressure increase at measuring point 10 will be parallel to the control
pressure at an engaging clutch and modulated.

8003-20
TESTING THE CHANGEOVER FROM FIELD / ROAD MODE
● Shift through the power shift stages by means of external energisation through the “Y” adapter 1TSW
528-56, operate the corresponding latching valves in parallel when doing so. Energise the characteristic
curve valve Y25 during several power shifts During the power shift procedure, the engine will be
subjected to a load, caused by the artificially extended overlapping of clutches. This will be
audible.
● Do not energise Y25 and carry out several further power shifts. Loading of the engine is now barely
audible. This test shows whether the characteristic curve valve Y25, the reversing valve and the 2-stage
valve are functioning.
.

The power shift does not shift to another stage, • Electrical or electronic fault. Pilot control valve Y21
when a button is pressed (error codes might be or Y22 is not operated.
displayed).
• Pilot control valve Y21 or Y22 is defective.
• The slide of gear valve G1, G2 or of the forward/
reverse valve jams due to dirt.
When shifting to a particular power shift stage, the • Excess leakage in the pressure oil supply to a
red transmission oil pressure indicator lamp L27 particular power shift clutch (defective piston ring
lights up and an error code is displayed. When seal, defective piston seal or the ball of the valve in
driving off in a particular power shift stage, the the piston is missing).
power shift shifts into neutral.
When driving off in a various power shift stage, the • Fault in the modulation valve: Control slide or air
power shift sometimes shifts into neutral. bleed valve slide is jammed.
Power shift is extremely abrupt in all stages. • Pressure modulation is inoperative: Control slide in
the modulation valve is jammed.
• The slide in the resetting valve is jammed.
When power shifting under towing (load) conditions, • Electrical or electronic fault: Pilot control valve Y23
“drop outs” in the power transmission are noticed or Y24 is not operated.
(error codes might be displayed).
• Solenoid valve defective (only use valves with a
metal housing for Y23 or Y24).
• The slide of latching valve H1 or H2 is jammed.
• The slide in safety valve S2 is jammed.
• The plastic ball in the shuttle valve is missing.
“Drop outs” are also noticeable when power shifting • The transmission control electronics box is
under no-load conditions. incorrectly programmed.
• Electronics box is defective.
When power shifting under acceleration or pulling • Characteristic curve valve Y25 is energised.
heavy loads, slight “drop outs” are noticeable (in all
power shift stages).
• The control slide in Y25 or the reversing valve is
jammed.
When power shifting under acceleration or pulling • Worn clutch disks in a power shift clutch.
heavy loads, slight “drop outs” are noticeable (only
in certain power shift stages).
• The piston in a power shift clutch is sluggish.
• 2-stage piston or the slide in a modulation valve is
jammed.
When shifting to a particular power shift stage, the • The slide in a latching valve is jammed:
engine speed drops noticeably. 3 clutches are engaged.
127(If intermittently jamming control slides are detected, during troubleshooting by pressure testing
and dirt is not the cause, it may be that the power shift block has been secured in such a way, that the
housing is distorted by tension! Check the control block with a straight-edge before re-fitting it.
Always use new, original spare part seals. Use assembly guide pins (special tools). Tighten the M8
bolts from right to left in several stages to a torque of 23 Nm.

8003-21
TESTING THE CONTROL PRESSURE TO THE MAIN CLUTCH
(post Power Shuttle versions)
76:
SS99F055
Control valve Y3 is constantly supplied with P1 pressure. It is located behind the 6-speed gearbox. The
hydraulic control pressure to the main clutch is a function of the electrical control current.
If the control current increases from 400 mA DC to 1060 mA, with the engine running, the control pressure
increases from 1.5 bar to P1 pressure (18 to 19 bar). When engaging the clutch, using the clutch pedal, the
control pressure corresponds to the momentary pedal position.
When driving off using the lever switch or Multicontroller, the control pressure increases, within 3.5 sec’s., to
P1 pressure (18 to 19 bar) following a fixed characteristic curve. When the Neutral function is activated at
the lever switch, the control pressure must instantly drop to between 1.5 and 2 bar.
127(The insert of valve Y3 must only be tightened to a torque of 10 ± 2 Nm. Valve Y3 must only be
momentarily energised with 12 VDC.
TEST CONNECTION
The main clutch control pressure measuring point is located in the area of the 6-speed synchronous gearbox
shift rod clamping mechanism. Thread M 16x1.5
Remove the mat and floorboard from the cab. Remove the blanking plug from the test connection and
replace it with test connection 1TSW 642. Connect the 25 bar pressure gauge 1TSW 5025, using the mini
test line 1TSW 635.
TEST REQUIREMENTS
● Start the engine and carry out the test in accordance with the Measurement Table
MEASUREMENT VALUES – CONTROL PRESSURE TO THE MAIN CLUTCH
MOTOR speed OIL TEMPERATURE °C CONTROL PRESSURE, in CONTROL PRESSURE,
bar, clutch disengaged* in bar, clutch engaged
750 20 1.5 to 2 P1 minus 0.5 to 1
1500 20 1.5 to 2 P1 minus 0.5 to 1
2300 20 1.5 to 2 P1 minus 0.5 to 1
750 80 1.5 to 2 P1 minus 0.5 to 1
1500 80 1.5 to 2 P1 minus 0.5 to 1
2300 80 1.5 to 2 P1 minus 0.5 to 1
* Selected to “N" by means of the clutch pedal or the lever switch.

127( System function and test measurement values can be found in Functional Description/
Troubleshooting Chapter 6A and 6002.

8003-22

Tractor does not move, even though a synchronous • The crawler gear lever is not latched in any gear
gearbox gear is selected. position (interruption in the transmission chain
Tractor does not move, when the clutch is engaged between the power shift output and the main
using the clutch pedal, even though a synchronous clutch input).
gearbox gear is selected. An error code appears on
the display.
The main clutch partially engages, then the tractor • The control valve is jammed by dirt.
comes to a standstill and an error code appears on
the display.
• The oil feed filter above the control valve is dirty.
• The control valve housing has been secured too
tightly (max. 12 Nm).
• Clutch disks worn out.
• The piston rings on the clutch shaft are badly worn
(check the countershaft bearing adjustment).
• The piston seal in the clutch is leaking.
• The control current to Y3 does not reach the max.
value. Contact fault in the electrical connection
between the electronics box A68 and valve Y3.
• Electronics box is defective.
The main clutch does not fully disengage. • The valve housing or control slide is jammed.
• Control current too high when disengaged.
• Smooth disks not fitted in accordance with the
instructions, when the clutch was repaired (Lining
disks will be trapped).
The main clutch does not disengage fully at a high • Part of the rotary pressure compensation in the
engine speed. main clutch is incorrectly or incompletely
assembled (2 ‘O’ rings and one metal can).
• Piston in the clutch is jammed.
TESTING THE CLUTCH BOOSTER

and hydro-static clutch operation (pre Power Shuttle versions)
The main clutch does not fully disengage. • Air in the operating circuit 1 and/or 2.
• Sealing boots on the master or slave cylinder
piston are leaking.
Clutch slips at high torque. • Master or slave piston do not fully return to the
initial position (pressure in operating circuit 2 must
drop to 0 bar).
• Clutch booster defective (pressure in operating
circuit 2 must drop to 0 bar).
TESTING THE BRAKE BOOSTER

127( When testing the brake booster and hydro-static brake circuit, the same basic rules apply as
when testing the clutch booster and the hydro-static clutch operation.
Difference: Test the brake circuits individually!

8003-23
TESTING THE DIFFERENTIAL LOCK(S)
76:
SS99F056
The rear axle differential lock and front differential lock (if fitted) are operated in parallel by P1 pressure from
solenoid valve Y10 on the rear axle.
TEST CONNECTION
A test connection, with an M14x1.5 thread is located on the top of the rear axle housing in the immediate
vicinity of the control valve. Replace the blanking plug with the test connection 1TSW 641. Connect the 25
bar pressure gauge 1TSW 5025, using the mini test line 1TSW 635 .
TEST REQUIREMENTS
● Start the engine Test the differential lock function and control pressure in accordance with the Test
Measurement Table.
MOTOR speed OIL Control pressure in bar, Control pressure in bar,

TEMPERATURE diff. lock switched OFF diff. lock switched ON
°C
750 20 0 P1 minus 0.5 to 1
1500 20 0 P1 minus 0.5 to 1
2300 20 0 P1 minus 0.5 to 1
750 80 0 P1 minus 0.5 to 1
1500 80 0 P1 minus 0.5 to 1
2300 80 0 P1 minus 0.5 to 1
127( The control pressures listen in the table must not drop noticeably when the PTO shaft is
switched ON.
127(The internal leakage must not exceed 1 l/min., with the differential lock(s) switched ON.

8003-24

Front and rear differential locks do not switch ON. • The electrical control of solenoid valve Y10 does
not function.
• Solenoid valve Y10 defective (slide jams or
solenoid coil has an open circuit).
Nominal resistance = 8.5 Ohm ± 10 % at 20 °C.
The differential lock has no effect but the solenoid • Mechanical fault on the front differential lock:
valve operates (P1 pressure is available at the Radial locking bolts worn or the operating piston
measuring point). in the front axle jams.
• Mechanical fault on the rear differential lock:
Disks worn or piston jams.
The rear differential lock has little effect and the • The differential bearing has play instead of initial
control pressure is also lower than P1 pressure. tension (or) piston rings are badly worn (leaking).
• Piston ring seal leaking (quad-rings).
• The control pressure line in the rear axle is
leaking. Connection (union nut) loose or the line
has is cracked or ruptured.
The front differential lock remains effective and the • Operating piston or shift ring is jammed. Radial
control pressure drops to 0 bar, even though it is locking bolts jam.
switched OFF.

8003-25
TESTING THE 4-WHEEL DRIVE
76:
SS99F115
4-wheel drive is effected is by means of a hydraulically controlled multi-disk clutch. For safety reasons, the
4-wheel drive clutch is engaged by spring tension (disk spring) and electro-hydraulically disengaged
(opened) by control valve Y1 operated by P1 pressure. This method of operation must be remembered
when troubleshooting!
TEST CONNECTION
Apply the tractor’s handbrake, stop the engine and clean the low pressure hydraulic pump suction filter bowl
and the area around it. Remove the filter bowl with Micro and coarse filters.
Replace the swivelling screw fitting with the test connection 1TSW 631. Connect the 25 bar pressure gauge
1TSW 5025, using the mini test line 1TSW 635 .
Replace the oil filter Run the engine for a short period of time and check for leaks.
TEST REQUIREMENTS
● Start the engine and observe the control pressure at the engine speeds, oil temperatures and 4-wheel
drive functions stipulated in the table.
4-WHEEL DRIVE TEST VALUES
MOTOR speed OIL TEMPERATURE Control pressure in bar, Control pressure in bar,
°C 4-wheel drive switched 4-wheel drive switched
OFF ON
750 20 P1 minus 0.5 to 1 0
1500 20 P1 minus 0.5 to 1 0
2300 20 P1 minus 0.5 to 1 0
750 80 P1 minus 0.5 to 1 0
1500 80 P1 minus 0.5 to 1 0
2300 80 P1 minus 0.5 to 1 0
4-WHEEL DRIVE CLUTCH SLIP TORQUE 1800 to 2100 Nm

8003-26

4-wheel drive can not be switched ON or OFF. • Electrical fault or control slide in solenoid valve Y1
jams.
The driver reports that the 4-wheel drive slips too • The stipulated slip torque of 1800 to 2100 Nm is
easily. achieved during the test:
The tractor is operating with unsuitable weight
distribution (e.g. lifting heavy loads with the front-
end lifting gear, without rear-end ballast).
The 4-wheel drive does not achieve the stipulated slip • Clutch disks worn out.
torque, during testing with the engine stopped.
• Transmission oil is not of the recommended type.
• Incorrect air play adjustment during repair.
The 4-wheel drive does not achieve the stipulated slip • The control pressure does not drop to 0 bar, due
torque, during testing with the engine running. to a fault in control valve Y1: The slide jams due to
dirt or because the valve insert is tightened to the
incorrect torque (30 Nm). The ‘O’ ring between P
and A channels leaks.
4-wheel drive has residual torque when switched OFF • The control pressure is too low, due to a valve
(4-wheel drive clutch does not disengage completely). fault.
• Piston rings worn, elastic sealing rings (on piston)
and/or ‘O’ rings (3) leak.
• Control pressure too low because P1 pressure is
too low.

8003-27
TESTING THE REAR PTO SHAFT
76:
76:
6
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6
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OXEULFDWLRQRLOIORZ
WRWKHFOXWFK SS99F057
The rear PTO shaft is driven by a wet-multi disk clutch and through a mechanically operated 2- or 4-speed
gearbox. Both units are integrated into the rear axle. The clutch shaft bearing and clutch are pressure
lubricated. The control valve is located at the rear right-hand side, together with the differential lock(s)
control valve.
● pre Power Shuttle version tractors: The control valve block has solenoid valve Y5 bolted into it and an
integrated hydro-mechanical pressure controller, these allow the control pressure to rise continually. A
small hydro-reservoir (nitrogen pressure 2.5 bar) also supports the controlled rise.
● post Power Shuttle version tractors: the hydro-mechanical pressure control is not fitted. The control
valve block only has solenoid valve Y5fitted. When the PTO shaft is switched ON, the current to the
solenoid valve from the ECCU box is clocked during the first 3 sec’s. This allows an initial partial
pressure in the PTO shaft clutch cylinder to build up increasingly, which runs attached implements up
smoothly.
● With both versions, two-stage pressure lubrication ensures adequate cooling for the clutch when
engaging and lubrication for the PTO shaft bearings. All additional moving component parts in the PTO
shaft gearbox are splash and centrifugally lubricated.
● When the PTO shaft is switched OFF, the clutch is supplied with a small quantity of lubrication oil S1
through a throttle in the bearing flange The PTO shaft bearings are provided with lubrication oil S1,
whether the PTO shaft is switched ON or OFF.
● The clutch control pressure also acts in parallel on the face of the control slide in the reversing valve.
The auxiliary lubrication oil flow S2 is fed into the disk package and dissipates the heat generated by
friction when running an implement up.
127( The reversing valve’s spring loaded control slide must return to its original position, when the
PTO shaft is switched OFF, otherwise the large quantity of lubrication oil between the clutch’s open
disks, produces a considerable amount of slip torque.
127(For tractors with power shuttle, a speed signal must be fed to the ECCU when the PTO shaft is
switched ON, otherwise the PTO shaft will be shut down by the ECCU after 10 sec’s.

8003-28
TEST CONNECTIONS
● Testing the control pressure to the clutch:
Clean the PTO shaft clutch bearing flange. Remove the screw fitting from the reversing valve (top) and
screw in the test connection 1TSW 642. Connect the 25 bar pressure gauge 1TSW 5025, using the mini
test line 1TSW 635 .
● Testing the permanent lubrication S1
pre Power Shuttle versions:
Remove the lower line to the bearing flange. Connect the test connection 1TSW 636 to the line and
connect this to the bearing flange using high pressure hose 1-34-644-112. Connect the 10 bar pressure
gauge 1TSW 5010, using the mini test line 1TSW 635 .
post Power Shuttle versions:
Replace the lower line banjo bolt on the bearing flange with banjo bolt1609080037 . Fit test connection
1TSW 639 into the banjo bolt. Connect the 10 bar pressure gauge 1TSW 5010, using the mini test line
1TSW 635.
● Testing the auxiliary lubrication S2:
Remove the blanking plug M14x1.5 on the clutch bearing flange (parallel to the line connections) and
replace it with the test connection 1TSW 641. Connect the 10 bar pressure gauge 1TSW 5010, using the
mini test line 1TSW 635.
TEST REQUIREMENTS
● Start the engine and compare the lubrication pressure S1 with the values in the Test Measurement
Table, with the PTO shaft switched OFF.
● Start the engine and compare the lubrication pressure S2 with the values in the Test Measurement
Table, with the PTO shaft switched ON.
● Start the engine and compare the control pressure with the values in the Test Measurement Table, from
the moment the PTO shaft is switched ON.
LUBRICATION PRESSURE S1 AT THE BEARING FLANGE – REAR PTO SHAFT SWITCHED OFF
MOTOR speed OIL TEMPERATURE S1 in bar, pre S1 in bar, post

°C Power Shuttle Power Shuttle
750 20 approx. 1 approx. 1
750 80 approx. 0.5 approx. 0.5
2300 20 approx. 4 approx. 4 to 5
2300 80 approx. 3 approx. 3
LUBRICATION PRESSURE S2 and S1AT THE BEARING FLANGE – REAR PTO SHAFT SWITCHED ON
MOTOR speed OIL TEMPERATURE S1 and S2 in bar, pre S1 and S2 in bar, post
°C Power Shuttle Power Shuttle
750 20 0.2 to 0.5 0.4 to 0.5
750 80 0.2 to 0.3 0.2 to 0.3
2300 20 1.5 to 2 approx. 2
2300 80 1 to 3 2 to 3

8003-29
CONTROL PRESSURE TO THE PTO SHAFT CLUTCH – tractors without Power Shuttle
MOTOR speed OIL TEMPERATURE CONTROL PRESSURE CONTROL PRESSURE

°C in bar in bar
1 sec. after switching 4 sec. after switching
ON ON
750 20 to 80 1 to 2 P1 minus 0.5 to 1
1500 20 to 80 2 to 3 P1 minus 0.5 to 1
2300 20 to 80 2 to 3 P1 minus 0.5 to 1
CONTROL PRESSURE TO THE PTO SHAFT CLUTCH – tractors with Power Shuttle
MOTOR speed OIL CONTROL CONTROL CONTROL

TEMPERATURE PRESSURE in bar PRESSURE in bar PRESSURE in bar
°C 1 sec. after 3 sec. after 4 sec. after
switching ON switching ON switching ON
750 20 3 4 P1 minus 0.5 to 1
1500 20 4 6 P1 minus 0.5 to 1
2300 20 4 6 P1 minus 0.5 to 1
750 80 2 3 P1 minus 0.5 to 1
1500 80 3 5 P1 minus 0.5 to 1
2300 80 3 5 P1 minus 0.5 to 1
127(The control pressure must drop to 0 bar when the PTO shaft is switched OFF!

The ‘PTO shaft does not run, in spite of being • Pushbutton “ON" pressed for less than 3 sec’s.
switched ON and not under load (tractors without
Power Shuttle).
The ‘PTO shaft does not run, in spite of being • Pushbutton “ON" pressed for less than 1.5 sec’s.
switched ON and not under load (tractors with Power
Shuttle).
PTO shaft does not run, in spite of trying to switch ON • Fault in the electrical control system:
at all 3 “ON” buttons. Potential D+ to the “ON" buttons is missing, power
supply to the electronics is missing, defective
electronics, contact fault in the cable harness,
solenoid coil has an open circuit.
With PTO shaft gearbox, gear not selected.
PTO shaft does not run, in spite of trying to switch ON • Wiring fault or defective pushbutton contacts.
using an “ON” button.
PTO shaft can not be switched OFF, from any of the 3 • Fault in the electrical control system:
“OFF” buttons. Potential D+ to the “OFF" buttons is missing,
contact fault in the cable harness, defective
electronics.
PTO continues to run, in spite of trying to switch OFF • Wiring fault or defective pushbutton contacts.
using an “OFF” button.
The PTO shaft does not come to a standstill, in spite • Lubrication reversing valve slide jammed
of being switched OFF, under no load or light load (lubrication pressure S2 does not drop to 0 bar).
conditions.

8003-30

PTO shaft clutch slips under heavier load conditions. • Clutch disks worn out.
• Piston rings worn, bearing worn.
• Piston seal leaking.
• Piston is jammed.
• Control pressure too low because P1 pressure is
too low.
• The control slide in solenoid valve Y5 is jammed.
• Piston for the ball tension spring in the control
valve is jammed (without Power Shuttle).
PTO shaft runs up jerkily (without Power Shuttle). • No gas in the hydro-reservoir (2.5 bar).
PTO shaft runs up jerkily (with Power Shuttle). • ECCU does not clock after switching ON:
PTO shaft runs too quickly, ECCU defective.
Front or rear PTO shaft stops 10 sec’s. after being • Speed signal not received by the ECCU.
switched ON (without Power Shuttle).

Chapter
8004
TROUBLESHOOTING IN THE HIGH-PRESSURE

HYDRAULIC CIRCUIT
Post PFC – Reciprocating Pump versions
9105, 9115, 9125 and 9145

CS110, CS120, CS130 and CS150
8004
Technische Dokumentation/Training Center March, 2000
8004-2
TABLE OF CONTENTS
SPECIAL TOOLS .................................................................................................................3
AN INTRODUCTION TO TROUBLESHOOTING .................................................................5
TROUBLESHOOTING – SYSTEM POWER ........................................................................5
TEST – FEED PUMP PRESSURE.......................................................................................6
TEST – COOLING VALVE ...................................................................................................8
TEST – LOW STANDBY PRESSURE................................................................................10
Adjustment – Low stand-by pressure .................................................................................12
TEST – PFC PUMP MAXIMUM OIL PRESSURE ..............................................................14
Adjustment – maximum oil pressure...................................................................................17
TEST – STEERING PRESSURE .......................................................................................18
TEST – RAISE LIFTING GEAR..........................................................................................20
TEST – LOWER LIFTING GEAR .......................................................................................22
LEAK TESTING – LIFTING GEAR .....................................................................................23
TEST – AUXILIARY CONTROL UNIT FLOW RATE..........................................................24
TEST – MAXIMUM PUMP POWER ...................................................................................26
TEST – 4-WHEEL BRAKE .................................................................................................28
TEST – HADRAULIC TRAILER BRAKE ............................................................................30

8004-3
SPECIAL TOOLS
Hydraulics tester Union nut
SS99M143
1 x 190003559518 10L
SS98J047 1 x 190003559515 15L
1 x 1TSW 515-1
Sealing cone
Connection piece
SS99M131
1 x 155700753065 10L
1 x 133700730482 15L
SS98J048 Straight intermediate fitting

4 x 1288 730249 Plug-in connection
High-pressure hoses
SS98J035
1 x 1TSW 659 8L
1 x 1TSW 647 10L
SS98J050 1 x 1TSW 660 12L
3 x 1-32 -373 -010 NW13 (hose)
4 x 180327030007 Straight connection
4 x 190003098026 Sealing ring
Mini-measuring connection
Connection piece
SS98J032
1 x 1TSW 657 8L
SS99M126 1 x 1TSW 636 10L
1 x 180438030020 Plug-in connection 1 x 1TSW 658 12L
(trailer brakes)

8004-4
Mini-measuring connection Connection
SS99M142
1 x 1TSW 661
SS98J031
2 x 1TSW 639 M8x1 Reduction piece
2 x 1TSW 640 M10x1
Mini-measuring line
SD99M011
1 x 1TSW 644
Multimeter
SS98J030
2 x 1TSW 635
Pressure gauge 1/4"
SD99M014
1 x 1TSW 516-1
Measuring line
SD98J001
2 x 1TSW 5016 0-16 bar
1 x 1TSW 5025 0-25 bar
1 x 1TSW 5040 0-40 bar
2 x 1TSW 5250 0-250 bar
Pressure gauge connection

SD99M013
1 x 1TSW 528-11
”Y” - Adapter
SS98J033
6 x 1TSW 645 M16 - 1/4”
SD99M012
1 x 1TSW 528-6

8004-5
Read the FUNCTIONAL DESCRIPTION in chapters HYDRAULICS and ELECTRICS of the service training
manual; before trying to find the cause of a hydraulic problem or better still, before any problems occur. You
must also be familiarise yourself with the correct operation and function of the tractor (refer to the Operating
Instructions).
Before carrying out any tests, make sure that the hydraulic fluid level is correct and that the temperature of
the fluid in the system is between 60 and 80 °C. Determine whether the fault only affects one circuit or if
another or even all hydraulic functions are affected by it.
The tractor’s hydraulic circuits are controlled by different operating elements. For this reason, the source of
the problem (electrical, electronic or hydraulic) must be determined.
It may thus be necessary to first carry out certain electrical tests. In such cases, reference will be made to
chapter 8B (Functional Description and Troubleshooting EHR-D).
,03257$17 For electrical tests, use a multimeter with an internal resistance of at least 20 K Ω/V. Do
NOT use a test lamp, as certain types of switch and electronic control units can become damaged.
Once a fault has been clearly identified as a hydraulic problem, determine the repairs necessary, by using
the corresponding Troubleshooting Procedures and System Diagnosis Tests listed below. Do not remove
parts, which are working correctly!
• Test – Feed pump pressure • Test – Lifting gear
• Test – Cooling valve • Test – Auxiliary control unit flow rates
• Test – Low standby pressure for the PFC pump • Test – Maximum pump performance
• Adjustment – Low standby pressure • Test – 4-wheel brake, front axle brake pressure
• Test – Maximum PFC pump pressure • Test – Hydraulic trailer brake
• Adjustment – Maximum pressure
• Test – Steering pressure
127( In practice, the measured values can show slight deviations due to component tolerances .
When a defective part has been identified and must be removed from the tractor, the area around the part
and all screw fittings, which must be removed, must be cleaned. All open pipe/hose and other connections
must be fitted with protective caps or plugs.
TROUBLESHOOTING – SYSTEM POWER

The PFC reciprocating pump provides the operating pressure for all hydraulic circuits.
A fault in one hydraulic circuit can have a detrimental effect on the hydraulic power of the whole system.
The priority valves distribute the pressure within the hydraulic system.
The steering has priority over all other hydraulic circuits.
The hydraulic trailer brake or 4-wheel brake has second priority, followed by auxiliary control unit Q4, the
lifting gear and the other auxiliary control units.
A badly adjusted pump controller can lead to reduced total power throughout the system. These causes can
not always be derived from the power characteristics of the system but must be determined by testing and
recording the test results. The chapter ”TROUBLESHOOTING” contains diagnostic tests of the tractor’s
hydraulic system. These tests are designed so that problems can be identified and recommendations for
repair given.

8004-6
TEST – FEED PUMP PRESSURE
Cooling valve
11 10
SD99K024
Test connections
Connect the 16 bar pressure gauges 1TSW 5016 to measuring points 10 (feed pump pressure filter inlet)
and 11 (feed pump pressure filter outlet).
To do this, use the mini-measuring connections 1TSW 640 and mini-measuring lines 1TSW 635.
127( The high-pressure hose to the cooling valve is only disconnected to fit the mini-measuring
connection 10. The high-pressure hose must however be connected during testing.
Test requirements
• Secure the tractor with support trestles and chocks and remove the right-hand side rear wheel.

8004-7
Test procedure
• For tests without consumers, select all auxiliary control units to their neutral positions.
• Connect the plug-in connections of auxiliary control units Q3 and Q4 with a high-pressure hose or with the
hydraulics tester and set to maximum flow rate.
Measurement values
PRESSURES, WITHOUT CONSUMERS, AT MEASURING POINTS 10 AND 11

(control units Q3 and Q4 not operated)
Motor rpm Oil temperature °C Supply pump pressure / Supply pump pressure /
bar, measuring point 10 bar, measuring point 11
1000 70 3.0 2.8
2300 70 5.0 4.8
PRESSURE AT MEASURING POINTS 10 AND 11 AT PFC PUMP MAXIMUM FLOW RATE

(control units Q3 and Q4 operated)
Motor rpm Oil temperature °C Supply pump pressure / Supply pump pressure /
bar, measuring point 10 bar, measuring point 11
1000 70 1.5 1.2
2300 70 2.0 1.7
Insufficient supply pump pressure l Oil fill level too low

at measuring point 10 l Suction filter blockage
l Supply pump defective
l Short circuit valve defective
(only visual inspection possible)
l Cooling valve defective
Excessive supply pump pressure l Short circuit valve defective

at measuring point 10 (only visual inspection possible)
l Cooling valve defective
Insufficient supply pump pressure l Pressure filter blockage

at measuring point 11
127(If no fault can be localised, continue by testing the cooling valve!

8004-8
TEST – COOLING VALVE
11
Cooling valve
SD99K023
Test connections
Disconnect the high-pressure hose from the cooling valve.
Close off the cooling valve using the sealing cone 133700730482 and union nut 190003559515.
Connect the 16 bar pressure gauge 1TSW 5016 to measuring point 10.
To do this, use a mini-measuring connection 1TSW 640 and mini-measuring line 1TSW 635.

8004-9
Test requirements
:$51,1*All consumers must be switched OFF and the steering must not be operated.
Measurement values
PRESSURE AT MEASURING POINT 11

Motor rpm Oil temperature °C Pressure / bar
Measuring point 11
1000 70 4-6
2300 70 8 - 10
Insufficient pressure at measuring point 11 l Suction filter blockage

l Pressure filter blockage
l Supply pump defective
l Short circuit valve spring broken
l Short circuit valve jammed, dirty
Excessive pressure at measuring point 11 l Short circuit valve does not open

8004-10
TEST – LOW STANDBY PRESSURE
12
SD99K026
Test connections

8004-11
Test requirements
• Select all auxiliary control unit operating levers to the neutral position.
:$51,1*No consumers (including steering and brake) must be operated during this test.
Measurement values

Motor rpm Oil temperature °C Stand-by pressure / bar,
measuring point 12
1000 70 25 - 26
2300 70 25 - 26
Insufficient stand-by pressure l Control slide incorrectly adjusted

l Control slide spring broken
l Control slide jammed
l Control piston jammed
l Blocked throttle in the steering priority valve
l Steering priority valve defective
l Blocked shuttle valve in the priority block
Excessive stand-by pressure l Control slide incorrectly adjusted

l Control slide jammed
l Control piston jammed
l Blocked steering servo-stat throttle

8004-12
Adjustment – Low stand-by pressure
SD00B031
12
SD99K025
• Disconnect the load sensing line to the pump controller at the priority block (XLS). Clos off the connection
(XLS) at the priority block, using the sealing cone 155700753065 (A) and the union nut 190003559518.
• Remove the sealing cap (B) from the pump controller. Use an Allen key to turn the adjusting screw IN or OUT
until the given value has been set at measuring point 12.

Motor rpm Oil temperature °C Stand-by pressure / bar
Measuring point 12
1000 70 20 - 22
2300 70 20 - 22

8004-13
EMPTY PAGE

8004-14
TEST – PFC PUMP MAXIMUM OIL PRESSURE
12
SD99K026
13
SD00B032

8004-15
Test connections
To do this, use a ‘T’ junction with mini-measuring connection* 1TSW 636 an intermediate fitting 1TSW 647
and mini-measuring line 1TSW 635.
*) The ‘T’ junction with measuring connection is fitted as standard from version DBD0075021.
Test requirements
Test procedure
• Operate all consumers in succession, as shown in the table below, at a motor speed of 2300 rpm, (steering,
hydraulic trailer brake, 4-wheel brake, etc).
127( When testing the EHR control unit, raise the lifting gear to its upper end limit. Disconnect the
position sensor and operate the rear operating position ”RAISE” pushbutton to raise the lifting gear to
its upper end limit
127( For versions with independent suspension, raise the axle to the upper limit, using the manual
height adjustment switch. Hold the switch in the ”RAISE” position for at least 10 sec’s. (the pressure
reservoirs must be filled completely).
Measurement values

Consumer operated Motor rpm Oil temperature Pressure / bar, Pressure / bar,
°C measuring measuring
point 12 point 13
Steering 2300 70 200 - 210 170 - 180
(hold the steering wheel at full lock)
*Hydraulic trailer braking system 2300 70 150 - 170 130 - 150
*4-wheel brake 2300 70 100 - 120 80 - 100
Mechanical auxiliary control unit Q4 2300 70 200 - 210 200 - 210
Mechanical auxiliary control unit Q3 2300 70 200 - 210 200 - 210
Lifting gear (EHR) 2300 70 200 - 210 200 - 210
Electrical auxiliary control unit(s) 2300 70 200 - 210 200 - 210
*Front axle independent suspension 2300 70 200 - 210 200 - 210
* if fitted

8004-16
Insufficient pressure for all consumers l Pump controller, incorrectly adjusted

l Defective PFC pump safety valve
Insufficient pressure to one or more consumers l Leaking shuttle valve in the last consumer, at
which the correct pressure was measured
(shuttle valve internal leakage)
l Leaking shuttle valve in priority block LT41, LT43
or LT44
Insufficient pressure at one consumer l Leaking shuttle valve in the relevant

consumer (shuttle valve to the next
consumer leaking)
Excessive pressure l Pump controller, incorrectly adjusted

l Incorrect adjustment of the maximum pressure for
the hydraulic trailer brake at priority block LT43
l Incorrect adjustment of the maximum pressure for
the 4-wheel brake at priority block LT44

8004-17
Adjustment – maximum oil pressure
12
SD99K027
• In order that the maximum oil pressure is present, an auxiliary control unit must be operated.
• Remove the sealing cap (C) from the pump controller. Use an Allen key to turn the adjusting screw IN or OUT
until the given value has been set at measuring point 12.

Motor rpm Oil temperature °C Maximum pressure / bar,
measuring point 12
2300 70 200 - 210

8004-18
TEST – STEERING PRESSURE
14
SD99K014
Test connections
To do this, use a ‘T’ junction with mini-measuring connection* 1TSW 658 an intermediate fitting 1TSW 660
Test requirements
Test procedure
• Turn the steering wheel to full lock and turn it further, using only a little force, against the limit.

8004-19
Measurement values

Motor rpm Oil temperature °C Pressure / bar
Measuring point 14
1000 70 170 - 180
2300 70 170 - 180
Insufficient steering pressure l Max. pump pressure controller, incorrectly

adjusted
l Pressure limiting valve in the steering
servo-stat incorrectly adjusted
l Leaking shuttle valve in priority block LT41, LT43
or LT44
Excessive steering pressure l Pressure limiting valve in the steering

servo-stat incorrectly adjusted
Measured value correct but steering is heavy l Excessive front axle burden
l Steering column is damaged (bearing)
l Steering servo-stat is fitted under tension
l Steering cylinder distorted
Correct measured value but too many l Internal leakage of the steering cylinder
steering wheel turns are necessary l Leakages in the steering servo-stat

8004-20
TEST – RAISE LIFTING GEAR
16 15
SD99K022 SD99K019
Test connections
Connect the Multimeter ITSW 516-1 to measuring point 15 (raising solenoid on top of the control unit).
To do this, use measurement lines 1TSW 528-11 and a ”Y” adapter piece 1TSW 528-6.
Connect the hydraulics tester ITSW 515-1 to measuring point 16 (EHR control unit).
Use two high-pressure hoses 1-32-373-010 and a screw-in fitting 180327030007 to do this.
127(Ensure that the direction of flow through the hydraulics tester is correct. The hydraulics tester’s
pressure build-up valve must be full open.
Test requirements
Test procedure
• Prior to starting the test, operate the lifting gear ”RAISE” and ”LOWER” pushbuttons once.
• Set the lift limiting adjustment potentiometer to max. lifting height.
• Carry out the test in accordance with the measurement table.

8004-21
Measurement values
VOLTAGE AT MEASURING POINT 15 AND MAXIMUM FLOW RATE AT MEASURING POINT 16

Method of operation Motor rpm Oil temperature Voltage, raising Flow rate / l,
°C solenoid / V, measuring point 16
measuring point 15
Button on the 2000 70 6 80
multi-controller
Rear operating pos. 1500 70 ~ 3,5 ~ 37
pushbutton*
*) The lifting gear begins to rise slowly and accelerates to mid range, it then slows down again from the mid
range to the upper lifting limit.
Insufficient flow rate with the correct l defective PFC pump

voltage at the raising solenoid l defective 3-way oil flow regulator in
control unit Q4
l raise slider in the EHR control unit is jammed
l 2-way oil flow regulator in the EHR control unit
is jammed
l 2-way oil flow regulator in the EHR control unit is
dirty
l 2-way oil flow regulator spring in the
EHR control unit is broken
Insufficient flow rate with insufficient l Resistance of the raising solenoid or control unit
voltage at the raising solenoid cables is too high.
Refer to the documentation ”Functional
Description” and ”EHR-D Troubleshooting”,
chapter 8B
Insufficient flow rate with the correct l 2-way oil flow regulator in the EHR control unit
voltage at the raising solenoid is jammed or dirty

8004-22
TEST – LOWER LIFTING GEAR
Test connections
Connect the hydraulics tester ITSW 515-1 to measuring point 16.
Use two high-pressure hoses 1-32-373-010 and a screw-in fitting 180327030007 to do this.
Connect the Multimeter ITSW 516-1 to the lowering solenoid (at the bottom of the control unit).
To do this, use two measurement lines 1TSW 528-11 and a ”Y” adapter piece 1TSW 528-6.
Test requirements
• Fit an implement of approx. 200KG weight to the lifting gear.
Test procedure
• Prior to testing, RAISE and LOWER the lifting gear.
• Close the lowering throttle potentiometer.
• Operate the “LOWER” button on the multi-controller.
• Set the Setpoint potentiometer to “floating position”.
• Slowly open the lowering throttle.
Measurement values
VOLTAGE AT MEASURING POINT LOWERING SOLENOID AND FLOW RATE AT FLOW RATE AT
Operating Motor rpm Oil temperature Load Voltage, lowering Flow rate / l,
°C in KG solenoid / V measuring
point 16
minimum lowering
speed with lowering 1000 70 approx. 3 8
throttle 200
maximum lowering
speed with lowering 1000 70 approx. 6 25
throttle 200
MEASURING POINT 16
Insufficient flow rate with the correct l Pilot control cone or main cone on the
voltage at the lowering solenoid lowering valve is jammed or dirty
l Lowering valve maladjusted

8004-23
Insufficient flow rate with insufficient l Lowering speed potentiometer,

voltage at the lowering solenoid lowering solenoid or control unit cables’
resistance too high.
Refer to the documentation ”Functional
Description” and ”EHR-D Troubleshooting”,
chapter 8B
Insufficient flow rate with the correct l Lowering valve maladjusted, dirty or jammed
voltage at the lowering solenoid
LEAK TESTING – LIFTING GEAR
Test connections
Use the hydraulics tester in the same way as for testing ”Raise Lifting Gear”.
Test requirements
Test procedure
• Disconnect the position sensor.
• At a motor speed of 2300 rpm, use the rear operating position pushbutton to raise the lifting gear, until the
max. pump pressure (= max. lifting gear pressure) has been achieved.
Measurement values

Oil temperature Maximum lifting gear Pressure drop after
°C pressure at 2300 rpm / bar one minute / bar
70 200 - 210 approx. 20 *
*) This value was measured. The theoretical permissible leakage is 4 cm3/ min at 125 bar and a viscosity
of 35cst.
The pressure at measuring point 16 drops by more l Leaking safety valve in the EHR control unit
than the permissible level l Leaking lowering valve in the EHR control unit

8004-24
TEST – AUXILIARY CONTROL UNIT FLOW RATE
A B C
SD99K020
Test connections
Connect the hydraulics tester ITSW 515-1 to the relevant auxiliary control unit.
Use the high-pressure hoses 1-32-373-010 and the screw-in fitting 180327030007 to do this.
A Q4 control unit (MECHANICALLY operated)
B Q3 control unit (MECHANICALLY operated)
C Control unit (ELECTRICALLY operated)
Test requirements
• Adjust the oil flow regulator of the relevant control unit to give the maximum flow rate.
Test procedure
• Operate the auxiliary control unit, to which the hydraulics tester is connected.
• Use the throttle valve, on the hydraulics tester, to adjust the pressure according to the table.

8004-25
Measurement values
FLOW RATE AND PRESSURE AT THE AUXILIARY CONTROL UNIT Q4 WITH LATCHES
Motor rpm Oil temperature °C Pressure / bar Flow rate / l
Hydraulics tester Measuring point Q4
1000 70 - 45
2300 70 - 84
1000 70 150 42
2300 70 180 84
FLOW RATE AND PRESSURE AT THE AUXILIARY CONTROL UNIT Q3 WITHOUT LATCHES
Hydraulics tester Measuring point Q3
1000 70 - 45
2300 70 - 84
1000 70 150 42
2300 70 180 84
FLOW RATE AND PRESSURE AT THE ELECTRICAL AUXILIARY CONTROL UNIT

Hydraulics tester Measuring point ZSG
1000 70 - 44
2300 70 - 50
1000 70 150 36
2300 70 180 36
Insufficient flow rate l Insufficient low stand-by pressure

l Leaking shuttle valve
l Oil flow regulator not set to maximum
flow rate
l Control slider not fully open
(Bowden cable maladjusted)
l 3-way oil flow regulator in the Q4 control unit
is jammed
l 2-way oil flow regulator of the relevant
control unit is jammed
Excessive flow rate or precise metering l 3-way oil flow regulator in the Q4 control unit
of the flow rate is impossible is jammed
l 2-way oil flow regulator of the relevant
control unit is jammed

8004-26
TEST – MAXIMUM PUMP POWER
SD99K021
Test connections
Connect the hydraulics tester 1TSW 515-1 to the relevant control unit.
Use the high-pressure hoses 1-32-373-010 and the screw-in fitting 180327030007 to do this.
In addition, use a high-pressure hose 1-32-373-010 and two connection pieces 1288 730249.
Test requirements
• Set the oil flow regulators of both control units to maximum flow rate.

8004-27
Test procedure
• Connect the hydraulics tester (1TSW 515-1) to control unit Q4, measure the oil flow rate and make a note
of it.
• Subsequently connect the hydraulics tester (1TSW 515-1) to control unit Q3 and connect the plug-in
connections on control unit Q4 with the high-pressure hose (1-32-373-010) and the connection pieces
(1288 730249).
• Operate both control units and make a note of the flow rate at control unit Q3.
Maximum pump power = flow rate Q4 + flow rate Q3
127(Testing is simpler, if two hydraulics testers (1TSW 515-1) are used.
Measurement values
FLOW RATES AT THE MEASURING POINTS

Measuring point Motor rpm Oil temperature Flow rate / l
°C
Q4 control unit 2300 70 88
Q3 control unit 2300 70 20
Maximum 108
pump power
Insufficient flow rate l PFC pump defective

l Defective controller on the PFC pump
l 3-way oil flow regulator in the Q4 control unit
jammed, blocked
l Defective 2-way oil flow regulator in the Q3 control
unit
l Control slider not fully open
(Bowden cable maladjusted)

8004-28
TEST – 4-WHEEL BRAKE
17
SD99M003
18
SD99M002
Test connections
To do this, remove the air-bleed nipple from priority block LT44 and fit the connector 1TSW 661, the mini-
measuring connector 1TSW 639 and the mini-measuring line 1TSW 635 in its place.
To do this, use a ‘T’ junction with mini-measuring connection 1TSW 657 an intermediate fitting 1TSW 659

8004-29
Test requirements
Test procedure
• Operate both brake pedals (interlocked).
:$51,1*Do not operate the brake pedals abruptly, as this can destroy the 40 bar pressure gauge.
Measurement values

Pressure Front axle braking
Motor rpm Oil temperature °C Control head / bar, pressure / bar
measuring point 17 Measuring point 18
1000 70 4 15
1000 70 10 40
1000 70 15 60
1000 70 20 80
1000 70 25 95
1000 70 40 95
Insufficient front axle brake pressure l leaking shuttle valve in priority block LT44
at measuring point 18 l Insufficient system pressure
l defective priority valve in priority block LT44
l Proportional valve (4-wheel brake) jammed or dirty
l Pressure limiting spring for maximum
brake pressure is broken
Excessive front axle brake pressure l incorrect pressure limiting spring

at measuring point 18 l incorrect proportional valve
(control piston ∅ 20 mm) in LT43
:$51,1* The difference between the priority blocks is the diameter of the control piston in the
proportional valve.
LT 43 piston ∅= 20 mm
LT 44 piston ∅= 12 mm

8004-30
TEST – HADRAULIC TRAILER BRAKE
19
SD99M003
20
SD99M004
Test connections
To do this, remove the air-bleed nipple from priority block LT43 and fit the connector 1TSW 661, the mini-
measuring connector 1TSW 639 and the mini-measuring line 1TSW 635 in its place.
To do this, use the connection piece 180438030020, a reduction piece 1TSW 644, a mini-measuring
connection 1TSW 639 and a mini-measuring line 1TSW 635.

8004-31
Test requirements
Test procedure
• Operate both brake pedals (interlocked).
Measurement values

Motor rpm Oil temperature °C Pressure / bar Pressure / bar
1000 70 2 20
1000 70 3 32
1000 70 5 55
1000 70 10 108
1000 70 15 140 - 150
1000 70 20 140 - 150
Insufficient trailer brake pressure l Insufficient system pressure

at measuring point 20 l leaking shuttle valve in priority block LT43
l Defective proportional valve in LT 43
l Broken pressure spring for maximum trailer brake
pressure
l incorrect spring
l incorrect proportional valve
(control piston ∅ 12 mm) in LT44
Excessive trailer brake pressure l Incorrect pressure limiting spring for maximum
at measuring point 20 trailer brake pressure
l Proportional valve dirty

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Electrical Schematics (GE/EN).................................................................................4001 Don 7-70640

Troubleshooting transmissioncontrol - electric and electronic (post Power-Shuttle) ...6002 7-97180

&1+gVWHUUHLFK*PE+ Copyright © 2002 CNH Österreich GmbH

M968 CS68 from DBD0040007

M9078 CS78 from DBD0055001

9105 CS110 from DBD0075001

SPECIAL TOOLS .....................................................................................................................5

FOR THE USER ......................................................................................................................7

SAFETY REGULATIONS ........................................................................................................8

ENGINE DATA .........................................................................................................................9

TECHNICAL DATA ................................................................................................................10

Sva Sva 7-98510 EN Edition 05/00

Sva Sva 7-98510 EN Edition 05/00

Sva Sva 7-98510 EN Edition 05/00

Pressing tool for valve guides

Pressing tool for the rear crankshaft

Valve spring tensioning lever

Pressing tool for

Cylinder liner extractor

Sva 7-98510 EN Edition 05/00

FOR THE USER

Engine serial number

320 420 620

Sva 7-98510 EN Edition 05/00

Sva 7-98510 EN Edition 05/00

Lifting the engine

The engine is lifted safely by means of a lifting device,

A = Engine lifting eyes

Sva 7-98510 EN Edition 05/00

Sva 7-98510 EN Edition 05/00

Sva 7-98510 EN Edition 05/00

Sva 7-98510 EN Edition 05/00

crankshaft inertia weight (engine type 420)

Sva 7-98510 EN Edition 05/00

Pistons, piston rings and piston pins

Sva 7-98510 EN Edition 05/00

Lubrication oil pump (320, 420)

Lubrication oil pump (620)

Coolant temperature switch

Cooling water pump (620)

Sva 7-98510 EN Edition 05/00

NOTE: Use washers for aluminium parts.

If no particular tightening torques are specified,

Bolts for the self-supporting oil sump

Sva 7-98510 EN Edition 05/00

Sva 7-98510 EN Edition 05/00

Sva 7-98510 EN Edition 05/00

Sva 7-98510 EN Edition 05/00

Sva 7-98510 EN Edition 05/00

Sva 7-98510 EN Edition 05/00

Intake / exhaust system

Sva 7-98510 EN Edition 05/00

C. Checking the cylinder block

B. Removing the cylinder liner D. Replacing the camshaft bush

Sva 7-98510 EN Edition 05/00

The numbering starts at the front end of the engine.

Spare part number Bore hole diameter

E. Oversize bushes for the camshaft

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