Deutz-Fahr Tractor Agrofarm TTV 430 Workshop Manual

Description

Contents:
Introduction
1.1. Introduction​
1.2. Tightening torques for nuts and bolts of Deutz engines​
1.3. Tightening torques for nuts and bolts of electrical connections​
1.4. Pump tightening torques​
1.5. Installation of solenoid valves and cartridge valves​
1.6. Installation of quick couplers​
Technical characteristics
1.1. Engine​
1.1.1. Components of the 2012 2V UPS engine​
1.1.2. Test data and settings​
1.1.3. Tightening requirements 2012 2V UPS engine​
1.2. Transmission​
1.2.1. Transmission​
1.2.2. Input clutch and hydrostatic unit​
1.2.3. Mechanical speed variator and “Work” and “Transport” clutches​
1.2.4. Shuttle unit​
1.2.5. Bevel pinion and range gearbox assembly​
1.2.6. Electrohydraulic four-wheel drive engagement assembly​
1.2.7. Differential unit​
1.2.8. Brakes and rear axle assembly​
1.2.9. Rear PTO​
1.2.10. PTO clutch assembly​
1.2.11. 2-speed PTO and groundspeed PTO​
1.2.12. 3-speed PTO​
1.3. Front axle​
1.3.1. Front axle​
1.4. Bodywork – Cab – Platform​
1.4.1. General introduction to the A/C system​
1.4.2. Changes of the state of matter​
1.4.3. Air conditioning system – General system​
1.4.4. Compressor​
1.4.5. Condenser​
1.4.6. Filter-drier​
1.4.7. Expansion valve​
1.4.8. Evaporator​
1.4.9. Air conditioning system – Diagnostics​
1.4.10. Charging the A/C system​
1.5. Hydraulic system​
1.5.1. Hydraulic system​
1.5.2. Hydraulic steering, brakes and services diagram – Standard version​
1.5.3. Hydraulic steering, brakes and services diagram – Version with front PTO​
1.5.4. Steering and services circuit pressure ports​
1.5.5. Hydraulic lift and remote control valve circuit diagram – Basic version​
1.5.6. Hydraulic lift and remote control valve circuit diagram – 8-way version with hydraulic trailer braking and supplementary pump​
1.5.7. Hydraulic lift and auxiliary services spool valve circuit diagram – 8-way version with hydraulic trailer braking and front lift​
Calibrations and electronic diagnosis
1.1. Diagnostic tools​
1.1.1. Position of ECUs and diagnostic instruments​
1.1.2. All Round Tester (ART®)​
1.1.3. ART® – Diagnostic socket connection​
1.1.4. SDF Analyser​
1.1.5. SDF Analyser – Diagnostic socket connection​
1.1.6. SERDIA 2000 level III” software​
1.1.7. SERDIA – Diagnostic socket connection​
1.2. Diagnostic tool screens​
1.2.1. ECU interrogation​
1.2.2. ART® transmission screen pages – Introduction​
1.2.3. ART® transmission screen pages – Tester structure​
1.2.4. ART® transmission screen pages – Tester structure​
1.2.5. ART® transmission screen pages – Monitor​
1.2.6. ART® transmission screen pages – Monitor -> Transmission​
1.2.7. ART® transmission screen pages – Calibration​
1.2.8. ART® transmission screen pages – Test​
1.2.9. ART® transmission screen pages – Test -> Transmission​
1.2.10. ART® transmission screen pages – Alarms​
1.2.11. ART® transmission screen pages – Alarms -> HLHP Alarms​
1.2.12. ART® transmission screen pages – Alarms -> Engine Alarms​
1.2.13. ART® transmission screen pages – Alarms -> Clearing​
1.3. Commissioning and calibrating the tractor​
1.3.1. Digital Instrument Calibration​
1.3.2. Wheel constants​
1.3.3. Commissioning – Purpose of the document​
1.3.4. Commissioning – Instruments and information required​
1.3.5. Commissioning – Description of the commissioning procedure​
1.3.6. Commissioning – Basic procedure​
1.3.7. Commissioning – EEPROM Re-initialisation​
1.3.8. Commissioning – Model configuration​
1.3.9. Commissioning – Model options selection​
1.3.10. Commissioning – Clutch pedal calibration​
1.3.11. Commissioning – Hand throttle and pedal accelerator calibration​
1.3.12. Commissioning – Front PTO configuration​
1.3.13. Commissioning – Entering the rear PTO calibration value​
1.3.14. Commissioning – Electrohydraulic spool valves configuration​
1.3.15. Commissioning – ASM sensor calibration​
1.3.16. Commissioning – Calibration of the draft sensor​
1.3.17. Commissioning – Rear lift calibration​
1.3.18. Commissioning – Hydrostatic unit automatic calibration​
1.3.19. Commissioning – Automatic calibration of the Work and Reverse clutches​
1.3.20. Commissioning – Manual calibration of the Work and Reverse clutches​
1.3.21. Commissioning – Hydrostatic unit manual calibration​
1.3.22. Commissioning – Rear PTO automatic calibration​
1.3.23. ART Transmission screen pages – Introduction​
1.3.24. ART Transmission screen pages – Tester structure​
1.3.25. ART Transmission screen pages – Main Menu​
1.3.26. ART Transmission screen pages – Monitor Screen Pages​
1.3.27. ART Transmission screen pages – Calibration Screen Pages​
1.3.28. ART Transmission screen pages – Test Screen Pages​
1.3.29. ART Transmission screen pages – Alarm Screen Pages​
1.3.30. PTO operation​
1.3.31. Electrohydraulic spool valves​
1.4. ECU alarms​
1.4.1. ECU alarms​
1.4.2. Alarms – Emergency operating mode​
1.4.3. Engine alarms​
1.4.4. Transmission alarms​
1.4.5. Instrument panel alarms​
1.4.6. HLHP alarms​
1.4.7. Lift alarms​
Method of intervention
1.1. Tools for engine disassembly and reassembly​
1.2. Workshop tools for engine disassembly and reassembly​
1.3. Workshop tools for transmission disassembly and reassembly​
1.4. B0 – Engine​
1.4.1. Compression test​
1.4.2. Assembly and disassembly of the engine on the assembly stand​
1.4.3. Adjustment of valve clearance​
1.4.4. Removal and refitting of the rocker arms and pedestals​
1.4.5. Disassemble and complete the rocker and support, check​
1.4.6. Disassembly and assembly of the cylinder head​
1.4.7. Grinding the cylinder head seal surface​
1.4.8. Measuring piston protrusion​
1.4.9. Valve assembly and disassembly​
1.4.10. Valve check​
1.4.11. Check the valve guide​
1.4.12. Replacing the valve guide (oversized – cast)​
1.4.13. Check the valve residual​
1.4.14. Replacing the lined valve seat (oversized)​
1.4.15. Check the endfloat of the crankshaft​
1.4.16. Check the crankshaft​
1.4.17. Replace the crankshaft O-ring (flywheel end)​
1.4.18. Replacing the crankshaft O-ring (opposite end to flywheel)​
1.4.19. Check the connecting rod drum​
1.4.20. Fitting and removing piston pin bush​
1.4.21. Assembly and disassembly of the crankshaft​
1.4.22. Fitting and removing counterweight shafts, checking​
1.4.23. Disassembly and assembly of the piston and connecting rod drum​
1.4.24. Check the piston​
1.4.25. Check the piston rings and piston grooves​
1.4.26. Assembly and disassembly of piston cooling nozzles​
1.4.27. Removal and refitting of the crankcase breather​
1.4.28. Check the cylinder​
1.4.29. Removal and refitting of the front cover (opposite end to flywheel)​
1.4.30. Disassembly and assembly of the connector box​
1.4.31. Fitting and removing the camshaft bearings, checking​
1.4.32. Disassembly and assembly of the gear case cover​
1.4.33. Assembly and disassembly of the camshaft​
1.4.34. Check the camshaft​
1.4.35. Removal and refitting of the rotation device​
1.4.36. Removing and fitting the V-belt pulley​
1.4.37. Fitting, removing, checking and setting adjuster rod​
1.4.38. Removal and refitting of the heater​
1.4.39. Removal and refitting of the turbocharger​
1.4.40. Removal and refitting of the charge air duct​
1.4.41. Fitting and removing injection pump​
1.4.42. Determine the thickness of the shim (engine without injection advance variator)​
1.4.43. Determine the thickness of the shim (engine with injection advance variator)​
1.4.44. Determination of the overall dimensions of the injection pump (engine without the injection advance variator)​
1.4.45. Determination of the overall dimensions of the injection pump (engine with the injection advance variator)​
1.4.46. Fitting and removing injection valves​
1.4.47. Checking the injection valves​
1.4.48. Removal and refitting of the fuel lift pump​
1.4.49. Removal and refitting of the oil pickup pipe​
1.4.50. Removing and fitting the lubricant oil sump pan (cast iron lubricant oil sump)​
1.4.51. Disassembly and assembly of the lubricant oil sump (lubricant oil sump-plate)​
1.4.52. Removal and refitting of the oil cooler​
1.4.53. Disassembly and assembly of the oil radiator housing​
1.4.54. Removal and refitting of the oil pressure switch​
1.4.55. Removal and refitting of the water pump​
1.4.56. Testing the thermostat (after removal)​
1.4.57. Removal and refitting of the thermostat​
1.4.58. Removal and assembly of the fan support​
1.4.59. Removal and refitting of the fan support​
1.4.60. Removal and refitting of the flywheel​
1.4.61. Replacing the starter motor ring gear on the flywheel​
1.5. C0 – Engine accessories​
1.5.1. Removing and fitting the engine governor​
1.5.2. Removal and refitting of the exhaust manifold​
1.5.3. Removal and refitting of the fuel filter head​
1.5.4. Assembly and disassembly of the temperature sender​
1.5.5. Removal and refitting the engine block​
1.5.6. Removal and refitting of the alternator (with drivebelt)​
1.5.7. Disassembly and assembly of the starter​
1.6. D0 – Transmission​
1.6.1. Sealants application​
1.6.2. Transmission wiring​
1.6.3. Hydraulic system components​
1.6.4. INPUT clutch disc replacement​
1.6.5. INPUT unit​
1.6.6. INPUT unit disassembly​
1.6.7. Hydrostatic unit​
1.6.8. Hydrostatic unit pipes​
1.6.9. Complete front casing (with INPUT unit and hydrostatic unit)​
1.6.10. Replacing the variator input shaft bearings​
1.6.11. Replacing the WORK and TRANSPORT clutch assemblies (with the intermediate casing installed)​
1.6.12. Intermediate casing​
1.6.13. Variator unit input gear assembly​
1.6.14. Disassembling the variator input gear unit​
1.6.15. WORK and TRANSPORT clutch-planetary reduction gearbox assembly​
1.6.16. Planetary reduction gearbox for the WORK and TRANSPORT clutches​
1.6.17. Disassembling the WORK and TRANSPORT planetary reduction gearbox​
1.6.18. Disassembling the WORK and TRANSPORT clutches​
1.6.19. REVERSE clutch-planetary reduction unit​
1.6.20. Disassembling the REVERSE planetary reduction unit​
1.6.21. Pump unit flange​
1.6.22. Disassembling the pump support flange​
1.6.23. Speed range gear shafts​
1.6.24. Disassembling the range gear control lever​
1.6.25. Disassembling the transfer case gear​
1.6.26. PTO engagement clutch​
1.6.27. PTO casing​
1.6.28. Disassembling the PTO casing​
1.6.29. Disassembling PTO engagement clutch​
1.6.30. PTO drive shaft​
1.6.31. PTO speed selection lever​
1.6.32. PTO driven shaft​
1.6.33. Disassembling the PTO driven shaft​
1.6.34. P.T.O. output shaft. – Nut torquing​
1.6.35. Differential pinion​
1.6.36. Disassembling the differential pinion​
1.6.37. Disassembling the HD (Heavy Duty) range gear​
1.6.38. 4WD shaft​
1.6.39. Disassembling the dual traction shaft​
1.7. E0 – Rear axle​
1.7.1. Axle casing​
1.7.2. Adjustment of supports​
1.7.3. Wheel mount disassembly​
1.7.4. Disassembling the rear differential case​
1.7.5. Removing rear differential​
1.7.6. Controlling and adjusting the clearance of the teeth on the pinion and the differential crown wheel​
1.7.7. Rear differential​
1.7.8. Park brake unit​
1.7.9. Disassembling the park brake unit​
1.8. F0 – Front axle​
1.8.1. Steering knuckle housing and half-shaft​
1.8.2. Front brake discs​
1.8.3. Adjustment of steering knuckle housing and axle shaft​
1.8.4. Pinion and differential assembly​
1.8.5. Planetary reduction gear​
1.8.6. Disassembly of the final drive unit​
1.8.7. Disassembly of the differential locking device​
1.8.8. Differential pinion unit disassembly​
1.8.9. Adjustment of differential preload and pinion-crown wheel backlash​
1.8.10. Pinion positioning and preload adjustment​
1.8.11. Disassembly of the differential​
1.9. G0 – Bodywork – Cab – Platform​
1.9.1. Adjustment of Bowden cable​
1.10. H0 – Hydraulic system​
1.10.1. Spool valves​
1.10.2. Trailer air braking system operating control – Export D Version​
1.10.3. Supplementary pump​
1.10.4. TANDEM pump​
1.10.5. Power steering pump​
1.10.6. Transfer pump​
1.11. L0 – Electrical system​
1.11.1. Steering angle sensor​
1.12. M0 – Front PTO​
1.12.1. Clutch pack end float values check​
1.12.2. Cylindrical roller bearings​
1.13. R0 – Rear lift​
1.13.1. Stabiliser tie-rod carrier​
1.13.2. Internal lever setscrew​
1.13.3. Lift​
Wiring diagrams
1.1. Introduction​
1.1.1. Introduction​
1.1.2. Basic electronics for mechanics (1/2)​
1.1.3. Basic electronics for mechanics (2/2)​
1.1.4. Electrical and electronic components (1/2)​
1.1.5. Electrical and electronic components (2/2)​
1.2. Components​
1.2.1. A – Starting and charging​
1.2.2. B – Fuses​
1.2.3. C – Earths​
1.2.4. D – Intermediate connections​
1.2.5. E – On-board instruments and visual and audible indicators​
1.2.6. F – External lights​
1.2.7. G – Interior lights​
1.2.8. H – Electrical and manual controls​
1.2.9. I – Circuit breakers​
1.2.10. J – Relays​
1.2.11. K – Sensors and transmitters​
1.2.12. L – Electromagnets and solenoid valves​
1.2.13. M – Electrical/electronic devices, flasher units and timers​
1.2.14. N – Electric motors and actuators​
1.2.15. O – Resistors and rheostats​
1.2.16. P – Various services​
1.2.17. Q – Safety devices​
1.2.18. R – Diagnostics​
1.2.19. 04213097 – Engine ECU​
1.2.20. 2.8339.269.0/20 – Instrument panel​
1.2.21. 2.8519.101.0/20 – HLHP ECU​
1.3. Systems​
1.3.1. S001 – Starting and preheating​
1.3.2. S002 – Electronic engine governor​
1.3.3. S003 – Transmission​
1.3.4. S004 – Instrument panel​
1.3.5. S005 – Steering column switch unit lights – Version without front lift​
1.3.6. S006 – Steering column switch unit lights – Version with front lift​
1.3.7. S007 – Worklights – Version without front lift​
1.3.8. S008 – Worklights – Version with front lift​
1.3.9. S009 – Manual air conditioner​
1.3.10. S010 – Heating​
1.3.11. S011 – Power supply (+15)​
1.3.12. S012 – Power supply (+30) – Version with front battery​
1.3.13. S013 – Power supply (+30) – Version with lateral battery​
1.3.14. S014 – Negatives​
1.3.15. S015 – CAN BUS​
1.3.16. S016 – PTO – Version without front PTO​
1.3.17. S017 – PTO – Version with front PTO​
1.3.18. S018 – Brakes​
1.3.19. S019 – Spool valves and lifts​
1.3.20. S020 – Windscreen wipers​
1.3.21. S021 – Diagnostics – Accessories​
1.4. Wiring harnesses​
1.4.1. 0.017.1063.4 – Cab earth​
1.4.2. 0.017.9016.4/10 – Battery negative – Version with front battery​
1.4.3. 0.017.8922.4/10 – Battery negative – Version with lateral battery​
1.4.4. 0.017.0474.4 – Battery positive​
1.4.5. 0.015.1983.4/10 – Platform 1 power supply​
1.4.6. 0.015.1983.4/10 – Platform 2 power supply​
1.4.7. 0.015.1983.4/10 – Roof power supply​
1.4.8. 0.014.9195.4/20 – Preheating​
1.4.9. 0.014.8666.4/30 – Hood lights​
1.4.10. 0.013.4085.4/20 – RH hood worklights​
1.4.11. 0.013.4085.4/20 – LH hood worklights​
1.4.12. 0.016.2000.4/20 – Engine – Version with front battery​
1.4.13. 0.016.2001.4/10 – Engine – Version with lateral battery​
1.4.14. 04215098 – Engine control – Engine side​
1.4.15. 0.016.8047.4 – Engine control – Cab side​
1.4.16. 0.012.2756.3 – Front PTO solenoid valve​
1.4.17. 0.011.3797.3 – SBA​
1.4.18. 0.015.9040.4/60 – Central wiring​
1.4.19. 0.017.8385.4/10 – Side console wiring​
1.4.20. 0.010.6468.3/10 – Pneumatic seat​
1.4.21. 0.017.2347.4/5159.4 – Multifunction control lever​
1.4.22. 0.014.9570.4/10 – ISO 11786​
1.4.23. 0.015.9041.4/50 – Transmission​
1.4.24. 0.015.9043.4/40 – Transmission solenoid valves​
1.4.25. 0.016.0373.4/30 – Cab power supply​
1.4.26. 0.015.6272.4/40 – Roof​
1.4.27. 0.015.7266.4/40 – Air conditioning condenser fan​
1.4.28. 0.016.0664.4 – Front lights​
1.4.29. 04411923.4 – Lower RH headlight​
1.4.30. 04411923.4 – Lower LH headlight​
1.4.31. 0.014.3927.4/40 – Supplementary RH worklight on arm​
1.4.32. 0.014.3927.4/40 – Supplementary LH worklight on arm​
1.4.33. 0.011.3597.3 – Windscreen wiper​
1.4.34. 0.013.6327.4 – RH side rotating beacon​
1.4.35. 0.013.6327.4 – LH side rotating beacon​
1.4.36. 0.016.1001.4/20 – Hydraulic trailer braking valve​
1.4.37. 0.014.1645.4/10 – Compressed air pressure sensor​