It is workshop manual for Same tractors. Models included: 160 180 200 language:english number of pages: 804 (full digital version) Main sections: HYDRAULIC SYSTEM.................................................. 1 INTRODUCTION.................................................................. 1 HYDRAULIC DIAGRAM (1/3)............................................... 4 HYDRAULIC DIAGRAM (2/3)............................................... 5 HYDRAULIC DIAGRAM (3/3)............................................... 6 A. OIL LEVEL MAINTENANCE CIRCUIT ............................ 7 B. STEERING AND POWER SHIFT CONTROL CIRCUIT ....................................................... 7 C. AUXILIARY SERVICES AND LUBRICATION CIRCUIT................................................ 8 OIL LEVEL MAINTENANCE CIRCUIT PUMP ............. 9 VARIABLE DISPLACEMENT PUMP......................... 10 AUXILIARY SERVICES CONTROL VALVE .............. 24 DEFINITIONS OF VALVE ELEMENTS ............................... 25 CONTROL VALVE TYPES................................................. 26 MAIN CLUTCH CONTROL VALVE ............................ 28 POWER SHIFT CONTROL VALVE............................. 29 SERVICES CONTROL VALVE.................................... 38 RANGE GEARBOX CONTROL VALVE...................... 39 POWER STEERING .................................................... 40 TRAILER BRAKING VALVE........................................ 41 ITALY VERSION ............................................................... 41 EXPORT VERSION........................................................... 43 POWER SHIFT TRANSMISSION ............................... 45 FRONT AXLE .............................................................. 63 REAR AXLE................................................................. 65 REAR PTO.................................................................. 67 REAR POWER LIFT .................................................... 72 BRAKING SYSTEM..................................................... 77 HYDRAULIC FRONT AXLE SUSPENSION ............... 83 FRONT SUSPENSION CONTROL VALVE................. 84 SYSTEM FOR TESTING AND CALIBRATION OF ELECTRONIC COMPONENTS System conformation .......................................................1 Connection of the Tester to the ECU ...............................2 Introductory screen ..........................................................3 ENGINE ECU TESTER Manual ..............................................................................5 List of alarm codes .........................................................23 TRANSMISSION ECU TESTER Manual ............................................................................27 List of alarm codes .........................................................41 LIFT ECU TESTER Manual ............................................................................53 List of alarm codes .........................................................68 ARMREST ECU TESTER Manual ............................................................................71 List of alarm codes .........................................................86 Alarm codes for BOSCH electro-hydraulic control valve ....................................................................87 ELECTRICAL DIAGRAMS Functional diagram......................................................... 89 0.011.5375.4/03 Suspended front axle wiring ............... 90 0.011.5376.4/02 Suspended front axle cab wiring (1/2) 91 0.011.5376.4/02 Suspended front axle cab wiring (2/2) 92 0.011.5445.4/00 Diagnostic wiring................................. 93 0.011.7032.4/00 Wiring for press. cab (Germany) ......... 94 0.010.8700.4/21 Cab roof wiring (1/2) ........................... 95 0.010.8700.4/21 Cab roof wiring (2/2) ........................... 96 0.011.9237.4/11 Cab FPS wiring (1/2) ........................... 97 0.011.9237.4/11 Cab FPS wiring (2/2) ........................... 98 0.011.8683.4/12 40S Front wiring (1/2).......................... 99 0.011.8683.4/12 40S Front wiring (2/2)........................ 100 0.010.8707.4/10 Draft angle sensor wiring .................. 101 0.010.8708.4/82 HS subframe wiring (1/4) .................. 102 0.010.8708.4/82 HS subframe wiring (2/4) .................. 103 0.010.8708.4/82 HS subframe wiring (3/4) .................. 104 0.010.8708.4/82 HS subframe wiring (4/4) .................. 105 0.010.8710.4/41 HS central wiring (1/2)....................... 106 0.010.8710.4/41 HS central wiring (2/2)....................... 107 0.011.8420.4/01 Link-box wiring ................................. 108 0.011.8453.4/00 Fans guard ........................................ 109 0.011.8481.4/03 40S Lights-fans wiring ...................... 110 0.010.8711.4/20 Rear light cables ............................... 111 0.010.8712.4/32 Switches wiring (1/2)......................... 112 0.010.8712.4/32 Switches wiring (2/2)......................... 113 0.010.8714.4/44 Light cables....................................... 114 0.011.8468.04/01 Battery cables ................................. 115 0.011.9245.4/00 Rear wiring (1/2) ................................ 116 0.011.9245.4/00 Rear wiring (2/2) ................................ 117 0.011.9236.4/11 FPS wiring (1/2)................................. 118 0.011.9236.4/11 FPS wiring (2/2)................................. 119 0.011.9260.4/01 Filter clogging wire............................ 120 0.010.9139.4/12 Manual climate control wiring ........... 121 0.011.8454.4/11 A/C compressor wiring ..................... 122 0.011.8747.4/01 wiring with 3 relays for steering column lights switch...................................................... 123 0.011.9643.4/00 35S Wiper timer wiring...................... 124 0.011.9439.4/00 Air pressure switch wiring Italy. ........ 125 0.011.9430.4/11 Air pressure switch wiring Germany . 126 2.8399.146.0/50 Instrument with computer L1............ 127 ENGINE HOOD, SIDE PANELS AND GRILLE Removal ...................................................................... 1 Adjustment.................................................................. 1 STARTER MOTOR Removal ...................................................................... 3 Refitting....................................................................... 3 ALTERNATOR Removal ...................................................................... 4 Refitting...................................................................... 4 TENSIONING AND RENEWAL OF THE ALTERNATOR DRIVEBELT ........................................ 5 AIR COMPRESSOR (for air trailer braking) Removal ...................................................................... 7 Refitting....................................................................... 8 TRAILER AIR BRAKING UNITS AND THE CAB SUSPENSION (EXPORT D Version) Removal ...................................................................... 9 Refitting..................................................................... 11 AIR CONDITIONING SYSTEM Operation .................................................................. 13 Servicing ................................................................... 14 CONDENSER COOLING FANS Tensioning................................................................. 14 DISCHARGING, FLUSHING AND RECHARGING THE AIR CONDITIONING SYSTEM........................... 15 AIR CONDITIONING COMPRESSOR Removal .................................................................... 16 Refitting..................................................................... 16 CONDENSER COOLING FANS Removal .................................................................... 18 Refitting..................................................................... 18 RECEIVER-DRIER Removal .................................................................... 19 Refitting..................................................................... 19 CONDENSER ASSEMBLY Removal .................................................................... 20 Refitting..................................................................... 20 FANS - CONDENSER - RECEIVER/DRIE ASSEMBLY Removal .................................................................... 21 Refitting..................................................................... 23 AUTOCLEAN SCREEN Removal .................................................................... 24 Refitting..................................................................... 25 INTERCOOLER Removal .................................................................... 26 Refitting..................................................................... 27 GEARBOX OIL COOLER Removal .................................................................... 28 Refitting..................................................................... 28 FRONT PTO OIL COOLER Removal .................................................................... 29 Refitting..................................................................... 29 RADIATOR Removal .................................................................... 30 Refitting..................................................................... 32 EXPANSION TANK Removal .................................................................... 33 Refitting..................................................................... 33 THERMOSTAT VALVES Removal .................................................................... 34 Refitting..................................................................... 34 COOLANT PUMP Removal .................................................................... 35 Refitting..................................................................... 37 OIL PRESSURE SENSOR AND SENDER UNIT Inspection and renewal............................................. 38 ELECTRONIC ACTUATOR Removal .................................................................... 39 Refitting..................................................................... 39 Calibration................................................................. 40 INJECTION PUMPS Removal .................................................................... 41 Refitting..................................................................... 42 SUCTION FILTER Removal .................................................................... 43 Refitting..................................................................... 44 EXHAUST PIPE AND SILENCER Removal .................................................................... 45 Refitting..................................................................... 47 TURBOCHARGER Removal .................................................................... 48 Refitting..................................................................... 49 ROCKER COVERS Removal.....................................................................50 Refitting .....................................................................51 ENGINE SPEED SENSOR (PICK-UP UNIT) Removal.....................................................................52 Refitting .....................................................................52 FRONT CRANKSHAFT SEAL Renewal .....................................................................53 Refitting .....................................................................55 BRAKE PUMPS Removal.....................................................................57 Refitting .....................................................................57 BRAKE PEDALS AND MICROSWITCHES Adjustment and alignment.........................................58 BRAKING SYSTEM Bleeding.....................................................................59 POWER STEERING Checking....................................................................60 Removal.....................................................................61 Refitting .....................................................................62 Dismantling................................................................63 Assembly ...................................................................70 FRONT WHEELS Removal.....................................................................80 Refitting .....................................................................80 FRONT BRAKES Overhaul ....................................................................81 Assembly ...................................................................84 EPICYLIC REDUCTION UNITS OF THE FRONT AXLE Dismantling................................................................85 Assembly ...................................................................89 STUB AXLE HOUSINGS AND FRONT HALFSHAFTS Dismantling................................................................90 Assembly ...................................................................96 STEERING SENSOR Removal...................................................................101 Refitting ...................................................................101 STEERING CYLINDERS Removal...................................................................102 Refitting ...................................................................102 FRONT LIFT CYLINDERS AND ROCKERS Removal...................................................................103 Refitting ...................................................................104 FRONT SUSPENSION SOLENOID VALVES Removal...................................................................105 Refitting ...................................................................105 FRONT SUSPENSION CYLINDERS (when fitted) Removal...................................................................106 Refitting ...................................................................107 STEERING CYLINDERS AND FRONT SUSPENSION Dismantling and assembly.......................................108 FRONT AXLE AND SUPPORT ASSEMBLY (Version with front suspension) Removal .................................................................. 112 Refitting................................................................... 114 FRONT SUSPENSION POSITION SENSOR Positioning .............................................................. 115 FRONT AXLE DIFFERENTIAL Dismantling ............................................................. 116 Assembly ................................................................ 127 FRONT AXLE SUPPORT BUSHINGS Renewal .................................................................. 140 Assembly ................................................................ 141 ADJUSTING END FLOAT OF FRONT AXLE MOUNTINGS..................................... 142 FRONT CARRIER (Version with front suspension) Removal .................................................................. 144 Refitting................................................................... 146 FRONT PTO Removal .................................................................. 147 Refitting................................................................... 149 Dismantling ............................................................. 150 Assembly ............................................................... 162 ANTISHOCK VALVE AND ACCUMULATORS OF THE FRONT LIFT Removal .................................................................. 172 Refitting................................................................... 172 BATTERY SUPPORT Removal .................................................................. 173 Refitting................................................................... 174 FUEL TANKS (Normal and supplementary) Removal .................................................................. 175 Refitting................................................................... 177 PROPELLER SHAFTS Removal .................................................................. 178 Refitting................................................................... 178 RENEWAL OF THE FRONT AXLE PINION OIL SEAL Renewal .................................................................. 179 CLUTCH CONTROL UNIT Removal .................................................................. 180 Refitting................................................................... 181 Dismantling ............................................................. 182 Assembly ................................................................ 183 REAR WHEELS Removal .................................................................. 184 Refitting................................................................... 184 COMPLETE PUMP ASSEMBLY Removal .................................................................. 185 Refitting................................................................... 185 TESTING THE AUXILIARY SERVICES PUMP ........ 186 30-iii PUMPS Removal .................................................................. 187 Refitting................................................................... 190 PUMP DRIVE Dismantling ............................................................. 191 Assembly ................................................................ 193 POWER SHIFT CONTROL VALVE Removal .................................................................. 194 Refitting................................................................... 194 Dismantling ............................................................. 195 Assembly ................................................................ 199 SHUTTLE ASSEMBLY Removal and dismantling ....................................... 200 Assembly and refitting ............................................ 202 Dismantling and adjustment ................................... 203 Assembly ................................................................ 208 RANGE GEARBOX CONTROL UNIT Removal .................................................................. 209 Refitting................................................................... 209 Dismantling ............................................................. 210 Assembly ................................................................ 213 AUXILIARY CONTROL VALVE ASSEMBLY Removal .................................................................. 214 Refitting................................................................... 216 Dismantling ............................................................. 217 Assembly ................................................................ 221 SUPPLEMENTARY LIFT CYLINDERS Dismantling and assembly...................................... 222 LIFT DRAFT SENSOR Removal .................................................................. 223 Refitting................................................................... 223 LIFT Removal .................................................................. 224 Refitting................................................................... 227 Dismantling ............................................................. 228 Assembly ............................................................... 233 ARM-REST CONTROLS Removal .................................................................. 234 Refitting................................................................... 234 STEERING WHEEL, STEERING COLUMN SWITCH UNIT, INSTRUMENT PANEL Removal .................................................................. 235 Refitting................................................................... 236 INSTRUMENT PANEL SHROUD Removal .................................................................. 237 Refitting................................................................... 238 RIGHT-HAND CONSOLE Removal .................................................................. 239 Refitting................................................................... 242 LEFT-HAND CONSOLE Removal .................................................................. 243 Refitting................................................................... 244 ELECTRONIC CONTROL UNITS Removal .................................................................. 245 Refitting................................................................... 245 FUSE BLOCK Removal .................................................................. 246 Refitting................................................................... 246 ACCELERATOR POTENTIOMETER Renewal .................................................................. 247 Refitting................................................................... 247 CLUTCH PEDAL AND CONNECTED DEVICES...... 248 CONTROL CABLES OF THE AUXILIARY SERVICE VALVES Renewal .................................................................. 249 Refitting................................................................... 250 STANDARD CONTROL LEVERS AND PUSHBUTTON PANEL FOR THE AUXILIARY SERVICE VALVES Removal .................................................................. 251 Refitting................................................................... 252 CROSS-GATE CONTROL LEVER AND PUSHBUTTON PANEL FOR THE AUXILIARY SERVICE VALVES Removal .................................................................. 253 Refitting................................................................... 254 HEATER VALVE Removal .................................................................. 255 Refitting................................................................... 255 HEATER MATRIX Removal .................................................................. 256 Refitting................................................................... 258 AIR CONDITIONING EVAPORATOR Removal .................................................................. 259 Refitting................................................................... 260 RIGHT-HAND BLOWER OF THE AIR CONDITIONING SYSTEM Removal .................................................................. 261 Refitting................................................................... 261 LEFT-HAND BLOWER OF THE AIR CONDITIONING SYSTEM Removal .................................................................. 262 Refitting................................................................... 262 WINDSCREEN WIPERS Removal .................................................................. 263 Refitting................................................................... 263 Section 40 about engine transmission and another thing