Workshop manual

R3 EVO 85 -> 16001

R3 EVO 85 -> 20001
R3 EVO 100 -> 16001
R3 EVO 100 -> 20001
R3 EVO 110 -> 1001
R3 EVO 110 -> 5001
CONTENTS
0 - Introduction
0.1 - Introduction 0-2
0.1.1 - Safety notes 0-2
0.1.2 - General safety 0-2
0.1.3 - Precautions to use during performance of the work 0-3
0.1.4 - Lifting instructions 0-4
0.1.5 - Tightening torques 0-5
0.1.6 - Thread lock, adhesive, sealant and lubrication materials 0-8
0.1.7 - Unit of measurement conversion table 0-10
0.2 - Introduction - Engines 0-11
0.2.1 - Safety notes 0-11
0.2.2 - General safety 0-11
0.2.3 - Precautions to use during performance of the work 0-12
0.2.4 - Lifting instructions 0-13
0.2.5 - Tightening torques 0-14
0.2.6 - Thread lock, adhesive, sealant and lubrication materials 0-17
0.2.7 - Unit of measurement conversion table 0-19
0.3 - Tightening torques 0-20
0.3.1 - General information 0-20
0.3.2 - Tightening classes and categories 0-20
0.3.3 - Coefficient of friction 0-20
0.3.4 - Tightening torques 0-21
0.4 - Tightening torques for nuts and bolts of electrical connections 0-30
0.4.1 - Standard tightening torques 0-30
0.4.2 - Battery terminal tightening torques 0-30
0.4.3 - Starter motor tightening torques 0-31
0.4.4 - Alternator tightening torques 0-31
0.5 - Wheel rim to hub screws and nuts tightening torques 0-32
0.6 - Installation of solenoid valves and cartridge valves 0-33
0.6.1 - Installation 0-33
0.6.2 - Solenoid valve tightening torques 0-33
0.6.3 - Cartridge valve tightening torques 0-34
0.7 - Installation of quick couplers 0-35
0.7.1 - Table of tightening torques 0-35

10 - Technical characteristics
10.1 - Engine 10-2
10.1.1 - Components of the 2012 2V UPS engine 10-2
10.1.2 - Test data and settings 10-8
10.1.3 - Tightening requirements 2012 2V UPS engine 10-9
10.2 - Transmission 10-13
10.2.1 - Transmission (R3 EVO 110 -> 1001) 10-13
10.2.2 - Transmission (R3 EVO 85 -> 16001) 10-23
10.2.3 - Transmission (R3 EVO 85 -> 20001) 10-32
10.2.4 - Transmission (R3 EVO 100 -> 16001) 10-43
10.2.5 - Transmission (R3 EVO 100 -> 20001) 10-52
10.2.6 - Transmission (R3 EVO 110 -> 5001) 10-65
III
 CONTENTS
10.2.7 - Rear PTO (R3 EVO 110 -> 1001, R3 EVO 110 -> 5001) 10-73
10.2.8 - Rear P.T.O. (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3 EVO 85 -> 16001, R3
EVO 85 -> 20001) 10-77
10.2.9 - 2 and 4-speed PTO and Syncro PTO (R3 EVO 110 -> 1001, R3 EVO 110 -> 5001) 10-81
10.2.10 - 2 and 4-speed PTO and Groundspeed PTO (R3 EVO 100 -> 16001, R3 EVO 100 ->
20001, R3 EVO 85 -> 16001, R3 EVO 85 -> 20001) 10-84
10.3 - Front axle 10-87
10.3.1 - Front axle (R3 EVO 110 -> 1001, R3 EVO 110 -> 5001) 10-87
10.3.2 - Front axle (R3 EVO 110 -> 5001) 10-90
10.3.3 - Front axle (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3 EVO 85 -> 16001, R3 EVO
85 -> 20001) 10-95
10.4 - Hydraulic system 10-100
10.4.1 - Hydraulic system (R3 EVO 110 -> 1001) 10-100
10.4.2 - Hydraulic system (R3 EVO 85 -> 16001) 10-110
10.4.3 - Hydraulic system (R3 EVO 100 -> 16001) 10-115
10.4.4 - Hydraulic system (R3 EVO 85 -> 20001) 10-120
10.4.5 - Hydraulic system (R3 EVO 100 -> 20001) 10-127
10.4.6 - Hydraulic system (R3 EVO 110 -> 5001) 10-134
10.4.7 - Steering circuit pump - lift circuit pump () 10-139
10.4.8 - Power steering valve (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
10-141
10.4.9 - Power steering valve (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
10-142
10.4.10 - Ancillary utility distributor 4-way version (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001, R3 EVO 85 -> 20001) 10-144
10.4.11 - Remote control valve - 6-way version (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 110 -> 5001) 10-145
10.4.12 - Hydraulic lift control valve (R3 EVO 110 -> 1001) 10-145
10.4.13 - Braking system (R3 EVO 110 -> 1001) 10-152
10.4.14 - Trailer braking valve (R3 EVO 110 -> 1001) 10-153
10.4.15 - Trailer braking valve (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3 EVO 110 ->
5001, R3 EVO 85 -> 16001) 10-157
10.4.16 - Trailer braking valve (R3 EVO 85 -> 20001) 10-160
10.4.17 - Park Brake system (R3 EVO 110 -> 1001) 10-163
10.4.18 - Park Brake valve (R3 EVO 110 -> 1001) 10-168
10.4.19 - Separate-Brakes valve (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3 EVO 110 ->
5001, R3 EVO 85 -> 16001, R3 EVO 85 -> 20001) 10-168
10.4.20 - Pressure holding valves assembly (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001, R3 EVO 85 -> 20001) 10-174
10.4.21 - Services solenoid valves assembly - Pressure holding valves (R3 EVO 110 -> 1001) 10-176
10.4.22 - Shuttle solenoid valves assembly (R3 EVO 110 -> 1001) 10-179

20 - Calibrations and electronic diagnosis

20.1 - Diagnostic tools 20-2
20.1.1 - Position of ECUs and diagnostic instruments 20-2
20.1.2 - All Round Tester (ART® SAME) 20-3
20.1.3 - SDF Analyser 20-8
20.1.4 - Serdia 2000 20-12

IV
CONTENTS
20.2 - Diagnostic tool screens 20-14
20.2.1 - ECU interrogation 20-14
20.3 - Commissioning and calibrating the tractor 20-17
20.3.1 - Digital instrument calibration 20-17
20.3.2 - Renewal of the shuttle ECU - Introduction (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001,
R3 EVO 85 -> 20001) 20-22
20.3.3 - Renewal of the shuttle ECU - Initialisation of the ECU (R3 EVO 100 -> 20001, R3 EVO
110 -> 1001, R3 EVO 85 -> 20001) 20-22
20.3.4 - Renewal of the shuttle ECU - Line end programming (R3 EVO 100 -> 20001, R3 EVO 110
-> 1001, R3 EVO 85 -> 20001) 20-25
20.3.5 - Renewal of the shuttle ECU - Introductory notes (R3 EVO 100 -> 20001, R3 EVO 110 ->
1001, R3 EVO 85 -> 20001) 20-32
20.3.6 - Renewal of the shuttle ECU - Automatic calibration (R3 EVO 100 -> 20001, R3 EVO 110
-> 1001, R3 EVO 85 -> 20001) 20-33
20.3.7 - Renewal of the shuttle ECU - Manual calibration (R3 EVO 100 -> 20001, R3 EVO 110 ->
1001, R3 EVO 85 -> 20001) 20-35
20.3.8 - Renewal of the shuttle ECU - Editing the comfort parameters (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 20-41
20.3.9 - Renewal of the shuttle ECU - Calibration of the clutch pedal (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 20-42
20.3.10 - Renewal of the engine ECU - Introduction 20-45
20.3.11 - Renewal of the engine ECU - Calibration of the accelerator pedal 20-45
20.3.12 - Renewal of the engine ECU - Calibration of the hand throttle lever 20-48
20.4 - ECU alarms 20-51
20.4.1 - Key to the “ECU alarms” tables 20-51
20.4.2 - FMI code 20-52
20.4.3 - Engine alarms 20-52
20.4.4 - Transmission alarms 20-61
20.4.5 - Instrument panel alarms 20-66

30 - Method of intervention
30.1 - Tools for engine disassembly and reassembly 30-2
30.1.1 - Commercially available tools 30-2
30.2 - Workshop tools for engine disassembly and reassembly 30-6
30.2.1 - Workshop tools for engine disassembly and reassembly 30-6
30.3 - B0 - Engine 30-13
30.3.1 - Air conditioning compressor drive belt 30-13
30.3.2 - Tension adjustment of the fan and air conditioning compressor drive belt 30-13
30.3.3 - Alternator, fuel pump and water pump drive belt 30-14
30.3.4 - Tension adjustment of the alternator, fuel pump and water pump drive belt 30-15
30.3.5 - Compression test 30-15
30.3.6 - Assembly and disassembly of the engine on the assembly stand 30-18
30.3.7 - Adjustment of valve clearance 30-22
30.3.8 - Removal and refitting of the rocker arms and pedestals 30-26
30.3.9 - Disassemble and complete the rocker and support, check 30-29
30.3.10 - Disassembly and assembly of the cylinder head 30-32
30.3.11 - Grinding the cylinder head seal surface 30-39

V
 CONTENTS
30.3.12 - Measuring piston protrusion 30-42
30.3.13 - Valve assembly and disassembly 30-45
30.3.14 - Valve check 30-50
30.3.15 - Check the valve guide 30-51
30.3.16 - Replacing the valve guide (oversized - cast) 30-52
30.3.17 - Check the valve residual 30-56
30.3.18 - Replacing the lined valve seat (oversized) 30-58
30.3.19 - Check the endfloat of the crankshaft 30-64
30.3.20 - Check the crankshaft 30-69
30.3.21 - Replace the crankshaft O-ring (flywheel end) 30-72
30.3.22 - Replacing the crankshaft O-ring (opposite end to flywheel) 30-76
30.3.23 - Check the connecting rod drum 30-80
30.3.24 - Fitting and removing piston pin bush 30-88
30.3.25 - Assembly and disassembly of the crankshaft 30-93
30.3.26 - Fitting and removing counterweight shafts, checking 30-100
30.3.27 - Disassembly and assembly of the piston and connecting rod drum 30-107
30.3.28 - Check the piston 30-113
30.3.29 - Check the piston rings and piston grooves 30-115
30.3.30 - Assembly and disassembly of piston cooling nozzles 30-119
30.3.31 - Removal and refitting of the crankcase breather 30-120
30.3.32 - Check the cylinder 30-122
30.3.33 - Removal and refitting of the front cover (opposite end to flywheel) 30-123
30.3.34 - Disassembly and assembly of the connector box 30-128
30.3.35 - Fitting and removing the camshaft bearings, checking 30-130
30.3.36 - Disassembly and assembly of the gear case cover 30-135
30.3.37 - Assembly and disassembly of the camshaft 30-139
30.3.38 - Check the camshaft 30-143
30.3.39 - Removal and refitting of the rotation device 30-144
30.3.40 - Removing and fitting the V-belt pulley 30-146
30.3.41 - Fitting, removing, checking and setting adjuster rod 30-148
30.3.42 - Removal and refitting of the heater 30-153
30.3.43 - Removal and refitting of the turbocharger 30-155
30.3.44 - Removal and refitting of the charge air duct 30-159
30.3.45 - Fitting and removing injection pump 30-163
30.3.46 - Determine the thickness of the shim (engine without injection advance variator) 30-175
30.3.47 - Determine the thickness of the shim (engine with injection advance variator) 30-177
30.3.48 - Determination of the overall dimensions of the injection pump (engine without the
injection advance variator) 30-179
30.3.49 - Determination of the overall dimensions of the injection pump (engine with the injection
advance variator) 30-183
30.3.50 - Fitting and removing injection valves 30-188
30.3.51 - Checking the injection valves 30-192
30.3.52 - Removal and refitting of the fuel lift pump 30-196
30.3.53 - Removal and refitting of the oil pickup pipe 30-198
30.3.54 - Removing and fitting the lubricant oil sump pan (cast iron lubricant oil sump) 30-199
30.3.55 - Disassembly and assembly of the lubricant oil sump (lubricant oil sump-plate) 30-203
30.3.56 - Removal and refitting of the oil cooler 30-208
30.3.57 - Disassembly and assembly of the oil radiator housing 30-211

VI
CONTENTS
30.3.58 - Removal and refitting of the oil pressure switch 30-216
30.3.59 - Removal and refitting of the water pump 30-218
30.3.60 - Testing the thermostat (after removal) 30-220
30.3.61 - Removal and refitting of the thermostat 30-222
30.3.62 - Removal and assembly of the fan support 30-224
30.3.63 - Removal and refitting of the fan support 30-230
30.3.64 - Removal and refitting of the flywheel 30-232
30.3.65 - Replacing the starter motor ring gear on the flywheel 30-234
30.4 - C0 - Engine accessories 30-236
30.4.1 - Starter motor 30-236
30.4.2 - Removing and fitting the engine governor 30-237
30.4.3 - Removal and refitting of the exhaust manifold 30-239
30.4.4 - Removal and refitting of the fuel filter head. 30-242
30.4.5 - Assembly and disassembly of the temperature sender 30-244
30.4.6 - Removal and refitting the engine block 30-246
30.4.7 - Removal and refitting of the alternator (with drivebelt) 30-247
30.4.8 - Disassembly and assembly of the starter 30-251
30.5 - D0 - Transmission 30-253
30.5.1 - Changing the transmission oil (D0.00.01) (R3 EVO 110 -> 1001) 30-253
30.5.2 - Range selector assembly (R3 EVO 110 -> 1001) 30-254
30.5.3 - Disassembly of the range selector (R3 EVO 110 -> 1001) 30-255
30.5.4 - Separation of housing from transmission (D0.02.01) (R3 EVO 110 -> 1001) 30-257
30.5.5 - Shuttle assembly - complete unit (D0.03.01) (R3 EVO 110 -> 1001) 30-261
30.5.6 - Disassembly of the shuttle unit (R3 EVO 110 -> 1001) 30-263
30.5.7 - Disassembly of the cover unit (R3 EVO 110 -> 1001) 30-266
30.5.8 - Disassembly of the forward drive clutch assembly (R3 EVO 110 -> 1001) 30-268
30.5.9 - Disassembly of the reverse drive clutch assembly (R3 EVO 110 -> 1001) 30-272
30.5.10 - Gearbox and Hi-Lo assembly (R3 EVO 110 -> 1001) 30-277
30.5.11 - Disassembly of the Hi-Lo unit (D0.04.01) (R3 EVO 110 -> 1001) 30-278
30.5.12 - Disassembly of the planet carrier (R3 EVO 110 -> 1001) 30-284
30.5.13 - Disassembly of the Hi range clutch housing (R3 EVO 110 -> 1001) 30-286
30.5.14 - Hi-Lo unit output shaft disassembly procedure (R3 EVO 110 -> 1001) 30-295
30.5.15 - Disassembly of the gearbox input shaft (R3 EVO 110 -> 1001) 30-296
30.5.16 - Torsional spring plate (R3 EVO 110 -> 1001) 30-299
30.5.17 - Disassembly of the primary shaft - Version with Hi-Lo (R3 EVO 110 -> 1001) 30-300
30.5.18 - Secondary shaft - Version with Hi-Lo (R3 EVO 110 -> 1001) 30-301
30.5.19 - Disassembly of the secondary shaft - Version with Hi-Lo (R3 EVO 110 -> 1001) 30-305
30.5.20 - Range gearbox and differential assembly - complete assembly (R3 EVO 110 -> 1001) 30-308
30.5.21 - Complete gearbox assembly - Version with Hi-Lo (D0.09.04) (R3 EVO 110 -> 1001) 30-308
30.5.22 - Adjustment of the differential - Bevel gear pair (R3 EVO 110 -> 1001) 30-310
30.5.23 - Disassembly of the rear pinion (D0.11.01) (R3 EVO 110 -> 1001) 30-317
30.5.24 - Disassembly of the 4WD output shaft (R3 EVO 110 -> 1001) 30-322
30.5.25 - PTO clutch. (D0.12.02) (R3 EVO 110 -> 1001) 30-324
30.5.26 - Disassembly of the PTO clutch (R3 EVO 110 -> 1001) 30-328
30.5.27 - Pump drive PTO - Outer gear (R3 EVO 110 -> 1001) 30-332
30.5.28 - Pump drive PTO - Inner gear (R3 EVO 110 -> 1001) 30-334
30.5.29 - PTO output shaft - 4 speed version (D0.14.01) (R3 EVO 110 -> 1001) 30-336
30.5.30 - Disassembly of the PTO output shaft - 4 speed version (R3 EVO 110 -> 1001) 30-340

VII
 CONTENTS
30.5.31 - Disassembly of the Groundspeed PTO output shaft (R3 EVO 110 -> 1001) 30-344
30.5.32 - Disassembly of the Groundspeed PTO engagement device (R3 EVO 110 -> 1001) 30-346
30.5.33 - Disassembly of the 4WD engagement device - Easyshift (R3 EVO 110 -> 1001) 30-347
30.6 - E0 - Rear axle 30-350
30.6.1 - Right-hand rear axle (E0.02.01) (R3 EVO 110 -> 1001) 30-350
30.6.2 - Disassembly of LH/RH rear axle (R3 EVO 110 -> 1001) 30-352
30.6.3 - Left-hand rear axle (E0.02.02) (R3 EVO 110 -> 1001) 30-356
30.6.4 - Disassembly of the planet carrier (R3 EVO 110 -> 1001) 30-357
30.6.5 - Rear differential (E0.02.07) (R3 EVO 110 -> 1001) 30-358
30.6.6 - Disassembly of the rear differential (R3 EVO 110 -> 1001) 30-360
30.6.7 - Park Brake assembly 30-363
30.6.8 - Park Brake unit disassembly 30-365
30.7 - F0 - Front axle 30-369
30.7.1 - Separation of front support from engine (F0.01.01) (R3 EVO 110 -> 1001) 30-369
30.7.2 - Front support (R3 EVO 110 -> 1001) 30-372
30.7.3 - 4WD front axle (F0.03.01) (R3 EVO 110 -> 1001) 30-374
30.7.4 - Adjusting the front axle end float (R3 EVO 110 -> 1001) 30-376
30.7.5 - Steering cylinders (R3 EVO 110 -> 1001) 30-378
30.7.6 - Steering cylinders disassembly (R3 EVO 110 -> 1001) 30-380
30.7.7 - Steering knuckle housing and half-shaft (R3 EVO 110 -> 1001) 30-383
30.7.8 - Adjustment of steering knuckle housing and axle shaft (R3 EVO 110 -> 1001) 30-388
30.7.9 - Differential unit (R3 EVO 110 -> 1001) 30-390
30.7.10 - Differential disassembly (R3 EVO 110 -> 1001) 30-392
30.7.11 - Differential unit adjustment (R3 EVO 110 -> 1001) 30-394
30.7.12 - Bevel gear pair (R3 EVO 110 -> 1001) 30-397
30.7.13 - Adjustment of the bevel gear pair (R3 EVO 110 -> 1001) 30-401
30.7.14 - Disassembly of the differential (R3 EVO 110 -> 1001) 30-409
30.7.15 - 4WD shaft (F0.04.01) (R3 EVO 110 -> 1001) 30-411
30.7.16 - Planetary reduction gear (F0.06.01) (R3 EVO 110 -> 1001) 30-413
30.7.17 - Disassembly of the planetary reduction gear (R3 EVO 110 -> 1001) 30-414
30.7.18 - Front brake discs (R3 EVO 110 -> 1001) 30-420
30.7.19 - Front axle brake piston (R3 EVO 110 -> 1001) 30-420
30.8 - G0 - Bodywork - Cab - Platform 30-422
30.8.1 - Cab (G0.03.01) (R3 EVO 110 -> 1001) 30-422
30.8.2 - Front hood and side panels (G0.01.01) (R3 EVO 110 -> 1001) 30-428
30.8.3 - Battery support (G0.01.04) (R3 EVO 110 -> 1001) 30-429
30.8.4 - Cab access steps (G0.03.03) (R3 EVO 110 -> 1001) 30-431
30.8.5 - Fenders (G0.04.01) 30-431
30.8.6 - Right-hand console (G0.06.01) (R3 EVO 110 -> 1001) 30-432
30.8.7 - Left-hand console (G0.06.02) (R3 EVO 110 -> 1001) 30-433
30.8.8 - Front instrument panel (G0.06.04) (R3 EVO 110 -> 1001) 30-434
30.8.9 - Roof lining - Version with high visibility cab (G0.06.07) (R3 EVO 110 -> 1001) 30-437
30.8.10 - Heating fan - Version with high visibility cab (R3 EVO 110 -> 1001) 30-438
30.8.11 - Air conditioning system controls - High-visibility roof system (G0.09.01) (R3 EVO 110 ->
1001)30-439
30.8.12 - Air conditioning system - Standard roof version (R3 EVO 110 -> 1001) 30-442
30.8.13 - Heating and air conditioning unit - Version with high visibility cab (G0.09.03) (R3 EVO
110 -> 1001) 30-444
VIII
CONTENTS
30.8.14 - Heating control cable (R3 EVO 110 -> 1001) 30-446
30.8.15 - Condenser - Version with high-visibility roof (R3 EVO 110 -> 1001) 30-447
30.8.16 - Receiver drier - Version with high visibility roof (R3 EVO 110 -> 1001) 30-448
30.8.17 - Conditioner evaporator - Version with standard roof (R3 EVO 110 -> 1001) 30-449
30.8.18 - Air-conditioning evaporator - Version with high-visibility roof (R3 EVO 110 -> 1001) 30-450
30.8.19 - Heating valve - Version with high visibility cab (R3 EVO 110 -> 1001) 30-450
30.8.20 - Heater matrix - Version with high-visibility roof (R3 EVO 110 -> 1001) 30-451
30.8.21 - Heating radiator - Version with standard roof (R3 EVO 110 -> 1001) 30-451
30.8.22 - Heating and air conditioning unit fan - Version with standard roof (R3 EVO 110 -> 1001)30-453
30.8.23 - Expansion valve - Version with high visibility roof (R3 EVO 110 -> 1001) 30-454
30.8.24 - Expansion valve - Version with standard roof (R3 EVO 110 -> 1001) 30-455
30.8.25 - Antifreeze sensor - Version with high visibility roof (R3 EVO 110 -> 1001) 30-455
30.8.26 - Condenser cooling fans - Version with high-visibility roof (R3 EVO 110 -> 1001) 30-456
30.8.27 - Condenser fan control pressure switch - Version with high visibility roof (R3 EVO 110 ->
1001)30-456
30.8.28 - Air conditioning temperature control thermostat - Version with standard roof (R3 EVO
110 -> 1001) 30-457
30.8.29 - Remote valve control cables (R3 EVO 110 -> 1001) 30-457
30.8.30 - Adjustment of the control levers (R3 EVO 110 -> 1001) 30-459
30.9 - H0 - Hydraulic system 30-463
30.9.1 - Pump for hydraulic lift and auxiliary services (R3 EVO 110 -> 1001) 30-463
30.9.2 - Power steering valve (H0.02.01) (R3 EVO 110 -> 1001) 30-464
30.9.3 - Power steering disassembly (R3 EVO 110 -> 1001) 30-466
30.9.4 - Pressure relief valve setting (R3 EVO 110 -> 1001) 30-478
30.9.5 - Power steering pump (R3 EVO 110 -> 1001) 30-478
30.9.6 - Gearbox oil cooler (R3 EVO 110 -> 1001) 30-480
30.9.7 - Rear remote control valve (H0.07.01) (R3 EVO 110 -> 1001) 30-481
30.9.8 - Bleeding the braking circuit (E0.03.01) (R3 EVO 110 -> 1001) 30-483
30.9.9 - Parking brake control valve (R3 EVO 110 -> 1001) 30-484
30.9.10 - Braking distributor valve (R3 EVO 110 -> 1001) 30-486
30.9.11 - Services solenoid valve assembly (H0.10.01) (R3 EVO 110 -> 1001) 30-486
30.9.12 - Pressure reduction and holding valve disassembly (R3 EVO 110 -> 1001) 30-489
30.9.13 - Shuttle solenoid valves assembly 30-490
30.10 - L0 - Electrical system 30-492
30.10.1 - Lateral battery (R3 EVO 110 -> 1001) 30-492
30.10.2 - Alternator (R3 EVO 110 -> 1001) 30-493
30.10.3 - Clutch pedal potentiometer (R3 EVO 110 -> 1001) 30-494
30.10.4 - Shuttle output speed sensor (R3 EVO 110 -> 1001) 30-495
30.10.5 - Accelerator pedal position sensor (R3 EVO 110 -> 1001) 30-497
30.10.6 - Hand throttle position sensor (R3 EVO 110 -> 1001) 30-497
30.10.7 - Steering column switch (R3 EVO 110 -> 1001) 30-498
30.10.8 - Shuttle ECU and forward/reverse selector (R3 EVO 110 -> 1001) 30-499
30.11 - M0 - Front PTO 30-501
30.11.1 - Front PTO 30-501
30.11.2 - PTO assembly. 30-504
30.11.3 - Pump assembly 30-513
30.11.4 - Front PTO oil cooler 30-514
30.11.5 - Clutch-brake assembly 30-515
IX
 CONTENTS
30.11.6 - Solenoid valve assembly 30-520
30.12 - N0 - Front lift 30-521
30.12.1 - Front lift 30-521
30.12.2 - Disassembly of front lift cylinders 30-523
30.13 - R0 - Rear lift 30-526
30.13.1 - Lift - Complete assembly (R0.02.03) (R3 EVO 110 -> 1001) 30-526
30.13.2 - Disassembly of the lift- complete assembly (R3 EVO 110 -> 1001) 30-529
30.13.3 - Lift cylinder (R3 EVO 110 -> 1001) 30-533
30.13.4 - Bushes (R3 EVO 110 -> 1001) 30-534
30.13.5 - Auxiliary lift cylinders (R3 EVO 110 -> 1001) 30-535
30.13.6 - Disassembly of the lift control valve (R3 EVO 110 -> 1001) 30-536
30.13.7 - Mechanical draft sensor (R3 EVO 110 -> 1001) 30-541
30.13.8 - Mechanical draft sensor disassembly (R3 EVO 110 -> 1001) 30-542
30.13.9 - 3-point linkage (R3 EVO 110 -> 1001) 30-543
30.14 - S0 - Wheels 30-546
30.14.1 - Front wheels 30-546
30.14.2 - Rear wheels 30-546
30.15 - V0 - Ballast - towing hitches 30-548
30.15.1 - Towing hitch slide (V0.02.01) (R3 EVO 110 -> 1001) 30-548

40 - Wiring diagrams
40.1 - Introduction 40-2
40.1.1 - Introduction 40-2
40.1.2 - Basic electronics for mechanics (1/2) 40-4
40.1.3 - Basic electronics for mechanics (2/2) 40-7
40.1.4 - Electrical and electronic components (1/2) 40-13
40.1.5 - Electrical and electronic components (2/2) 40-21
40.2 - Components 40-26
40.2.1 - A - Starting and charging (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)40-26
40.2.2 - A - Starting and charging (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)40-26
40.2.3 - B - Fuses (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-27
40.2.4 - B - Fuses (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-35
40.2.5 - B - Fuses (R3 EVO 85 -> 16001) 40-47
40.2.6 - C - Earths (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-58
40.2.7 - C - Earths (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-61
40.2.8 - C - Earths (R3 EVO 85 -> 16001) 40-65
40.2.9 - D - Intermediate connections (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001) 40-69
40.2.10 - D - Intermediate connections (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-81
40.2.11 - D - Intermediate connections (R3 EVO 85 -> 16001) 40-95
40.2.12 - E - On-board instruments and visual and audible indicators (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-110
40.2.13 - E - On-board instruments and visual and audible indicators (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001) 40-112
40.2.14 - E - On-board instruments and visual and audible indicators (R3 EVO 85 -> 16001) 40-114

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40.2.15 - F - External lights (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-116
40.2.16 - F - External lights (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-118
40.2.17 - G - Interior lights (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-121
40.2.18 - G - Interior lights (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-121
40.2.19 - H - Electrical and manual controls (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3
EVO 85 -> 20001) 40-121
40.2.20 - H - Electrical and manual controls (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3
EVO 85 -> 16001) 40-122
40.2.21 - I - Circuit breakers (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)40-122
40.2.22 - I - Circuit breakers (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-130
40.2.23 - I - Circuit breakers (R3 EVO 85 -> 16001) 40-140
40.2.24 - J - Relays (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-150
40.2.25 - J - Relays (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-153
40.2.26 - K - Sensors and transmitters (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001) 40-157
40.2.27 - K - Sensors and senders (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-160
40.2.28 - K - Sensors and transmitters (R3 EVO 85 -> 16001) 40-162
40.2.29 - L - Electromagnets and solenoid valves (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001,
R3 EVO 85 -> 20001) 40-165
40.2.30 - L - Electromagnets and solenoid valves (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001,
R3 EVO 85 -> 16001) 40-165
40.2.31 - M - Electrical/electronic devices, flasher units and timers (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-166
40.2.32 - M - Electrical/electronic devices, flasher units and timers (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001) 40-166
40.2.33 - M - Electrical/electronic devices, flasher units and timers (R3 EVO 85 -> 16001) 40-167
40.2.34 - N - Electric motors and actuators (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO
85 -> 20001) 40-168
40.2.35 - N - Electric motors and actuators (R3 EVO 85 -> 16001) 40-168
40.2.36 - N - Electric motors and actuators (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-169
40.2.37 - O - Resistors and rheostats (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)40-169
40.2.38 - O - Resistors and rheostats (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)40-170
40.2.39 - P - Various services (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
40-170
40.2.40 - P - Various services (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
40-171
40.2.41 - R - Diagnostics (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-173
40.2.42 - R - Diagnostics (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-173
40.2.43 - T - Power supply points (+15 o +30) (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3
EVO 85 -> 20001) 40-173
40.2.44 - T - Power supply points (+15 o +30) (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3
EVO 85 -> 16001) 40-173
40.3 - Systems 40-175
40.3.1 - S001 - Starting and preheating (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001) 40-175
40.3.2 - S001A - Starting and preheating - Version with analog instrument panel (R3 EVO 100 ->

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16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-203
40.3.3 - S001D - Starting and preheating - Version with digital instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-229
40.3.4 - S002 - Electronic engine governor (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3
EVO 85 -> 20001) 40-254
40.3.5 - S002A - Electronic engine governor - Version with analog instrument panel (R3 EVO 85 ->
16001)40-262
40.3.6 - S002D - Electronic engine governor - Version with digital instrument panel (R3 EVO 85 ->
16001)40-269
40.3.7 - S002A - Electronic engine governor - Version with analog instrument panel (R3 EVO 100
-> 16001, R3 EVO 110 -> 5001) 40-276
40.3.8 - S002D - Electronic engine governor - Version with digital instrument panel (R3 EVO 100
-> 16001, R3 EVO 110 -> 5001) 40-283
40.3.9 - S003 - Diagnostics and accessories - Version with standard cab (R3 EVO 100 -> 20001,
R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-290
40.3.10 - S003A - Accessories and diagnostics - Version with analog instrument panel (R3 EVO
100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-305
40.3.11 - S003D - Accessories and diagnostics - Version with standard cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-315
40.3.12 - S004 - Diagnostics and accessories - Version with high-visibility cab (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-327
40.3.13 - S004A - Accessories and diagnostics - Version with high-visibility cab - Version with
analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)40-342
40.3.14 - S004D - Accessories and diagnostics - Version with high-visibility cab - Version with
digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)40-354
40.3.15 - S005 - Instrument panel (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)40-369
40.3.16 - S005A - Instrument panel - Version with analog instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-383
40.3.17 - S005D - Instrument panel - Version with digital instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-397
40.3.18 - S006 - Work lights - Version with standard cab without front lift (R3 EVO 100 -> 20001,
R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-411
40.3.19 - S006A - Work lights - Version with standard cab without front lift - Version with analog
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-429
40.3.20 - S006D - Work lights - Version with standard cab without front lift - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-437
40.3.21 - S007 - Work lights - Version with standard cab with front lift (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-445
40.3.22 - S007A - Work lights - Version with standard cab with front lift - Version with analog
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-457
40.3.23 - S007D - Work lights - Version with standard cab with front lift - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-465
40.3.24 - Work lights - Version with high-visibility cab without front lift (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-473
40.3.25 - S008A - Work lights - Version with high-visibility cab without front lift - Version with front

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instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-490
40.3.26 - S008D - Work lights - Version with high-visibility cab without front lift - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-503
40.3.27 - S009 - Work lights - Version with high-visibility cab with front lift (R3 EVO 100 -> 20001,
R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-516
40.3.28 - S009A - Work lights - Version with high-visibility cab with front lift - Version with analog
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-528
40.3.29 - S009D - Work lights - Version with high-visibility cab with front lift - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-536
40.3.30 - S010 - Heating - Version with standard cab (R3 EVO 100 -> 20001, R3 EVO 110 ->
1001, R3 EVO 85 -> 20001) 40-543
40.3.31 - S010A - Heating - Version with standard cab - Version with digital instrument panel (R3
EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-552
40.3.32 - S010D - Heating - Version with standard cab - Version with digital instrument panel (R3
EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-560
40.3.33 - S011 - Heating - Version with high-visibility cab (R3 EVO 100 -> 20001, R3 EVO 110 ->
1001, R3 EVO 85 -> 20001) 40-568
40.3.34 - S011A - Heating - Version with high-visibility cab - Version with digital instrument panel
(R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-577
40.3.35 - S011DA - Heating - Version with high-visibility cab - Version with digital instrument panel
(R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-585
40.3.36 - S012 - Manual climate control - Version with standard cab (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-593
40.3.37 - S012A - Heating - Version with standard cab - Version with digital instrument panel (R3
EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-611
40.3.38 - S012D - Manual climate control - Version with standard cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-629
40.3.39 - S013 - Manual climate control - Version with standard cab (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-647
40.3.40 - S013A - Manual climate control - Version with standard cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-664
40.3.41 - S013D - Manual climate control - Version with standard cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-682
40.3.42 - S014 - Manual climate control - Version with high-visibility cab (R3 EVO 100 -> 20001,
R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-701
40.3.43 - S014A - Manual climate control - Version with high-visibility cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-720
40.3.44 - S014D - Manual climate control - Version with high-visibility cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-738
40.3.45 - S015 - Steering column lights switch - Version with cab without front lift (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-756
40.3.46 - S015A - Steering column lights switch - Version with cab without front lift - Version with
analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)40-770
40.3.47 - S015D - Steering column lights switch - Version with cab without front lift - Version with
digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)40-784
40.3.48 - S016 - Steering column lights switch – Version with cab with front lift (R3 EVO 100 ->

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20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-798
40.3.49 - S016A - Steering column lights switch - Version with cab without front lift - Version with
analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)40-812
40.3.50 - S016D - Steering column lights switch - Version with cab with front lift - Version with
digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)40-827
40.3.51 - S017 - +30 Positives (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)40-840
40.3.52 - S017A - +30 Positives - Version with analog instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-848
40.3.53 - S017A - +30 Positives - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-856
40.3.54 - S018 - +15 Positives (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)40-864
40.3.55 - S018A - +15 Positives - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-866
40.3.56 - S018D - +15 Positives - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-868
40.3.57 - S019 - Windscreen wipers - Version with standard cab (R3 EVO 100 -> 20001, R3 EVO
110 -> 1001, R3 EVO 85 -> 20001) 40-870
40.3.58 - S019AD - Windscreen wipers - Version with standard cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-882
40.3.59 - S019D - Windscreen wipers - Version with standard cab - Version with digital instrument
panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-890
40.3.60 - S020 - Windscreen wipers - Version with high-visibility cab (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-898
40.3.61 - S020A - Windscreen wipers - Version with high-visibility cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-910
40.3.62 - S020D - Windscreen wipers - Version with high-visibility cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-922
40.3.63 - S021 - Transmission (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)40-934
40.3.64 - S021A - Transmission - Version with analog instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-951
40.3.65 - S021D - Transmission - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-959
40.3.66 - S022 - PTO (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-967
40.3.67 - S022A - PTO - Version with analog instrument panel (R3 EVO 100 -> 16001, R3 EVO
110 -> 5001, R3 EVO 85 -> 16001) 40-981
40.3.68 - S022D - PTO - Version with digital instrument panel (R3 EVO 100 -> 16001, R3 EVO
110 -> 5001, R3 EVO 85 -> 16001) 40-991
40.3.69 - S023 - Can Bus (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-1003
40.3.70 - S023A - Can bus - Version with analog instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1008
40.3.71 - S023D - Can bus - Version with digital instrument panel (R3 EVO 100 -> 16001, R3 EVO
110 -> 5001, R3 EVO 85 -> 16001) 40-1012
40.3.72 - S024 - Brakes (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-1016

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40.3.73 - S024A - Brakes - Version with analog instrument panel (R3 EVO 100 -> 16001, R3 EVO
110 -> 5001, R3 EVO 85 -> 16001) 40-1031
40.3.74 - S024D - Brakes - Version with digital instrument panel (R3 EVO 100 -> 16001, R3 EVO
110 -> 5001, R3 EVO 85 -> 16001) 40-1044
40.3.75 - S025 - Negatives (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)40-1056
40.3.76 - S025A - Negatives - Version with analog instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1058
40.3.77 - S025D - Negatives - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1061
40.3.78 - S026 - Steering column lights switch – Version with cab without front lift (U.S.A.) (R3
EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-1064
40.3.79 - S026D - Steering column lights switch - Version with cab without front lift - Version with
digital instrument panel (USA) (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85
-> 16001) 40-1079
40.3.80 - S027 - Steering column lights switch – Version with cab with front lift (U.S.A.) (R3 EVO
100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-1094
40.3.81 - S027D - Steering column lights switch - Version with cab without front lift - Version with
digital instrument panel (USA) (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85
-> 16001) 40-1109
40.3.82 - S028 - PTO (U.S.A.) (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)40-1124
40.3.83 - S028D - PTO (U.S.A.) - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1139
40.3.84 - S029 - Brakes (U.S.A.) (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)40-1153
40.3.85 - S029D - Brakes (U.S.A.) - Version with digital instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1168
40.4 - Wiring harnesses 40-1180
40.4.1 - 0.008.0913.3 - Front PTO 40-1180
40.4.2 - 0.009.7853.3/20 - Air conditioning condenser fan - Version with standard cab 40-1180
40.4.3 - 0.010.2147.2 - Heating - Version with standard cab 40-1182
40.4.4 - 0.010.2153.2 - Air conditioning - Version with standard cab 40-1183
40.4.5 - 0.010.4516.3 - Windscreen wiper - Version with standard cab 40-1186
40.4.6 - 0.011.3597.3 - Windscreen wiper - Version with high-visibility cab 40-1187
40.4.7 - 0.013.4909.4 - Rear lights (U.S.A.) 40-1188
40.4.8 - 0.013.6327.4 - LH rotating beacon 40-1190
40.4.9 - 0.013.6327.4 - RH rotating beacon 40-1190
40.4.10 - 0.014.1645.4/10 - Compressed air pressure sensor 40-1191
40.4.11 - 0.014.3927.4/40 - LH auxiliary work lights - Version with high-visibility cab 40-1192
40.4.12 - 0.014.3927.4/40 - RH auxiliary work lights - Version with high-visibility cab 40-1192
40.4.13 - 0.014.8107.4/30 - Hood lights (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001) 40-1193
40.4.14 - 0.014.9195.4/20 - Preheating 40-1195
40.4.15 - 0.015.1418.4/30 - Cab shuttle (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001) 40-1196
40.4.16 - 0.015.1435.4/20 - RH auxiliary work lights - Version with standard cab (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-1197
40.4.17 - 0.015.1435.4/20 - LH auxiliary work lights - Version with standard cab (R3 EVO 100 ->

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20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) 40-1198
40.4.18 - 0.015.1983.4/10 - Power supplies 1 40-1199
40.4.19 - 0.015.1983.4/10 - Power supplies 2 40-1200
40.4.20 - 0.015.1983.4/10 - Power supplies 3 40-1201
40.4.21 - 0.015.1998.4/10 - Drivetrain shuttle (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3
EVO 85 -> 20001) 40-1202
40.4.22 - 0.015.6123.4 - Rear wiper - Version with standard cab (R3 EVO 100 -> 20001, R3 EVO
110 -> 1001, R3 EVO 85 -> 20001) 40-1203
40.4.23 - 0.015.6272.4/40 - Cab roof - Version with high-visibility cab 40-1204
40.4.24 - 0.015.7021.4/70 - Central - Version with digital instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1206
40.4.25 - 0.015.7021.4/70 - Central wiring (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO
85 -> 20001) 40-1209
40.4.26 - 0.015.7023.4/50 - Driveline - Version with digital instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1213
40.4.27 - 0.015.7023.4/50 - Drivetrain (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001) 40-1214
40.4.28 - 0.015.7266.4/40 - Air conditioning condenser fan - Version with high-visibility cab () 40-1216
40.4.29 - 0.015.7266.4/40 - Air conditioning condenser fan - Version with standard cab () 40-1217
40.4.30 - 0.015.7310.4 - Hood lights (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)40-1219
40.4.31 - 0.016.0373.4/30 - Cab power supply 40-1220
40.4.32 - 0.016.0484.4/60 - Central (U.S.A.) 40-1221
40.4.33 - 0.016.0664.4 - Front lights 40-1225
40.4.34 - 0.016.0865.4/10 - Cab roof - Version with standard cab (R3 EVO 100 -> 20001, R3 EVO
110 -> 1001, R3 EVO 85 -> 20001) 40-1227
40.4.35 - 0.016.0865.4/10 - Cab roof - Version with standard cab (R3 EVO 100 -> 16001, R3 EVO
110 -> 5001, R3 EVO 85 -> 16001) 40-1229
40.4.36 - 0.016.0866.4/10 - Front-rear work lights - Version with standard cab 40-1231
40.4.37 - 0.016.1001.4/20 - Hydraulic trailer braking valve (R3 EVO 100 -> 20001, R3 EVO 110 ->
1001, R3 EVO 85 -> 20001) 40-1232
40.4.38 - 0.016.1999.4/10 - Driveline - Version with analog instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1233
40.4.39 - 0.016.2000.4/20 - Engine - Version with front battery 40-1234
40.4.40 - 0.016.2001.4/10 - Engine - Version with lateral battery 40-1237
40.4.41 - 0.016.2002.4/60 - Central - Version with analog instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001) 40-1238
40.4.42 - 0.017.0473.4 - Battery negative 40-1241
40.4.43 - 0.017.0474.4 - Battery positive 40-1242
40.4.44 - 0.017.1063.4 - Cab earth 40-1242
40.4.45 - 0.018.5825.4 - Cab roof - Version with standard cab (R3 EVO 100 -> 16001, R3 EVO
110 -> 5001, R3 EVO 85 -> 16001) 40-1243
40.4.46 - 0.018.5825.4 - Cab roof - Version with standard cab (R3 EVO 100 -> 20001, R3 EVO
110 -> 1001, R3 EVO 85 -> 20001) 40-1245
40.4.47 - 04214707 - Engine (R3 EVO 85 -> 16001) 40-1247
40.4.48 - 04215655 - Engine (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001) 40-1248
40.4.49 - 04215655 - Engine (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
40-1249

XVI
CONTENTS
40.4.50 - 04411923.4 - RH lower headlights 40-1250
40.4.51 - 04411923.4 - LH lower headlights 40-1251

XVII
 CONTENTS

PAGE LEFT INTENTIONALLY BLANK

XVIII
0 - Introduction

0-1
 Introduction
0.1 - Introduction
This workshop manual has been prepared to provide instructions for repair technicians and as a practical guide to improve the
quality of repairs. This manual is intended as a guide for repair technicians to give them a thorough understanding of the machine,
and describes the correct procedures for troubleshooting and performing repair jobs safely, the methods and conditions necessary
for checking the dimensions of and visually inspecting parts subject to repair and, lastly, indicates the products, tightening torques,
and correct adjustment or setting data to be used. The material contained in this manual is of a confidential technical nature, and is
intended for dealers and authorised workshops only. In the event of any changes of a strictly technical nature regarding the machines,
the intended recipients will be notified promptly with supplements to the manual illustrating modifications, updates and additional
optional devices. Technicians and their employees shall not distribute, reproduce or divulge the material contained herein to others
without written permission from the Manufacturer who is the exclusive owner thereof and who reserves the right to take legal action
based on current laws to protect its rights.
0.1.1 - Safety notes
For the machine to continue to function correctly, it is crucial that all repairs are performed properly by a service centre authorised to
repair and service these machines. The testing and repair techniques recommended and described in this manual are effective and
safe methods for obtaining good operation. Some of the described operations require the use of special and dedicated tools; these
can be requested from the Manufacturer who has specifically designed them for their intended purpose. DO NOT USE IMPROVISED
TOOLS; they could create potentially dangerous situations and do not always correspond to the specific functions for which they
are created and used. If a dangerous situation occurs or is anticipated, consider safety first of all and take the necessary actions to
handle the situation
0.1.2 - General safety
l Even if you are completely familiar with the construction, functions and controls of this machine, always observe extreme cau-
tion when manoeuvring and operating the machine Always bear in mind that a machine brought to the workshop is in need of
repair or servicing, and may therefore react unpredictably to controls.
l Before starting work, clean the machine thoroughly to remove mud, dust and gravel. Also clean the cab thoroughly to remove
all residue of oil, snow or ice from the steps, handles and grips normally used to access and leave the cab.
l When climbing into or out of the machine, maintain three points of contact at all times prevent loss of balance and the risk of
falling.
l Observe extreme caution when troubleshooting faults, which must often be performed by two operators: never stand in front
of the wheels while the engine is running.
l When performing tests and repairs, always wear close fitting clothing, goggles and gloves suitable for the operation to perform
(cleaning, draining fluids, repairs). Do not go near moving parts with long hair that has not been tied back, hair can get caught
and create serious injury.
l Keep unauthorised persons away from the machine they must be required to remain at a safe distance.
l Keep away from moving parts; with the engine on, some parts are not very visible and thus, even if protected, may represent
a potential danger of being drawn in.
l When starting the engine, make sure that the area is well ventilated to avoid a build up of toxic gases; always apply the ex-
haust pipe of the forced fume extraction devices.
l Absolutely avoid running the engine without guards; all repair and/or adjustment operations must be performed with the en-
gine off.
l Do not fill up fuel, oil or coolant with the engine running.
l Do not smoke when filling up fuel or lubricant and make sure there are no open flames in the vicinity. Do not charge the battery
on board the machine.
l Before working on the battery to check it or remove it, stop the engine and remove the key.
l Remove the battery and recharge it in a well ventilated area and with a temperature greater than 0°C.
l Do not smoke during battery testing and recharging, and do not go near it with open flames since the hydrogen emitted during
chemical reactions may explode.
l The liquid (electrolyte) contained in the battery is dangerous for the skins and above all for the eyes; for this reason when test-
ing the battery always wear gloves and safety goggles with side shields. If you accidentally get electrolyte on you immediately
wash the contaminated parts for a long time with water; if your clothes are contaminated change them as quickly as possible.
If you accidentally swallow electrolyte, drink plenty of water, milk, vegetable oil and antacids such as magnesium, bicarbonate,
etc., and go to an emergency room as soon as possible.
l If work needs to be done on the electrical circuits, disconnect the terminals from the battery.

0-2
Introduction
DANGER
First disconnect the negative terminal (--) then the positive one (+); after the repair work, first connect the positive pole
(+) then the negative one (--).

l If any arc welding is necessary (which is permitted in certain special cases only on implements attached to the machine),
disconnect the battery terminals, all electronic control unit connectors and the alternator.
l When filling up or changing lubricants, always use waterproof gloves.
l Do not wear clothing contaminated with engine oil or hydraulic circuit oil; prolonged contact with the skin may be harmful and
for some people cause allergic reactions.
l Engine oil and hydraulic circuit oil are considered special wastes; recover the lubricants and have them disposed of according
to current laws.
l Discharge any remaining pressure before working on the hydraulic and pneumatic circuits.
l Wait for the oil and water to cool before working on the hydraulic circuits and on the engine.
l During the removal and installation of certain assemblies on the machine, the weight of the engine must be adequately sup-
ported; use saw horses, jacks or blocks suitable for the weight to support and put it in a triangular position to prevent it from
flipping over.
l Use a hoist or a crane to lift heavy components. Make sure that metal cables, chains or fibre belts are not worn and that the
hooks are not damaged.
l Always use lifting equipment which can easily support the weight of the units to remove and connect correctly.
l When lifting or supporting an assembly or part of the machine, work slowly to prevent swinging and collisions with other parts,
which may cause injury or damage.
l Never work on parts or units hanging on a hoist or crane.
l If removing the screws from units which can fall, always leave two opposite screws for safety purposes; remove these screws
only after having hooked the unit to a lifting device or after having positioned support blocks.
l If fuel or oil drips on the floor during removal or assembly operations, clean it as soon as possible to avoid operators slipping
and possible fires.
l If electrical cables or wires are removed, make sure that they are reassembled with their original fastening, to prevent machine
vibration from damaging them.
l Never insert your hands or fingers to check the alignment between two holes, use soft material pins.
l When installing units or parts, always use the torques indicated in the general tables; the torques indicated in the paragraphs
regarding assembly, are specific torques whose values have been determined by testing and they must absolutely be com-
plied with.
l If installing parts subject to strong vibrations or which turn at high speed, pay particular attention during the final test of the
installation.

0.1.3 - Precautions to use during performance of the work

When disassembling or assembling a part, always follow the general precautions below.
Precautions for disassembly
l Unless indicated otherwise, lower all implements to the ground.
l After disconnecting the pipes of the hydraulic system and fuel supply system, fit the caps to prevent impurities from entering.
l Before removing a cylinder, retract the piston completely and secure it in this position with a clamp.
l Use a container with sufficient capacity to recover oil, coolant or fuel.
l Before removing a machine part, check the alignment references which indicate the correct assembly position. Add additional
marks if necessary to avoid incorrect assembly.
l When disassembling the connectors, always hold them tightly to prevent forcing on the electrical cables.
l Mark the electrical cables and pipes if necessary to avoid mixing them up during assembly.
l Check the number and height of the shims and put them in a safe place.
l Use lifting equipment of suitable load capacity when lifting the machine or parts thereof.
l When using eye-bolts to remove parts of the machine, ensure that there are not damaged; completely tighten them and then
align the direction of the eye with the lifting hook.
l Before removing a part, accurately clean the surrounding area and, after removing the part, cover it to prevent dirt and dust
from getting on it.

0-3
 Introduction
Precautions for assembly
l Tighten nuts and screws with the specified torques.
l Fit hoses and wiring being careful not to bend or twist them.
l Replace gaskets, O-rings, split pins and safety stop rights with new parts; make sure the tines of the split pin are separated
and bent and thus so they cannot come out of their seats.
l After fitting the snap rings, make sure they are well inserted in their seat.
l When you need to lock threading with sealant, clean the part removing oil and grease, then apply drops of adhesive in order
to uniformly cover the threading.
l To apply sealants, clean the involved surface, remove any residual oil and grease, make sure there are no dents or dirt, then
apply the sealant uniformly making sure it completely surrounds any holes.
l Clean all the parts, remove dirt, oxidation, carbonaceous deposits, burrs and dents.
l Apply a film of engine oil to all moving parts.
l When fitting the electrical system connectors, remove oil, dust or water which can penetrate between the contacts and then
connect them tightly; when required force the connectors until the twin lock catch.
l Lock the flanged couplings uniformly, tightening the screws in a crossed and alternating sequence.
Precautions to observe at the end of disassembly/assembly operations
l If you drained the coolant, screw down the drain cap and add new coolant up to the level. Start the engine and let the coolant
circulated in the cooling system and then top up.
l When the hydraulic equipment has been disassembled, add oil up to the indicated level. Start the engine and let the oil circu-
late in the hydraulic circuits and then top up.
l When the variable displacement pump is removed, connect the drain pipe and fill the casing using the cap provided for this
purpose.
l After having reassembled the joint boxes, cylinder joints and driveshafts, grease completely.

0.1.4 - Lifting instructions

DANGER
Machine units with a weight over 25 kg or with large dimensions, must be supported or removed with a lifting device
and metal cables or polyester belts.

Metal cables - belts

l Use cables or polyester belts suitable for the weight to lift, referring to the following tables:
Table 1
METAL CABLES (standard «S» or «Z» twisted type) POLYESTER BELTS (with slots - simple)
cable Ø mm Capacity (kg) Width (mm) Capacity (kg)
60° 90° 60° 90°

8 650 620 500 25 500 400 860 700

10 1000 1740 1420 50 1000 800 1730 1410
12 1450 2500 2050 62 1250 1000 2160 1760
14 2000 3460 2820 75 1400 1120 2420 1980
16 2600 4500 3670 100 2000 1600 3460 2820
18 3300 5710 4660 150 2500 2000 4330 3530
Note
The capacity is calculated with a safety coefficient.

l The cables and belts must be connected to the lifting hook in the central part; hooking the cables towards the end may cause
the load to slide during lifting.
l Never hang a heavy load from just one cable; always use two or more symmetrical cables.
DANGER
Suspension from just one cable can cause the load to rotate and cause the cable to come untwisted, or slide from the
winding position; these possibilities can cause serious accidents.

0-4
Introduction
l Do not lift a heavy load when the two ends of the cables form a wide suspension angle. The permitted load (kg) decreases
when the suspension angle increases; the table below, indicates the variation in permitted load (based on the suspension
angle), for two Ø 10 mm diameter cables each with a load capacity of 1000 kg.

2000
1900
Capacità di carico: kg
1700
2000
1400

1000
1000
500

30° 60° 90° 120° 150°

Angolo di sospensione:

Fig. 1

0.1.5 - Tightening torques

Screws and nuts
DANGER
The specific torques for important parts and the tightening to perform with special procedures, are given within the
individual assembly paragraphs.

The indicated torques refer to screws and nuts fitted without lubrication, possible with threading spread with anaerobic threadlock.
The values indicated refer to tightening on steel or cast iron material; for soft material such as aluminium, copper or plastics, plated
or panels, the torques need to be reduced by 50%.
See para. 0.3 - Tightening torques - page 0-20
Unions
The indicated torques refer to fitting unions on any material.
Table 2
MET- Unions with straight Unions with “T” ends Unions with “L” ends Unions with 90° ends
RIC ends

Thread Spanner Torque Nm Spanner Torque Nm Spanner Torque Nm Spanner Torque Nm

±10% ±10% ±10% ±10%
M10x1.25 17 14 14 14 14 14 14 14
19 14 17 14 17 14
M12x1.25 19 30 17 30 17 30 17 30
M14x1.5 19 40 19 40 19 40 19 40
M16x1.5 22 48 22 48 22 48 22 48
M18x1.5 24 58 24 58 24 58 24 58
M20x1.5 27 65 27 65 27 65 27 65
M22x1.5 30 73 30 73 30 73 30 73
M26x1.5 36 95 36 95 36 95 36 95
M27x2 36 100 36 100 36 100 36 100
M33X2 41 160 41 160 41 160 41 160
M42x2 50 250 50 250 50 250 50 250

0-5
 Introduction
M48x2 60 305 60 305 60 305 60 305
G 1/8” 17 13 14 13 14 13 14 13
19 13
G 1/4” 19 37 19 37 19 37 19 37
22 37
G 3/8” 24 53 24 53 24 53 24 53
G 1/2” 27 73 27 73 27 73 27 73
30 73
G 3/4” 36 100 36 100 36 100 36 100
G 1” 41 160 41 160 41 160 41 160
46 160
G 1 1/4” 50 250 50 250 50 250 50 250
G 1 1/2” 60 305 60 305 60 305 60 305
Plugs
Table 3
Hexagonal head plugs Socket head threaded plugs

Thread Spanner Torque Nm ±10% Spanner Torque Nm ±10%

MET- M6x1 10 10 – –
RIC M8x1 13 12 – –
M10x1 13 14 5 14
M10x1.25 13 14 – –
M10x1.5 13 14 – –
M12x1.25 17 30 – –
M12x1.5 17 30 6 30
M12x1.75 17 30 – –
M14x1.5 19 40 6 40
M14x2 19 40 – –
M16x1.5 22 48 8 48
M16x2 22 48 – –
M18x1.5 17 58 10 58
M18x2.5 17 58 – –
M20x1.5 19 65 – –
M22x1.5 – – 12 73
M24x1.5 22 80 12 80
M24x2 22 80 – –
M27x2 22 100 – –
M28x1.5 – – 17 110
M30x1.5 22 130 – –
M32x1.5 – – 19 150
M35x1.5 – – 22 180
M40x1.5 – – 24 225
G 1/8” 14 13 – –
G 1/4” 19 37 – –
G 3/8” 22 53 – –
G 1/2” 19 73 – –
G 5/8” 22 85 – –
G 3/4” 22 100 – –
G 1” 22 160 – –

0-6
Introduction
Unions with seal at 37°
Table 4

Thread Spanner Torque Nm ±10%

7/16” - 20 14 13
1/2” - 20 16 19
9/16” - 18 17 28
3/4” - 16 22 47
7/8” - 14 27 76
1 1/16” - 12 32 110
36 110
1 3/16” - 12 36 138
1 5/16” - 12 38 155
1 5/8” - 12 50 215
1 7/8” - 12 60 290
2 1/2” - 12 75 345
Union for pipes with eye mounting
These torques refer to tightening of unions with new copper sealing washers.
Table 5
One-way pipe unions Three-way pipe unions Four-way pipe unions

Thread Spanner Torque Nm Spanner Torque Nm Spanner Torque Nm

±10% ±10% ±10%
M8x1 – 12 14 – –
M8x1.25 13 14
M10x1 – – 14 20 14 20
M10x1.25 13 20 – – – –
M12x1.25 17 30 – – – –
M12x1.5 – – 17 30 17 30
M14x1.5 19 40 19 40 19 40
M16x1.5 22 48 22 48 22 48
M18x1.5 22 58 24 58 24 58
M20x1.5 27 65 – – – –
M22x1.5 – – 27 73 27 73
M24x1.5 32 80 – – – –
M26x1.5 – – 32 95 32 95
M28x1.5 36 110 – – – –
M30x1.5 – – 36 130 36 130
M35x2 41 180 – – – –
M38x1.5 – – 46 200 46 200
M42x2 50 250 – – – –
M45x1.5 – – 55 280 55 280
M50x2 60 320 – – – –
M52x1.5 – – 60 320 60 320
M65x2 – – 75 450 75 450

0-7
 Introduction
0.1.6 - Thread lock, adhesive, sealant and lubrication materials
Table 6
FUNCTION DESIGNATION DESCRIPTION
THREAD LOCK Loctite 222 Colour: opaque fluorescent Anaerobic product suitable for weak thread locking of set, adjust-
purple ing and precision screws and nuts. It must be used after having
removed all traces of lubricant with a specific activator.
Loctite 242 Colour: fluorescent blue Anaerobic product suitable for preventing loosening of all types
of screws and nuts and to replace mechanical locks. Used for
medium resistance thread locking. It must be used after having
removed all traces of lubricant with a specific activator.
Loctite 243 Colour: opaque fluorescent Alternative product to 242 which, since it is oil compatible, it does
blue not require the activation of slightly lubricated surfaces.
Loctite 270 Colour: fluorescent green Anaerobic product for extra strength locking of threaded parts,
bolts and stud bolts which normally do not need to be removed.
Removal of parts may require heating to around 80°C. It must be
used after having removed all traces of lubricant with a specific
activator.
DEGREASING Loctite 703 Product for degreasing and cleaning parts before application of
AGENTS AND AC- Loctite anaerobic products; after it is allowed to dry, thread locks
TIVATORS will cure uniformly
Loctite 747 Specific product for treatment of surfaces not very active towards
anaerobic products with slow curing (series 5 and 6). It can also
be used to accelerate curing in low temperatures or if there is a
lot of backlash between parts.
SEALANTS (for Loctite 510 Colour: Red Very fast anaerobic product suitable for sealing between metallic
surfaces and surfaces, can be used to eliminate traditional gaskets, since it can
unions) fills gaps up to 0.4 mm. Since it does not settle, the torque does
not need to be reset.
Loctite 542 Colour: Brown Anaerobic product used as a liquid gasket for sealing threaded
unions with a measurement under 3/4” gas; it cures quickly and
the parts can be disassembled with normal tools.
Loctite 554 Colour: Red Anaerobic sealant and locking product used to seal cooling and
industrial fluid circuits. It cures slowly and is also suitable for use
on non-ferrous alloys
Loctite 572 Colour: White Anaerobic sealant and locking product used to seal pipes and
threaded unions up to a diameter of 2”. It cures very slowly on
most metallic surfaces.
Loctite 573 Colour: green Thixotropic anaerobic product suitable for sealing metal surfaces.
It ensures total contact between the surfaces with a maximum
backlash of 0.10 mm even filling microspaces due to planarity
imperfections. It cures very slowly on most metallic surfaces and
requires the use of an activator.
Loctite 576 Colour: brown Anaerobic product used as a liquid gasket for sealing large di-
mension threaded unions (up to 2”). It cures very slowly and is
also suitable for non-ferrous alloys and parts which require later
removal.
INSTANT ADHE- Loctite 401 Colour: colourless Instant cyanoacrylate adhesive suitable for bonding acid and
SIVES porous surfaces of a wide range of materials including ceramic,
wood, rubber and plastic (with the exception of polyolefins). It
cures in just a few seconds due to the effect of the atmospheric
humidity on the surfaces to bond, regardless of the ambient con-
ditions.
Loctite 495 Colour: colourless Instant cyanoacrylate adhesive suitable for bonding rubber and
plastics even in different combinations, including metals.

0-8
Introduction
SILICON SEAL- Silastic 738 (Dow Corning) colour: milky Single compound silicon adhesive/sealant, not settling, ready for
ANTS white use. It cures into a solid rubbery consistency when it reacts with
humidity in the air and makes it possible to eliminate traditional
gaskets on elastic joints covering backlashes even greater than
a millimetre.
Dirko Transparent Colour: transparent Single compound silicon adhesive/sealant, settling, ready for
use. It cures quickly forming a rubbery solid when curing starts
due to moisture in the air and it is resistant to high temperatures.
POLYURETHANE Betaseal HV3 (Gurit Essex) Colour: Black Polyurethane prepolymer based adhesive and sealant which is
SEALANTS highly viscose, suitable for highly resistant permanent elastic
bonding. It cures slowly and is used for bonding glass on struc-
tures, metallic protection meshes, plates, etc., after degreasing
with a primer.
RETAINERS Loctite 601 Colour: fluorescent green Fast curing anaerobic product with high mechanical resistance. It
is suitable for sealing and retaining freely moving cylindrical cou-
plings with backlash up to 0.10 mm, for fastening shafts on rotors,
gears, bearings, pulleys, bushes, main bearings, etc.
Loctite 638 Colour: fluorescent green Fast curing anaerobic structural adhesive with very high me-
chanical resistance; suitable for fastening non-ferrous alloy freely
moving cylindrical couplings.
Loctite 648 Colour: fluorescent green Fast curing anaerobic structural adhesive with high mechanical
resistance; suitable for retaining freely moving cylindrical cou-
plings, permanent retaining of threaded parts, sealing of cooling
systems, fastening of bearings, etc. It is an alternative product to
Loctite 601 for use at higher operating temperatures.
Loctite 986/AVX Colour: fluorescent red Anaerobic sealant and retaining product for cylindrical couplings
between metallic parts. It cures slowly and offers a good mechan-
ical and temperature resistance as well as excellent resistance to
chemical pressure. It must be used after activation of the parts.
LUBRICANTS Grease (NLGI 2 EP ASTM D217: 265/295) Multi-purpose lithium grease used to lubricate gaskets, prevent
oxidation and make assembly operations easier.
Molikote (Dow Corning) Anti-wear lubricant compound, containing Molybdenum disul-
phide, used pure or diluted with a percentage of engine oil during
engine main bearing assembly phases.
Vaseline Neutral PH compound used to protect the poles and terminals of
batteries from oxidation and corrosion.
10W - 30 engine oil Used to dilute Molikote anti-wear lubricant during engine assem-
bly phases.

0-9
 Introduction
0.1.7 - Unit of measurement conversion table
Conversion from imperial to metric units
Table 7
inch x 25.40 = mm
foot x 0.305 =m
yard x 0.914
Eng.miles x 1.609 = km
Sq.in. x 6.452 = cm²
Sq.ft. x 0.093 = m²
Sq.yard x 0.835
Cu.in. x 16.39 = cm³
Cu.ft. x 28.36 = m³
Cu.yard x 0.763
Imp.gall. x 4.547 = litres
US gall. x 3.785
pint x 0.568
quart x 1.137
US.gpm x 3.785 = ,/min
oz. x 0.028 = kg
lb. x 0.454
lb.ft. x 0.139 = kgm
lb.in. x 17.87 = kg/m
psi x 0.070 = kg/cm²
lb./Imp.gall x 0.100 = kg/,
lb./US.gall x 0.120
lb./cu.ft. x 16.21 = kg/m³
lb.ft. x 1.356 = Nm
psi x 1.379 = bar
Conversion from metric to imperial units
Table 8
mm x 0.0394 = inch
m x 3.281 = foot
m x 1.094 = yard
km x 0.622 = Eng.miles
cm² x 0.155 = Sq.in.
m² x 10.77 = Sq.ft.
m² x 1.197 = Sq.yard
cm³ x 0.061 = Cu.in.
m³ x 0.035 = Cu.ft
m³ x 1.311 = Cu.yard
litres x 0.220 = Imp.gall.
litres x 0.264 = US gall.
litres x 1.762 = pint
litres x 0.880 = quart
,/min x 0.2642 = US.gpm
kg x 35.25 = oz.
kg x 2.203 = lb.
kgm x 7.233 = lb.ft.
kg/m x 0.056 = lb.in.
kg/cm² x 14.22 = psi
kg/, x 10.00 = lb./Imp.gal.
kg/, x 8.333 = lb./US.gal.
kg/m³ x 0.062 = lb./cu.ft.
Nm x 0.737 = lb.ft.
bar x 14.503 = psi

0-10
Introduction
0.2 - Introduction - Engines
This workshop manual has been prepared to provide instructions for repair technicians and as a practical guide to improve the quality
of repairs. The pages composing the manual serve as a guide for repair technicians for an accurate knowledge of the engine, and
indicates the correct manner for troubleshooting, carrying out repair jobs without being exposed to danger, methods and conditions
necessary for accurate dimension testing and/or inspection of parts subject to repair and lastly indicates the products, torques, and
adjustment or setting data to use. The material contained in this manual is of a confidential technical nature intended for Dealers
and Authorised Service Centres who will be promptly informed of any changes of a mainly technical nature involving the engines, by
sending files showing the modifications, updates and additions regarding optional devices. Technicians and their employees shall not
distribute, reproduce or divulge the material contained herein to others without written permission from the Manufacturer who is the
exclusive owner thereof and who reserves the right to take legal action based on current laws to protect its rights.
0.2.1 - Safety notes
Correctly performed repairs are extremely important for regular operation of the engines entrusted to a Workshop for a repair or
overhaul. The testing and repair techniques recommended and described in this manual are effective and safe methods for obtaining
good operation. Some of the described operations require the use of special and dedicated tools; these can be requested from the
Manufacturer who has specifically designed them for their intended purpose. DO NOT USE IMPROVISED TOOLS; they could create
potentially dangerous situations and do not always correspond to the specific functions for which they are created and used. If a
dangerous situation occurs or is anticipated, consider safety first of all and take the necessary actions to handle the situation
0.2.2 - General safety
l Even if you know the engine perfectly in terms of composition, operations and controls, be very careful when making ma-
noeuvres or movements; it is a good idea to remember that the engine delivered to the Workshop needs to be repaired or
overhauled and may have unpredictable reactions.
l Before starting to work, accurately clean the engine to remove mud, dust and gravel.
l When performing tests and repairs, always wear close fitting clothing, goggles and gloves suitable for the operation to perform
(cleaning, draining fluids, repairs). Do not go near moving parts with long hair that has not been tied back, hair can get caught
and create serious injury.
l Do not let unauthorised individuals near the engine; they must be required to remain at a safe distance.
l Keep away from moving parts; with the engine on, some parts are not very visible and thus, even if protected, may represent
a potential danger of being drawn in.
l When starting the engine, make sure that the area is well ventilated to avoid a build up of toxic gases; always apply the ex-
haust pipe of the forced fume extraction devices.
l Absolutely avoid running the engine without guards; all repair and/or adjustment operations must be performed with the en-
gine off.
l Do not fill up fuel, oil or coolant with the engine running.
l Do not smoke when filling up fuel or lubricant and make sure there are no open flames in the vicinity.
l Before working on the battery to check it or remove it, stop the engine and remove the key.
l Remove the battery and recharge it in a well ventilated area and with a temperature greater than 0°C.
l Do not smoke during battery testing and recharging, and do not go near it with open flames since the hydrogen emitted during
chemical reactions may explode.
l The liquid (electrolyte) contained in the battery is dangerous for the skins and above all for the eyes; for this reason when test-
ing the battery always wear gloves and safety goggles with side shields. If you accidentally get electrolyte on you immediately
wash the contaminated parts for a long time with water; if your clothes are contaminated change them as quickly as possible.
If you accidentally swallow electrolyte, drink plenty of water, milk, vegetable oil and antacids such as magnesium, bicarbonate,
etc., and go to an emergency room as soon as possible.
l If work needs to be done on the electrical circuits, disconnect the terminals from the battery.
DANGER
First disconnect the negative terminal (--) then the positive one (+); after the repair work, first connect the positive pole
(+) then the negative one (--).

l Welding work should not be done on the engine.

l When filling up or changing lubricants, always use waterproof gloves.
l Do not wear clothing contaminated with engine oil or hydraulic circuit oil; prolonged contact with the skin may be harmful and
for some people cause allergic reactions.
l Engine oil and hydraulic circuit oil are considered special wastes; recover the lubricants and have them disposed of according
to current laws.
l Discharge any remaining pressure before working on the hydraulic and pneumatic circuits.

0-11
 Introduction
l Wait for the oil and water to cool before working on the hydraulic circuits and on the engine.
l During removal and assembly operations for some groups, it is necessary to support the engine; use saw horses, jacks or
blocks suitable for the weight to support and put it in a triangular position to prevent it from flipping over.
l Use a hoist or a crane to lift heavy components. Make sure that metal cables, chains or fibre belts are not worn and that the
hooks are not damaged.
l Always use lifting equipment which can easily support the weight of the units to remove and connect correctly.
l When lifting or supporting a unit or part of the engine, work slowly to prevent dangerous swinging and damaging collisions
with other parts.
l Never work on parts or units hanging on a hoist or crane.
l If removing the screws from units which can fall, always leave two opposite screws for safety purposes; remove these screws
only after having hooked the unit to a lifting device or after having positioned support blocks.
l If fuel or oil drips on the floor during removal or assembly operations, clean it as soon as possible to avoid operators slipping
and possible fires.
l If electrical cables or wires are removed, make sure that they are reassembled with their original fastening, to prevent machine
vibration from damaging them.
l Never insert your hands or fingers to check the alignment between two holes, use soft material pins.
l When installing units or parts, always use the torques indicated in the general tables; the torques indicated in the paragraphs
regarding assembly, are specific torques whose values have been determined by testing and they must absolutely be com-
plied with.
l If installing parts subject to strong vibrations or which turn at high speed, pay particular attention during the final test of the
installation.

0.2.3 - Precautions to use during performance of the work

When disassembling or assembling a part, always follow the general precautions below.
Precautions for disassembly
l After disconnecting the pipes of the hydraulic system and fuel supply system, fit the caps to prevent impurities from entering.
l Use a container with sufficient capacity to recover oil, coolant or fuel.
l Before removing a machine part, check the alignment references which indicate the correct assembly position. Add additional
marks if necessary to avoid incorrect assembly.
l When disassembling the connectors, always hold them tightly to prevent forcing on the electrical cables.
l Mark the electrical cables and pipes if necessary to avoid mixing them up during assembly.
l Check the number and height of the shims and put them in a safe place.
l To lift the engine or parts of it, use equipment that is adequate for the component weight.
l When using eye-bolts to remove engine parts, make sure they are not deformed; completely tighten them and then align the
direction of the eye with the lifting hook.
l Before removing a part, accurately clean the surrounding area and, after removing the part, cover it to prevent dirt and dust
from getting on it.
Precautions for assembly
l Tighten nuts and screws with the specified torques.
l Fit hoses and wiring being careful not to bend or twist them.
l Replace gaskets, O-rings, split pins and safety stop rights with new parts; make sure the tines of the split pin are separated
and bent and thus so they cannot come out of their seats.
l After fitting the snap rings, make sure they are well inserted in their seat.
l When you need to lock threading with sealant, clean the part removing oil and grease, then apply drops of adhesive in order
to uniformly cover the threading.
l To apply sealants, clean the involved surface, remove any residual oil and grease, make sure there are no dents or dirt, then
apply the sealant uniformly making sure it completely surrounds any holes.
l Clean all the parts, remove dirt, oxidation, carbonaceous deposits, burrs and dents.
l Apply a film of engine oil to all moving parts.
l When fitting the electrical system connectors, remove oil, dust or water which can penetrate between the contacts and then
connect them tightly; when required force the connectors until the twin lock catch.
l Lock the flanged couplings uniformly, tightening the screws in a crossed and alternating sequence.

0-12
Introduction
Precautions to observe at the end of disassembly/assembly operations
l If you drained the coolant, screw down the drain cap and add new coolant up to the level. Start the engine and let the coolant
circulated in the cooling system and then top up.
l When the hydraulic equipment has been disassembled, add oil up to the indicated level. Start the engine and let the oil circu-
late in the hydraulic circuits and then top up.
l When the variable displacement pump is removed, connect the drain pipe and fill the casing using the cap provided for this
purpose.
l After having reassembled the joint boxes, cylinder joints and driveshafts, grease completely.

0.2.4 - Lifting instructions

DANGER
Machine units with a weight over 25 kg or with large dimensions, must be supported or removed with a lifting device
and metal cables or polyester belts.

Metal cables - belts

l Use cables or polyester belts suitable for the weight to lift, referring to the following tables:
Table 9
METAL CABLES (standard «S» or «Z» twisted type) POLYESTER BELTS (with slots - simple)
cable Ø mm Capacity (kg) Width (mm) Capacity (kg)
60° 90° 60° 90°

8 650 620 500 25 500 400 860 700

10 1000 1740 1420 50 1000 800 1730 1410
12 1450 2500 2050 62 1250 1000 2160 1760
14 2000 3460 2820 75 1400 1120 2420 1980
16 2,600 4500 3670 100 2000 1600 3460 2820
18 3300 5710 4660 150 2500 2000 4330 3530

The capacity is calculated with a safety coefficient.

l The cables and belts must be connected to the lifting hook in the central part; hooking the cables towards the end may cause
the load to slide during lifting.
l Never hang a heavy load from just one cable; always use two or more symmetrical cables.
DANGER
Suspension from just one cable can cause the load to rotate and cause the cable to come untwisted, or slide from the
winding position; these possibilities can cause serious accidents.

l Do not lift a heavy load when the two ends of the cables form a wide suspension angle. The permitted load (kg) decreases
when the suspension angle increases; the table below, indicates the variation in permitted load (based on the suspension
angle), for two Ø 10 mm diameter cables each with a load capacity of 1000 kg.

0-13
 Introduction

2000
1900

Capacità di carico: kg
1700
2000
1400

1000
1000
500

30° 60° 90° 120° 150°

Angolo di sospensione:

Fig. 1

0.2.5 - Tightening torques

Screws and nuts
DANGER
The specific torques for important parts and the tightening to perform with special procedures, are given within the
individual assembly paragraphs.

The indicated torques refer to screws and nuts fitted without lubrication, possible with threading spread with anaerobic threadlock.
The values indicated refer to tightening on steel or cast iron material; for soft material such as aluminium, copper or plastics, plated
or panels, the torques need to be reduced by 50%.
See para. 0.3 - Tightening torques - page 0-20
Unions
The indicated torques refer to fitting unions on any material.
Table 10
MET- Unions with straight Unions with “T” ends Unions with “L” ends Unions with 90° ends
RIC ends

Thread Wrench Torque Nm Wrench Torque Nm Wrench Torque Nm Wrench Torque Nm

±10% ±10% ±10% ±10%
M10x1.25 17 14 14 14 14 14 14 14
19 14 17 14 17 14
M12x1.25 19 30 17 30 17 30 17 30
M14x1.5 19 40 19 40 19 40 19 40
M16x1.5 22 48 22 48 22 48 22 48
M18x1.5 24 58 24 58 24 58 24 58
M20x1.5 27 65 27 65 27 65 27 65
M22x1.5 30 73 30 73 30 73 30 73
M26x1.5 36 95 36 95 36 95 36 95
M27x2 36 100 36 100 36 100 36 100
M33x2 41 160 41 160 41 160 41 160
M42x2 50 250 50 250 50 250 50 250
M48x2 60 305 60 305 60 305 60 305

0-14
Introduction
G 1/8” 17 13 14 13 14 13 14 13
19 13
G 1/4” 19 37 19 37 19 37 19 37
22 37
G 3/8” 24 53 24 53 24 53 24 53
G 1/2” 27 73 27 73 27 73 27 73
30 73
G 3/4” 36 100 36 100 36 100 36 100
G 1” 41 160 41 160 41 160 41 160
46 160
G 1 1/4” 50 250 50 250 50 250 50 250
G 1 1/2” 60 305 60 305 60 305 60 305
Plugs
Table 11
Hexagonal head plugs Socket head threaded plugs

Thread Wrench Torque Nm ±10% Wrench Torque Nm ±10%

MET- M6x1 10 10 - -
RIC M8x1 13 12 - -
M10x1 13 14 5 14
M10x1.25 13 14 - -
M10x1.5 13 14 - -
M12x1.25 17 30 - -
M12x1.5 17 30 6 30
M12x1.75 17 30 - -
M14x1.5 19 40 6 40
M14x2 19 40 - -
M16x1.5 22 48 8 48
M16x2 22 48 - -
M18x1.5 17 58 10 58
M18x2.5 17 58 - -
M20x1.5 19 65 - -
M22x1.5 - - 12 73
M24x1.5 22 80 12 80
M24x2 22 80 - -
M27x2 22 100 - -
M28x1.5 - - 17 110
M30x1.5 22 130 - -
M32x1.5 - - 19 150
M35x1.5 - - 22 180
M40x1.5 - - 24 225
G 1/8” 14 13 - -
G 1/4” 19 37 - -
G 3/8” 22 53 - -
G 1/2” 19 73 - -
G 5/8” 22 85 - -
G 3/4” 22 100 - -
G 1” 22 160 - -

0-15
 Introduction
Unions with seal at 37°
Table 12

Thread Wrench Torque Nm ±10%

7/16” - 20 14 13
1/2” - 20 16 19
9/16” - 18 17 28
3/4” - 16 22 47
7/8” - 14 27 76
1 1/16” - 12 32 110
36 110
1 3/16” - 12 36 138
1 5/16” - 12 38 155
1 5/8” - 12 50 215
1 7/8” - 12 60 290
2 1/2” - 12 75 345
Union for pipes with eye mounting
These torques refer to tightening of unions with new copper sealing washers.
Table 13
One-way pipe unions Three-way pipe unions Four-way pipe unions

Thread Wrench Torque Nm Wrench Torque Nm Wrench Torque Nm

±10% ±10% ±10%
M8x1 - 12 14 - -
M8x1.25 13 14
M10x1 - - 14 20 14 20
M10x1.25 13 20 - - - -
M12x1.25 17 30 - - - -
M12x1.5 - - 17 30 17 30
M14x1.5 19 40 19 40 19 40
M16x1.5 22 48 22 48 22 48
M18x1.5 22 58 24 58 24 58
M20x1.5 27 65 - - - -
M22x1.5 - - 27 73 27 73
M24x1.5 32 80 - - - -
M26x1.5 - - 32 95 32 95
M28x1.5 36 110 - - - -
M30x1.5 - - 36 130 36 130
M35x2 41 180 - - - -
M38x1.5 - - 46 200 46 200
M42x2 50 250 - - - -
M45x1.5 - - 55 280 55 280
M50x2 60 320 - - - -
M52x1.5 - - 60 320 60 320
M65x2 - - 75 450 75 450

0-16
Introduction
0.2.6 - Thread lock, adhesive, sealant and lubrication materials
Table 14
FUNCTION DESIGNATION DESCRIPTION
THREAD LOCK Loctite 222 Colour: opaque fluorescent Anaerobic product suitable for weak thread locking of set, adjust-
purple ing and precision screws and nuts. It must be used after having
removed all traces of lubricant with a specific activator.
Loctite 242 Colour: fluorescent blue Anaerobic product suitable for preventing loosening of all types
of screws and nuts and to replace mechanical locks. Used for
medium resistance thread locking. It must be used after having
removed all traces of lubricant with a specific activator.
Loctite 243 Colour: opaque fluorescent Alternative product to 242 which, since it is oil compatible, it does
blue not require the activation of slightly lubricated surfaces.
Loctite 270 Colour: fluorescent green Anaerobic product for extra strength locking of threaded parts,
bolts and stud bolts which normally do not need to be removed.
Removal of parts may require heating to around 80°C. It must be
used after having removed all traces of lubricant with a specific
activator.
DEGREASING Loctite 703 Product for degreasing and cleaning parts before application of
AGENTS AND AC- Loctite anaerobic products; after it is allowed to dry, thread locks
TIVATORS will cure uniformly
Loctite 747 Specific product for treatment of surfaces not very active towards
anaerobic products with slow curing (series 5 and 6). It can also
be used to accelerate curing in low temperatures or if there is a
lot of backlash between parts.
SEALANTS (for Loctite 510 Colour: Red Very fast anaerobic product suitable for sealing between metallic
surfaces and surfaces, can be used to eliminate traditional gaskets, since it can
unions) fills gaps up to 0.4 mm. Since it does not settle, the torque does
not need to be reset.
Loctite 542 Colour: Brown Anaerobic product used as a liquid gasket for sealing threaded
unions with a measurement under 3/4” gas; it cures quickly and
the parts can be disassembled with normal tools.
Loctite 554 Colour: Red Anaerobic sealant and locking product used to seal cooling and
industrial fluid circuits. It cures slowly and is also suitable for use
on non-ferrous alloys
Loctite 572 Colour: White Anaerobic sealant and locking product used to seal pipes and
threaded unions up to a diameter of 2”. It cures very slowly on
most metallic surfaces.
Loctite 573 Colour: green Thixotropic anaerobic product suitable for sealing metal surfaces.
It ensures total contact between the surfaces with a maximum
backlash of 0.10 mm even filling microspaces due to planarity
imperfections. It cures very slowly on most metallic surfaces and
requires the use of an activator.
Loctite 576 Colour: brown Anaerobic product used as a liquid gasket for sealing large di-
mension threaded unions (up to 2”). It cures very slowly and is
also suitable for non-ferrous alloys and parts which require later
removal.
INSTANT ADHE- Loctite 401 Colour: colourless Instant cyanoacrylate adhesive suitable for bonding acid and
SIVES porous surfaces of a wide range of materials including ceramic,
wood, rubber and plastic (with the exception of polyolefins). It
cures in just a few seconds due to the effect of the atmospheric
humidity on the surfaces to bond, regardless of the ambient con-
ditions.
Loctite 495 Colour: colourless Instant cyanoacrylate adhesive suitable for bonding rubber and
plastics even in different combinations, including metals.

0-17
 Introduction
SILICON SEAL- Silastic 738 (Dow Corning) colour: milky Single compound silicon adhesive/sealant, not settling, ready for
ANTS white use. It cures into a solid rubbery consistency when it reacts with
humidity in the air and makes it possible to eliminate traditional
gaskets on elastic joints covering backlashes even greater than
a millimetre.
Dirko Transparent Colour: transparent Single compound silicon adhesive/sealant, settling, ready for
use. It cures quickly forming a rubbery solid when curing starts
due to moisture in the air and it is resistant to high temperatures.
POLYURETHANE Betaseal HV3 (Gurit Essex) Colour: Black Polyurethane prepolymer based adhesive and sealant which is
SEALANTS highly viscose, suitable for highly resistant permanent elastic
bonding. It cures slowly and is used for bonding glass on struc-
tures, metallic protection meshes, plates, etc., after degreasing
with a primer.
RETAINERS Loctite 601 Colour: fluorescent green Fast curing anaerobic product with high mechanical resistance. It
is suitable for sealing and retaining freely moving cylindrical cou-
plings with backlash up to 0.10 mm, for fastening shafts on rotors,
gears, bearings, pulleys, bushes, main bearings, etc.
Loctite 638 Colour: fluorescent green Fast curing anaerobic structural adhesive with very high me-
chanical resistance; suitable for fastening non-ferrous alloy freely
moving cylindrical couplings.
Loctite 648 Colour: fluorescent green Fast curing anaerobic structural adhesive with high mechanical
resistance; suitable for retaining freely moving cylindrical cou-
plings, permanent retaining of threaded parts, sealing of cooling
systems, fastening of bearings, etc. It is an alternative product to
Loctite 601 for use at higher operating temperatures.
Loctite 986/AVX Colour: fluorescent red Anaerobic sealant and retaining product for cylindrical couplings
between metallic parts. It cures slowly and offers a good mechan-
ical and temperature resistance as well as excellent resistance to
chemical pressure. It must be used after activation of the parts.
LUBRICANTS Grease (NLGI 2 EP ASTM D217: 265/295) Multi-purpose lithium grease used to lubricate gaskets, prevent
oxidation and make assembly operations easier.
Molikote (Dow Corning) Anti-wear lubricant compound, containing Molybdenum disul-
phide, used pure or diluted with a percentage of engine oil during
engine main bearing assembly phases.
Vaseline Neutral PH compound used to protect the poles and terminals of
batteries from oxidation and corrosion.
10W - 30 engine oil Used to dilute Molikote anti-wear lubricant during engine assem-
bly phases.

0-18
Introduction
0.2.7 - Unit of measurement conversion table
Conversion from imperial to metric units
Table 15
inch x 25.40 = mm
foot x 0.305 =m
yard x 0.914
Eng.miles x 1.609 = km
Sq.in. x 6.452 = cm²
Sq.ft. x 0.093 = m²
Sq.yard x 0.835
Cu.in. x 16.39 = cm³
Cu.ft. x 28.36 = m³
Cu.yard x 0.763
Imp.gall. x 4.547 = litres
US gall. x 3.785
pint x 0.568
quart x 1.137
US.gpm x 3.785 = ,/min
oz. x 0.028 = kg
lb. x 0.454
lb.ft. x 0.139 = kgm
lb.in. x 17.87 = kg/m
psi x 0.070 = kg/cm²
lb./Imp.gall x 0.100 = kg/,
lb./US.gall x 0.120
lb./cu.ft. x 16.21 = kg/m³
lb.ft. x 1.356 = Nm
psi x 1.379 = bar
Conversion from metric to imperial units
Table 16
mm x 0.0394 = inch
m x 3.281 = foot
m x 1.094 = yard
km x 0.622 = Eng.miles
cm² x 0.155 = Sq.in.
m² x 10,77 = Sq.ft.
m² x 1,197 = Sq.yard
cm³ x 0.061 = Cu.in.
m³ x 0,035 = Cu.ft
m³ x 1,311 = Cu.yard
litres x 0.220 = Imp.gall.
litres x 0.264 = US gall.
litres x 1.762 = pint
litres x 0.880 = quart
,/min x 0.2642 = US.gpm
kg x 35.25 = oz.
kg x 2.203 = lb.
kgm x 7.233 = lb.ft.
kg/m x 0.056 = lb.in.
kg/cm² x 14.22 = psi
kg/, x 10.00 = lb./Imp.gal.
kg/, x 8.333 = lb./US.gal.
kg/m³ x 0.062 = lb./cu.ft.
Nm x 0.737 = lb.ft.
bar x 14.503 = psi

0-19
 Introduction
0.3 - Tightening torques
0.3.1 - General information
This chapter specifies the tightening torque values and resulting tension forces for tightening standard fastener hardware with ISO
metric threads.
It is not applicable for components with special self-locking systems, such as micro capsules, nylon lock rings etc.
0.3.2 - Tightening classes and categories
Four different tightening torque categories are applicable (1, 2, 3, 4), for three different joint classes (A, B, C), in accordance with
procedure GSPO PSM 13.0.0.
Table 17
Tightening categories
1 2 3 4
Joint classes A Torque/angle con- Torque control tight-
trol tightening with ening with manual
manual or auto- or automatic tools
matic tools, subject subject to periodic
to monitoring and/ inspection and used
or with certification, by trained personnel
and used by trained
personnel
B Torque/angle con- Torque control tight- Torque control tight-
trol tightening with ening with manual ening with manual
manual or auto- or automatic tools or automatic tools
matic tools, subject subject to periodic subject to periodic
to monitoring and/ inspection and used inspection
or with certification, by trained personnel
and used by trained
personnel
C Torque control tight- Manual tightening
ening with manual with suitable tools,
or automatic tools with no specified
subject to periodic torque value
inspection
Tolerances
Table 18
Tightening class Tolerance Application
1 ± 7.5% very difficult
2 ± 15% difficult
3 ± 30% common
4 None no specification

0.3.3 - Coefficient of friction

The friction coefficients used to calculate tightening torques have been defined in relation to the surface treatment applied.
Table 19
Surface treatment Coefficient of friction Reference symbol
With black post-treatment (Geoblack) μ 0.10 VI
Anti-seize phosphating μ 0.14 VII
Electrolytic zinc plating µ 0.17% II

0-20
Introduction
0.3.4 - Tightening torques
The method used to calculate tightening torques (Cs) and traction forces (F0) is compliant with the standard VDI 2230-1.
The coefficient of safety applied is 0.70 of the yield strength of the material.
Tightening torques for 4.8 UNI EN ISO 898-1 screws
Table 20
Thread Category Nominal tightening torques
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
4x0.70 1 0.9 1.1 1.2
2 0.8 1.0 1.1
3 0.7 0.9 1.0
5x0.80 1 1.8 2.2 2.4
2 1.7 2.0 2.3
3 1.5 1.8 2.0
6x1.00 1 3.0 3.6 4.0
2 2.8 3.4 3.8
3 2.5 3.0 3.3
7x1.00 1 4.9 6.0 6.7
2 4.6 5.6 6.3
3 4.0 5.0 5.6
8x1.00 1 7.8 9.7 10.9
2 7.3 9.1 10.2
3 6.5 8.0 9.0
8x1.25 1 7.3 9.0 10.0
2 6.9 8.4 9.4
3 6.1 7.4 8.3
10x1.00 1 15.9 20.0 22.5
2 14.9 18.7 21.1
3 13.2 16.6 18.6
10x1.25 1 15.2 18.9 21.2
2 14.2 17.7 19.8
3 12.6 15.6 17.5
10x1.50 1 14.4 17.8 19.9
2 13.5 16.7 18.6
3 12.0 14.7 16.4
12X1.25 1 27 34 38
2 25 31 35
3 22 28 31
12x1.50 1 26 32 36
2 24 30 34
3 21 27 30
12x1.75 1 25 31 34
2 23 29 32
3 20 25 28
14x1.50 1 42 53 59
2 40 49 56
3 35 44 49
14x2.00 1 39 49 54
2 37 46 51
3 33 40 45
16x1.50 1 65 82 92
2 61 76 86
3 54 67 76
16x2.00 1 61 76 85
2 57 71 80
3 51 63 70
18x1.50 1 94 119 134
2 88 111 125
3 78 98 111
18x2.50 1 85 105 117
2 79 98 109
3 70 87 97

0-21
 Introduction
Thread Category Nominal tightening torques
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
20x1.50 1 130 166 187
2 122 155 175
3 108 137 155
20x2.00 1 125 157 177
2 117 147 165
3 103 130 146
20x2.50 1 119 148 166
2 112 139 155
3 99 123 137
22x1.50 1 177 225 255
2 165 210 238
3 146 186 211
22x2.50 1 163 204 229
2 153 191 214
3 135 169 189
24x2.00 1 222 280 317
2 207 262 296
3 183 232 262
24x3.00 1 206 256 286
2 192 239 268
3 170 211 237
27x3.00 1 301 376 422
2 281 351 395
3 249 311 349
Tightening torques for 5.8 UNI EN ISO 898-1 screws and 5 UNI EN ISO 898-1 nuts
Table 21
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
4x0.70 1 1.1 1.4 1.5
2 1.1 1.3 1.4
3 0.9 1.1 1.3
5x0.80 1 2.2 2.7 3.0
2 2.1 2.5 2.8
3 1.8 2.2 2.5
6x1.00 1 3.7 4.5 5.0
2 3.5 4.2 4.7
3 3.1 3.7 4.2
7x1.00 1 6.1 7.5 8.4
2 5.7 7.0 7.9
3 5.1 6.2 7.0
8x1.00 1 9.8 12.1 13.6
2 9.1 11.3 12.7
3 8.1 10.0 11.2
8x1.25 1 9.2 11.3 12.5
2 8.6 10.5 11.7
3 7.6 9.3 10.4
10x1.00 1 19.9 25.0 28.2
2 18.6 23.4 26.3
3 16.5 20.7 23.3
10x1.25 1 19.0 23.6 26.5
2 17.8 22.1 24.8
3 15.7 19.6 21.9
10x1.50 1 18.1 22.3 24.9
2 16.9 20.8 23.2
3 15.0 18.4 20.6
12X1.25 1 34 42 47
2 31 39 44
3 28 35 39

0-22
Introduction
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
12x1.50 1 32 40 45
2 30 37 42
3 27 33 37
12x1.75 1 31 38 43
2 29 36 40
3 26 32 35
14x1.50 1 53 66 74
2 49 62 70
3 44 55 61
14x2.00 1 49 61 68
2 46 57 64
3 41 50 56
16x1.50 1 81 102 115
2 76 95 107
3 67 84 95
16x2.00 1 77 95 107
2 72 89 100
3 63 79 88
18x1.50 1 117 148 168
2 110 139 157
3 97 123 139
18x2.50 1 106 131 146
2 99 122 137
3 88 108 121
20x1.50 1 163 207 234
2 152 194 219
3 135 171 194
20x2.00 1 156 196 221
2 146 183 207
3 129 162 183
20x2.50 1 149 185 208
2 140 173 194
3 123 153 172
22x1.50 1 221 281 319
2 206 263 298
3 183 232 264
22x2.50 1 204 255 286
2 191 238 268
3 169 211 237
24x2.00 1 277 350 396
2 259 327 370
3 229 290 327
24x3.00 1 257 319 358
2 240 299 335
3 213 264 296
27x3.00 1 376 470 528
2 351 439 493
3 311 388 436

0-23
 Introduction
Tightening torques for 6.8 UNI EN ISO 898-1 screws and 6 UNI EN ISO 898-1 nuts
Table 22
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
4x0.70 1 1.4 1.7 1.8
2 1.3 1.5 1.7
3 1.1 1.4 1.5
5x0.80 1 2.7 3.3 3.6
2 2.5 3.0 3.4
3 2.2 2.7 3.0
6x1.00 1 4.5 5.4 6.0
2 4.2 5.1 5.7
3 3.7 4.5 5.0
7x1.00 1 7.3 9.0 10.1
2 6.9 8.4 9.4
3 6.1 7.5 8.3
8x1.00 1 11.7 14.6 16.3
2 10.9 13.6 15.3
3 9.7 12.0 13.5
8x1.25 1 11.0 13.5 15.1
2 10.3 12.6 14.1
3 9.1 11.2 12.5
10x1.00 1 23.9 30.0 33.8
2 22.3 28.1 31.6
3 19.8 24.8 28.0
10x1.25 1 22.8 28.4 31.8
2 21.3 26.5 29.7
3 18.9 23.5 26.3
10x1.50 1 21.7 26.7 29.8
2 20.3 25.0 27.9
3 18.0 22.1 24.7
12X1.25 1 40 50 57
2 38 47 53
3 33 42 47
12x1.50 1 39 48 54
2 36 45 50
3 32 40 45
12x1.75 1 37 46 51
2 35 43 48
3 31 38 42
14x1.50 1 63 79 89
2 59 74 83
3 52 66 74
14x2.00 1 59 73 82
2 55 68 76
3 49 60 67
16x1.50 1 97 122 138
2 91 114 129
3 80 101 114
16x2.00 1 92 114 128
2 86 107 120
3 76 94 106
18x1.50 1 141 178 201
2 132 166 188
3 116 147 166
18x2.50 1 127 157 176
2 119 147 164
3 105 130 145
20x1.50 1 196 248 281
2 183 232 263
3 162 205 232

0-24
Introduction
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
20x2.00 1 187 235 265
2 175 220 248
3 155 195 219
20x2.50 1 179 223 249
2 167 208 233
3 148 184 206
22x1.50 1 265 337 382
2 248 315 358
3 219 279 316
22x2.50 1 245 306 343
2 229 286 321
3 203 253 284
24x2.00 1 332 420 475
2 311 393 444
3 275 348 393
24x3.00 1 309 383 429
2 288 358 401
3 255 317 355
27x3.00 1 451 564 633
2 422 527 592
3 373 466 524

Tightening torques for 8.8 UNI EN ISO 898-1 screws and 8 UNI EN ISO 898-1 nuts
Table 23
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
4x0.70 1 1.8 2.2 2.4
2 1.7 2.1 2.3
3 1.5 1.8 2.0
5x0.80 1 3.5 4.3 4.8
2 3.3 4.1 4.5
3 2.9 3.6 4.0
6x1.00 1 5.9 7.3 8.1
2 5.5 6.8 7.5
3 4.9 6.0 6.7
7x1.00 1 9.8 12.1 13.5
2 9.1 11.3 12.6
3 8.1 10.0 11.1
8x1.00 1 15.6 19.4 21.8
2 14.6 18.2 20.3
3 12.9 16.1 18.0
8x1.25 1 14.7 18.0 20.1
2 13.7 16.8 18.8
3 12.1 14.9 16.6
10x1.00 1 31.9 40.0 45.1
2 29.8 37.4 42.2
3 26.3 33.1 37.3
10x1.25 1 30.4 37.8 42.4
2 28.4 35.4 39.6
3 25.2 31.3 35.1
10x1.50 1 29.0 35.6 39.8
2 27.1 33.3 37.2
3 23.9 29.5 32.9
12X1.25 1 54 67 76
2 50 63 71
3 44 56 63
12x1.50 1 52 64 72
2 48 60 67
3 43 53 59

0-25
 Introduction
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
12x1.75 1 50 61 68
2 46 57 64
3 41 51 56
14x1.50 1 85 106 119
2 79 99 111
3 70 88 98
14x2.00 1 79 97 109
2 74 91 102
3 65 81 90
16x1.50 1 130 163 184
2 121 153 172
3 107 135 152
16x2.00 1 122 152 170
2 114 142 159
3 101 126 141
18x1.50 1 188 237 268
2 175 222 251
3 155 196 222
18x2.50 1 170 210 234
2 159 196 219
3 140 173 194
20x1.50 1 261 331 375
2 244 310 350
3 216 274 310
20x2.00 1 250 314 354
2 234 293 330
3 207 260 292
20x2.50 1 239 297 332
2 223 277 311
3 197 245 275
22x1.50 1 353 450 510
2 330 421 477
3 292 372 422
22x2.50 1 327 408 458
2 305 381 428
3 270 337 379
24x2.00 1 443 560 633
2 414 524 592
3 366 463 524
24x3.00 1 411 511 573
2 385 478 535
3 340 423 473
27x3.00 1 601 752 844
2 562 703 789
3 497 622 698

0-26
Introduction
Tightening torques for 10.9 UNI EN ISO 898-1 screws and 10 UNI EN ISO 898-1 nuts
Table 24
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
4x0.70 1 2.6 3.2 3.6
2 2.5 3.0 3.4
3 2.2 2.7 3.0
5x0.80 1 5.2 6.4 7.1
2 4.9 6.0 6.6
3 4.3 5.3 5.9
6x1.00 1 8.7 10.7 11.8
2 8.1 10.0 11.1
3 7.2 8.8 9.8
7x1.00 1 14.4 17.7 19.8
2 13.4 16.5 18.5
3 11.9 14.6 16.3
8x1.00 1 22.9 28.5 32.0
2 21.4 26.7 29.9
3 19.0 23.6 26.4
8x1.25 1 21.5 26.5 29.5
2 20.1 24.7 27.6
3 17.8 21.9 24.4
10x1.00 1 46.8 58.8 66.2
2 43.7 55.0 61.9
3 38.7 48.6 54.8
10x1.25 1 44.7 55.6 62.3
2 41.8 51.9 58.2
3 36.9 46.0 51.5
10x1.50 1 42.5 52.4 58.4
2 39.7 48.9 54.6
3 35.2 43.3 48.3
12X1.25 1 79 99 111
2 74 92 104
3 65 82 92
12x1.50 1 76 94 106
2 71 88 99
3 63 78 87
12x1.75 1 73 90 100
2 68 84 94
3 60 74 83
14x1.50 1 124 155 175
2 116 145 163
3 103 129 144
14x2.00 1 116 143 160
2 108 134 149
3 96 118 132
16x1.50 1 190 240 270
2 178 224 253
3 157 198 223
16x2.00 1 180 223 250
2 168 209 234
3 149 185 207
18x1.50 1 276 349 394
2 258 326 368
3 228 288 326
18x2.50 1 249 308 344
2 233 288 321
3 206 254 284
20x1.50 1 383 486 551
2 358 455 515
3 317 402 455

0-27
 Introduction
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
20x2.00 1 367 461 519
2 343 431 485
3 304 381 429
20x2.50 1 351 436 488
2 328 407 456
3 290 360 404
22x1.50 1 519 661 749
2 485 618 700
3 429 546 619
22x2.50 1 480 599 673
2 448 560 629
3 397 495 556
24x2.00 1 651 823 930
2 608 769 869
3 538 681 769
24x3.00 1 604 751 841
2 565 702 786
3 500 621 695
27x3.00 1 883 1104 1240
2 826 1032 1159
3 730 913 1025

Tightening torques for 12.9 UNI EN ISO 898-1 screws and 12 UNI EN ISO 898-1 nuts
Table 25
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
4x0.70 1 3.1 3.8 4.2
2 2.9 3.5 3.9
3 2.6 3.1 3.5
5x0.80 1 6.1 7.5 8.3
2 5.7 7.0 7.8
3 5.0 6.2 6.9
6x1.00 1 10.2 12.5 13.9
2 9.5 11.7 13.0
3 8.4 10.3 11.5
7x1.00 1 16.8 20.7 23.1
2 15.7 19.4 21.6
3 13.9 17.1 19.1
8x1.00 1 26.8 33.4 37.4
2 25.1 31.2 35.0
3 22.2 27.6 30.9
8x1.25 1 25.2 31.0 34.5
2 23.6 28.9 32.3
3 20.8 25.6 28.5
10x1.00 1 54.8 68.8 77.5
2 51.2 64.3 72.5
3 45.3 56.9 64.1
10x1.25 1 52.3 65.0 72.9
2 48.9 60.8 68.1
3 43.2 53.8 60.3
10x1.50 1 49.8 61.3 68.3
2 46.5 57.3 63.9
3 41.1 50.7 56.5
12X1.25 1 92 116 130
2 86 108 122
3 76 96 108
12x1.50 1 89 110 124
2 83 103 115
3 73 91 102

0-28
Introduction
Thread Category Coefficient of friction
µ 0,10 (VI) μ 0.14 (VII) μ 0.17 (II)
Cs* nom (Nm) Cs* nom (Nm) Cs* nom (Nm)
12x1.75 1 85 105 117
2 80 98 110
3 70 87 97
14x1.50 1 145 182 204
2 136 170 191
3 120 150 169
14x2.00 1 136 167 187
2 127 157 175
3 112 138 155
16x1.50 1 223 280 316
2 208 262 296
3 184 232 261
16x2.00 1 210 262 293
2 197 244 274
3 174 216 242
18x1.50 1 323 408 461
2 302 381 431
3 267 337 381
18x2.50 1 291 360 402
2 272 337 376
3 241 298 333
20x1.50 1 448 569 644
2 419 532 602
3 371 471 533
20x2.00 1 430 540 608
2 402 504 568
3 355 446 502
20x2.50 1 410 510 571
2 384 477 534
3 339 422 473
22x1.50 1 607 773 876
2 567 723 819
3 502 639 725
22x2.50 1 561 701 787
2 525 655 736
3 464 580 651
24x2.00 1 762 963 1088
2 712 900 1017
3 630 797 900
24x3.00 1 707 878 984
2 661 821 920
3 585 726 814
27x3.00 1 1034 1292 1451
2 966 1208 1357
3 855 1068 1200

0-29
 Introduction
0.4 - Tightening torques for nuts and bolts of electrical connec-
tions
Tighten all nuts and bolts of wiring harnesses, leaving the battery negative cable until last.
l For closing torque, where not specified use class 9 N.93810

0.4.1 - Standard tightening torques

Table 26
General table
Pitch Torque
6x1 5.5
8x1 14.4
8x1.25 13.4
10x1 29.5
10x1.5 26.5
12x1.25 50
12x1.75 46
14x1.5 79
Table 27
General table
Pitch Torque
14x2 73
16x1.5 121
16x2 113
Tolerance ±20%

0.4.2 - Battery terminal tightening torques

Fig. 2

0-30
Introduction
0.4.3 - Starter motor tightening torques

Fig. 3

0.4.4 - Alternator tightening torques

Fig. 4

0-31
 Introduction
0.5 - Wheel rim to hub screws and nuts tightening torques
DANGER
These tightening torques are not applicable to special self-locking fixing systems.

Table 28
p/n Description Class Tightening torque Tolerance
2.0122.511.6 Screw M14x1.5 8.8 120 Nm (12.2 kgm) ± 5%
2.0122.615.2 Screw M16x1.5 8.8 184.5 Nm (18.8 kgm) ± 5%
2.0399.235.6 Screw M16x1.5 10.9 271 Nm (27.6 kgm) ± 5%
2.0399.129.6 Screw M18x1.5 10.9 395 Nm (40.3 kgm) ± 5%
2.0399.140.6 Screw M18x1.5 10.9 395 Nm (40.3 kgm) ± 5%
2.0399.003.6/10 Screw M20x1.5 10.9 550 Nm (56 kgm) ± 5%
2.1011.308.6 Nut M14x1.5 8 120 Nm (12.2 kgm) ± 5%
01101323 Nut M18x1.5 10 395 Nm (40.3 kgm) ± 5%
2.1099.175.6 Nut M18x1.5 10 395 Nm (40.3 kgm) ± 5%
0.012.8307.0 Nut M20x1.5 10 550 Nm (56 kgm) ± 5%
2.1019.176.6 Nut M20x1.5 10 550 Nm (56 kgm) ± 5%
2.1099.083.0/20 Nut M20x1.5 10 550 Nm (56 kgm) ± 5%
01104070 Nut M20x1.5 10 550 Nm (56 kgm) ± 5%
2.1099.085.0/20 Nut M22x1.5 10 745 Nm (76 kgm) ± 5%
2.1099.177.6 Nut M22x1.5 10 650 Nm (66.2 kgm) ± 5%

0-32
Introduction
0.6 - Installation of solenoid valves and cartridge valves
0.6.1 - Installation
1. Remove packaging and protective coverings from solenoid valve bodies and cartridge valves only at the moment of installa-
tion, so as to minimize the risk of contamination.
2. Lubricate all O-rings fitted to solenoid valves and valve cartridges using a suitable mineral oil or grease compatible with AK-
ROS oil.
Contamination of lubricating fluid must be no higher than level 18/15, as specified in ISO 4406.
For further information on contamination, refer to SAME specification 92349
Containers of lubricating fluids must be closed and fitted with the specific dispensing nozzle.
The use of open containers or brushes is not permissible.
3. Screw the solenoid valves and cartridge valves into the relative seats by hand, engaging at least one turn of the thread.
Power drivers must not be used at this stage.
4. Complete the tightening operation, applying torques as specified in the table of headings 3 and 4.

0.6.2 - Solenoid valve tightening torques

Table 29
Type of solenoid valve Threads p/n Tightening torque
A (Nm) B (Nm)
7/8”-14 UNF 2.3719.750.0/XX 15-20 5-8
2.3729.410.0/XX
2.3729.610.0/XX

Fig. 5
7/8”-14 UNF 2.3729.250.0/XX 15-20 5±0.5
2.3729.270.0/XX
2.3729.290.0/XX
2.3729.300.0/XX
2.3729.697.0/XX
2.3729.600.0/XX 15-20 5-8
M18X1.5 2.3729.330.0/XX 15-20 5±0.5
2.3729.340.0/XX
2.3729.400.0/XX
Fig. 6
7/8”-14 UNF 2.3729.310.0/XX 15-20 5±0.5
2.3729.698.0/XX
2.3729.718.0/XX

Fig. 7
3/4”-16 UNF 2.3719.510.0/XX 15-20 20-25

Fig. 8

0-33
 Introduction
Type of solenoid valve Threads p/n Tightening torque
A (Nm) B (Nm)
M33X2 2.3729.709.0/XX 45-50 5-8

Fig. 9

0.6.3 - Cartridge valve tightening torques

Table 30
Type of valve Threads p/n Tightening torque
A (Nm)
M18X1.5 2.3729.686.0/XX 35-40
2.3719.760.0/XX

Fig. 10
3/4”-16 UNF 2.3729.691.0/XX 35-40

Fig. 11
M22X1.5 2.3729.692.0/XX 45-50
M18X1.5 2.3719.630.0/XX 35-40

Fig. 12
7/8”-14 UNF 0.006.6161.4/XX 45-50
0.015.5426.4/XX 45-50

Fig. 13

0-34
Introduction
0.7 - Installation of quick couplers
0.7.1 - Table of tightening torques
Table 31
Type of quick coupler Threads p/n Tightening
torque A (Nm)
M22X1.5 0.010.8473.0/XX 60-66

Fig. 14
M22X1.5 0.010.9832.0/XX 60-66

Fig. 15

0-35
 Introduction

PAGE LEFT INTENTIONALLY BLANK

0-36
10 - Technical
characteristics

10-1
 Technical characteristics
10.1 - Engine
10.1.1 - Components of the 2012 2V UPS engine
Engine type
These instructions concern the following engine types:
l TCD 2012 L04 2V
l TCD 2012 L06 2V
l TCD 2013 L04 2V
l TCD 2013 L06 2V
l TD 2012 L04 2V m
l TCD 2012 L04 2V m
l TCD 2013 L04 2V m
Table 32
TCD
T Turbocharger
C Turbocharging air radiator
D Diesel
Table 33
2012/2013
2012 Series
2013 Series
Table 34
L04/L06
L In series
04 Number of cylinders
06 Number of cylinders
Table 35
2V
2V Number of valves
Table 36
m
m Mechanical injection system
Nozzle line pump
Exhaust gas emission regulation
The engines in this manual comply with the following regulations on exhaust gas emissions:
l EU Level IIIA
l USA EPA Tier III
Plate
Model plate
The engine type A, the engine number B and the data concerning the power are
engraved on the plate.
Each spare part order must include the engine type and number.

Fig. 16

10-2
Technical characteristics
Location of the model plate
Plate C is fixed on the cylinder head cowling or on the crankcase.

Fig. 17

Engine number
The engine number D is punched on the crankcase (arrow) and on the model
plate.

Fig. 18

Cylinder numbering
Cylinder layout
The cylinders are numbered progressively from (1) from the flywheel side.
Direction of rotation
View from flywheel side.
Left hand rotation: Anticlockwise.
Engine sides
View from flywheel side.

Fig. 19

10-3
 Technical characteristics
Illustration of the 2012 2V UPS engine
View from right hand side (example)

Fig. 20
Key:
1. Crankcase breather
2. Lubricant oil filler cap
3. Injection pump
4. Lubricant oil dipstick
5. Lubricant oil radiator
6. Lubricant oil cartridge filter
7. Lubricant oil drain screw
8. Fuel cartridge filter
9. V-belt
10. Alternator

10-4
Technical characteristics
View from left hand side (example)

Fig. 21
Key:
1. Combustion air intake
2. Coolant outlet
3. Coolant inlet
4. Supply air radiator connections
5. Exhaust gas outlet
6. Starter

10-5
 Technical characteristics
Lubrication oil system

Fig. 22
Key: (Example)
1. Lubricant oil sump
2. Lubricant oil pump
3. Pressure relief valve TD/TCD 2013
4. Lubricant oil radiator
5. Check valve TD/TCD 2012
6. Bypass valve
7. Bypass valve
8. Pressure regulator valve
9. Lubricant oil filter
10. Primary lubricant oil channel
11. Piston cooling nozzle
12. Rocker
13. Exhaust gas recirculation with internal connection TCD 2012/2013L06
14. Turbocharger
15. Air compressor

10-6
Technical characteristics
Coolant diagram (example)

Fig. 23
Key: (Example)
1. Cooler
2. Coolant inlet
3. Coolant pump
4. Recirculated portion of the coolant to the lubricant oil cooler
5. Lubricant oil radiator
6. Coolant feed line for engine cooling
7. Cylinder sleeve/head cooling
8. Fitting for cab heater
9. Heat exchanger
10. Return line
11. Coolant return to the thermostat
12. Coolant outlet
13. Compensation line
14. Breather line

10-7
 Technical characteristics
10.1.2 - Test data and settings
T00 81
1. Cylinder and side view
4-cylinder
A = curve side B = control side
A

1 2 3 4

© 39619-1

Fig. 24

T01 63
1. Valve clearance setting
4-cylinder
Firing order: 1 - 3 - 4 - 2
Table 37

Valves Cylinders
set 1 3 4 2
at overlap 4 2 1 3
angle
1 2 3 4

NOTE
“Valve overlap” means that while the intake valve starts to
© 46608-0
open the exhaust valve starts to close. Fig. 25

T01 63
Valve clearance setting
6 cylinders
Firing order: 1 - 5 - 3 - 6 - 2 - 4
Table 38
Valves Cylinders
set 1 5 3 6 2 4
at overlap 6 2 4 1 5 3
angle

NOTE
“Valve overlap” means that while the intake valve starts to open the exhaust valve starts to close.

10-8
Technical characteristics
10.1.3 - Tightening requirements 2012 2V UPS engine
Table 39
Designation Screw type Indications/notes Tightening Retightening
value/pre- value
load value
Clamping support on engine Nut screw 70 Nm
mount
Clamping support on assembly 90 Nm
stand adaptor
Feet/engine mount on crank- 260 Nm
case
Support, engine mount on M12x35-10.9 95 Nm
crankcase M12x40-10.9
M12x55-10.9
M12x60-10.9
M12x75-10.9
M12x85-10.9
M12x90-10.9
M12x220-10.9
Support, engine mount on M16x40-10.9, 260 Nm
crankcase M16x45-10.9,
M16x50-10.9,
M16x75-10.9,
M16x85-10.9,
M16x105-10.9,
M16x110-10.9,
M16x140-10.9,
M16x155-10.9,
M16x220-10.9.
Cylinder head on the crankcase Observe the tightening sequence. 30 Nm +80 Nm +90°
Lightly oil the screws.
Sealing surfaces free of oil. In the case of written
certification, the cylindrical head screws can be
used a maximum of 3 times, otherwise replace
them each time they are removed.
Rocker support on the cylinder Assembly instructions: Adjust the rocker sym- 21 Nm
head metrically to the central valve axis.
Cylindrical head screw.
Valve clearance adjustment 20 Nm
screw check nut
Casing on the cylinder head M6 11 Nm
Main bearing on the crankcase M14x1, 5x140- In the case of written certification, the cylindri- 50 Nm +90° +90°
10.9 cal head screws can be used a maximum of 3
times, otherwise replace them each time they
are removed
Bearing cover on the connect- Comply with the assembly instructions. Lightly 30 Nm +60° +30°
ing rod drum oil the screws.
Use new screws
Hole blanking screw (mass 9 Nm
compensation shaft) on the
crankcase
Front cover of the crankcase Observe the tightening sequence. 3 Nm +21 Nm
Lubricant oil sump of the crank- Observe the tightening sequence. 30 Nm
case Note that the screws are of different lengths.
Lubricant oil sump hole blank- M18x1.5 Use a Cu seal ring. 55 Nm
ing screw
Crankcase bleed screw on the 21 Nm
cylinder head casing

10-9
 Technical characteristics
Designation Screw type Indications/notes Tightening Retightening
value/pre- value
load value
Hose clip for the return line 13 Nm
Return line on the check valve Hollow screw 30 Nm
Check valve on the crankcase 80 Nm
Crankcase connector box M12x80 Observe the tightening sequence. 99 Nm
M12x150
Crankcase connector box M16x75 Observe the tightening sequence. 243 Nm
M16x140
Connection box casing 9 Nm
Gear case on crankcase M16x60-10.9 Observe the tightening sequence. 70 Nm
Gear case on crankcase M8x35-10.9 Observe the tightening sequence. 30 Nm
M8x45-10.9
M8x50-10.9
Cover on the gear case (hy- M8x55-10.9 21 Nm
draulic pump actuation)
Gear case/crankcase speed 17 Nm
regulator
Engine block on the crankcase 21 Nm
Crankcase adjustment rod 10 Nm
Speed regulator/supply air line Hollow screw 18 Nm
pilot line
Exhaust pipe on the cylinder M8 Nut on the stud bolt. 25 Nm
head Nut on the stud bolt.
Stud screw on cylinder head M10/M8x72 15 Nm
short or long
Turbocharger on the exhaust Nut 20 Nm
pipe Stud screw Use new stud bolts. Insert them with the assem- 8 Nm
bly product DEUTZ AP 1908.
Supply air line on the cylinder M6x75-10.9 11 Nm
head M6x95-10.9
Heater to charge air duct M8x100-10.9 tighten crosswise 3 Nm 30 Nm
M8x140-10.9
Turbocharging air line manifold M8x30-10.9 30 Nm
M8x95-10.9
Flexible pipe connection on the M8x30-10.9 30 Nm
turbocharging manifold
Tightening bracket, injection 16 Nm
valve on the cylinder head
Injectors, tightening nut 35 Nm
Injection valve/injection pump Comply with the assembly instructions. 25 Nm
lines
Crankcase injection pump Comply with the assembly instructions. 5 Nm 150°
Fuel supply pump on the sup- M8x25-10.9 22 Nm
port
V-belt pulley on the fuel supply 27 Nm
pump
Fastening of the fuel pipes Hose clips 30 Nm
Fuel pipe on the fuel filter con- Hollow screw 39 Nm
sole
Fuel pipe on the fuel supply D12 hollow 49 Nm
pump screw
Fuel filter console on the lubri- 30 Nm
cating oil radiator casing
Fuel filter (slip-on filter) Oil the seal lightly. Tighten clockwise. 25 Nm
Oil filter (slip-on filter) Oil the seal lightly. Tighten clockwise. 25 Nm
Oil filter (interchangeable filter) Oil the seal lightly. Tighten clockwise. Manual tight-
ening 15- 17
Nm

10-10
Technical characteristics
Designation Screw type Indications/notes Tightening Retightening
value/pre- value
load value
Oil pump oil intake pipe. Oil in- M8x25 M8x16 21 Nm
take pipe support on the crank-
case
Lubricant oil filler cap on the lu- 38 Nm
bricant oil sump
Lubricant oil filler cap on the 30 Nm
crankcase mount
Lubricant oil pipe on the turbo- Hollow screw 18 Nm
charger
Lubricant oil pipe (turbocharger) Hollow screw 34 Nm
on the crankcase
Pipe sleeve (oil return) on the 22 Nm
turbocharger
Lubricant oil and oil return pipe 13 Nm
hose clip
support bracket (oil return) on 21 Nm
the crankcase
Oil radiator casing on the crank- Note that the screws are of different lengths. 30 Nm
case Pay attention to the tightening sequence.
Oil radiator on the oil radiator M8x20-10.9 Insert the new gaskets with the assembly prod- 22 Nm
casing uct.
Observe the tightening sequence
Oil pressure switch sensor on 40 Nm
the oil radiator casing
Thermostat casing on the cylin- M10x85-10.9 70 Nm
der head
Fan console/thermostat casing 30 Nm
outlet
Coolant pump on the crankcase 30 Nm
V-belt pulley on the coolant 30 Nm
pump
Temperature transmitter on the 24 Nm
cylinder head
Fan console on the crankcase 30 Nm
Fan drive on the fan console 60 Nm
Flywheel on the crankshaft M10x30 Observe the tightening sequence. 30 Nm +60 ° +30 °
M10x35 Use new screws. Oil lightly. 30 Nm +60 ° +60 °
M10x40
M10x45M10x
50 M10x55
M10x60
M10x70
M10x75
M10x80
M10x85
Torsional vibration damper/trap- M16x1.5 Use new screws 40 Nm +60 ° +60 °
ezoidal grooved pulley on the Oil slightly.
crankshaft
V-belt pulley on the trapezoidal M12x25-10.9 130 Nm
grooved pulley
V-belt pulley on the trapezoidal M10x20-10.9 70 Nm
grooved pulley
Flange hub for the viscous cou- M12x40-10.9 110 Nm
pling joint on the torsional vibra-
tion damper

10-11
 Technical characteristics
Designation Screw type Indications/notes Tightening Retightening
value/pre- value
load value
Belt tensioner on the fan con- 80 Nm
sole
Pipe screwing D6 M10x1 ban- 6mm pipe annular part 29 Nm
jo bolt
Pipe screwing D8 M12x1-5 8mm pipe annular part 39 Nm
banjo bolt
Pipe screwing D10 M 14x1-5 10mm pipe annular part 49 Nm
banjo bolt
Hose clip, fastening M6 13 Nm
Hose clip, cable bundle fasten- M8 30 Nm
ing
Starter on crankcase M10x38-10.9 60 Nm
M8 nut 40 Nm
Stud screw 60 Nm
Alternator on the console (V- M8-10.9 M10- 30 Nm 60 Nm
belt) 10.9
Alternator on the tightening 30 Nm
bracket (V-belt)
Tightening bracket on the crank- 30 Nm
case (toothed belt)
Cable attachment on the heat- Retain the hexagon Retain the negative pole 20 Nm
er. Earth cable on the negative
pole, heater

10-12
Technical characteristics
10.2 - Transmission
10.2.1 - Transmission (R3 EVO 110 -> 1001)
Introduction
l This tractor series can be supplied in a version with 5 synchronised speeds and 4 ranges (20 FWD + 20 REV).
l The rear transmission casing also houses the drive train for the rear PTO, which is supplied in the following versions:
m 2-speed PTO (540 - 1000)
m 4-speed PTO (540 - 540E - 1000 - 1000E)
m Syncro (groundspeed) PTO supplied with versions in points a and b.

l All PTO versions are mechanical with non sychronised gears and electrohydraulic engagement control, while the Syncro PTO
is engaged by way of a mechanical control.

Fig. 26 - Main assemblies

Main assemblies
1. Shuttle unit
2. Hi-Lo unit
3. Main gearbox and range gearbox assembly
4. Differential unit
5. Rear PTO
Description
l The transmission receives drive from the engine and transmits it through the shuttle unit (1), gearbox (2), Hi-Lo unit (3) and
range gearbox (4) to bevel gear pair (5). Drive is then transmitted to final drive reduction units (6) and then to wheels (7). Be-
tween bevel gear pair (5) and final drive reduction unit (6) is installed braking device (8) that acts as the main service brake,
while the parking brake is fitted on the 4WD output shaft (9).

10-13
 Technical characteristics

Fig. 27 - Power flow diagram

10-14
Technical characteristics
Shuttle unit

Fig. 28 - Shuttle unit

Key
1. Flywheel
2. Torsional spring plate
3. Shuttle speed sensor
4. Support
5. Reverse gear drive shaft
6. Forward gear drive shaft
7. Rear PTO drive shaft
8. Reverse drive piston
9. Reverse drive clutch
10. Forward drive clutch
11. Flange
12. Forward drive piston
13. Pulse wheel

10-15
 Technical characteristics
Hi-Lo unit

3 4 5
1 2

16

15
14
13
12

11 10 9 8 7 6 D0048170

Fig. 29 - Hi-Lo unit

Key
1. Gearbox input shaft
2. Cover
3. Hi speed piston return spring
4. Hi speed clutch cylinder
5. Planet pinion
6. Secondary shaft
7. Hi-Lo unit output shaft
8. Planet carrier
9. Lo speed clutch
10. Lo speed piston
11. Hi speed clutch
12. Hi speed piston
13. Lo speed engagement springs
14. Bearing
15. Nut
16. Cover

10-16
Technical characteristics
Gearbox assembly - version with Hi-Lo
3

4 5

1 2

D0048180

14 13 12 11 10 9

17 16 15

Fig. 30 - Gearbox assembly - version with Hi-Lo

Key
1. Reverse gear input shaft
2. Forward gear drive shaft
3. Gearbox support
4. Reverse driving gear
5. Forward driving gear
6. Rear PTO drive shaft
7. Main shaft
8. Hi-Lo unit output shaft
9. Gearbox output shaft
10. 5th speed driven gear
11. 4th-5th speed synchronizer
12. 4th speed driven gear
13. 3rd speed driven gear
14. 2nd-3rd speed synchronizer

10-17
 Technical characteristics
3

4 5

1 2

D0048180

14 13 12 11 10 9

17 16 15

Fig. 30 - Gearbox assembly - version with Hi-Lo

15. 2nd speed driven gear
16. 1st speed driven gear
17. 1st speed synchronizer

10-18
Technical characteristics
Bevel pinion and range gearbox assembly

Fig. 31 - Bevel pinion and range gearbox assembly

Key
1. Hi-Lo range engagement
2. Lo-creeper range idler gear
3. 4WD drive gear
4. Bevel pinion
5. 4WD driven gear
6. Creeper range driven gear
7. Medium or creeper range selector
8. Medium-low range idler gear
9. 4WD shaft

10-19
 Technical characteristics
Electrohydraulic four-wheel drive engagement assembly

Fig. 32 - Electrohydraulic four-wheel drive engagement assembly

Key
1. 4WD output hub
2. 4WD engagement sleeve
3. 4WD engagement spring

10-20
Technical characteristics
Differential unit

Fig. 33 - Differential unit (1/2)

Key
1. Bevel pinion
2. Pinion bearing
3. Differential carrier
4. Differential cage
5. Differential lock sleeve
6. Side gear
7. Planet pinion
8. Differential carrier

10-21
 Technical characteristics
9. Side gear
10. Crown wheel

Fig. 34 - Differential unit (2/2)

Key
1. Spring
2. Spacer
3. Spring pin
4. Spool
5. Differential lock fork
6. Spring
7. Piston

10-22
Technical characteristics
Brakes and rear axle assembly

Fig. 35 - Brakes and rear axle assembly

Key
1. Half-shaft
2. Dust seal
3. Bearing
4. Oil seal
5. Bearing
6. Crown wheel
7. Brake cylinder
8. Park Brake operating spring
9. Piston
10. Friction disc
11. Steel disc
12. Half-shaft
13. Park Brake engagement piston
14. Flange
15. Planet pinion
16. Planet carrier
17. Brake take-up device

10.2.2 - Transmission (R3 EVO 85 -> 16001)

Introduction
This tractor series can be supplied in a version with 5 synchronised gears and either 3 ranges (12 FWD + 12 REV) or 4 ranges (20
FWD + 20 REV).
The rear transmission casing also houses the drive train for the rear PTO, which is supplied in the following versions:
1. 2-speed PTO (540 - 1000)
2. 4-speed PTO (540 - 540E - 1000 - 1000E)
3. Groundspeed PTO supplied with the versions described in points 1 and 2.
All PTO versions are mechanical with unsychronised gears and electrohydraulic engagement control, while the Groundspeed PTO
is operated by a mechanical control.
Main assemblies

10-23
 Technical characteristics

1 2 3 4

D0066050

Fig. 36 - Main assemblies

1. Clutch housing
2. Gearbox, reverse shuttle, underdrive and ranges assembly
3. Differential unit
4. Rear PTO
Description
The transmission receives drive from the engine and transmits it through clutch assembly (1), gearbox and shuttle assembly (2), ran-
ge gearbox (3) to bevel gear pair (4). Drive is then transmitted to final drive reduction units (5) and then to wheels (6). Between bevel
gear pair (4) and final drive reduction unit (5) is installed braking device (7) that acts as the main service brake, while the parking
brake is fitted on the 4WD output shaft (8).

10-24
Technical characteristics

2
1
REV FW

E V L 4

N SR
6
8

Fig. 37 - Power flow diagram

Clutch housing

10-25
 Technical characteristics

Fig. 38 - Clutch housing

1. Rear PTO drive shaft
2. Flywheel
3. 12” main clutch disk
4. Main clutch thrust bearing
5. Main clutch sleeve
6. Sleeve support
7. Transmission drive shaft
8. Main clutch lever
9. Reaction pin
10. Clutch piston

10-26
Technical characteristics
Gearbox and shuttle assembly
2

1 3 4 5 6

16 15 14 13 12 11 10 9
D0066060

Fig. 39 - Gearbox and shuttle assembly

1. Cover
2. Gearbox support
3. Reverse driving gear
4. Shuttle synchronizer
5. Forward driving gear
6. Gearbox input shaft
7. Primary shaft
8. Secondary shaft
9. 5th speed driven gear
10. 4th-5th speed synchronizer
11. 4th speed driven gear
12. 3rd speed driven gear
13. 2nd-3rd speed synchronizer
14. 2nd speed driven gear
15. 1st speed driven gear
16. 1st speed synchronizer
Bevel drive and range gearbox assembly (3 range version)

2
3 4

1
V L

8
N SR

D0066070

7 6 5

Fig. 40 - Bevel drive and range gearbox assembly

1. High-Low range synchronizer
2. Lo-creeper range idler gear

10-27
 Technical characteristics
2
3 4

1
V L

8
N SR

D0066070

7 6 5

Fig. 40 - Bevel drive and range gearbox assembly

3. 4WD drive gear and medium range driven gear
4. Bevel pinion
5. 4WD driven gear and medium range drive gear
6. Medium range selector
7. Medium speed range idler gear
8. 4WD shaft

10-28
Technical characteristics
Bevel drive and range gearbox assembly (4 range version)

2 3 4

1
V L

9
N SR

D0036342
8 7 6 5

Fig. 41 - Bevel drive and range gearbox assembly

1. High-Low range synchronizer
2. Lo-creeper range idler gear
3. 4WD drive gear and medium range driven gear
4. Bevel pinion
5. 4WD driven gear and medium range drive gear
6. Creeper range driven gear
7. Medium or creeper range selector
8. Medium-low range idler gear
9. 4WD shaft

10-29
 Technical characteristics
Four-wheel drive engagement and parking brake assembly

A
2

4 9 7 8 7 6 5
D0066080

A-

Fig. 42 - Four-wheel drive engagement and parking brake assembly

1. Sleeve
2. 4WD output hub
3. 4WD selector fork
4. Parking brake cam
5. Parking brake lever
6. 4WD engagement lever
7. Friction shoe
8. Steel disc
9. Spacer
Differential unit

1 2

11 12 13 14 15 16 17
3

10

D0025200

8 7 6 5

Fig. 43 - Differential unit

10-30
Technical characteristics
1. Bevel pinion
2. Pinion bearing
3. Differential carrier
4. Differential cage
5. Differential lock sleeve
6. Planetary reduction gear
7. Planet pinion
8. Differential carrier
9. Planetary reduction gear
10. Crown wheel
11. Spring
12. Spacer
13. Spring pin
14. Rod
15. Differential lock fork
16. Spring
17. Piston
Brakes and rear axle assembly

Fig. 44 - Brakes and rear axle assembly

1. Halfshaft
2. Dust seal
3. Oil seal
4. Bearing
5. Bearing
6. Ring gear
7. Pin (Qty. 3)
8. Brake cylinder
9. Piston
10. Friction disc
11. Halfshaft
12. Planet pinion
13. Planet carrier

10-31
 Technical characteristics
10.2.3 - Transmission (R3 EVO 85 -> 20001)
Introduction
l This tractor series can be supplied in a version with 5 synchronised speeds and 4 ranges (20 FWD + 20 REV).
l The rear transmission casing also houses the drive train for the rear P.T.O., which is supplied in the following versions which
is supplied in the following versions:
m 2-speed P.T.O. (540 - 1000)
m 4-speed P.T.O. (540 - 540E - 1000 - 1000E)
m Groundspeed P.T.O. supplied with the versions of points a and b.

l All P.T.O. versions are mechanical with unsychronised gears and electrohydraulic engagement control, while the Ground-
speed P.T.O. is engaged by means of a mechanical control.

1 2 3 4 5

D0040540

Fig. 45 - Main assemblies

Key
1. Shuttle unit
2. Hi-Lo unit
3. Main gearbox and range gearbox assembly
4. Differential unit
5. Rear P.T.O.
Description
l The transmission receives drive from the combustion engine and transmits it through the shuttle unit (1), gearbox (2), Hi-Lo
unit (3) and range gearbox (4) to bevel gear pair (5). Drive is then transmitted to final drive reduction units (6) and then to
wheels (7). Between bevel gear pair (5) and final drive reduction unit (6) is installed braking device (8) that acts as the main
service brake, while the parking brake is fitted on the 4WD output shaft (9).

10-32
Technical characteristics

AV

IN

E V L 5

6
3
N SR
7
2 9

4 D0040550

Fig. 46 - Power flow diagram

10-33
 Technical characteristics
Shuttle unit

Fig. 47 - Shuttle unit

Key
1. Steering wheel
2. Torsional spring plate
3. Shuttle speed sensor
4. Support
5. Reverse gear drive shaft
6. Forward gear drive shaft
7. Rear P.T.O. drive shaft
8. Reverse drive piston

10-34
Technical characteristics
9. Reverse drive clutch
10. Forward drive clutch
11. Flange
12. Forward drive piston
13. Pulse wheel
Hi-Lo unit

Fig. 48 - Hi-Lo unit

Key
1. Gearbox input shaft
2. Cover
3. Hi speed piston return spring
4. Hi speed clutch cylinder
5. Planet pinion
6. Secondary shaft
7. Hi-Lo unit output shaft
8. Planet carrier
9. Hi speed clutch
10. Hi speed clutch
11. Lo speed clutch
12. Lo speed piston
13. Lo speed engagement springs
14. Bearing
15. Nut
16. Cover

10-35
 Technical characteristics
Gearbox assembly

Fig. 49 - Gearbox assembly

Key
1. Reverse gear input shaft
2. Cover
3. Forward gear drive shaft
4. Gearbox support
5. Reverse driving gear
6. Forward driving gear
7. Rear P.T.O. drive shaft
8. Main shaft

10-36
Technical characteristics
9. Secondary shaft
10. 5th speed driven gear
11. 4th-5th speed synchronizer
12. 4th speed driven gear
13. 3rd speed driven gear
14. 2nd-3rd speed synchronizer
15. 2nd speed driven gear
16. 1st speed driven gear
17. 1st speed synchronizer
Gearbox assembly - version with Hi-Lo

Fig. 50 - Gearbox assembly - version with Hi-Lo

10-37
 Technical characteristics
Key
1. Reverse gear input shaft
2. Forward gear drive shaft
3. Gearbox support
4. Reverse driving gear
5. Forward driving gear
6. Rear P.T.O. drive shaft
7. Main shaft
8. Hi-Lo unit output shaft
9. Gearbox output shaft
10. 5th speed driven gear
11. 4th-5th speed synchronizer
12. 4th speed driven gear
13. 3rd speed driven gear
14. 2nd-3rd speed synchronizer
15. 2nd speed driven gear
16. 1st speed driven gear
17. 1st speed synchronizer

10-38
Technical characteristics
Bevel pinion and range gearbox assembly

Fig. 51 - Bevel pinion and range gearbox assembly

Key
1. Hi-Lo range engagement
2. Lo-creeper range idler gear
3. 4WD drive gear
4. Pinion
5. 4WD driven gear
6. Creeper range driven gear
7. Medium or creeper range selector
8. Medium-low range idler gear
9. 4WD shaft

10-39
 Technical characteristics
Mechanical four-wheel drive engagement and parking brake assembly

Fig. 52 - Mechanical four-wheel drive engagement and parking brake assembly

Key
1. Sleeve
2. 4WD output hub
3. 4WD selector fork
4. Parking brake cam
5. Parking brake lever
6. 4WD engagement lever
7. Friction shoe
8. Steel disc
9. Spacer
Electrohydraulic four-wheel drive engagement and parking brake assembly

Fig. 53 - Electrohydraulic four-wheel drive engagement and parking brake assembly

Key
1. 4WD output hub
2. 4WD engagement sleeve
3. 4WD engagement spring

10-40
Technical characteristics

Fig. 53 - Electrohydraulic four-wheel drive engagement and parking brake assembly

4. Parking brake cam
5. Parking brake lever
6. Friction shoe
7. Steel disc
8. Spacer
Differential unit

Fig. 54 - Differential unit

Key
1. Pinion
2. Pinion bearing
3. Differential carrier
4. Differential cage

10-41
 Technical characteristics

Fig. 54 - Differential unit

5. Differential lock sleeve
6. Side gear
7. Planet pinion
8. Differential carrier
9. Side gear
10. Differential crown wheel
11. Spring
12. Spacer
13. Spring pin
14. Rod
15. Differential lock fork
16. Spring
17. Piston

10-42
Technical characteristics
Brakes and rear axle assembly

Fig. 55 - Brakes and rear axle assembly

Key
1. Half-shaft
2. Dust seal
3. Bearing
4. Oil seal
5. Bearing
6. Ring gear
7. Pin (Qty. 3)
8. Brake cylinder
9. Piston
10. Friction disc
11. Half-shaft
12. Planet pinion
13. Planet carrier

10.2.4 - Transmission (R3 EVO 100 -> 16001)

Introduction
This tractor series can be supplied in a version with 5 synchronised gears and either 3 ranges (12 FWD + 12 REV) or 4 ranges (20
FWD + 20 REV).
The rear transmission casing also houses the drive train for the rear PTO, which is supplied in the following versions:
1. 2-speed PTO (540 - 1,000)
2. 4-speed PTO (540 - 540E - 1,000 - 1,000E)
3. Groundspeed PTO supplied with the versions described in points 1 and 2.
All PTO versions are mechanical with unsychronised gears and electrohydraulic engagement control, while the Groundspeed PTO
is operated by a mechanical control.

10-43
 Technical characteristics
Main assemblies

1 2 3 4

D0065980

Fig. 56 - Main assemblies

1. Connector housing
2. Gearbox, reverse shuttle, underdrive and ranges assembly
3. Differential assembly
4. Rear PTO
Description
The transmission receives drive from the engine and transmits it through clutch assembly (1), gearbox and shuttle assembly (2),
range gearbox (3) to bevel gear pair (4). Drive is then transmitted to planetary reduction gearbox (5) and then to wheels (6). Between
bevel gear pair (4) and planetary reduction gearbox (5) is installed braking device (7) that acts as the main service brake, while the
parking brake is fitted on the 4WD output shaft (8).

10-44
Technical characteristics

2
1
REV FW

E V L 4

N SR
6
8

Fig. 57 - Power flow diagram

Connector housing

10-45
 Technical characteristics

Fig. 58 - Connector housing

1. Rear PTO drive shaft
2. Flywheel
3. 13” main clutch disk
4. Main clutch thrust bearing
5. Main clutch sleeve
6. Sleeve support
7. Transmission drive shaft
8. Main clutch lever
9. Reaction pin
10. Clutch piston

10-46
Technical characteristics
Gearbox and shuttle assembly
2

1 3 4 5 6

16 15 14 13 12 11 10 9
D0066000

Fig. 59 - Gearbox and shuttle assembly

1. Cover
2. Gearbox support
3. Reverse driving gear
4. Shuttle synchronizer
5. Forward driving gear
6. Gearbox input shaft
7. Primary shaft
8. Secondary shaft
9. 5th speed driven gear
10. 4th-5th speed synchronizer
11. 4th speed driven gear
12. 3rd speed driven gear
13. 2nd-3rd speed synchronizer
14. 2nd speed driven gear
15. 1st speed driven gear
16. 1st speed synchronizer

10-47
 Technical characteristics
Bevel drive and range gearbox assembly (3 range version)

2 3 4

1 V L

8
M SR

D0066030

7 6 5
Fig. 60 - Bevel drive and range gearbox assembly
1. High-Low range synchronizer
2. Lo-creeper range idler gear
3. 4WD drive gear and medium range driven gear
4. Pinion
5. 4WD driven gear and medium range drive gear
6. Medium range selector
7. Medium-low range idler gear
8. 4WD shaft

10-48
Technical characteristics
Bevel drive and range gearbox assembly (4 range version)

2 3 4

L
1 V

9
M SR

D0066040
8 7 6 5

Fig. 61 - Bevel drive and range gearbox assembly

1. High-Low range synchronizer
2. Lo-creeper range idler gear
3. 4WD drive gear
4. Pinion
5. 4WD driven gear
6. Creeper range driven gear
7. Medium or creeper range selector
8. Medium-low range idler gear
9. 4WD shaft

10-49
 Technical characteristics
Four-wheel drive engagement and parking brake assembly

A
2

4 9 7 8 7 6 5
D0036350

A -A

Fig. 62 - Four-wheel drive engagement and parking brake assembly

1. Sleeve
2. 4WD output hub
3. 4WD selector fork
4. Parking brake cam
5. Parking brake lever
6. 4WD engagement lever
7. Friction shoe
8. Steel disc
9. Shim
Differential assembly

10-50
Technical characteristics

1 2

11 12 13 14 15 16 17
3

10

D0047810

8 7 6 5

Fig. 63 - Differential assembly

1. Pinion
2. Pinion bearing
3. Differential carrier
4. Differential case
5. Differential lock sleeve
6. Sun gear
7. Planetary gear unit
8. Differential carrier
9. Sun gear
10. Crown wheel
11. Spring
12. Shim
13. Spring pin
14. Rod
15. Differential lock fork
16. Spring
17. Piston

10-51
 Technical characteristics
Rear brakes and axle assembly

6 7 8 9

1 2 3 4 5

10

12

11

D0047820

Fig. 64 - Rear brakes and axle assembly

1. Axle shaft
2. Dust seal
3. Bearing
4. O-ring
5. Bearing
6. Ring gear
7. Brake cylinder
8. Piston
9. Friction disc
10. Axle shaft
11. Planetary gear unit
12. Planetary gear carrier

10.2.5 - Transmission (R3 EVO 100 -> 20001)

Introduction
l This tractor series can be supplied in a version with 5 synchronised speeds and 4 ranges (20 FWD + 20 REV).
l The rear transmission casing also houses the drive train for the rear PTO, which is supplied in the following versions:
m 2-speed PTO (540 - 1,000)
m 4-speed PTO (540 - 540E - 1,000 - 1,000E)
m Groundspeed PTO supplied with the versions described in points a and b.

l All PTO versions are mechanical with unsychronised gears and electrohydraulic engagement control, while the Groundspeed
PTO is operated by a mechanical control.

10-52
Technical characteristics

1 2 3 4 5

D0040540

Fig. 64 - Main assemblies

Main assemblies
1. Shuttle unit
2. Hi-Lo unit
3. Gearbox and range unit
4. Differential assembly
5. Rear PTO
Description
l The transmission receives drive from the engine and transmits it through the shuttle assembly (1), gearbox assembly (2),
the Hi-Lo gearbox (3) and the range gearbox (4) to bevel gear set (5). Drive is then transmitted to the planetary reduction
gearboxes (6) and then to wheels (7). The braking device (8) acting as the main service brake is installed between the bevel
gear set (5) and the planetary reduction gearbox (6), while the parking brake is installed on the dual traction output shaft (9).

10-53
 Technical characteristics

AV

IN

E V L 5

6
3
N SR
7
2 9

4 D0040550

Fig. 64 - Power flow diagram

10-54
Technical characteristics
Shuttle unit

6
7

13
D0040570

1 2 12 11 10 9 4 8

Fig. 65 - Shuttle unit

Key
1. Flywheel
2. Torsional spring plate
3. Shuttle speed sensor
4. Support
5. Reverse drive shaft
6. Forward drive shaft
7. Rear PTO drive shaft
8. Reverse drive piston

10-55
 Technical characteristics
9. Reverse drive clutch
10. Forward drive clutch
11. Flange
12. Forward drive piston
13. Tone wheel
Hi-Lo unit

3 4 5
1 2

16

15
14
13
12

11 10 9 8 7 6 D0048170

Fig. 65 - Hi-Lo unit

Key
1. Gearbox input shaft
2. Cover
3. High range piston return spring
4. High range clutch cylinder
5. Planetary gear unit
6. Secondary shaft
7. Hi-Lo unit output shaft
8. Planetary gear carrier
9. Low range clutch
10. Low range piston
11. High range clutch
12. High range piston
13. High range clutch selector springs
14. Bearing
15. Lock ring
16. Cover

10-56
Technical characteristics
Gearbox assembly

5 6

1 2 3

D0040580

14 13 12 11 10
17

16 15

Fig. 66 - Gearbox assembly

Key
1. Reverse input shaft
2. Cover
3. Forward input shaft
4. Gearbox support
5. Reverse driving gear
6. Forward driving gear
7. Rear PTO drive shaft
8. Primary shaft
9. Secondary shaft
10. 5th speed driven gear
11. 4th-5th speed synchronizer
12. 4th speed driven gear
13. 3rd speed driven gear

10-57
 Technical characteristics
4

5 6

1 2 3

D0040580

14 13 12 11 10
17

16 15

Fig. 66 - Gearbox assembly

14. 2nd-3rd speed synchronizer
15. 2nd speed driven gear
16. 1st speed driven gear
17. 1st speed synchronizer

10-58
Technical characteristics
Gearbox - version with HI-LO unit
3

4 5

1 2

D0048180

14 13 12 11 10 9

17 16 15

Fig. 66 - Gearbox - version with HI-LO unit

Key
1. Reverse input shaft
2. Forward input shaft
3. Gearbox support
4. Reverse driving gear
5. Forward driving gear
6. Rear PTO drive shaft
7. Primary shaft
8. Hi-Lo unit output shaft
9. Gearbox output shaft
10. 5th speed driven gear
11. 4th-5th speed synchronizer
12. 4th speed driven gear
13. 3rd speed driven gear
14. 2nd-3rd speed synchronizer

10-59
 Technical characteristics
3

4 5

1 2

D0048180

14 13 12 11 10 9

17 16 15

Fig. 66 - Gearbox - version with HI-LO unit

15. 2nd speed driven gear
16. 1st speed driven gear
17. 1st speed synchronizer

10-60
Technical characteristics
Bevel drive and range gearbox assembly

1 2 3 4
V L

9
M SR

D0040620
8 7 6 5

Fig. 67 - Bevel drive and range gearbox assembly

Key
1. High-Low range engagement
2. Lo-creeper range idler gear
3. 4WD drive gear
4. Pinion
5. 4WD driven gear
6. Creeper range driven gear
7. Medium or creeper range selector
8. Medium-low range idler gear
9. 4WD shaft

10-61
 Technical characteristics
Four-wheel drive mechanical engagement and parking brake assembly

A
2

4 9 7 8 7 6 5
D0036350

A -A

Fig. 68 - Four-wheel drive mechanical engagement and parking brake assembly

Key
1. Sleeve
2. 4WD output hub
3. 4WD selector fork
4. Parking brake cam
5. Parking brake lever
6. 4WD engagement lever
7. Friction shoe
8. Steel disc
9. Shim

10-62
Technical characteristics
Four-wheel drive electrohydraulical engagement and parking brake assembly

2 3

4 8 7 6 7 5
D0040630
A -A

Fig. 69 - Four-wheel drive electrohydraulical engagement and parking brake assembly

Key
1. 4WD output hub
2. Dual traction selector sleeve
3. Dual traction selector spring
4. Parking brake cam
5. Parking brake lever
6. Friction shoe
7. Steel disc
8. Shim

10-63
 Technical characteristics
Differential assembly

1 2

11 12 13 14 15 16 17
3

10

D0047810

8 7 6 5

Fig. 70 - Differential assembly

Key
1. Pinion
2. Pinion bearing
3. Differential carrier
4. Differential case
5. Differential lock sleeve
6. Sun gear
7. Planetary gear unit
8. Differential carrier
9. Sun gear
10. Crown wheel
11. Spring
12. Shim
13. Spring pin
14. Rod
15. Differential lock fork
16. Spring
17. Piston

10-64
Technical characteristics
Rear brakes and axle assembly

6 7 8 9

1 2 3 4 5

10

12

11

D0025210

Fig. 71 - Rear brakes and axle assembly

Key
1. Axle shaft
2. Dust seal
3. Bearing
4. O-ring
5. Bearing
6. Ring gear
7. Brake cylinder
8. Piston
9. Friction disc
10. Axle shaft
11. Planetary gear unit
12. Planetary gear carrier

10.2.6 - Transmission (R3 EVO 110 -> 5001)

Introduction
This tractor series can be supplied in a version with 5 synchronised speeds and 4 ranges (20 FWD + 20 REV).
The rear transmission casing also houses the drive train for the rear PTO, which is supplied in the following versions:
1. 2-speed PTO (540 - 1000)
2. 4-speed PTO (540 - 540E - 1000 - 1000E)
3. Groundspeed PTO supplied with the versions described in points 1 and 2.
All PTO versions are mechanical with unsychronised gears and electrohydraulic engagement control, while the Groundspeed PTO
is operated by a mechanical control.

10-65
 Technical characteristics
Main assemblies

1 2 3 4

D0065980

Fig. 72 - Main assemblies

1. Clutch housing
2. Gearbox, reverse shuttle, underdrive and ranges assembly
3. Differential unit
4. Rear PTO
Description
The transmission receives drive from the engine and transmits it through clutch assembly (1), gearbox and shuttle assembly (2), ran-
ge gearbox (3) to bevel gear pair (4). Drive is then transmitted to final drive reduction units (5) and then to wheels (6). Between bevel
gear pair (4) and final drive reduction unit (5) is installed braking device (7) that acts as the main service brake, while the parking
brake is fitted on the 4WD output shaft (8).

10-66
Technical characteristics

2
1
REV FW

E V L 4

N SR
6
8

Fig. 73 - Power flow diagram

Clutch housing

10-67
 Technical characteristics

Fig. 73 - Clutch housing

1. Rear PTO drive shaft
2. Flywheel
3. 13” main clutch disk
4. Main clutch thrust bearing
5. Main clutch sleeve
6. Sleeve support
7. Transmission drive shaft
8. Main clutch lever
9. Reaction pin
10. Clutch piston

10-68
Technical characteristics
Gearbox and shuttle assembly
2

1 3 4 5 6

16 15 14 13 12 11 10 9
D0066000

Fig. 74 - Gearbox and shuttle assembly

1. Cover
2. Gearbox support
3. Reverse driving gear
4. Shuttle synchronizer
5. Forward driving gear
6. Gearbox input shaft
7. Primary shaft
8. Secondary shaft
9. 5th speed driven gear
10. 4th-5th speed synchronizer
11. 4th speed driven gear
12. 3rd speed driven gear
13. 2nd-3rd speed synchronizer
14. 2nd speed driven gear
15. 1st speed driven gear
16. 1st speed synchronizer

10-69
 Technical characteristics
Bevel drive and range gearbox assembly

2 3 4

1 V L

9
M SR

D0066010
8 7 6 5
Fig. 75 - Bevel drive and range gearbox assembly
1. High-Low range synchronizer
2. Lo-creeper range idler gear
3. 4WD drive gear
4. Bevel pinion
5. 4WD driven gear
6. Creeper range driven gear
7. Medium or creeper range selector
8. Medium-low range idler gear
9. 4WD shaft

10-70
Technical characteristics
Four-wheel drive engagement and parking brake assembly

A
2

4 9 7 8 7 6 5
D0066020

A-

Fig. 76 - Four-wheel drive engagement and parking brake assembly

1. Sleeve
2. 4WD output hub
3. 4WD selector fork
4. Parking brake cam
5. Parking brake lever
6. 4WD engagement lever
7. Friction shoe
8. Steel disc
9. Spacer
Differential unit

10-71
 Technical characteristics

1 2

11 12 13 14 15 16 17
3

10

D0047810

8 7 6 5

Fig. 76 - Differential unit

1. Bevel pinion
2. Pinion bearing
3. Differential carrier
4. Differential cage
5. Differential lock sleeve
6. Planetary reduction gear
7. Planet pinion
8. Differential carrier
9. Planetary reduction gear
10. Crown wheel
11. Spring
12. Spacer
13. Spring pin
14. Rod
15. Differential lock fork
16. Spring
17. Piston

10-72
Technical characteristics
Brakes and rear axle assembly

6 7 8 9

1 2 3 4 5

10

12

11

D0047820

Fig. 76 - Brakes and rear axle assembly

1. Halfshaft
2. Dust seal
3. Bearing
4. Oil seal
5. Bearing
6. Ring gear
7. Brake cylinder
8. Piston
9. Friction disc
10. Halfshaft
11. Planet pinion
12. Planet carrier

10.2.7 - Rear PTO (R3 EVO 110 -> 1001, R3 EVO 110 -> 5001)
Description
The rear power take-off allows drive to be transmitted to an implement at a predetermined rotation speed. Rotary drive is taken di-
rectly from the engine and the operator controls engagement of the PTO via the pushbutton on the right-hand side of the driving posi-
tion. The 540, 540 ECO, 1000 and 1000 ECO rear PTO speeds are engaged by way of the electrohydraulically operated PTO clutch,
while the Syncro PTO (when present) is engaged by way of a mechanical control. The PTO speed is selected by mechanical control.
The rear PTO is supplied in 2 versions with two or four rotation speeds:
l 540-1000 PTO
l 540 - 540 ECO - 1000 and 1000 ECO PTO
In addition, a further shaft for the Syncro PTO may be installed. The speed of the Syncro PTO is directly proportional to the rotation
speed of the rear wheels with a fixed ratio between the PTO shaft and wheel speeds.

10-73
 Technical characteristics
Power flow diagram

Fig. 77 - 2-speed PTO

Fig. 78 - 4-speed PTO

10-74
Technical characteristics
PTO clutch assembly

Fig. 79 - PTO clutch assembly

1. Hub
2. PTO clutch
3. Clutch housing
4. Body
5. PTO brake clutch piston
6. PTO brake clutch
7. PTO engagement piston
8. Piston return spring
9. Accumulator cylinder
10. Accumulator spring
11. Accumulator piston
12. Pressure relief valve
Operation
The following is a description of what happens when the PTO is engaged.
l When the operator activates PTO engagement, solenoid valve (1) is energized and the pressurised oil from regulator valve
(2) flows into line A.
l The pressurised oil from regulator valve (2) thus flows into chamber b of accumulator (3).
l As the pressure in chamber b increases, the force exerted by the oil on piston (4) compresses springs (5). The increased
stroke of piston (4) corresponds to an increase in the pressure in chamber b and chamber c of piston (6). For this reason, the
clutch engagement pressure is modulated within the range of 2 to 12 bar. At the same time the oil in passage d is returned to
tank and the pressure acting on piston (7) decreases, thereby allowing the hub (8) to rotate.

10-75
 Technical characteristics

Fig. 80 - PTO engagement

The following is a description of what happens when the PTO is disengaged.
l The PTO is disengaged by de-energizing solenoid valve (1).
l The pressurised oil in line a is sent to the return circuit through solenoid valve (1).
l As a result of the decrease in pressure in line a, piston (4) is pushed to the right by the force of the springs (5) and spring (9)
pushes piston (6) to the right, thereby returning it to the rest position. At the same time pressurised oil from regulator valve (2)
flows into line d. This causes piston (7) to move to the right, thus activating the PTO brake and stopping rotation of hub (8).

Fig. 81 - PTO disengagement.

10-76
Technical characteristics
10.2.8 - Rear P.T.O. (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3 EVO 85 -> 16001, R3
EVO 85 -> 20001)
Description
The rear power take-off allows drive to be transmitted to an implement at a predetermined rotation speed. Rotary drive is taken
directly from the engine and the operator controls engagement of the P.T.O. via the pushbutton on the right-hand side of the driving
position. Engagement of the rear P.T.O. , for the speeds 540, 540 ECO, 1000 and 1000 ECO, is controlled by the P.T.O. clutch unit
and is electro-hydraulic, while it is via a mechanical control for the Groundspeed P.T.O. (for tractors fitted with this option). The P.T.O.
speed is a selected by mechanical controls.
The rear P.T.O. is supplied in 2 versions with two or four rotation speeds:
l 540-1000 P.T.O.
l P.T.O. 540 - 540 ECO - 1000 and 1000 ECO
and a further shaft can be fitted for the groundspeed P.T.O. The characteristic of the groundspeed velocity is that of being directly
proportional to the rotation speed of the rear wheels according to a fixed ratio of the P.T.O. shaft revolutions and the wheel revolutions.
Power flow diagram

Fig. 82 - 2-speed P.T.O.

Fig. 83 - 4-speed P.T.O.

10-77
 Technical characteristics
P.T.O. clutch assembly.

Fig. 84 - P.T.O. clutch assembly.

1. Hub
2. P.T.O. clutch.
3. Clutch housing
4. Body
5. P.T.O. brake clutch piston.
6. P.T.O. brake clutch.
7. P.T.O. engagement piston.
8. Piston return spring
9. Accumulator cylinder
10. Accumulator spring
11. Accumulator piston
12. Pressure relief valve

10-78
Technical characteristics
Operation
The following text describes what happens when the P.T.O. is engaged.
l When the operator activates P.T.O. engagement, solenoid valve (1) is energized and the pressurized oil from regulator valve
(2) flows in line A.
l The pressurized oil from regulator valve (2) is thus introduced into chamber b of accumulator (3).
l As the pressure in chamber b, increases, the force exerted by the pressure on piston (4) compresses springs (5). The in-
creased stroke of piston (4) corresponds to an increase in the pressure in chamber b and chamber c of piston (6). For this
reason, the clutch engagement pressure is modulated within the range of 2 to 12 bar. Simultaneously the oil in passage d is
returned to tank and the pressure acting on piston (7) decreases, thereby allowing the hub to rotate (8).

Fig. 85 - P.T.O. engagement.

The following text describes what happens when the P.T.O. is disengaged.
l The P.T.O. is disengaged by de-energizing solenoid valve (1).
l The pressurised oil in line a is sent to the return circuit through solenoid valve (1).
l Because of the decrease in pressure in passage a, piston (4) is pushed to the right by springs (5) and force of spring (9)
pushes piston (6) to the right, bringing it to the rest position. At the same time, the pressurised oil from regulator valve (2) flows
into passage d. For this reason, the piston (7) is moved to the right, thus activating the P.T.O. brake and stopping rotation of
hub (8).

10-79
 Technical characteristics

Fig. 86 - P.T.O. disengagement.

10-80
Technical characteristics
10.2.9 - 2 and 4-speed PTO and Syncro PTO (R3 EVO 110 -> 1001, R3 EVO 110 -> 5001)
2-speed PTO and Syncro PTO

Fig. 87 - 4-speed PTO and Syncro PTO (1/2)

1. Drive shaft
2. Bearing
3. 1000 PTO driving gear
4. Bearing
5. Cover
6. Bearing
7. 540-1000 PTO output shaft
8. Syncro PTO output shaft
9. Bearing
10. 540 PTO driven gear
11. 1000 PTO driven gear
12. Bearing

10-81
 Technical characteristics

Fig. 88 - 4-speed PTO and Syncro PTO (2/2)

1. Selector sleeve
2. Selector fork
3. Speed selector lever
4. Shoe

10-82
Technical characteristics
4-speed PTO and Syncro PTO

Fig. 89 - 4-speed PTO and Syncro PTO (1/2)

1. PTO input shaft
2. Normal/ECO PTO selector sleeve
3. ECO PTO drive shaft
4. Flange
5. Normal PTO driving gear
6. ECO PTO driving gear
7. Bearing
8. Cover
9. Bearing
10. 540-1000 PTO output shaft
11. Syncro PTO output shaft
12. Bearing
13. 540 PTO driven gear
14. 540/1000 PTO selector sleeve
15. ECO -1000 PTO driven gear
16. Bearing

10-83
 Technical characteristics

Fig. 90 - 4-speed PTO and Syncro PTO (2/2)

1. Yoke
2. Shoe
3. Normal/ECO PTO selector lever
4. 540/1000 PTO selector lever
5. Shoe
6. Yoke

10.2.10 - 2 and 4-speed PTO and Groundspeed PTO (R3 EVO 100 -> 16001, R3 EVO 100
-> 20001, R3 EVO 85 -> 16001, R3 EVO 85 -> 20001)
2-speed PTO and Groundspeed PTO

10-84
Technical characteristics

Fig. 91 - 2-speed PTO and Groundspeed PTO

1. Drive shaft
2. Bearing
3. 1000 PTO driving gear
4. Bearing
5. Cover
6. Bearing
7. 540-1000 PTO output shaft
8. Groundspeed PTO output shaft
9. Bearing
10. 540 PTO driven gear
11. 1000 PTO driven gear
12. Bearing
13. Selector sleeve
14. Fork
15. Speed selector lever
16. Shoe

10-85
 Technical characteristics
4-speed PTO and Groundspeed PTO

Fig. 92 - 4-speed PTO and Groundspeed PTO

1. PTO input shaft
2. Normal/ECO PTO selector sleeve
3. ECO PTO drive shaft
4. Flange
5. Normal PTO driving gear
6. ECO PTO driving gear
7. Bearing
8. Cover
9. Bearing
10. 540-1000 PTO. output shaft
11. Groundspeed PTO output shaft
12. Bearing
13. ECO -1000 PTO driven gear
14. 540/1000 PTO selector sleeve
15. 540 PTO driven gear
16. Bearing
17. Fork
18. Shoe
19. Normal/ECO PTO selector lever
20. 540/1000 PTO selector lever
21. Shoe
22. Fork

10-86
Technical characteristics
10.3 - Front axle
10.3.1 - Front axle (R3 EVO 110 -> 1001, R3 EVO 110 -> 5001)
From Serial No.
l Explorer³ 110: 5036 ->
l R3 evo 110: 5039 ->
l XB max 110: 5002 ->
l Agrofarm 430: 5051 ->

X–2

1769

D0024080

Fig. 93 - Steering angle “A”

l Version with double-acting steering cylinders: 55°

10-87
 Technical characteristics
Final drive
5
4 6
3 7
2
8
1
9

23

22

21

20 10

11

12

19 18 17 16 15 14 13
D0048240

Fig. 94 - Final drive

1. Planet carrier
2. Oil seal
3. Ring gear
4. Brake disc
5. Steering knuckle housing
6. Upper kingpin
7. Gasket
8. Top bearing
9. Halfshaft
10. Roller bearing
11. Oil seal
12. Lower bearing
13. Gasket
14. Lower kingpin
15. Brake piston
16. Steel disc
17. Spool return spring
18. Friction disc
19. Bearing
20. Cover
21. Cover disc
22. Planet pinion
23. Pivot pin

10-88
Technical characteristics
Pinion, differential and differential lock
1 2 3 4
18
5
19
7 6
23

22

21

24

20
17 8
16 3 9

15 10

11
14
12
13 D0048730

Fig. 95 - Pinion, differential and differential lock

1. Axle housing
2. Crown wheel
3. Planet pinion
4. Side gear
5. Differential carrier
6. Differential lock
7. Halfshaft
8. Bearing
9. Bearing
10. Spacer
11. Bearing
12. Oil seal
13. Oil seal
14. Nut:
15. Bevel pinion
16. Differential carrier
17. Bearing
18. Side gear
19. Differential carrier
20. Piston
21. Shock absorber spring
22. Return spring
23. Differential lock engagement lever
24. Shoe

10-89
 Technical characteristics
10.3.2 - Front axle (R3 EVO 110 -> 5001)
Up to Serial No.
l Explorer³ 110: 5035 <-
l R3 evo 110: 5038 <-
l XB max 110: 5001 <-
l Agrofarm 430: 5050 <-

X–2

1769

D0024080

Fig. 96 - Steering angle “A”

l Version with single-acting steering cylinders: 50°
l Version with double-acting steering cylinders: 55°

10-90
Technical characteristics
Final drive

5
4 6
3 7
2
8
1
9

22

21

20

19 10

11

12

18 17 16 15 14 13
D0036570

Fig. 97 - Final drive

1. Planet carrier
2. Oil seal
3. Ring gear
4. Brake disc
5. Steering knuckle housing
6. Upper kingpin
7. Gasket
8. Top bearing
9. Halfshaft
10. Roller bearing
11. Oil seal
12. Lower bearing
13. Gasket
14. Lower kingpin
15. Brake piston
16. Steel disc
17. Friction disc
18. Bearing
19. Cover
20. Cover disc

10-91
 Technical characteristics

5
4 6
3 7
2
8
1
9

22

21

20

19 10

11

12

18 17 16 15 14 13
D0036570

Fig. 97 - Final drive

21. Planet pinion
22. Pivot pin

10-92
Technical characteristics
Pinion, differential and differential lock

1 2 3 4
18
5
19
7 6
23

22

21

24

20
17 8
16 3 9
D0025260

15 10

11
14
12
13

Fig. 98 - Pinion, differential and differential lock

1. Axle housing
2. Crown wheel
3. Planet pinion
4. Side gear
5. Differential carrier
6. Differential lock
7. Halfshaft
8. Bearing
9. Bearing
10. Spacer
11. Bearing
12. Oil seal
13. Oil seal
14. Oil seal
15. Nut:
16. Bevel pinion
17. Differential carrier
18. Bearing
19. Side gear
20. Differential carrier
21. Piston
22. Shock absorber spring
23. Return spring
24. Differential lock engagement lever

10-93
 Technical characteristics

1 2 3 4
18
5
19
7 6
23

22

21

24

20
17 8
16 3 9
D0025260

15 10

11
14
12
13

Fig. 98 - Pinion, differential and differential lock

25. Shoe

10-94
Technical characteristics
10.3.3 - Front axle (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3 EVO 85 -> 16001, R3
EVO 85 -> 20001)

X–2

1769

D0024080

Fig. 98 - Steering angle “A”

l Single-acting steering cylinders version: 50°
l Double-acting steering cylinders version: 55°

10-95
 Technical characteristics
Final drive

5
4 6
3 7
2
8
1
9

22

21

20

19 10

11

12

18 17 16 15 14 13
D0036570

Fig. 98 - Final drive

1. Planet carrier
2. Oil seal
3. Ring gear
4. Brake disc
5. Steering knuckle housing
6. Upper kingpin
7. Gasket
8. Top bearing
9. Axle shaft
10. Needle roller bearings
11. Oil seal
12. Lower bearing
13. Gasket
14. Lower kingpin
15. Brake piston
16. Steel disc
17. Friction disc
18. Bearing
19. Cover
20. Protective disc

10-96
Technical characteristics

5
4 6
3 7
2
8
1
9

22

21

20

19 10

11

12

18 17 16 15 14 13
D0036570

Fig. 98 - Final drive

21. Planet gear
22. Planet shaft

10-97
 Technical characteristics
Pinion, differential and differential lock

1 2 3 4
18
5
19
7 6
23

22

21

24

20
17 8
16 3 9
D0025260

15 10

11
14
12
13

Fig. 98 - Pinion, differential and differential lock

1. Axle housing
2. Differential crown wheel
3. Planet gear
4. Sun gear
5. Differential carrier
6. Differential lock device
7. Axle shaft
8. Bearing
9. Bearing
10. Spacer
11. Bearing
12. Oil seal
13. Oil seal
14. Oil seal
15. Nut
16. Pinion
17. Differential carrier
18. Bearing
19. Sun gear
20. Differential carrier
21. Piston
22. Shock absorber spring
23. Return spring
24. Differential lock engagement lever

10-98
Technical characteristics

1 2 3 4
18
5
19
7 6
23

22

21

24

20
17 8
16 3 9
D0025260

15 10

11
14
12
13

Fig. 98 - Pinion, differential and differential lock

25. Shoe

10-99
 Technical characteristics
10.4 - Hydraulic system
10.4.1 - Hydraulic system (R3 EVO 110 -> 1001)
Description
The tractors in this series are equipped with a hydraulic system with two main circuits:
1. Steering, brakes and services circuit.
2. Lift and remote control valve circuit.
Each of these circuits is supplied with oil by a hydraulic gear pump that converts the power supplied by the engine into hydraulic
energy. The oil flow generated by the pumps is sent to the devices that control the distribution of the oil pressure to the actuators,
where the hydraulic energy is converted into mechanical energy.

7 8 9 10 11 12 13 14
16

A B

17
5

18
4

15
2
21 19
20 1

D0048250

Fig. 99 - Hydraulic schematic

Key
1. Suction line filter
2. Steering circuit gear pump
3. Resonator
4. Power steering valve
5. Steering cylinders
6. Pressurized filter
7. Hydraulic reverse shuttle solenoid valves assembly
8. Front brakes pilot valve
9. Park Brake valve
10. Hi-Lo solenoid valves assembly
11. 4WD engagement device
12. Differential lock engagement device
13. Rear PTO clutch
14. Services solenoid valve assembly
15. Lift gear pump
16. Remote control valve

10-100
Technical characteristics
7 8 9 10 11 12 13 14
16

A B

17
5

18
4

15
2
21 19
20 1

D0048250

Fig. 99 - Hydraulic schematic

17. Hydraulic lift control valve
18. Lift cylinder
19. Transfer pump
20. Filter
21. Shuttle lubrication

10-101
 Technical characteristics
Hydraulic diagram
Hydraulic steering, brakes and services system - diagram 1

Fig. 100 - Hydraulic steering, brakes and services system - diagram 1

Key
1. Suction line filter (90 μm)
2. Hydraulic pump (14 cc/rev)
3. Resonator
4. Power steering valve
5. Steering cylinders
6. Pressure line filter (19 μm - ß>1000)
7. Pressure limiting valve
8. Services solenoid valve assembly
9. Rear PTO clutch
10. PTO and shuttle shaft lubrication
11. Shuttle solenoid valves assembly
12. Shuttle unit

10-102
Technical characteristics

Fig. 100 - Hydraulic steering, brakes and services system - diagram 1

13. Hydraulic shuttle lubrication
14. Oil cooler
15. Transfer pump
16. Washable filter with metal mesh
17. Front differential locking device
18. Rear differential locking device
19. Hi-Lo unit
20. 4WD engagement device

10-103
 Technical characteristics
Hydraulic steering, brakes and services diagram - diagram 2 - (standard version)

Fig. 101 - Hydraulic steering, brakes and services diagram - diagram 2 - (standard version)
Key
1. Front brakes pilot valve
2. Front axle brake
3. Brake fluid reservoir
4. Master cylinder
5. Non-return valve (check valve)
6. Park Brake accumulator circuit
7. Park Brake valve
8. Rear axle brake

10-104
Technical characteristics
Hydraulic steering, brakes and services diagram - diagram 2 - (version with hydraulic trailer braking)

Fig. 102 - Hydraulic steering, brakes and services diagram - diagram 2 - (version with hydraulic trailer braking)
Key
1. Front brakes pilot valve
2. Front axle brake
3. Brake fluid reservoir
4. Master cylinder
5. Non-return valve (check valve)
6. Park Brake accumulator circuit
7. Park Brake valve
8. Rear axle brake
9. Hydraulic trailer braking valve

10-105
 Technical characteristics
Hydraulic lift and remote control valve circuit diagram (standard version)

Fig. 103 - Hydraulic lift and remote control valve circuit diagram - standard version
Key
1. Suction line filter (90 μm)
2. Hydraulic pump (22.5 cc/rev)
3. Free drain
4. 6-way remote control valve
5. Hydraulic lift control valve
6. Lift cylinders
7. Lift cover
8. Brake discs lubrication
9. PTO bearing lubrication system

10-106
Technical characteristics
Hydraulic lift and remote control valve circuit diagram ( version with hydraulic trailer braking)

Fig. 104 - Hydraulic lift and remote control valve circuit diagram - version with hydraulic trailer braking
Key
1. Suction line filter (90 μm)
2. Hydraulic pump (22.5 cc/rev)
3. Hydraulic trailer braking valve
4. Free drain
5. 6-way remote control valve
6. Lift cylinder
7. Hydraulic lift control valve
8. Lift cover
9. Brake discs lubrication
10. PTO bearing lubrication system

10-107
 Technical characteristics
Hydraulic lift and remote control valve circuit diagram ( version with hydraulic trailer braking and front lift)

Fig. 105 - Hydraulic lift and remote control valve circuit diagram - version with hydraulic trailer braking and front
lift
Key
1. Suction line filter (90 μm)
2. Hydraulic pump (22.5 cc/rev)
3. Hydraulic trailer braking valve
4. Free drain
5. 6-way remote control valve
6. Front lift
7. Damper valve assembly
8. Rate of drop control valve
9. Lift cylinder
10. Hydraulic lift control valve
11. Lift cover
12. Brake discs lubrication
13. PTO bearing lubrication system

10-108
Technical characteristics
Hydraulic lift and remote control valve circuit diagram ( version with hydraulic trailer braking and front loader)

Fig. 106 - Hydraulic lift and remote control valve circuit diagram - version with hydraulic trailer braking and front
loader
Key
1. Suction line filter (90 μm)
2. Hydraulic pump (22.5 cc/rev)
3. Hydraulic trailer braking valve
4. Front loader control valve
5. 6-way remote control valve
6. Free drain
7. Lift cylinder
8. Hydraulic lift control valve
9. Lift cover
10. Brake discs lubrication
11. PTO bearing lubrication system

10-109
 Technical characteristics
10.4.2 - Hydraulic system (R3 EVO 85 -> 16001)
Description
The tractors in this series are equipped with a hydraulic system with two main circuits:
l Steering and services circuit.
l Lift and remote control valve circuit.
Each of these circuits is supplied with oil by a hydraulic gear pump that converts the power supplied by the engine into hydraulic
energy. The oil flow generated by the pumps is sent to the devices that control the distribution of the oil pressure to the actuators,
where the hydraulic energy is converted into mechanical energy.

7 8 9 10 11 12

A 13

B
6
14

5
15

2 3 16
4 17

D0025320

Fig. 107 - Hydraulic schematic

1. Suction line filter
2. Steering circuit gear pump
3. Lift gear pump
4. Suction line filter
5. Power steering valve
6. Steering cylinders
7. HML solenoid valve assembly
8. Hydraulic reverse shuttle solenoid valves assembly
9. 4WD engagement device
10. Differential lock engagement device
11. Rear PTO clutch
12. Services solenoid valve assembly
13. Remote control valve
14. Hydraulic lift control valve
15. Lift cylinder
16. HML and secondary shaft assembly lubrication

10-110
Technical characteristics

7 8 9 10 11 12

A 13

B
6
14

5
15

2 3 16
4 17

D0025320

Fig. 107 - Hydraulic schematic

17. Ejector

10-111
 Technical characteristics
Hydraulic system diagrams
Hydraulic steering and services diagram

7
6 32 cm3

5
0.8-8 bar
5
L R
0.5-1 L/min.

13
12

12 bar
T

Ø2 Ø1.1

Front Rear
150 Bar 8
4
P T

0.5-1 L/min.
1135 cm 3

11 bar
P C
M12x1.5 C1 M12x1.5 L C B A

21 bar 12 bar 5 bar

P1

T 500 µm T 500 µm
P P
90 µm
H

9
T T
11
10
E Sx 2

-0.5 bar

44 µm
1

D0036483
Rear gear box

Fig. 108 - Hydraulic steering and services diagram

1. Suction filter (44 µm)
2. Hydraulic pump (14 cc/rev)
3. Resonator
4. Power steering valve
5. Steering cylinders
6. Cooler
7. Rear PTO clutch engagement control
8. Differential lock

10-112
Technical characteristics
9. Pressure holding valves assembly
10. Filter
11. Services solenoid valve assembly
12. Rear PTO. shaft lubrication
13. PTO brake.
Hydraulic lift and remote control valve circuit diagram - standard version
6

B1 A1 B2 A2

4 5
T 210 bar

Ø1.2
T
Ø1
190 bar

RV
1 1

P H.P.C
T T T
Lif Lower
0 0 0.7x4 t
Ø1
2 2
0 1

Neutral
6 bar

2
Dx

-0.5 bar

44 µm 44 µm

0.03 bar

D0036491

Rear gear box

Fig. 109 - Hydraulic lift and remote control valve circuit diagram - standard version
1. Suction filter (44 µm)
2. Hydraulic pump (22.5 cc/rev)
3. Free drain
4. 4-way remote control valve
5. Hydraulic lift control valve
6. Lift cylinders

10-113
 Technical characteristics
Hydraulic lift and remote control valve circuit diagram - full optional version

7 v0= 0.7 L
p0= 130 bar

v0= 0.7 L 70 bar

p0= 130 bar

6
8
Q regol.
16 L/min

B1 A1 B2 A2 B3 A3
5
T T

190 bar

RV
1 1 1

P H.P.C

0 0 0

2 2 2 10
2 0 1 3
1
2 0

9
11 bar

T B
3 210 bar
Ø1.2
Freno trattore Sx
Lf Tractor brake

Ø1
T

Y2 N

Y1
T T T
Lift Lo wer
P 0.7x4
Comando ON/OFF Freno
Freno trattore Dx

Ø1
Rh Tractor brake

ON/OFF brake control

Neutral

6 bar

2
Dx T

-0.5 bar

1
44 µm 44 µm

0.03 bar

D0036531

Rear gear box

Fig. 110 - Hydraulic lift and remote control valve circuit diagram - full optional version
1. Suction filter (44 µm)
2. Hydraulic pump (22.5 cc/rev)
3. Hydraulic trailer braking valve
4. 6-way remote control valve
5. Free drain
6. Front lift
7. Damper valves assembly
8. Rate of drop control valve
9. Electronic lift directional control valve

10-114
Technical characteristics
10. Lift cylinders

10.4.3 - Hydraulic system (R3 EVO 100 -> 16001)

Description
The tractors in this series are equipped with a hydraulic system with two main circuits:
l Steering and services circuit.
l Hitch and ancillary utility distributor circuit.
Each of these circuits is supplied with oil by a hydraulic gear pump that converts the power supplied by the engine into hydraulic
energy. The oil flow generated by the pumps is sent to the devices that control the distribution of the oil pressure to the actuators,
where the hydraulic energy is converted into mechanical energy.

7 8 9 10 11 12

A 13

B
6
14

5
15

2 3 16
4 17

D0025320

Fig. 111 - Hydraulic system

1. Suction line filter
2. Steering circuit gear pump
3. Hitch gear pump
4. Suction line filter
5. Power steering
6. Steering cylinders
7. HML solenoid valve assembly
8. Hydraulic reverse shuttle solenoid valves assembly
9. 4WD engagement device
10. Differential lock engagement device
11. Rear PTO clutch
12. Services solenoid valve assembly
13. Ancillary utility distributor
14. Hitch control distributor
15. Hitch cylinder

10-115
 Technical characteristics
7 8 9 10 11 12

A 13

B
6
14

5
15

2 3 16
4 17

D0025320

Fig. 111 - Hydraulic system

16. HML and secondary shaft assembly lubrication
17. Ejector

10-116
Technical characteristics
Hydraulic system diagrams
Hydraulic steering and services diagram

9
6 32 cm3
5 5 0.8-8 bar

L R
0.5-1 L/min.

11
10

12 bar
T

Ø2 Ø1.1

150 Bar
4
P T

0.5-1 L/min.
1135 cm 3

11 bar
P C
M12x1.5 C1 M12x1.5 L C B A

21 bar 12 bar 5 bar

P1

T 500 µm T 500 µm
P P
90 µm
H

T T
7 8

E Sx 2

-0.5 bar

44 µm
1

D0036501
Rear gear box

Fig. 112 - Hydraulic steering and services diagram

1. Pickup filter (25 µm)
2. Hydraulic pump (14 cc/rev)
3. Resonator
4. Power steering
5. Steering cylinders
6. Cooler
7. Pressure regulator valve
8. Hi-Lo unit engage control solenoid valve

10-117
 Technical characteristics
9. Rear PTO clutch engagement control
10. PTO and shuttle shaft lubrication
11. PTO brake.
Hydraulic hitch and ancillary utility distributor circuit diagram - standard version

B1 A1 B2 A2

4 5
T 210 bar

Ø1.5
Ø1 T
RV

190 bar

1 1

P H.P.C.
Ø1 T T
Lif Lower
0 0 t
T Ø1
2 2
0 1

Neutral
6 bar

2
Dx

-0.5 bar

44 µm 44 µm

0.03 bar

D0036511
Rear gear box

Fig. 113 - Hydraulic hitch and ancillary utility distributor circuit diagram - standard version
1. Pickup filter (44 µm)
2. Hydraulic pump (22,5 cc/rev)
3. Free drain
4. 4-way ancillary utility distributor
5. Hitch control distributor
6. Hitch cylinders

10-118
 Technical characteristics
Hydraulic hitch and ancillary utility distributor circuit diagram - full optional version

7 v0= 0.7 L
p0= 130 bar

v0= 0.7 L 70 bar

p0= 130 bar

6
8
Q regol.
16 L/min

B1 A1 B2 A2 B3 A3
5
T T

190 bar

RV
1 1 1

P H.P.C

0 0 0

2 2 2 10
2 0 1 3
1
2 0

9
11 bar

T B
3 210 bar
Ø1.2
Freno trattore Sx
Lf Tractor brake

Ø1
T

Y2 N

Y1
Ø1 T T
Lift Lo wer
P T 0.7x4
Comando ON/OFF Freno
Freno trattore Dx

Ø1
Rh Tractor brake

ON/OFF brake control

Neutral

6 bar

2
Dx T

-0.5 bar

1
44 µm 44 µm

0.03 bar

D0036532
Rear gear box

Fig. 114 - Hydraulic hitch and ancillary utility distributor circuit diagram - full optional version
1. Pickup filter (44 µm)
2. Hydraulic pump (22,5 cc/rev)
3. Hydraulic trailer braking valve
4. Free drain
5. 8-way ancillary utility distributor
6. Front hitch
7. Damper valve assembly
8. Rate of drop control valve
9. Hitch cylinder

10-119
 Technical characteristics
10. Hitch unit auxiliary cylinder
11. Electronic hitch directional control valve

10.4.4 - Hydraulic system (R3 EVO 85 -> 20001)

Description
The tractors in this series are equipped with a hydraulic system with two main circuits:
1. Steering and services circuit.
2. Hitch and ancillary utility distributor circuit.
Each of these circuits is supplied with oil by a hydraulic gear pump that converts the power supplied by the engine into hydraulic
energy. The oil flow generated by the pumps is sent to the devices that control the distribution of the oil pressure to the actuators,
where the hydraulic energy is converted into mechanical energy.

7 8 9 10 11 12
14

A B

15
5

16
4

13
2
19 17
1
18

D0040650

Fig. 115 - Hydraulic schematic

Key
1. Suction line filter
2. Steering circuit gear pump
3. Resonator
4. Power steering
5. Steering cylinders
6. Delivery line filter
7. Hydraulic reverse shuttle solenoid valves assembly
8. Hi-Lo solenoid valves assembly
9. 4WD engagement device
10. Differential lock engagement device
11. Rear PTO clutch
12. Services solenoid valve assembly
13. Hitch gear pump
14. Ancillary utility distributor
15. Hitch control distributor

10-120
Technical characteristics
7 8 9 10 11 12
14

A B

15
5

16
4

13
2
19 17
1
18

D0040650

Fig. 115 - Hydraulic schematic

16. Hitch cylinder
17. Oil transfer pump
18. Filter
19. Shuttle lubrication

10-121
 Technical characteristics
Hydraulic circuit diagram
Hydraulic steering and services diagram (standard version)

1 L/min max 1 L/min max 14

AV RM
7
32 cm 3
0,5-1 L/min.
0.8-8 bar
5 5 Ø4,2

L R

LUB INV
18 19

RM
AV

12 bar
T
4 bar 4 2

S2 3 1 S1

Ø2 Ø1,1

Ø4,5
500 µm Ø4,0
150 bar
4 13
P T

p0= 10 bar 15 8
v0= 0.16 lt Front Rear

12

11 0,5-1 L/min

3.4 bar
3
1135 cm

3 6 2.4 bar
11 bar

P C
M12x1.5 C1 M12x1.5 L D C B A E

21 bar 12 bar 5 bar

P1 A A

P T T 500 µm T 500 µm P
T
H P P

Dx Sx 2 9
T T
10

-0.5 bar

16 Dx

90 µm
1 900 µm
17

Rear gear box Front gear box

D0040711

Fig. 116 - Hydraulic steering and services diagram (standard version)

Key
1. Suction filter (90 µm)
2. Hydraulic pump (14 cc/rev)
3. Resonator
4. Power steering
5. Steering cylinders
6. Delivery line filter (19µm - ß>1000)
7. Rear PTO clutch engagement control
8. Differential lock
9. Pressure holding valves assembly
10. Services solenoid valve assembly

10-122
Technical characteristics
1 L/min max 1 L/min max 14
AV RM
7
32 cm 3
0,5-1 L/min.
0.8-8 bar
5 5 Ø4,2

L R

LUB INV
18 19

RM
AV

12 bar
T
4 bar 4 2

S2 3 1 S1

Ø2 Ø1,1

Ø4,5
Ø4,0
500 µm
150 bar
4 13
P T

p0= 10 bar 15 8
v0= 0.16 lt Front Rear

12

11 0,5-1 L/min

3.4 bar
3
1135 cm

3 6 2.4 bar
11 bar

P C
M12x1.5 C1 M12x1.5 L D C B A E

21 bar 12 bar 5 bar

P1 A A

P T T 500 µm T 500 µm P
T
H P P

Dx Sx 2 9
T T
10

-0.5 bar

16 Dx

90 µm
1 900 µm
17

Rear gear box Front gear box

D0040711

Fig. 116 - Hydraulic steering and services diagram (standard version)

11. Cooler
12. Accumulator
13. Shuttle solenoid valves assembly
14. Shuttle unit
15. Shuttle lubrication
16. Oil transfer pump (13x0.8 cc/rev)
17. Washable filter with metal mesh
18. PTO and shuttle shaft lubrication
19. PTO brake.

10-123
 Technical characteristics
Hydraulic steering and services diagram - full optional version

1 L/min max 1 L/min max 14

AV RM
7
32 cm 3
0,5-1 L/min.
0.8-8 bar
5 5 Ø4,2

20
L R

LUB INV
18 21

RM
AV

12 bar
T
4 bar 4 2

S2 3 1 S1 19
3
Ø2 Ø1,1
3
9,8 cm 12,2 cm

Ø4,5
Ø4,0
3,3-3,7 bar 8-10,3 bar

H L
150 bar
4 13 500 µm

P T 0.5 bar

p0= 10 bar 15
v0= 0.16 lt
Ø2
12

M12x1.5

11 Front Rear
3.4 bar
8
3
1135 cm

3 6 2.4 bar
11 bar

0,5-1 L/min
P C
M12x1.5 C1 M12x1.5 L D B
C A E

21 bar 12 bar 5 bar

P1

T 500 µm T 500 µm T 500 µm T 500 µm

H P P P P

Dx Sx 2 9
T T
10

-0.5 bar

16 Dx
90 µm 900 µm
1 17
D0040721
Rear gear box Front gear box

Fig. 117 - Hydraulic steering and services diagram - full optional version
Key
1. Suction filter (90 µm)
2. Hydraulic pump (14 cc/rev)
3. Resonator
4. Power steering
5. Steering cylinders
6. Delivery line filter (19µm - ß>1000)
7. Rear PTO clutch engagement control
8. Differential lock
9. Pressure holding valves assembly
10. Services solenoid valve assembly
11. Cooler

10-124
Technical characteristics

1 L/min max 1 L/min max 14

AV RM
7
32 cm 3
0,5-1 L/min.
0.8-8 bar
5 5 Ø4,2

20
L R

LUB INV
18 21

RM
AV

12 bar
T
4 bar 4 2

S2 3 1 S1 19
3
Ø2 Ø1,1
3
9,8 cm 12,2 cm

Ø4,5
Ø4,0
3,3-3,7 bar 8-10,3 bar

H L
150 bar
4 13 500 µm

P T 0.5 bar

p0= 10 bar 15
v0= 0.16 lt
Ø2
12

M12x1.5

11 Front Rear
3.4 bar
8
3
1135 cm

3 6 2.4 bar
11 bar

0,5-1 L/min
P C
M12x1.5 C1 M12x1.5 L D B
C A E

21 bar 12 bar 5 bar

P1

T 500 µm T 500 µm T 500 µm T 500 µm

H P P P P

Dx Sx 2 9
T T
10

-0.5 bar

16 Dx
90 µm 900 µm
1 17
D0040721
Rear gear box Front gear box

Fig. 117 - Hydraulic steering and services diagram - full optional version
12. Accumulator
13. Shuttle solenoid valves assembly
14. Shuttle unit
15. Shuttle lubrication
16. Oil transfer pump (13x0.8 cc/rev)
17. Washable filter with metal mesh
18. PTO and shuttle shaft lubrication
19. Hi-Lo unit
20. 4WD engagement device
21. PTO brake.

10-125
 Technical characteristics
Hydraulic hitch and ancillary utility distributor circuit diagram - standard version

4 5
B1 A1 B2 A2

210 bar

Ø1.2
T

T
190 bar Ø1.0

RV
1 1
P H.P.C.
T
0.7x4 T T Lift Lower
0 0
2 2
Ø1
0 1

Neutral
6 bar T

3 7

8 9

2 Dx E

-0.5 bar

1 90 µm
D0040741

Rear gear box

Fig. 118 - Hydraulic hitch and ancillary utility distributor circuit diagram - standard version
Key
1. Suction filter (90 µm)
2. Hydraulic pump (22,5 cc/rev)
3. Free drain
4. 4-way ancillary utility distributor
5. Hitch control distributor
6. Hitch cylinders
7. Hitch cover
8. Brake discs lubrication
9. PTO bearing lubrication system
Hydraulic hitch and ancillary utility distributor circuit diagram - full optional version

10-126
Technical characteristics
5
v0= 0.7 L
v0= 0.7 L 7 P P
p0= 130 bar
p0= 130 bar

B1 A1 B2 A2 B3 A3

Q regol.
70 bar 6
16 L/min
T T

190 bar
8

3
RV
1 1 1
P H.P.C.

0 0 0

2 2 2
10

3
2 0 1

2 0 1
5

11 bar
9

T B
3 210 bar

Ø1.2
Ø1
T
N

Y2

Y1

T
0.7x4 T T Lift Lower
P
Ø1.0

Neutral
6 bar T
11
P
2 Dx E Sx

12
-0.5 bar D0040730

13

1 90 µm

Rear gear box

Fig. 119 - Hydraulic hitch and ancillary utility distributor circuit diagram - full optional version
Key
1. Suction filter (90 µm)
2. Hydraulic pump (22,5 cc/rev)
3. Hydraulic trailer braking valve
4. 6-way ancillary utility distributor
5. Free drain
6. Front hitch
7. Damper valve assembly
8. Rate of drop control valve
9. Hitch control distributor
10. Hitch cylinders
11. Hitch cover
12. Brake discs lubrication
13. PTO bearing lubrication system

10.4.5 - Hydraulic system (R3 EVO 100 -> 20001)

Description
The tractors in this series are equipped with a hydraulic system with two main circuits:
1. Steering and services circuit.
2. Lift and remote control valve circuit.
Each of these circuits is supplied with oil by a hydraulic gear pump that converts the power supplied by the engine into hydraulic
energy. The oil flow generated by the pumps is sent to the devices that control the distribution of the oil pressure to the actuators,
where the hydraulic energy is converted into mechanical energy.

10-127
 Technical characteristics
7 8 9 10 11 12
14

A B

15
5

16
4

13
2
19 17
1
18

D0040650

Fig. 120 - Hydraulic schematic

Key
1. Suction line filter
2. Steering circuit gear pump
3. Resonator
4. Power steering valve
5. Steering cylinders
6. Pressure line filter
7. Hydraulic reverse shuttle solenoid valves assembly
8. Hi-Lo solenoid valves assembly
9. 4WD engagement device
10. Differential lock engagement device
11. Rear PTO clutch
12. Services solenoid valve assembly
13. Lift gear pump
14. Remote control valve
15. Hydraulic lift control valve
16. Lift cylinder
17. Transfer pump
18. Filter
19. Shuttle lubrication

10-128
Technical characteristics
Hydraulic circuit diagram
Hydraulic steering and services diagram (standard version)

1 L/min max 1 L/min max 12

AV RM
9
3
32 cm
0,5-1 L/min.
0.8-8 bar
5 5 Ø4,2

L R

LUB INV
10 18

RM
AV

12 bar
11 T
4 2

4 bar
S2 3 1 S1

µm Ø2 Ø1,1

150 bar
4 p0= 10 bar
v0= 0.16 lt µm
P T

13
14

0,5-1 L/min

17
3
1135 cm

3.4 bar
3
11 bar

6 2.4 bar
P C
M12x1.5 C1 M12x1.5 L DB
C A E

µm
21 bar 12 bar 5 bar

P1 A A

P T T µm T µm P T
H P P

Dx Sx 2 7
T T
8

-0.5 bar

15 Dx

µm
1 µm 16

Rear gear box Front gear box D0040751

Fig. 121 - Hydraulic steering and services diagram (standard version)

Key
1. Suction filter (90 µm)
2. Hydraulic pump (14 cc/rev)
3. Resonator
4. Power steering valve
5. Steering cylinders
6. Pressure line filter (19µm, ß>1000)
7. Pressure holding valve
8. Services solenoid valve assembly
9. Rear PTO clutch engagement control
10. PTO and shuttle shaft lubrication

10-129
 Technical characteristics

1 L/min max 1 L/min max 12

AV RM
9
3
32 cm
0,5-1 L/min.
0.8-8 bar
5 5 Ø4,2

L R

LUB INV
10 18

RM
AV

12 bar
11 T
4 2

4 bar
S2 3 1 S1

µm Ø2 Ø1,1

150 bar
4 p0= 10 bar
v0= 0.16 lt µm
P T

13
14

0,5-1 L/min

17
3
1135 cm

3.4 bar
3
11 bar

6 2.4 bar
P C
M12x1.5 C1 M12x1.5 L DB
C A E

µm
21 bar 12 bar 5 bar

P1 A A

P T T µm T µm P T
H P P

Dx Sx 2 7
T T
8

-0.5 bar

15 Dx

µm
1 µm 16

Rear gear box Front gear box D0040751

Fig. 121 - Hydraulic steering and services diagram (standard version)

11. Shuttle solenoid valves assembly
12. Shuttle unit
13. Hydraulic shuttle lubrication
14. Differential lock
15. Oil transfer pump (13x0.8 cc/rev)
16. Washable filter with metal mesh
17. Cooler
18. PTO brake.

10-130
Technical characteristics
Hydraulic steering and services diagram - full optional version

1 L/min max
AV RM
1 L/min max 12
5 5 9

3
32 cm
0.8-8 bar
18

L R
10 0,5-1 L/min.

LUB INV
19

12 bar
RM
AV
T
11
4 2

4 bar

S2 3 1 S1

500 µm Ø2 Ø 1.1
9,8 cm
3

3,3-3,7 bar
12,2 cm
8-10,3 bar
3
17
H L
150 bar

p0= 10 bar
v0= 0.16 lt
500 µm
P T 0.5 bar

13 Ø2

M12x1.5
19 µm (c)
B > 1000

14
3.4 bar
3

3
1135 cm

0,5-1 L/min
2.4 bar
11 bar

P C

M12x1.5 C1 M12x1.5 L D C B A E

21 bar 12 bar 5 bar

P1

500 µm 500 µm 500 µm 500 µm

3
14 cm /giro
T T T T
(12,9-36,1 L/min)
2 H P P P P

Dx Sx 7
T T
825-2300 RPM
i = 55/49
8

-0.5 bar

15 3
13x0,8 cm /giro

Dx (9,6-26,8 L/min)

1 i = 55/49 (valori con n )

v
16
90 µm 900 µm

D0040701

Fig. 122 - Hydraulic steering and services diagram - full optional version
Key
1. Suction filter (90 µm)
2. Hydraulic pump (14 cc/rev)
3. Resonator
4. Power steering valve
5. Steering cylinders
6. Pressure line filter (19µm, ß>1000)
7. Pressure holding valve
8. Services solenoid valve assembly
9. Rear PTO clutch engagement control
10. PTO and shuttle shaft lubrication
11. Shuttle solenoid valves assembly

10-131
 Technical characteristics
1 L/min max
AV RM
1 L/min max 12
5 5 9

3
32 cm
0.8-8 bar
18

L R
10 0,5-1 L/min.

LUB INV
19

12 bar
RM
AV
T
11
4 2

4 bar

S2 3 1 S1

500 µm Ø2 Ø 1.1
9,8 cm
3

3,3-3,7 bar
12,2 cm
8-10,3 bar
3
17
H L
150 bar

p0= 10 bar
v0= 0.16 lt
500 µm
P T 0.5 bar

13 Ø2

M12x1.5
19 µm (c)
B > 1000

14
3.4 bar
3

3
1135 cm

0,5-1 L/min
2.4 bar
11 bar

P C

M12x1.5 C1 M12x1.5 L D C B A E

21 bar 12 bar 5 bar

P1

500 µm 500 µm 500 µm 500 µm

3
14 cm /giro
T T T T
(12,9-36,1 L/min)
2 H P P P P

Dx Sx 7
T T
825-2300 RPM
i = 55/49
8

-0.5 bar

15 3
13x0,8 cm /giro

Dx (9,6-26,8 L/min)

1 i = 55/49 (valori con n )

v
16
90 µm 900 µm

D0040701

Fig. 122 - Hydraulic steering and services diagram - full optional version
12. Shuttle unit
13. Hydraulic shuttle lubrication
14. Differential lock
15. Oil transfer pump (13x0.8 cc/rev)
16. Washable filter with metal mesh
17. Hi-Lo unit
18. 4WD engagement device
19. PTO brake.

10-132
Technical characteristics
Hydraulic lift and remote control valve circuit diagram - standard version

3 6

B1 A1 B2 A2

4 5 Q regol.
16 L/min

210 bar
T

Ø 1.5
T

Ø1
T
190 bar

RV

1 1

P H.P.C.
Ø1
0 0 T T Lift Lower

T
2 2

Ø1
1

0
T

Neutral
6 bar

3
22.5 cm /giro
(20,8-58,1 L/min)

2 Dx Sx 8 9
825-2300 RPM
i = 55/49

-0.5 bar

90 µm

D0040690

Fig. 123 - Hydraulic lift and remote control valve circuit diagram - standard version
Key
1. Suction filter (90 µm)
2. Hydraulic pump (22.5 cc/rev)
3. Free drain
4. 4-way remote control valve
5. Hydraulic lift control valve
6. Lift cylinders
7. Lift cover
8. Brake discs lubrication
9. PTO bearing lubrication system
Hydraulic lift and remote control valve circuit diagram - full optional version

10-133
 Technical characteristics
4 6
7
v0= 0.7 L
p0= 130 bar
v0= 0.7 L P P
p0= 130 bar

B1 A1 B2 A2 B3 A3
8
5
70 bar
Q regol.
16 L/min

T T

190 bar

RV

1 1 1

H.P.C.
P

0 0 0

2 2 2 10 9 10

3
2 0 1

1
2 0
11
11 bar

T B

3 210 bar
Ø1

Ø 1.5
Ø1 T

N
Y2

Y1

Ø1
T T Lift Lower
P
T
Ø1

12 T

Neutral
6 bar

3
22.5 cm /giro
P
(20,8-58,1 L/min)

2
Dx Sx T

13
825-2300 RPM
i = 55/49

-0.5 bar

14
1
90 um

D0040681

Fig. 124 - Hydraulic lift and remote control valve circuit diagram - full optional version
Key
1. Suction filter (90 µm)
2. Hydraulic pump (22.5 cc/rev)
3. Hydraulic trailer braking valve
4. Free drain
5. 6-way remote control valve
6. Front lift
7. Damper valves assembly
8. Rate of drop control valve
9. Lift cylinder
10. Lift unit auxiliary cylinder
11. Hydraulic lift control valve
12. Lift cover
13. Brake discs lubrication
14. PTO bearing lubrication system

10.4.6 - Hydraulic system (R3 EVO 110 -> 5001)

Description
The tractors in this series are equipped with a hydraulic system with two main circuits:
1. Steering, brakes and services circuit.
2. Lift and remote control valve circuit.
Each of these circuits is supplied with oil by a hydraulic gear pump that converts the power supplied by the engine into hydraulic
energy. The oil flow generated by the pumps is sent to the devices that control the distribution of the oil pressure to the actuators,
where the hydraulic energy is converted into mechanical energy.

10-134
Technical characteristics
7 8 9 10 11 12 13 14
16

A B

17
5

18
4

15
2
21 19
20 1

D0048250

Fig. 124 - Hydraulic schematic

Key
1. Suction line filter
2. Steering circuit gear pump
3. Resonator
4. Power steering valve
5. Steering cylinders
6. Pressure line filter
7. Hydraulic reverse shuttle solenoid valves assembly
8. Front brakes pilot valve
9. Park Brake valve
10. Hi-Lo solenoid valves assembly
11. 4WD engagement device
12. Differential lock engagement device
13. Rear PTO clutch
14. Services solenoid valve assembly
15. Lift gear pump
16. Remote control valve
17. Hydraulic lift control valve
18. Lift cylinder
19. Transfer pump
20. Filter
21. Shuttle lubrication

10-135
 Technical characteristics
Hydraulic circuit diagram
Hydraulic steering and services diagram

9
6 32 cm3
5 5 0.8-8 bar

L R
0.5-1 L/min.

11
10

12 bar
T

Ø2 Ø1.1

150 Bar
4
P T

0.5-1 L/min.
1135 cm 3

11 bar
P C
M12x1.5 C1 M12x1.5 L C B A

21 bar 12 bar 5 bar

P1

T 500 µm T 500 µm
P P
90 µm
H

T T
7 8

E Sx 2

-0.5 bar

44 µm
1

D0036501
Rear gear box

Fig. 125 - Hydraulic steering and services diagram

1. Suction filter (25 µm)
2. Hydraulic pump (14 cc/rev)
3. Resonator
4. Power steering valve
5. Steering cylinders
6. Cooler
7. Pressure holding valve
8. Hi-Lo unit engage control solenoid valve

10-136
Technical characteristics
9. Rear PTO clutch engagement control
10. PTO and shuttle shaft lubrication
11. PTO brake.
Hydraulic lift and remote control valve circuit diagram - standard version

6
5

3
220 bar

Ø3
B1 A1 B2 A2
Ø2 T

T 190 bar T

RV

1 1 Ø1
P T T Lift Lower
H.P.C. T
0 0 Ø1

Neutral
2 2
6 bar T
0 1

7
22.5 cm³ /giro
(20,8-58,1 L/min)

2 Dx Sx

8 9
-0.5 bar
-0.5 bar

1
44 µm
44 µm 44 µm

D0066250

Rear gear box

Fig. 126 - Hydraulic lift and remote control valve circuit diagram - standard version
Key
1. Suction filter (44 µm)
2. Hydraulic pump (22.5 cc/rev)
3. Free drain
4. 6-way remote control valve
5. Hydraulic lift control valve
6. Lift cylinders
7. Lift cover
8. Brake discs lubrication
9. PTO bearing lubrication system

10-137
 Technical characteristics
Hydraulic lift and remote control valve circuit diagram ( version with hydraulic trailer braking and front lift)
v0= 0.7 L
p0= 130 bar
6
7
4 v0= 0.7 L
p0= 130 bar P P

8
B1 A1 B2 A2 B3 A3 70 bar
Q regol.
16 L/min
T
5 190 bar T
P rest.
3

RSM
1 1 1
P H.P.C.

0 0 0
2 2 2
20 1

20 13
P reg.
P rest.

10
11 bar

220 bar
T B Ø3
To front axle brake valve

3
Lh Tractor brake

T
Ø2

Y
Ø1
T T Lift Lower
Rh Tractor brake

Neutral
Ø1
ON/OFF brake control P
6 bar T

22.5 cm³ /giro 11

(20,8-58,1 L/min)
T

2 Dx Sx

825-2300 RPM
i = 55/49
-0.5 bar
-0.5 bar
12
1
13
44 µm 44 µm D0066260

Rear gear box

Fig. 127 - Hydraulic lift and remote control valve circuit diagram - version with hydraulic trailer braking and front
lift
Key
1. Suction filter (44 µm)
2. Hydraulic pump (22.5 cc/rev)
3. Hydraulic trailer braking valve
4. Free drain
5. 6-way remote control valve
6. Front lift
7. Damper valves assembly
8. Rate of drop control valve
9. Lift cylinder
10. Hydraulic lift control valve
11. Lift cover
12. Brake discs lubrication
13. PTO bearing lubrication system

10-138
Technical characteristics
10.4.7 - Steering circuit pump - lift circuit pump ()
Steering circuit gear pump

D0021760

Fig. 128 - Steering circuit gear pump

l Displacement: 14 cc/rev
l Maximum operating pressure: 155 bar

10-139
 Technical characteristics
Lift circuit gear pump

D0021770

Fig. 129 - Lift circuit gear pump

l Displacement: 22.5 cc/rev
l Maximum operating pressure: 190 bar

10-140
Technical characteristics
10.4.8 - Power steering valve (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)

Fig. 130 - Power steering valve

Operation
l The power steering system consists of a control valve with a rotary spool; these components feature hydrostatic operation.
l When the steering wheel is turned, the rotary spool control valve sends the oil from the pump to one side or the other of the
steering cylinder. The rotary spool ensures that that the volume of oil delivered to the cylinder is proportional to the angle
through which the steering wheel is turned.
l In the event of a malfunction of the power steering pump, the rotary spool valve automatically functions as a manual pump to
ensure emergency steering.
Technical characteristics
l Pressure relief valve setting: 150-155 bar
l Displacement: 125 cc/rev

10-141
 Technical characteristics
10.4.9 - Power steering valve (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)

Fig. 131 - Power steering valve

Operation
l The power steering system consists of a control valve with a rotary spool; these components feature hydrostatic operation.
l When the steering wheel is turned, the rotary spool control valve sends the oil from the pump to one side or the other of the
steering cylinder. The rotary spool ensures that that the volume of oil delivered to the cylinder is proportional to the angle
through which the steering wheel is turned.
l In the event of a malfunction of the power steering pump, the rotary spool valve automatically functions as a manual pump to
ensure emergency steering.
Technical characteristics
l Pressure relief valve setting: 150 ... 155 bar
l Displacement: 80 cc/rev
l Anticavitation valves: nr.2 (Included)
l Check valve: Included
l Threaded holes
m “P” and “T” = M 22 x 1.5
m “L” and “R” = M 18 x 1.5

l Spool adjustment angle: 15°

10-142
Technical characteristics
Power steering hydraulic diagram

Fig. 132 - Power steering hydraulic diagram

10-143
 Technical characteristics
10.4.10 - Ancillary utility distributor 4-way version (R3 EVO 100 -> 16001, R3 EVO 100 ->
20001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001, R3 EVO 85 -> 20001)

1 2

B1 B2

A1 A2

4
3 2 4 1
B1 A1 B2 A2

190 bar
T

H.P.C.
1 1

P 0 0

2 2

1
0

D0036620

Fig. 133 - Ancillary utility distributor

Key
1. Double-acting section
2. Detent section
3. Pressure relief valve
4. Double/single acting conversion screw

10-144
Technical characteristics
10.4.11 - Remote control valve - 6-way version (R3 EVO 100 -> 16001, R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 110 -> 5001)

Fig. 134 - Remote control valve - 6-way version

Key
1. Flow divider valve
2. Kick-Out section
3. Detent section
4. Float section
5. Pressure relief valve
6. Non-return valve (check valve)
7. Inlet ( P )
8. Single-acting control valve (x2)
9. Outlet ( T )

10.4.12 - Hydraulic lift control valve (R3 EVO 110 -> 1001)
Hydraulic lift control valve
E

D D

C C
B B

A A
E
D0047930

Fig. 135 - Hydraulic lift control valve – Key to sectional views

10-145
 Technical characteristics
1 2 3

A- A
P 4 5
6 T1 7

B- B T

ł1.5 210 bar

ł1

7
T1
Lift Lower
T T
ł1

6 bar

T
D0047940
5 3
Fig. 136 - Hydraulic lift control valve (1/2)
Components
1. Spacer
2. Pilot/enabling valve spring
3. Pilot/enabling valve
4. Enabling valve
5. Enabling valve spring
6. Lift control spool return spring
7. Lift control spool

10-146
Technical characteristics
1 2 3 4 5

C- C
A
6 7 8

9 8 3 D-D

A
210 bar
9
ł1.5

ł1

T1
Lift Lower
T T
ł1

6 bar

P
E- E
T D0047950

Fig. 137 - Hydraulic lift control valve (2/2)

Components
1. Relief valve
2. Plug
3. Rate of drop control valve spool (Valvematic)
4. Plunger
5. Rate of drop regulator valve spring
6. One-way valve actuator piston
7. Spool
8. Non-return valve (check valve)
9. Inlet valve
Connections
l P - Control valve supply
l T - Drain
l A - Lift control
l T1 - Drain

10-147
 Technical characteristics
Function
l The function of the lift control valve is to direct oil pressure to the lifting cylinder, thereby allowing the implement to be raised
and lowered.
l It contains the following valves:
m Check valve (1)
m Rate of drop control valve (Valvematic) (2)
m Inlet valve (3)
m Enabling valve (4)
m Pilot/enabling valve (5)
m Relief valve (6)

Fig. 138 - Lift control valve

Operation
When the lift control is in neutral position
l The pressurised oil from pump (1) flows to line a. As all the passages are closed, the pressure increases and when the force
exerted on enabling valve (2) overcomes that of spring (3), valve (2) shifts to the right to allow oil to flow to tank.

10-148
Technical characteristics

Fig. 139 - Operation in neutral position

When the lift is lowered
l When spool (4) is shifted to the right, lift lowering begins; this can be divided into two stages:
STAGE 1
l When spool (4) is shifted to the right, this connects:
m line b with line c thereby allowing piston (6) to move to the right.
m line d with discharge line h thus enabling a reduction in the pressure in line e.

10-149
 Technical characteristics

Fig. 140 - Operation in ‘lower’ position - Stage 1

STAGE 2
l As piston (6) moves to the right, ball (7) is also shifted to the right, thereby connecting chamber m of check valve (8) with line e.
Consequently the pressure in chamber m decreases and the force exerted on piston (6) by the pressure in chamber n pushes
valve (8) to the right to connect line p with line e, thereby allowing the oil to flow and the lift to be be lowered. The regulator
valve (9) controls the rate of drop; when it shifts downwards, it limits the flow of oil between port t and line p.

10-150
Technical characteristics

Fig. 141 - Operation in ‘lower’ position - Stage 2

When the lift is raised
l When spool (4) is shifted to the left, this opens the connecting passages between lines b and d, f and g, a and e. When the
force exerted by the pressure in line e overcomes the pressure in chamber m, valve (8) is shifted to the right and oil can flow
into line p and from there, through valve (9), to port t and lifting cylinder (10). To increase the lifting speed, i.e. the flow of oil
to lifting cylinder (10), a one-way valve (11) is installed in parallel with spool (4); this ensures that oil is only supplied during
the lifting stage.

Fig. 142 - Operation in ‘raise’ position

10-151
 Technical characteristics
10.4.13 - Braking system (R3 EVO 110 -> 1001)
Description
The braking system is composed of 4 braking devices (1 for each wheel) operated by two hydraulic master cylinders with mechanical
control.
When the brake pedals are latched together, all the braking systems are operated simultaneously on all 4 wheels (front and back).
When the brake pedals are operated separately (latch disengaged), only the rear brakes are applied, with each pedal operating the
brake on the corresponding side of the tractor (right pedal - right brake, left pedal - left brake).
The front braking devices are operated simultaneously and independently by the brake pedal pressed (only one or both) thanks to
the pilot valve that intercepts the oil from both master cylinders selecting the circuit with the higher pressure value as the pilot circuit.
The pilot valve thus directs oil from the hydraulic services circuit to the front brakes, modulating the pressure according to the pilot
pressure from the brake master cylinders. In contrast, the rear braking devices are each operated by a separate master cylinder,
thereby allowing the operator to brake on one side only and thus reduce the steering radius.

Fig. 143 - Braking system diagram

1. Front axle
2. Master cylinder for Rh brakes
3. Master cylinder for Lh brakes
4. Pilot valve for front brakes
5. Rear axle

10-152
Technical characteristics
Servo-brake valve for front axle

Fig. 144 - Servo-brake valve for front axle

Connections
l Port R - Valve supply
l Port N - Drain
l Port T - To front axle brakes
l Port B1 - Pilot valve
l Port B2 - Pilot valve

10.4.14 - Trailer braking valve (R3 EVO 110 -> 1001)

ITALY version
Function
The trailer braking valve is fitted when hydraulic trailer braking is required.

10-153
 Technical characteristics
Operation

Fig. 145 - Trailer braking valve - ITALY version

Valve control lever in position “1”
l When lever (1) is in position “1” (valve activated) and the brake pedals are not pressed, there is a pressure of 12.5 bar (181.3
psi) available at port B.
l This pressure is supplied constantly to the trailer to release the parking brake. In this condition, the pressure detected by pres-
sure switch (2) is higher than the pressure setting and consequently indicator light (3) on the instrument panel is switched off.
l When the operator engages the parking brake, solenoid valve (4) is energised. The pressure at port B is thus eliminated and
pressure switch (2), on detecting the lack of pressure, illuminates indicator light (3) on the instrument panel.
l The pressure at port B is directly proportional to the pressure in the tractor braking circuit.
Valve control lever in position “O”
l When lever (1) is in position “O” (valve deactivated), there is no pressure at port B. As a result, pressure switch (2) detects the
lack of pressure and illuminates indicator light (3) on the instrument panel. In this condition, the pressure at port B remains null
regardless of the pressure in the tractor braking circuit.

10-154
Technical characteristics

Fig. 146 - Connections

Connections
l P - Supply to valve
l N - To remote control valve
l B - To trailer brake
l T - Drain
l Y1-Y2 - Connection to tractor braking system
l E - Parking brake pressure switch
Technical characteristics
l Maximum operating pressure at port N: 220 bar
l Minimum constant pressure at port B: 12.5±2.5 bar
l Maximum pressure at port B: 130±10 bar
l Oil supply flow rate: 20 to130 l/min
EXPORT version
Function
The trailer braking valve is fitted when hydraulic trailer braking is required.

10-155
 Technical characteristics
Operation

Fig. 147 - Trailer braking valve - EXPORT version

l When the brakes are not applied there is no pressure at port B.
l When the operator applies the tractor brakes, the pressure in the circuit pilots the braking valve and the pressure at port B
increases proportionally to the pressure in the tractor braking circuit.

Fig. 148 - Connections

Connections
l P - Supply to valve
l N - To remote control valve
l B - To trailer brake
l T - Drain
l Y1-Y2 - Connection to tractor braking system
Technical characteristics
l Maximum operating pressure at port N: 200 bar
l Minimum constant pressure at port B: 0 bar
l Maximum pressure at port B: 130 to150 bar
l Oil supply flow rate: 20 to 80 l/min

10-156
Technical characteristics
10.4.15 - Trailer braking valve (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3 EVO 110
-> 5001, R3 EVO 85 -> 16001)
ITALY version
Function
The trailer braking valve is fitted when hydraulic trailer braking is required.
Operation

Fig. 149 - Trailer braking valve - ITALY version

Valve control lever in position “1”.
l When lever (1) is in position “1” (valve activated) and the brake pedals are not pressed, there is a pressure of 12.5 bar (181.3
psi) available at port B.
l This pressure is supplied constantly to the trailer to release the parking brake. In this condition, the pressure detected by pres-
sure switch (2) is higher than the pressure setting and consequently indicator light (3) on the instrument panel is switched off.
l When the driver applies the handbrake, this operates lever (4). The pressure at port B is thus eliminated and pressure switch
(2), on detecting the lack of pressure, illuminates indicator light (3) on the instrument panel.
l The pressure at port B is directly proportional to the pressure in the tractor braking circuit.
Valve control lever in position “O”.
l When lever (1) is in position “O” (valve deactivated), there is no pressure at port B. As a result, pressure switch (2) detects the
lack of pressure and illuminates indicator light (3) on the instrument panel. In this condition, the pressure at port B remains null
regardless of the pressure in the tractor braking circuit.

10-157
 Technical characteristics

Fig. 150 - Connections

Connections
l P - Supply to valve
l N - To remote control valve
l B - To trailer brake
l T - Drain
l Y1-Y2 - Connection to tractor braking system
l E - Parking brake pressure switch
Technical characteristics
l Maximum operating pressure at port N: 200 bar (2900 psi)
l Minimum constant pressure at port B: 12.5±2 bar (181.3±29 psi)
l Maximum pressure at port B: 135±5 bar (1885±72.5 psi)
l Oil supply flow rate: 20-80 ,/min (5.3 - 79.7 US.gpm)
EXPORT version
Function
The trailer braking valve is fitted when hydraulic trailer braking is required.

10-158
Technical characteristics
Operation

Fig. 151 - Trailer braking valve - EXPORT version

l When the brakes are not applied there is no pressure at port B.
l When the operator applies the tractor brakes, the pressure in the circuit pilots the braking valve and the pressure at port B
increases proportionally to the pressure in the tractor braking circuit.

Fig. 152 - Connections

Connections
l P - Supply to valve
l N - To remote control valve
l B - To trailer brake
l T - Drain
l Y1-Y2 - Connection to tractor braking system
Technical characteristics
l Maximum operating pressure at port N: 200 bar (2900 psi)
l Minimum constant pressure at port B: 0 bar (0 psi)
l Maximum pressure at port B: 130-135 bar (1885÷1957.5 psi)

10-159
 Technical characteristics
l Oil supply flow rate: 20-80 l/min (5.3 - 8.7 US.gpm)

10.4.16 - Trailer braking valve (R3 EVO 85 -> 20001)

ITALY version
Function
The trailer braking valve is fitted when hydraulic trailer braking is required.
Operation

Fig. 153 - Operating diagram

l Valve control lever in position “1”
m When lever (1) is in position “1” (valve activated) and the brake pedals are not pressed, there is a pressure of 12.5 bar

(181.3 psi) available at port B.

m This pressure is supplied constantly to the trailer to release the parking brake. In this condition, the pressure detected

by pressure switch (2) is higher than the pressure setting and consequently indicator light (3) on the instrument panel
is switched off.
m When the driver applies the handbrake, this operates lever (4). The pressure at port B is thus eliminated and pressure

switch (2), on detecting the lack of pressure, illuminates indicator light (3) on the instrument panel.
m The pressure at port B is directly proportional to the pressure in the tractor braking circuit.

l Valve control lever in position “O”

m When lever (1) is in position “O” (valve deactivated), there is no pressure at port B. As a result, pressure switch (2)

detects the lack of pressure and illuminates indicator light (3) on the instrument panel. In this condition, the pressure at
port B remains null regardless of the pressure in the tractor braking circuit.

10-160
Technical characteristics
Connections

Fig. 154 - Connections

P - Valve supply
N - To auxiliary services control valve
B - To trailer brake
T - Drain
Y1-Y2 - Connection to tractor braking system
E - Parking brake pressure switch
Characteristics
l Maximum operating pressure at port N: 200 bar (2900 psi)
l Minimum constant pressure at port B: 12.5±2 bar (181.3±29 psi)
l Maximum pressure at port B: 135±5 bar (1885±72.5 psi)
l Oil supply flow rate: 20÷80 l/min (5.3 - 79.7 US.gpm)
EXPORT version
Function
The trailer braking valve is fitted when hydraulic trailer braking is required.

10-161
 Technical characteristics
Operation

Fig. 155 - Operating diagram

When the brakes are not applied there is no pressure at port B.
When the operator applies the tractor brakes, the pressure in the circuit pilots the braking valve and the pressure at port B increases
proportionally to the pressure in the tractor braking circuit.

Fig. 156 - Diagram

Connections
P - Valve supply
N - To auxiliary services control valve
B - To trailer brake
T - Drain
Y1-Y2 - Connection to tractor braking system
LS - Load Sensing signal
Characteristics
l Maximum operating pressure at port N: 200 bar (2900 psi)

10-162
Technical characteristics
l Minimum constant pressure at port B: 0 bar (0 psi)
l Maximum pressure at port B: 1305±bar (1885±72.5 psi)
l Oil supply flow rate: 20÷80 l/min (5.3 - 79.7 US.gpm)

10.4.17 - Park Brake system (R3 EVO 110 -> 1001)

Introduction
The Park Brake system is a braking device with three main functions:
1. parking brake
2. service brake
3. emergency brake
Park Brake - right-hand side view

Fig. 157 - Right-hand side view

Components
1. Pressure holding valve
2. Non-return valve (check valve)
3. Hydraulic accumulator (vol = 0.16 litres, precharge pressure = 10 ± 0.5 bar, maximum operating pressure = 20 bar)
4. Park Brake valve
5. Rear brake assembly
6. Hydraulic pump

10-163
 Technical characteristics
Park Brake - left-hand side view

Fig. 158 - Left-hand side view

Components
1. Hydraulic pump
2. Park Brake valve
3. Rear brake assembly
Main characteristics
The Park Brake offers the following advantages over a conventional parking brake:
l it is designed to meet the requirements of future standards
l it satisfies the need for enhanced braking capacity created by the increase in travel speeds
l it significantly reduces the amount energy required for vehicle motion as it eliminates the oil-immersed discs of a conventional
parking brake
l increased brake disc clearance and take-up device for the service brake piston
l adoption of a front axle servo valve to increase the overall braking capacity
Operation
The Park Brake system is based on a dual function braking device:
l negative parking brake
l service brake
Negative parking brake
The negative parking brake is applied when hydraulic pressure is removed from the braking device by moving lever (1) from position
“0” to position “1”. In the absence of hydraulic pressure, piston (2) is pushed to the right under the force exerted by Belleville springs
(3). Piston (2) thus pushes device brake piston (4) to the right, forcing friction discs (5) against counter discs (6), thereby generating
the braking force. The braking force of the parking brake is directly proportional to the force exerted by the Belleville springs.

10-164
Technical characteristics

Fig. 159 - Operation of the parking brake (1/2)

To release the parking brake, the operator needs to move lever (1) from position “1” to position “0”, thereby sending oil under pres-
sure into chamber PB and moving piston (2) to the left. This eliminates the force exerted on piston (4), leaving friction discs (5) free
to rotate.

10-165
 Technical characteristics

Fig. 160 - Operation of the parking brake (2/2)

NOTE
In an emergency, such as a failure of the tractor braking system with consequent loss of service brake operation (as a
result of a lack of hydraulic pressure or a malfunction of the braking system itself), the operator can apply the tractor
parking brake, modulating the braking force using the Park Brake lever.
Note
In the event of tractor malfunction, the parking brake can be applied manually by operating the emergency pump
located on the Park Brake valve. This forces pressurised oil into the parking brake circuit thereby braking the tractor.

Service brake
The service brake is always active, but is only effective when the Park Brake system is deactivated (i.e. when pressurised oil flows
into chamber PB and piston (2) is shifted to the left). In this case, the oil pressure, modulated by the operator using the brake pedal
and master cylinders (7), is directed into chamber PF. Parking brake piston (4) is thus pushed to the right, forcing friction discs (5)
against counter disks (6), thereby generating a braking force proportional to brake pedal travel.

10-166
Technical characteristics

Fig. 161 - Service brake

10-167
 Technical characteristics
10.4.18 - Park Brake valve (R3 EVO 110 -> 1001)
Description

Fig. 162 - Park Brake valve

Components
1. Operating lever
2. Emergency pump
3. Parking brake indicator light switch
4. Outlet for 15 bar pressure switch
Connections
l R - Supply pressure: M16 x 1.5 - ISO 6149
l N - Drain (immersed): M16 x 1.5 - ISO 6149
l B - Parking brake control (spring operated): M16 x 1.5 - ISO 6149
l B’ - Pressure switch (15 bar): M12 x 1.75

10.4.19 - Separate-Brakes valve (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001, R3 EVO 110
-> 5001, R3 EVO 85 -> 16001, R3 EVO 85 -> 20001)
Function
The Separate-Brakes valve serves to exclude front wheel braking when the operator presses only one of the brake pedals.

10-168
Technical characteristics

Fig. 163 - Separate-Brakes valve

Key
1. Left pedal
2. Right pedal
3. Both pedals

10-169
 Technical characteristics
Components

Fig. 164 - Valve components

Key
1. Control shaft
2. End cover
3. Flange
4. Control knob
5. Piston
6. Spring
7. Plunger
8. Ball
9. Spring
10. Spring
11. Ball

10-170
Technical characteristics
Operation
When the valve is not activated
l In the following explanation it is assumed that the operator presses just one of the brake pedals; operation with both pedals
pressed is the same.

Fig. 164 - Operation with valve not activated

l When the valve is not activated, piston (1) in the lower position and the force of springs (2) push spools (3) downwards.
l When one of the brake pedals is pressed (e.g. the RH pedal), the oil pressure pushes plunger (3) upwards against piston (1),
thereby opening the connecting passage between chambers a and b.
l This allows the oil pressure to reach both brakes on the side corresponding to the pedal that is pressed.
When the valve is activated and just one brake pedal is pressed
l When the valve is activated, pistons (1) are in their high position.
l When one of the brake pedals is pressed (e.g. the left pedal), the oil pressure pushes plunger (3) upwards, overcoming the
force of spring (2).
l At the same time ball (4) is pushed upwards by spring (5) so that it closes the connecting passage between chambers a and b.
l As a result, the oil flow from the pump is directed only towards the rear wheel brake.

10-171
 Technical characteristics

Fig. 165 - Operation with the valve activated and just one pedal pressed
When the valve is activated and both brake pedals are pressed
l When the valve is activated and both brake pedals are pressed, the oil flow is directed to chambers c and d.
l As the pressure acting on plungers (3) is the same, they are pushed downward exclusively by the force of springs (2).
l As a result, the oil flow from the master cylinders is directed to the front and rear brakes on both sides of the tractor.
l Even if the operator forgets to deactivate the valve after finishing field work, as soon as both brake pedals are pressed, braking
on all four wheels is ensured.

10-172
Technical characteristics

Fig. 166 - Operation with the valves activated and both brake pedals pressed

10-173
 Technical characteristics
10.4.20 - Pressure holding valves assembly (R3 EVO 100 -> 16001, R3 EVO 100 -> 20001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001, R3 EVO 85 -> 20001)
6 B

2
3

5 C C

B A A-A

5 6
P C
C1 L

4 21 bar 12 bar 5 bar

1
P1
2 D0047950

C-C
H

1 T
B-B 3 4 D0048280

Fig. 167 - Pressure holding valves assembly

Components
1. Non-return valve
2. Services circuit supply pressure control valve
3. Cooler by-pass valve
4. Lubrication pressure control valve
5. Pressure control valve test point
6. Cooler by-pass valve pressure test point

10-174
Technical characteristics

C1 P1
L

P C
C1 L

21 bar 12 bar 5 bar

P1
T
D0047950

D0048290

Fig. 168 - Pressure holding valves assembly

Connections
l P1 - Oil supply
l T – Tank
l H - Services solenoid valve supply
l L - To lubrication
l C1 - To cooler

10-175
 Technical characteristics
10.4.21 - Services solenoid valves assembly - Pressure holding valves (R3 EVO 110 ->
1001)
Services solenoid valve assembly

Fig. 169 - Services solenoid valve assembly

Components
1. 4WD control solenoid valve
2. PTO engagement solenoid valve
3. Differential lock engagement solenoid valve
4. Hi-Lo control solenoid valve
5. Pressure switch (11 bar)
Connections
l H - Oil supply (from pressure holding valves)
l T - Drain

10-176
Technical characteristics
l A - To rear PTO clutch
l B - To rear PTO brake clutch
l C - To differential lock engagement device
Pressure holding valves assembly

6 B

2
3

5 C C

B A A-A

5 6
P C
C1 L

4 21 bar 12 bar 5 bar

1
P1
2 D0047950

C-C
H

1 T
B-B 3 4 D0048280

Fig. 169 - Pressure holding valves assembly

Components
1. Non-return valve (check valve)
2. Services circuit supply pressure control valve
3. Cooler by-pass valve
4. Lubrication pressure control valve
5. Pressure control valve test point
6. Cooler by-pass valve pressure test point

10-177
 Technical characteristics

C1 P1
L

P C
C1 L

21 bar 12 bar 5 bar

P1
T
D0047950

D0048290

Fig. 169 - Pressure holding valves assembly

Connections
l P1 - Oil supply
l T - Drain
l H - Services solenoid valve supply
l L - To lubrication
l C1 - To cooler

10-178
Technical characteristics
10.4.22 - Shuttle solenoid valves assembly (R3 EVO 110 -> 1001)

Fig. 170 - Shuttle solenoid valves assembly (1/2)

Components
1. Accumulator
2. Pressure switch (4 bar)
3. Solenoid-operated proportional valve
4. Reverse gear solenoid valve
5. Forward gear solenoid valve
6. Forward gear pressure test point
7. Reverse gear pressure test point
8. Shuttle lubrication pressure test point
9. Temperature sensor

10-179
 Technical characteristics

Fig. 171 - Shuttle solenoid valves assembly (2/2)

Connections
l P - Supply
l T - Drain
l LI - Shuttle lubrication
l RM - To reverse drive clutch
l AV - To forward drive clutch
l L - Lubrication supply
l TA - Drain

10-180
20 - Calibrations and
electronic diagnosis

20-1
 Calibrations and electronic
diagnosis
20.1 - Diagnostic tools
20.1.1 - Position of ECUs and diagnostic instruments

0
1
2
3
4
5
6
7
8
12 11 10 9

Fig. 172 - Position of ECUs and diagnostic instruments

1. Instruments
2. Hydraulic shuttle lever
3. Engine ECU
4. Diagnostics socket
1 - Instrument panel

Fig. 173

20-2
Calibrations and electronic
diagnosis
2 - Hydraulic shuttle lever

Fig. 174

3 - Engine ECU

Fig. 175

4 - Diagnostic socket
To access the fuse box, remove the cover on the left side of the instrument panel.

Fig. 176

20.1.2 - All Round Tester (ART® SAME)

All Round Tester (ART®) ()
Description
To facilitate the operations of fault diagnosis, putting the vehicle into service and testing electrical components of the engine and lift,
the technician is provided with a test instrument called All Round Tester (hereinafter ART®). Using the ART® the technician can:
l display errors (faults) that have occurred;
l calibrate the sensors;
l display data detected by the electronic control units (e.g. status of the sensors) managing the systems.
Data is exchanged between the ART® and the ECUs by way of a diagnostic socket incorporated in the combine wiring. The ART® is
supplied with a number of different interface cables, which are to be selected in accordance with the type of vehicle and the methods
described in the relative workshop manual or in the CD supplied with the tester.
Description of the kit

20-3
 Calibrations and electronic
diagnosis
the ART® is supplied to authorised service centres in a case containing:
l Case, complete (P/N 5.9030.730.6/30)
m 1 - All Round Tester (P/N 5.9030.730.0)
m 2 - Diagnostic cable for BOSCH EHR4 rear hydraulic lift - Diagnosis

and programming cable of electronic regulator, original type - Diag-

nostic cable for SBA system, original type (P/N 5.9030.681.3/10)
m 3 - Adapter cable for radar connector (P/N 5.9030.681.7)
m 4 - Adapter cable for wheel speed sensor connector (P/N

5.9030.681.5)
m 5 - Cable for diagnostic socket (P/N 5.9030.681.4) (As from 01/01/06
Fig. 177
the cable has been modified to allow the ART® to connect to all
control units. Contact the Technical Assistance Service for further
information)
m 6 - Adapter cable for diagnosis socket on armrest (P/N 0.011.6178.4)
m 7 - Cable for connection to diagnosis socket in engine, gearbox, and

lift ECUs zone (P/N 0.011.5445.4)

m 8 - EPROM port box (P/N 0.010.2154.2)
m 9 - CD ROM (P/N 307.1056.8/60)

Notes on use
The ART® is protected against battery polarity inversion and positive and negative over voltages of brief duration (1 msec). Do not
attempt to connect the ART® to any sockets other than those specifically designed for use with the tester and do not use extension
leads. The display is permanently backlit to ensure visibility on all light conditions. The knob on the side of the tester allows contrast
adjustment. If the display appears blank, it is possible that the contrast knob is positioned in such a way that the data are not visible
on the screen. The tester operates correctly at temperatures between 0 and 40°C; it is advisable to switch the tester off every 30
minutes to help prolong its service life. Before disconnecting the ART® from the diagnostic socket, turn the starter key to the “O”
(OFF) position.
Description of the tester
The ART® comprises:
1. Liquid crystal display featuring permanent backlighting
2. 16-key alphanumeric keypad
3. Contrast adjustment knob. Serves to adjust the contrast of the display. If the
display appears blank, it is possible that the contrast knob is positioned in
such a way that the data are not visible on the screen.
4. Parallel port (used to connect the ART® to systems with electronic control
units that do not have microprocessors).
5. Serial port (used to connect the ART® to systems with electronic control
units incorporating microprocessors).

Fig. 178

General notes on connecting and powering up the Tester

1. To connect the tester to the vehicle’s electronic system, proceed as follows:
2. Switch off the engine and remove the key from the starter switch;
3. Connect the ART® to a diagnostic;
4. Insert the key in the starter switch and turn it to “I” (ON).

20-4
Calibrations and electronic
diagnosis
5. On power up, the ART® will display the battery charge level test. If the volt-
age is below 10V, the ART® will not have sufficient voltage to connect to
the ECUs, while voltages in excess of 15V could damage the ART®. After
a few seconds, the tester will attempt to connect to the electronic system
and will display a screen (which may vary according to the vehicle type
or the connector to which it is connected) from which the technician can
choose to connect to an ECU and test the operation of components.

Fig. 179

Selection of the display language

1. The ART® has the possibility to display information in a number of different languages (factory setting: ITALIAN). To change
the display language, proceed as follows.
2. Switch off the engine and remove the key from the starter switch
3. Connect the ART® to a diagnostic socket
4. While holding pressed key A on the keypad, turn the starter key to “I” (ON).
5. Enter the password 1 2 3 F.

Fig. 180
6. Press “1 - Language SEL.”.

Fig. 181

20-5
 Calibrations and electronic
diagnosis
7. Press “C to change” and then the key corresponding to the desired lan-
guage. In the example above, key “2 - ENGLISH” was pressed to select
English.
Press “E EXIT” twice to quit
Turn the starter key to “O” (OFF) and disconnect the ART® from the diag-
nostic socket.

Fig. 182

Serial ports configuration

1. The vehicle electronic systems to which the ART® can be connected differ from one another and utilize different pinouts at
the diagnostic socket.
For this reason, the serial ports must first be configured so as to guarantee full compatibility of the ART® with all SAME elec-
tronic systems.
To change the configuration of the serial ports, proceed as follows.
2. Switch off the engine and remove the key from the starter switch
3. Connect the ART® to a diagnostic socket
4. While holding pressed key A on the keypad, turn the starter key to “I” (ON)
5. Enter the password 1 2 3 F.

Fig. 182
6. Press “2 - Serial Ports”.

Fig. 183

20-6
Calibrations and electronic
diagnosis
7. Enable all the serial ports by pressing “1 - Port Enable” seven times.
Press “E EXIT” twice to quit.
Turn the starter key to “O” (OFF) and disconnect the ART® from the diag-
nostic socket.

Fig. 184

ART® - Diagnostic socket connection

ART® - Diagnostic socket connection
Table 40
Components Image From: To:
All Round Tester (ART®) - -

Fig. 185
Cable for diagnostic socket (P/N (ART®) Tractor diagnostic
5.9030.681.4); A = Connection to the socket
ART®; B = Connection to diagnostic socket

Fig. 186
Tractor diagnostic socket - -

Fig. 187

20-7
 Calibrations and electronic
diagnosis
20.1.3 - SDF Analyser
SDF Analyser
Description
The SDF Analyser instrument lets the technician troubleshoot and commission the tractor correctly, and test the functions of the
electric components of the tractor’s on-board systems and engine.
Data is exchanged between the instrument and the electronic control units on the tractor via a diagnostic socket installed on the
tractor wiring harness.
The SDF Analyser lets the technician perform the following:
l View data received from the different electronic control units (e.g. sensor, button and potentiometer states etc.) managing the
tractor systems.
l Test the functions of the electric components installed on the tractor. (e.g. buttons, potentiometers, solenoid valves etc.)
l Perform the operations necessary for commissioning the tractor, calibrating the hydraulic reverse shuttle and calibrating sen-
sors.
l View errors (faults).
-
Advantages
Using the SDF Analyser offers a number of significant advantages because:
l It has a screen refresh rate two time faster than previous diagnostic systems.
l It is compatible with all laptop operating systems in use today. It is faster than the ART® (All Round Tester).
l It functions as an active interface, with its own microprocessor and flash memory. New software updates are easily installable
with a guided menu.
l It may be used on both old and new tractors, using the specific adapter cables included following the instructions given in the
relative training and workshop manuals.
l May be connected to the laptop either with a USB cable or by Bluetooth connection within a 10 metre range.
-
Description of Kit
The SDF Analyser is delivered to Authorised Service Centres in a case containing the following:
1. Complete SDF Analyser carrier case (P/N 5.9030.997.0) 6 7
2. Analyser tool (P/N 5.9030.997.1) 8
3. Base PC Tester diagnostic cable (P/N 5.9030.997.2)
4. Base EDS diagnostic cable (P/N 5.9030.997.4) 4
5. Bluetooth dongle (P/N 5.9030.997.5)
6. EDS adapter cable, first type (P/N 5.9030.997.6)
7. PC Tester adapter cable for Deutz (P/N 5.9030.997.7)
8. PC Tester adapter cable for Rubin /Iron (P/N 5.9030.997.8)
9. Case containing: 9

m CD-Rom for installing software on laptop and

10
m Multi-language handbook with installation instructions. 3 2
1 5
10. USB connection cable
Fig. 188

-
Installing the software
The minimum requisites for the laptop for installation of the SDF Analyser base
software and the PC diagnostic software are indicated in the multi-language hand-
book included in the case. The installation procedure is also described in the hand-
book. Installing the SDF Analyser software is simple and only takes a few minutes.
Once the software is installed, the icons for launching the 3 functions of the soft-
ware will be displayed on the desktop of the host laptop.

Fig. 189

20-8
Calibrations and electronic
diagnosis
-
Functions
The SDF Analyser software consists of 3 functions:
PC Tester
Generally used for connection to electronic control units on tractors with CANBUS network. There are
certain exceptions, however, which are described in detail in the specific training courses.
PCTester

CVT Diag
For connection to “Infocenter” on-board instruments.

CVT Diag

SDF Analyser
For connection to ZF electronic control units on tractors without CANBUS network.

SDF Analyser

-
Connecting tool and launching software
Side: Tool-Tractor
Connect the SDF Analyser to the electronic system of the tractor as follows:
1. Switch the tractor off and remove the ignition key,
2. Connect the SDF Analyser interface to the correct adapter cable (in relation to tractor diagnosed), then connect the cable to
the diagnostic socket on board the tractor,
3. Turn the ignition switch to “On”.
-
Tool-Laptop side
Connect the SDF Analyser to the laptop as follows:
l Use the Bluetooth dongle to connect via Bluetooth, or
l Enable Bluetooth on your laptop (if laptop has integrated Bluetooth module), or
l Connect the SDF Analyser interface to the laptop with the USB connector cable.
-
Launching functions
To launch any of the functions, double-click the respective icon on the desktop.
-
Basic settings in PC Tester
The user may configure a number of basic settings (e.g. language, COM ports, screen layout etc.) for the PC Tester function before
starting to use the function itself. Proceed as follows:

20-9
 Calibrations and electronic
diagnosis
Double-click the relative icon on the desktop and wait for the start screen.
Select “Tools” and then “Setup” from the option menu.

Fig. 190

-
Menus available:
l “Interface” / Interface,
l “Lines Selection” / Lines Selection,
l “Interface” / Interface.
-
“Interface” / Interface menu
The following may be selected from this menu:
l Interface and COM ports, and
l display language.

Fig. 191

-
“Visual Style” / Visual Style menu
The following may be selected from this menu:
l Background colour of screens,
l Font colour,
l Font type, and
l Enable “Microsoft Word” function
(reproduces PC Tester screens in a Word document.)

Fig. 192

-
“Lines Selection” / Lines Selection menu
The following may be selected from this menu:
l Tractor ECU pin mapping in manual mode.

Fig. 193

20-10
Calibrations and electronic
diagnosis
-
Base settings in SDF Analyser
The user may configure a number of basic settings for (e.g. language, COM ports, screen layout etc.) for the SDF Analyser function
before starting to use the function itself. Proceed as follows:
Double-click the relative icon on the desktop and wait for the start screen.
Select “Continue” / Continue from the options menu, then select “Configuration” /
Configuration.

Fig. 194

-
“Configuration” / Configuration menu
The following may be selected from this menu:
l Interface,
l Display language,
l COM ports,
l Font type, and
l Window layout.

Fig. 195

-
SDF Analyser - Diagnostic socket
SDF Analyser - Diagnostic socket
Table 41
Components Image From: To:
SDF Analyser - -

Fig. 196

20-11
 Calibrations and electronic
diagnosis
Components Image From: To:
Cable for diagnostic socket (P/N SDF Analyser Tractor diagnostic
5.9030.997.2); A = Connection to SDF socket
Analyser; B = Connection to diagnostic
socket

Fig. 197
Tractor diagnostic socket - -

Fig. 197

20.1.4 - Serdia 2000

SERDIA 2000 level III” software
SERDIA 2000 level III” software
To enable correct analysis of faults, facilitate the procedure of putting the tractor into service and check correct operation of the
engine electrical components, the Technician is provided with a software application called SERDIA (P/N. 5.9030.740.4/30), for in-
stallation on a portable computer. With SERDIA, the technician can:
l display errors (faults) that have occurred;
l program the control unit;
l carry out sensor calibration or setting procedures.
Description of the kit
The SERDIA software is supplied to Authorised Workshops in a carrying case with all the basic items needed for operation. The case
contains:

Fig. 198

20-12
Calibrations and electronic
diagnosis
Table 42
Pos. Code Description Qty
5.9030.740.4/30 Case, complete 1
1 5.9030.740.0/10 . Installation disk 1
2 5.9030.740.2/10 . Level III interface, General revision + USB cable 1
3 5.9030.741.0 Adapter cable (not included in kit) 1
Data is exchanged between the SERDIA software and the control units by way of a diagnostic socket incorporated in the tractor
wiring.
Accordingly, the SERDIA package is supplied with an interface cable that must be used on the particular model and version of tractor
being serviced.

20-13
 Calibrations and electronic
diagnosis
20.2 - Diagnostic tool screens
20.2.1 - ECU interrogation
Diagnostics
Diagnostics is the set of analytical and reporting activities which, through the measurement of certain physical parameters characteri-
sing the machine monitored, provide significant information on the status of the machine itself and on how its status varies over time,
to enable the evaluation and prediction of both short and long term reliability.
How diagnostics works
When connected to the diagnostic sockets of tractors with specific cables, the All Round Tester (ART®) and SDF Analyser tools con-
nect to and interrogate the different ECUs in the machine, and display the relative data acquired on screen.
ECUs interrogated by the All Round Tester (ART®) and SDF Analyser
The All Round Tester (ART®) and SDF Analyser tools may acquire and analyse data from the following electronic control units. Rear
hitch (EKR), front suspension, HPSA, HLHP1, HLHP2, PTO, Pre-heat, Hydraulic reverse shuttle (“Smart Lever”), Transmission, ZF
transmissions (TCU/VDC, SGR/FMGR), SLH engines, Instrument CLUSTER: INFOCENTER.
WARNING
The primary diagnostic functions of Deutz-AG ECUs are performed with the Serdia 2000/Serdia 2010 diagnostic tools.

WARNING
However, certain procedures are accessible and certain information viewable also with the All Round Tester (ART®)
and SDF Analyser diagnostic tools.

How to select the ECU interrogated

All Round Tester (ART®)
1. Switch the tractor off and remove the ignition key;
2. Connect the ART® to the diagnostic socket;
3. Turn the ignition switch to “I” (ON);
4. When the ART® tool switches on, the battery charge level test screen is displayed.
WARNING
A voltage of less than 10V is insufficient for the ART® to connect to the ECUs, whereas voltages above 15V may
damage the tool itself.

5. After a few seconds, the tester attempts to connect to the electronic system of M E N U
the tractor, and displays a screen (which differs in relation to tractor model and the = = = = = = = = = = = = = = = =
diagnostic connector used) in which the technician may select which ECU to con-
nect to, and analyse functions of components. 1 - E N G I N E E C U
3 - S M A R T L E V E R
=> The image aside shows an example of a selection screen visible when using
4 - C L U S T E R
the All Round Tester (ART®), in this case connected to the Agrofarm 115G tractor X - . . . . .
1 - “Engine ECU” / SHL Tier3a engine ECU, Y - . . . . .
2 - “Smart Lever” / Hydraulic reverse shuttle ECU integrated in “Smart Lever”
shuttle lever,
3 - “Cluster” / Digital on-board instrument cluster.

= = = = = = = = = = = = = = = =
[ E ] E x i t
Fig. 199

WARNING
To change from one ECU to another, switch the tractor off, reconnect and select the new ECU.

20-14
Calibrations and electronic
diagnosis
---
SDF Analyser
1. Switch the tractor off and remove the ignition key;
2. Connect the SDF Analyser to the diagnostic socket;
3. Turn the ignition switch to “I” (ON);
4. Launch the diagnostic programme on your computer;
5. After scanning the channels, the tester attempts to connect to the electronic
system of the tractor, and displays a screen (which differs in relation to tractor
model and the diagnostic connector used) showing the technician a list of the
ECUs recognised. Press “End”.
=> The image aside shows an example of a selection screen visible when using
the SDF Analyser, in this case connected to the Dorado³ 100 tractor:
● “Cluster” / Digital on-board instrument cluster.
● “Smart Lever” / Hydraulic reverse shuttle ECU integrated in “Smart Lever” shut-
tle lever,
● “Engine ECU” / SHL Tier3a engine ECU,
Fig. 200

WARNING
To interrogate a different ECU, simply select the name of the de-
sired ECU
(the image aside shows an example of a selection screen visible when using the
SDF Analyser -
in this case connected to the Dorado³ 100 tractor).

Fig. 201

Menus available for each ECU

The number of ECUs listed varies in relation to the model of tractor the tool is connected to.
After selecting an ECU, the list of options available usually consists of either
5 choices: M A I N M E N U
1. “Monitors”/Monitor Menu: = = = = = = = = = = = = = = = =
Analyses all sensors in monitor mode. View data received from the different
1 - M o n i t o r s
electronic control units (e.g. sensor, button and potentiometer states etc.) 2 - P a r a m e t e r s
managing the tractor systems. 3 - C a l i b r a t i o n s
2. “Parameters”/Parameter Menu: 4 - T e s t s
For setting certain machine options. 5 - A l a r m s
3. “Calibrations”/Calibration Menu:
For calibrating the different subsystems of the machine, performing the op-
erations necessary for commissioning the tractor, calibrating the hydraulic
reverse shuttle and calibrating sensors.
4. “Tests”/Test Menu:
For testing actuators and testing the functions of the electric components
= = = = = = = = = = = = = = = =
installed on the tractor. (e.g. buttons, potentiometers, solenoid valves etc.)
[ E ] E x i t
5. “Alarms”/Alarm list:
Displays all active and passive alarms. Alarms may also be cancelled from Fig. 202
this menu.
or

20-15
 Calibrations and electronic
diagnosis
4 choices: M A I N M E N U
1. “Monitors”/Monitor Menu: = = = = = = = = = = = = = = = =
Analyses all sensors in monitor mode. View data received from the different
1 - M o n i t o r s
electronic control units (e.g. sensor, button and potentiometer states etc.)
2 - C a l i b r a t i o n s
managing the tractor systems. 3 - T e s t s
2. “Calibrations”/Calibration Menu: 4 - A l a r m s
For calibrating the different subsystems of the machine, performing the op-
erations necessary for commissioning the tractor, calibrating the hydraulic
reverse shuttle and calibrating sensors.
3. “Tests”/Test Menu:
For testing actuators and testing the functions of the electric components
installed on the tractor. (e.g. buttons, potentiometers, solenoid valves etc.)
4. “Alarms”/Alarm list:
= = = = = = = = = = = = = = = =
Displays all active and passive alarms. Alarms may also be cancelled from
[ E ] E x i t
this menu.
Fig. 203

---
Hidden menus are also available for certain ECUs, which can only be accessed by M A I N M E N U
entering a specific password. = = = = = = = = = = = = = = = =

1 - M o n i t o r s
2 - P a r a m e t e r s
3 - C a l i b r a t i o n s
4 - T e s t s
5 - A l a r m s

C - I n i t i a l i t .

= = = = = = = = = = = = = = = =
[ E ] E x i t
Fig. 204

20-16
Calibrations and electronic
diagnosis
20.3 - Commissioning and calibrating the tractor
20.3.1 - Digital instrument calibration
Purpose
The following assembly standard (p/n 930774/09) is designed to provide instructions for correct calibration of the new digital Check
Panel.
Setting parameters with the ART® Diagnostic Tester
Using the ART diagnostic tester, the instrument panel can be set up so that it func-
A V A I L A B L E T E S T
tions correctly on any tractor model.
M E N U
l Machine configuration
l Wheels constant

Connect the tester to the diagnostics socket and turn the starter key to “power”. 1 - S M A R T L E V E R
The main tester page will display the names of the electronic control units con- 2 - C L U S T E R

nected to the serial line:

l Select “2 - Cluster”

C H O I C E

[ E ] E x i t

Fig. 205

The following screen appears, showing the SW version and the date:
C L U S T E R
Press E
- - - - - - - - - - - - - - - -
- - - - - - - - - - - - - - - -

F i r m w a r e I C 2 9 6 A D
0 2 / 0 2 / 2 0 1 2

[ E ] E x i t

Fig. 206

The “Main Menu” screen will appear.

M A I N M E N U
- - - - - - - - - - - - - - - -

1 - M o n i t o r s
2 - C a l i b r a t i o n s
3 - T e s t
4 - A l a r m L i s t

[ E ] E x i t

Fig. 207

20-17
 Calibrations and electronic
diagnosis
Press “2 - Calibrations” to enter the calibration menu.
C A L I B R A T I O N M E N U
The following screen will appear.
- - - - - - - - - - - - - - - -
Press “1 - Parameters” to enter the parameter calibration menu.
1 - P a r a m e t e r s

[ E ] E x i t

Fig. 208

Change machine configuration

l “Wheel” C A L I B R A T I O N
Wheels constant setting
- - - - - - - - - - - - - - - -
l “AlarmBelt”
Belt alarm setting
1 - W h e e l 3 3 0 9
l “ActiveConf”
2 - A l a r m B e l t 0
Instrument configuration setting
l “Vel” 3 - A c t i v e C o nf 2 1
4 - V e l [ 1 = m p h ] 0
Speed units of measurement setting:
m 0 = km/h
5 - C l o c k [ 1 = 1 2 h ] 0
m 1 = mph 6 - M a x T e m p 1 0 8

l “Clock”
Time display format setting:
m 0 = 24h
m 1 = 12h
[ E ] E x i t
l “MaxTemp” (°C)
Max. engine coolant temperature value above which the red warning light Fig. 209
on the instrument panel will illuminate.
Press “3 - ActiveConf” to configure the instrument on the basis of the machine on which it is installed:
Table 43
Tractor Version Hydraulic Lift Config. Instru-
Shuttle ment
Explorer³ 85, 100 (GS) EU-USA (Hi-Lo) Yes - 16
R3. Evo 85, 100 (GS)
XB Max 85, 100 (GS)
Agrofarm 410, 420 (GS)
Table 44
Tractor Version Hydraulic Lift Config. Instru-
Shuttle ment
Explorer³ 85, 100 (GS) EU-USA Yes - 17
R3. Evo 85, 100 (GS)
XB Max 85, 100 (GS)
Agrofarm 410, 420 (GS)
Table 45
Tractor Version Hydraulic Lift Config. Instru-
Shuttle ment
Explorer³ 110 (GS) EU-USA Yes - 18
R3. Evo 110 (GS)
XB Max 110 (GS)
Agrofarm 430 (GS)

20-18
Calibrations and electronic
diagnosis
Table 46
Tractor Version Hydraulic Lift Config. Instru-
Shuttle ment
Explorer³ (LS) Digitek option + Seat No - 25
R3. Evo (LS) control
XB Max (LS)
Agrofarm (LS)
Table 47
Tractor Version Hydraulic Lift Config. Instru-
Shuttle ment
Explorer³ (LS) Digitek option No - 20
R3. Evo (LS)
XB Max (LS)
Agrofarm (LS)
On the next screen, enter the configuration number for the machine on which the
3 - A c t i v e C o n f
instrument panel is installed:
- - - - - - - - - - - - - - - -
Press “E” to exit and then “C” to confirm and save the configuration.

A c t u a l : 2 1

N e w :

[ D ] E r a s e
[ E ] E x i t

Fig. 210

Edit or Input wheels constant

Return to the “Calibrations” menu.
C A L I B R A T I O N
Press “1 - Wheels”
- - - - - - - - - - - - - - - -

1 - W h e e l 3 3 0 9
2 - A l a r m B e l t 0
3 - A c t i v e C o nf 2 1
4 - V e l [ 1 = m p h ] 0
5 - C l o c k [ 1 = 1 2 h ] 0
6 - M a x T e m p 1 0 8

[ E ] E x i t

Fig. 210

20-19
 Calibrations and electronic
diagnosis
Enter the constant on the basis of the table shown.
1 - W h e e l
Press “E” to exit and then “C” to confirm and save the configuration.
- - - - - - - - - - - - - - - -

A c t u a l : 3 3 0 9

N e w :

[ D ] E r a s e
[ E ] E x i t

Fig. 211

Wheels constants
The wheels constant parameter to be entered in the instrument must represent the pulses for 25m generated by the speed measu-
rement sensor.
Table 48
Tyres constant
85 hp 100 - 110 hp
13.6 R38 5098 4671
14.9 R38 4518
16.9 R30 5429 4973
16.9 R34 5064 4640
16.9 R38 4348
18.4 R30 5240 4801
18.4 R34 4489
340/85 R38 5098 4671
380/85 R38 4489
420/85 R30 5429 4973
420/85 R34 5064 4640
420/85 R38 4348
460/85 R30 5240 4801
460/85 R34 4489
480/70 R30 5429 4973
480/70 R34 5064 4640
480/70 R38 4348
520/70 R34 4489
540/65 R30 5429 4973
540/65 R34 5064 4640
540/65 R38 4348

20-20
Calibrations and electronic
diagnosis
Changing the km/h - mp/h Parameter
Return to the “Calibrations” menu.
C A L I B R A T I O N
Press “4 - Vel” to enter the km/h or mp/h selection menu
- - - - - - - - - - - - - - - -
To display the speed in mph press (1) or press (0) to display the speed in km/h.
Press “E” to exit and then “C” to confirm and save the configuration. 1 - W h e e l 3 3 0 9
2 - A l a r m B e l t 0
3 - A c t i v e C o nf 2 1
4 - V e l [ 1 = m p h ] 0
5 - C l o c k [ 1 = 1 2 h ] 0
6 - M a x T e m p 1 0 8

[ E ] E x i t

Fig. 211

Setting parameters with the control buttons

The two buttons on the instrument panel are used set certain operating parameters and to select the various display functions.
Table 49
Description Abbreviation
Hour meter display button (high position) PD_H
Multifunction display button (low position) PD_L
Parameter Setting
Press buttons PD_H and PD_L simultaneously and hold them for more than 2 seconds to enter parameter setting mode. The first
parameter that can be set by pressing the buttons is the clock.
Press button PD_L briefly to increase the hours setting one unit at a time (if the hours digit is flashing) or the minutes setting (if the
minutes digit is flashing). The setting procedure always starts with the hours by default.
Press the PD_H button briefly to change the digit being edited, from hours to minutes or from minutes to hours.
A prolonged press of the PD_H button serves to save the new time and change the parameter being edited, from the time to the whe-
els constant. If, however, no buttons are pressed for 10 seconds, the system will quit parameter setting mode without saving any of
the changes made to the clock. When the new time has been saved or when the system times out and therefore quits programming,
the display stops flashing.
Likewise, brief presses of PD_L increase the digit being edited, while brief presses of PD_H serve to change the parameter subject
to editing (relative to the size of the tyres).
A prolonged press of PD_H serves to save the new tyre size and change the parameter being edited: after the tyre size parameter,
the next parameter to appear is the indicator light brightness. If, however, no buttons are pressed for 10 seconds the system will quit
parameter setting mode without saving any of the changes made to the tyre size (although the changes made to the time setting will
be saved).
Likewise, short presses of PD_L increase the digit being edited, which flashes at 1Hz (relative to the indicator lights brightness).
Check that the message LUM appears on the LCD3 followed by a flashing letter, which can be H, M, or L for the three brightness
levels High, Medium, and Low.
A prolonged press of PD_H serves to save the indicator lights brightness parameter and quit parameter setting mode. If, however,
no buttons are pressed for 10 seconds the system will quit parameter setting mode without saving the change made to the indicator
lights brightness setting (although changes made to the time and tyre size settings will be saved).
PD_H button
A brief press of the PD_H button makes it possible to change the information shown on the second line of the central display. When
the on-board panel is switched on, the total hour meter is displayed.
A short press of PD_H shows the metres counter (if available), while a second short press causes the display to return to the total
hours meter, and so forth. During display of the metres counter, a prolonged press of PD_H serves to reset the total. The total hour
meter cannot be reset. At each press (short or prolonged) of the button the buzzer emits a tone.

20-21
 Calibrations and electronic
diagnosis
PD_L button
A prolonged press of PD_L resets the partial hour meter. At each press (short or prolonged) of the button the buzzer emits a tone
(different from the tone associated with PD_H).
20.3.2 - Renewal of the shuttle ECU - Introduction (R3 EVO 100 -> 20001, R3 EVO 110 ->
1001, R3 EVO 85 -> 20001)
Each time the shuttle ECU is renewed, the technician must carry out the following operations:
1. Initialisation of the ECU,
2. Line end programming,
3. Automatic calibration of the shuttle clutches,
4. Manual calibration of the shuttle clutches
5. Editing the comfort parameters.
To perform these operations, connect the ART/PC to the connector on the left-
A V A I L A B L E T E S T
hand side of the instrument panel, select the shuttle ECU (SMART LEVER) from
M E N U
the “AVAILABLE TESTS” menu and proceed as described below.

1 - S M A R T L E V E R
2 - C L U S T E R

C H O I C E
[ E ] E x i t

Fig. 212

DANGER
The operations for ECU initialisation, clutch pedal calibration and configuration of optional devices are required after
renewal of the ECU and must be performed with the engine switched off, the gear and speed range levers in neutral
and the parking brake engaged.

20.3.3 - Renewal of the shuttle ECU - Initialisation of the ECU (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001)
Initialisation of the ECU
1. IMPORTANT
This procedure must be carried out each time the shuttle ECU is renewed.

2. From the main SMART LEVER menu, press “0” (zero) twice to access to
= = = = = = = = = = = = = = = =
the password prompt.
= S M A R T L E V E R =
= = = = = = = = = = = = = = = =
S N : 5 7 7 9

S W V e r s i o n
T C L E V - A A

D a t e :
2 2 - 1 0 - 2 0 0 9

C o n f i g u r a t i o n
T 5 0 0 0 G S 1 0 0 C V

[ E ] E x i t

Fig. 213

20-22
Calibrations and electronic
diagnosis
3. Enter the password “1-2-3-4-5-6”, then press “E” to return to the main
SMART LEVER menu.

P a s s w o r d : * * * * * *

Fig. 214
4. Once the password has been accepted, the option line “C - Initialization”
M A I N M E N U
will appear in the “Main Menu”.
- - - - - - - - - - - - - - - -
Press “C” to display the available options.
1 - M o n i t o r s
2 - P a r a m e t e r s
3 - C a l i b r a t i o n s
4 - A l a r m s
5 - T e s t
6 - E n g i n e

C - I n i t i a l i z a t i o n

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 215
5. Two options are displayed:
I N I T I A L I Z A T I O N
“1 - Reprog. Eeprom”/ Re-initialization of the ECU
- - - - - - - - - - - - - - - -
“2 - Mach. Start-Up” / Line end programming
M A C H I N E
Press “1” to start the ECU re-initialization procedure.
S T A R T U P

- - - - - - - - - - - - - - - -
1 - R e p r o g . E e p r o m
2 - M a c h . S t a r t - U p
- - - - - - - - - - - - - - - -

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 216

20-23
 Calibrations and electronic
diagnosis
6. Press “C” to continue or “E” to abort the operation.
R E I N I T . E E P R O M
CAUTION - - - - - - - - - - - - - - - -
If you continue with the procedure, all data in memory will be
overwritten with the default values and the ECU will have to
= = = = = = = = = = = = = = = =
be completely reprogrammed. ! A T T E N T I O N !
T H E M E M O R Y W I L L
B E C O M P L E T E L Y
R E P R O G R A M M E D
= = = = = = = = = = = = = = = =
P R E S S [ C ]
T O C O N T I N U E

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 217
7. On completion of the procedure, press “E” to return to the main menu and
R E I N I T . E E P R O M
proceed with the line end programming” operation (starting from point 5).
See para. 20.3.4 - Renewal of the shuttle... - page 20-25 - - - - - - - - - - - - - - - -

M E M O R Y
R E I N I T I A L I S E D
C O R R E C T L Y

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 218

20-24
Calibrations and electronic
diagnosis
20.3.4 - Renewal of the shuttle ECU - Line end programming (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001)
Line end programming
1. IMPORTANT
This procedure must be carried out each time the shuttle ECU is renewed but only after the initialization pro-
cedure has been carried out.

2. From the main SMART LEVER menu, press “0” (zero) twice to access to
= = = = = = = = = = = = = = = =
the password prompt.
= S M A R T L E V E R =
= = = = = = = = = = = = = = = =
S N : 5 7 7 9

S W V e r s i o n
T C L E V - A A

D a t e :
2 2 - 1 0 - 2 0 0 9

C o n f i g u r a t i o n
T 5 0 0 0 G S 1 0 0 C V

[ E ] E x i t

Fig. 219
3. Enter the password “1-2-3-4-5-6”, then press “E” to return to the main
SMART LEVER menu.

P a s s w o r d : * * * * * *

Fig. 220
4. Once the password has been accepted, the option line “C - Initialization”
M A I N M E N U
will appear in the “Main Menu”.
- - - - - - - - - - - - - - - -
Press “C” to display the available options.
1 - M o n i t o r s
2 - P a r a m e t e r s
3 - C a l i b r a t i o n s
4 - A l a r m s
5 - T e s t
6 - E n g i n e

C - I n i t i a l i z a t i o n

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 221

20-25
 Calibrations and electronic
diagnosis
5. Two options are displayed:
I N I T I A L I Z A T I O N
“1 - Reprog. Eeprom”/ Re-initialization of the ECU
- - - - - - - - - - - - - - - -
“2 - Mach. Start-Up” / Line end programming
M A C H I N E
Press “2” to start the line end programming procedure.
S T A R T U P

- - - - - - - - - - - - - - - -
1 - R e p r o g . E e p r o m
2 - M a c h . S t a r t - U p
- - - - - - - - - - - - - - - -

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 222
6. Press “C” to continue or “E” to abort the operation.
! ! A T T E N T I O N ! !
- - - - - - - - - - - - - - - -

T H E M A C H I N E
C A N N O T B E U S E D
U N T I L T H E E N D
O F T H E P R O C E D U R E

- - - - - - - - - - - - - - - -

P R E S S [ C ] T O
C O N T I N U E

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 223
7. The moment as line end programming is activated, the “Tractor family” con-
C O N F I G U R E F A M I L
figuration page will appear on the ART/PC tester.
- - - - - - - - - - - - - - - -
Select “1 - EXPLORER3” then press “E” to exit and “C” to confirm and move
1 - T y p e F a m i l y 1
on to the next screen.

1 : E X P L O R E R 3
2 : F R U T T _ D O R A D O

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 224

20-26
Calibrations and electronic
diagnosis
8. The ART/PC Tester will then display the engine selection page.
E N G I N E M O D E L
If commissioning is carried out on a complete machine (rather than just a
- - - - - - - - - - - - - - - -
cab) the control unit can identify the type of engine installed. The identified
engine type will therefore be proposed and the operator can simply confirm
the type by pressing [E]. If the configuration is not correct, or if no configu- 1 - T I E R 2
ration is proposed, the operator can in any case modify the configuration 2 - T I E R 3
by pressing [1] and choosing the engine type from among those proposed.
Select “2 - TIER 3” then press “E” to exit and “C” to confirm and move on
to the next screen.

[ E ] E x i t
[ C ] S t o r e

Fig. 225
9. Table 50
T R A N S . T Y P E
- - - - - - - - - - - - - - - -
Value Model transmission HP
E U R O 3
type
1 Explorer³ 85 T-4000 85
Agrofarm 410 1 : T 4 0 0 0 G S 8 5 H P
R3. EVO 85 2 : T 5 0 0 0 G S 1 0 0 H P
3 : T 5 1 0 0 G S 1 1 0 H P
XB MAX 85
2 Explorer³ 100 T-5000 100
Agrofarm 420
R3. EVO 100
XB MAX 100
3 Explorer³ 110 T-5100 110
[ E ] E x i t
Agrofarm 430
R3. EVO 110 [ C ] S t o r e
XB MAX 110
Fig. 226
Enter the value corresponding to the type of transmission installed on the
tractor, then press “C” and “E” to exit and move on to the next screen.
10. The ART/PC Tester will then display the accelerator pedal calibration page.
P E D A L C A L I B R .
Release the accelerator pedal and, when the value has stabilised, press
- - - - - - - - - - - - - - - -
“C” to confirm the parameter and proceed to the next calibration.

R e l e a s e
a c c e l e r a t o r
p e d a l t o m i n a n d
t h e n p r e s s [ C ]

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 227

20-27
 Calibrations and electronic
diagnosis
11. Fully depress the accelerator pedal and, when the value has stabilised,
P E D A L C A L I B R .
press “C” to confirm the parameter and terminate the calibration procedure.
- - - - - - - - - - - - - - - -

P r e s s
a c c e l e r a t o r
p e d a l t o m a x a n d
t h e n p r e s s [ C ]

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 228
12. If the calibration was not completed successfully, the following message
P E D A L C A L I B R .
will be displayed:
- - - - - - - - - - - - - - - -
“Error into calibration procedure”.
DANGER
C A L I B R A T I O N
In this case, check that the accelerator pedal sensor is not O K
faulty or installed incorrectly, then repeat the procedure.

If the calibration was successful, the following message will be displayed: E R R O R

I N T O C A L I B R A T I O N
“Calibration ok”.
P R O C E D U R E
Press “E” to go to the next screen page.

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 229
13. The ART/PC Tester will then display the hand throttle calibration page.
H A N D G A S C A L I B R .
Move the throttle lever towards the front of the tractor (MAX position) and
- - - - - - - - - - - - - - - -
press “C” to confirm the parameter.

P u s h h a n d g a s
t o m a x a n d
t h e n
p r e s s [ C ]

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 230

20-28
Calibrations and electronic
diagnosis
14. Move the throttle lever back towards the rear of the tractor (MIN position)
H A N D G A S C A L I B R .
and press “C” to confirm the parameter and terminate the calibration pro-
- - - - - - - - - - - - - - - -
cedure.

P u l l h a n d g a s
t o m i n a n d
t h e n
p r e s s [ C ]

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 231
15. If the calibration was successful, the following message will be displayed:
H A N D G A S C A L I B R .
“Calibration ok”.
- - - - - - - - - - - - - - - -
Press “E” to go to the next screen page.

C A L I B R A T I O N
O K

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 232
16. The ART/PC Tester will then display the clutch pedal calibration page.
C L U T C H P E D A L
Fully depress the clutch pedal and press “B”.
- - - - - - - - - - - - - - - -
- P r e s s t h e p e d a l
a l l t h e w a y
- P r e s s [ B ]
- R e l e a s e i t
- P r e s s [ A ]

S w i t c h C l u t c h O N

M i n . P o s . 1 . 7 4 7
C u r r e n t 1 . 7 3 7
M a x . P o s . 3 . 2 5 3
- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 233

20-29
 Calibrations and electronic
diagnosis
17. If the clutch pedal travel limit switch is not operated when “B” is pressed, the
C L U T C H P E D A L
ECU will display an error message.
- - - - - - - - - - - - - - - -
Press “B” to save the value and continue with calibration. - P r e s s t h e p e d a l
a l l t h e w a y
- P r e s s [ B ]
- R e l e a s e i t
- P r e s s [ A ]
S w i t c h C l u t c h O N
E r r o r : S w i t c h O N
[ A ] I g n o r e e r r o r
M i n . P o s . 1 . 7 4 7
C u r r e n t 1 . 7 3 7
M a x . P o s . 3 . 2 5 3
- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 234
18. Fully release the clutch pedal and then press “A”.
C L U T C H P E D A L
- - - - - - - - - - - - - - - -
- P r e s s t h e p e d a l
a l l t h e w a y
- P r e s s [ B ]
- R e l e a s e i t
- P r e s s [ A ]

S w i t c h C l u t c h OF F

Mi n . P o s . 1 . 7 4 7
C u r r e n t 1 . 7 3 7
Ma x . P o s . 3 . 2 5 3
- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 235
19. If the clutch pedal travel limit switch is operated when key “A” is pressed,
C L U T C H P E D A L
the control unit will display an error message.
- - - - - - - - - - - - - - - -
Press “A” to save the value and continue with the calibration. - P r e s s t h e p e d a l
Press “E” to go to the next screen page. a l l t h e w a y
- P r e s s [ B ]
- R e l e a s e i t
- P r e s s [ A ]
S w i t c h C l u t c h O F F
E r r o r : S w i t c h O F F
[ B ] I g n o r e e r r o r
M i n . P o s . 1 . 7 4 7
C u r r e n t 1 . 7 3 7
M a x . P o s . 3 . 2 5 3
- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 236

20-30
Calibrations and electronic
diagnosis
20. The ART/PC Tester will then display the page for selection of the optional
O P T I O N S
equipment installed on the tractor.
- - - - - - - - - - - - - - - -
Press “1” to access the menu “1-Hi-Lo”.
1 - H m l / H i - L o 1
2 - S m a r t W h e e l 1
3 - S t o p & G o 0

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 237
21. Select “1-Hml / Hi-Lo” to call up the HML / Hi-Lo menu.
1 - H i - L o
Enter the value corresponding to the tractor configuration, then press “E” to
- - - - - - - - - - - - - - - -
confirm the parameter.
IMPORTANT
If you enter the wrong value by mistake, press “D” to cancel A c t u a l : 1
the operation.
N e w : _

Table 51

Value Configuration
0 Hi-Lo absent
[ D ] C a n c e l
1 Hi-Lo present
[ E ] E x i t

Fig. 238
22. Press “C” to confirm the configuration or press “A” to cancel the operation
1 - H i - L o
and return to the “Options” menu in order to repeat the procedure.
- - - - - - - - - - - - - - - -

A c t u a l : 1

N e w : 0

[ A ] A b o r t
[ C ] C o n f i r m

Fig. 239

20-31
 Calibrations and electronic
diagnosis
23. If the procedure was successful, a screen confirming the configuration will
! ! A T T E N T I O N ! !
be displayed.
- - - - - - - - - - - - - - - -
Press “E” to return to the main menu.
Turn the starter key to “O” (OFF) and then back to “I” (ON) and proceed with
calibration of the shuttle clutches. M A C H I N E
S T A R T - U P
NOTE E N D E D
S U C C E S S F U L L Y
At the end of the procedure, alarm T10 is displayed prompt-
ing the technician to perform clutch calibration.
= = = = = = = = = = = = = = = =

R E S T A R T
T H E E N G I N E

[ E ] E x i t

Fig. 240

20.3.5 - Renewal of the shuttle ECU - Introductory notes (R3 EVO 100 -> 20001, R3 EVO
110 -> 1001, R3 EVO 85 -> 20001)
Introductory notes on the clutch calibration procedure
The shuttle clutch must be calibrated by the technician in the following cases:
l After renewal of one or both shuttle clutches.
l After renewal of the clutch control proportional solenoid valve.
l After the clutch has bedded in (in the case of new or revised tractors) or after years of use, if the clutch or automatic direction
change (without the use of the clutch pedal) is too sudden or too slow.
l Whenever the shuttle ECU is renewed.
l When the line programming procedure is carried out
l On appearance of the transmission alarm T10 - Shuttle clutches not calibrated.
The technician has the choice of three calibration procedures.
C A L I B R . R E V E R S E R
l “Automatic” / Automatic calibration - - - - - - - - - - - - - - - -
in which the control unit independently sets the parameters for clutch en-
gagement characteristics. 1 - A u t o m a t i c
l “Manual” / Manual calibration 2 - M a n u a l
where the technician can alter the parameter settings and thus create a 3 - C o m f o r t p a r a m
personalised clutch engagement curve to obtain a smoother, more comfort-
able response from the tractor during travel direction changes.
l “Comfort param” / Comfort parameters
where the technician can adjust tractor behaviour, the comfort settings and
speed at which manoeuvres are performed to suit personal requirements.

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 241

Depending the status of the tractor, the technician can decide to perform just one of the three calibration procedures.
The table below provides guidelines for the procedures to carry out according to the type of fault encountered.
Table 52
Problem encountered Automatic cali- Manual calibra- Editing the com-
bration tion fort parameters
Alarm T10 X
Renewal of control unit X
Renewal of mechanical/hydraulic assembly X
Replacement of proportional valve X
Asymmetric behaviour (one good clutch, one poor clutch) X
Irregular behaviour (both clutches too sharp or too slow) X
Customisation of shuttle behaviour X

20-32
Calibrations and electronic
diagnosis
20.3.6 - Renewal of the shuttle ECU - Automatic calibration (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001)
Automatic calibration of the shuttle clutches
1. IMPORTANT
This procedure should only be carried out if the technician finds during a test drive that shuttle clutch engage-
ment is either too sudden or too slow when moving off from stationary or during direction changes without using
the clutch pedal.
2. Start the engine and bring the transmission oil level to approximately 40°C.
3. Park the tractor on a flat tarmac surface with at least 5 metres free clearance in front and perform the following operations.
m Put the shuttle lever in neutral.
m Select 2nd gear in the fast range (hare symbol) .
m If the tractor is equipped with the Hi-Lo unit: select HI speed (hare symbol).

4. From the “Main Menu” select “3 - Calibrations” to access the calibrations

M A I N M E N U
menu.
- - - - - - - - - - - - - - - -
1 - M o n i t o r s
2 - P a r a m e t e r s
3 - C a l i b r a t i o n s
4 - A l a r m s
5 - T e s t
6 - E n g i n e

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 242
5. From the “Calibrations” menu, press “2 - Reverser” to access the hydraulic
C A L I B R A T I O N S
shuttle calibration menu.
- - - - - - - - - - - - - - - -

1 - P e d a l
2 - R e v e r s e r

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 243

20-33
 Calibrations and electronic
diagnosis
6. The press “1 - Automatic” to access the automatic clutch calibration pro-
C A L I B R . R E V E R S E R
cedure.
- - - - - - - - - - - - - - - -

1 - A u t o m a t i c
2 - M a n u a l
3 - C o m f o r t p a r a m

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 244
7. Press any key on ART. Select the travel direction to be calibrated (for ex-
A U T O M . C A L I B R A T .
ample FORWARD).
- - - - - - - - - - - - - - - -
C a l i b r a t i o n s
c o n d i t i o n s :
- - - - - - - - - - - - - - - -

1 ) O N L E V E L G R N D
2 ) 2 n d F a s t ( H i )
3 ) O i l T 3 5 - 4 5 C
4 ) 1 5 0 0 R P M E n g i n e

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 245
8. The tractor moves forward intermittently and the values shown on screen
A U T O M . C A L I B R A T .
change until the optimal values are found. When the calibration procedure
- - - - -
- - - - - - - -
- - -
is complete, the message “Calib. Complete” / Calibration completed. If you
O i l T
e m p . + 3 8
wish to repeat the procedure, return the shuttle lever to neutral and then E n g i n
e R
M P 1 5 6 1
move it back to the travel direction selected previously. To save the values - - - - F
O R W
R A D - - - - -
obtained during calibration, press “E”. P e a k c u r
n r t 5 6 5
“Oil Temp.” / Transmission oil temperature S t . e n d c
n r t 5 4 3
C o r r e c t i
n o + 1
“Engine RPM” / Engine speed
C A L I B . C O
M P L E T E
“Peak currnt” / Peak current
- - - - R E V E R S E - - - - -
“St.end crnt” / Final current P e a k c u r r n t 0
“Correction” S t . e n d c r n t 0
C o r r e c t i o n + 1

[ E ] E x i t

Fig. 246

20-34
Calibrations and electronic
diagnosis
9. Press “C” to save the data or press A” to quit without saving.
C O N F I R M
Repeat the calibration procedure from point 5 to point 8 for the other travel
- - - - - - - - - - - - - - - -
direction, then test the results by carrying out manoeuvres using the shut-
tle. If the result is not satisfactory, proceed with the manual calibration of C - C o n f i r m
the shuttle clutches. A - A b o r t

- - - - - - - - - - - - - - - -

Fig. 247

20.3.7 - Renewal of the shuttle ECU - Manual calibration (R3 EVO 100 -> 20001, R3 EVO
110 -> 1001, R3 EVO 85 -> 20001)
Procedure for manual calibration of the shuttle clutches
1. Start the engine and bring the transmission oil level to approximately 40°C.
2. Park the tractor on a flat tarmac surface with at least 5 metres free clearance in front and perform the following operations.
m Put the shuttle lever in neutral.
m Take the engine revs to 1500 rpm.
m Select 2nd gear in the fast range (hare symbol) .
m If the tractor is equipped with the Hi-Lo unit: select HI speed (hare symbol).

Notes on how to edit parameter settings during manual calibration

1. When the technician performs automatic clutch calibration, the control unit calculates the operating parameter values by ap-
plying an algorithm to define the ideal conditions. In some cases, these parameters, even if correct from a hydraulic or me-
chanical point of view, make the tractor response too sudden when the clutch is engaged. In this case, the technician should
first attempt to define the type of response by performing, in automatic mode (i.e. without using the clutch pedal), several
direction changes and standing starts in both directions and at various engine speeds (e.g. 1000, 1500, 2000 and max rpm)
and in calibration conditions (for details, see calibration procedures).
The possible responses are:
m Different response when changing between forward and reverse travel (balancing):

when changing direction from forward to reverse the tractor behaves differently than when changing from reverse to
forward.
m Direction change is too sudden (or too slow) (response): the tractor engages the requested direction very quickly, and

instead of moving off smoothly, it starts with a jerk (similar to the way a car moves if the driver suddenly releases the
clutch pedal).
m Direction change is too slow (or too fast) (acceleration): the tractor engages the requested direction smoothly but too

slowly.
Procedure for manual calibration of the shuttle clutches
1. IMPORTANT
This procedure should only be carried out if the technician finds during a test drive that shuttle clutch engage-
ment is either too sudden or too slow when moving off from stationary or during direction changes without using
the clutch pedal.
2. Start the engine and bring the transmission oil level to approximately 40°C.
3. Park the tractor on a flat tarmac surface with at least 50 metres free clearance in front and perform the following operations.
m Put the shuttle lever in neutral.
m Select 2nd gear in the fast range.
m If the tractor is equipped with the Hi-Lo unit: select HI speed (hare symbol).

20-35
 Calibrations and electronic
diagnosis
4. From the “Main Menu” select “3 - Calibrations” to access the calibrations
M A I N M E N U
menu.
- - - - - - - - - - - - - - - -
1 - M o n i t o r s
2 - P a r a m e t e r s
3 - C a l i b r a t i o n s
4 - A l a r m s
5 - T e s t
6 - E n g i n e

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 248
5. From the “Calibrations” menu, press “2 - Reverser” to access the hydraulic
C A L I B R A T I O N S
shuttle calibration menu.
- - - - - - - - - - - - - - - -

1 - P e d a l
2 - R e v e r s e r

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 249
6. The press “2 - Manual” to access the manual clutch calibration procedure.
C A L I B R . R E V E R S E R
- - - - - - - - - - - - - - - -

1 - A u t o m a t i c
2 - M a n u a l
3 - C o m f o r t p a r a m

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 250

20-36
Calibrations and electronic
diagnosis
7. “F/R balance” / Direction change response
M A N U A L C A L I B R A T .
To balance the response to direction change commands, select “1 - F/R - - - - - - - - - - - - - - - -
balance” to access the relative menu. 1 - F / R b a l a n c e
2 - R e v . R e s p o n s e
3 - R e v . A c c e l e r a t
4 - P e d a l B e h a v .

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 251
8. Press “C” or “D” to slow down or speed up the transition from reverse to
F / R B A L A N C E
forward travel.
- - - - - - - - - - - - - - - -
Press “A” or “7” to slow down or speed up the transition from forward to
reverse travel.
Press “E” to continue. I c o n t a c t F 5 4 3
I c o n t a c t R 5 5 9
Key:
“Fwd” / Forward
“Bwd” / Reverse
D : F w d + P r o m p t
“Prompt” / Response C : F w d - P r o m p t
7 : B w d + P r o m p t
A : B w d - P r o m p t
- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 252
9. Press “C” to confirm save the settings or press “A” to quit without saving.
C O N F I R M
- - - - - - - - - - - - - - - -

C - C o n f i r m
A - A b o r t

- - - - - - - - - - - - - - - -

Fig. 253

20-37
 Calibrations and electronic
diagnosis
10. “Rev. Response”/ Hydraulic shuttle response
M A N U A L C A L I B R A T .
To adjust the response of the hydraulic shuttle, select “2 - Rev. Response” - - - - - - - - - - - - - - - -
to access the relative menu. 1 - F / R b a l a n c e
2 - R e v . R e s p o n s e
IMPORTANT 3 - R e v . A c c e l e r a t
4 - P e d a l B e h a v .
The “Response” parameter regulates the characteristics of
the initial stage of direction change manoeuvres. This pa-
rameter can be adjusted to eliminate any grabbing in shuttle
clutches operation or the sensation that the clutches have
failed to engage.

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 253
11. Press “7” or “A” to increase or reduce shuttle response speed.
R E V E R . R E S P O N S E
Press “E” to continue.
- - - - - - - - - - - - - - - -
Key:
“More Prompt” / Faster response
“Less Prompt” / Slower response R e s p o n s e : 4 5 0

7 : M o r e P r o m p t
A : L e s s P r o m p t
- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 254
12. Press “C” to confirm save the settings or press “A” to quit without saving.
C O N F I R M
- - - - - - - - - - - - - - - -

C - C o n f i r m
A - A b o r t

- - - - - - - - - - - - - - - -

Fig. 254

20-38
Calibrations and electronic
diagnosis
13. “Rev. Accelerat” / Hydraulic shuttle speed
M A N U A L C A L I B R A T .
To adjust the speed of the travel direction changes, select “3 - Rev. Accel- - - - - - - - - - - - - - - - -
erat” to access the relative menu. 1 - F / R b a l a n c e
2 - R e v . R e s p o n s e
IMPORTANT 3 - R e v . A c c e l e r a t
4 - P e d a l B e h a v .
The “Acceleration” parameter regulates the speed at which
the direction change manoeuvre is brought to a conclusion.
This parameter should be changed when the time taken to
complete a direction change manoeuvre is either too long
or too short.

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 254
14. Press “7” or “A” to increase or reduce the speed of the shuttle.
R E V E R . A C C E L E R A T .
Press “E” to continue.
- - - - - - - - - - - - - - - -
Key:
“Quicker”
“Slower” A c c e l e r a t . : 6 0 0

7 : Q u i c k e r
A : S l o w e r
- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 255
15. Press “C” to confirm save the settings or press “A” to quit without saving.
C O N F I R M
- - - - - - - - - - - - - - - -

C - C o n f i r m
A - A b o r t

- - - - - - - - - - - - - - - -

Fig. 255

20-39
 Calibrations and electronic
diagnosis
16. “Pedal Behav.” / Clutch pedal release
M A N U A L C A L I B R A T .
To change the position of the clutch pedal at which torque transmission - - - - - - - - - - - - - - - -
begins, select “4 - Pedal Behav.” to access the relative menu. 1 - F / R b a l a n c e
2 - R e v . R e s p o n s e
IMPORTANT 3 - R e v . A c c e l e r a t
4 - P e d a l B e h a v .
The “Pedal Behav.” parameter is used to alter the position at
which the shuttle clutches start delivering driving torque to
the transmission during release of the clutch pedal.

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 255
17. Press “7” or “A” to raise or lower the release point.
P E D A L C L U T C H
Press “E” to continue.
- - - - - - - - - - - - - - - -
Key:
“Higher”
“Lower” I n c h i n g P o s : + 0

7 : H i g h e r
A : L o w e r
- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 256
18. Press “C” to confirm save the settings or press “A” to quit without saving.
C O N F I R M
- - - - - - - - - - - - - - - -

C - C o n f i r m
A - A b o r t

- - - - - - - - - - - - - - - -

Fig. 256

20-40
Calibrations and electronic
diagnosis
20.3.8 - Renewal of the shuttle ECU - Editing the comfort parameters (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
1. To access the menu for editing the comfort parameters, select “3 - Comfort
C A L I B R . R E V E R S E R
param” from the main calibration menu “Calibr. Reverser”.
- - - - - - - - - - - - - - - -

1 - A u t o m a t i c
2 - M a n u a l
3 - C o m f o r t p a r a m

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 257
2. The parameters are divided into the three possible manoeuvres and have
C O M F O R T P A R A M
the following meanings:
= = = = = = = = = = = = = = = =
m “Response”: determines the initial response of the clutches in the = = = = = = S t a r t = = = = =
various manoeuvres, in the stage immediately subsequent to the 1 - R e s p o n s e 3 0 0
2 - A c c e l e r a t 6 0 0
clutch fill time. Increase the setting to obtain a faster response (in = = = I n v e r s i o n = = = =
the case of delayed response, excessive initial clutch slip) and re- 3 - R e s p o n s e 4 5 0
duce the value if the clutch action is too sharp (sudden and jerky). 4 - A c c e l e r a t 7 5 0
m “Acceleration”: determines the speed at which the tractor performs = = = G e a r C h a n g e = = =
5 - R e s p o n s e 4 2 0
manoeuvres. The value should be increased to increase the speed 6 - A c c e l e r a t 1 0 0 0
at which manoeuvres are performed. = = = = = P e d a l = = = = = =
7 - I n c h i n g P o + 0
The “InchingPo” parameter represents the position of the pedal at which
the clutch starts to bites on releasing the pedal. - - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 258
3. The higher the value the higher the clutch biting point; to lower the clutch
7 - I n c h i n g P o
biting point a negative value must be entered.
- - - - - - - - - - - - - - - -
To enter negative numbers, proceed as follows:
m Press “7” to edit the “InchingPo” parameter.
m The following screen appears:
A c t u a l : 0

N e w : + _

[ B ] T o g g l e + -
[ D ] D e l e t e
[ E ] E x i t

Fig. 259

20-41
 Calibrations and electronic
diagnosis
4. Press [B] “Toggle + -” to change the sign of the value entered.
Set the desired value, press [E] and press [C] to confirm.
N e w : + 5 0

[ B ] T o g g l e + -

N e w : - 5 0

Fig. 260

20.3.9 - Renewal of the shuttle ECU - Calibration of the clutch pedal (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
1. To perform these operations, connect the ART/PC to the connector on the
A V A I L A B L E T E S T
left-hand side of the instrument panel, select the shuttle ECU (SMART
M E N U
LEVER) from the “AVAILABLE TESTS” menu and proceed as described
below.
DANGER 1 - S M A R T L E V E R
2 - C L U S T E R
The clutch pedal calibration operation must be carried out
with the engine off, the main gear and range gear levers in
neutral and the parking brake applied.
IMPORTANT
This procedure must be carried out each time the shuttle
ECU is renewed. C H O I C E
[ E ] E x i t

Fig. 261
2. From the presentation screen, press “E” to access the “Main Menu”.
= = = = = = = = = = = = = = = =
= S M A R T L E V E R =
= = = = = = = = = = = = = = = =
S N : 5 7 7 9

S W V e r s i o n
T C L E V - A A

D a t e :
2 2 - 1 0 - 2 0 0 9

C o n f i g u r a t i o n
T 5 0 0 0 G S 1 0 0 C V

[ E ] E x i t

Fig. 262

20-42
Calibrations and electronic
diagnosis
3. Press “3” to access the “Calibrations” menu.
M A I N M E N U
- - - - - - - - - - - - - - - -
1 - M o n i t o r s
2 - P a r a m e t e r s
3 - C a l i b r a t i o n s
4 - A l a r m s
5 - T e s t
6 - E n g i n e

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 263
4. From the “Calibrations” menu, press “1 - Pedal” to access the clutch pedal
C A L I B R A T I O N S
calibration menu.
- - - - - - - - - - - - - - - -

1 - P e d a l
2 - R e v e r s e r

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 264
5. The ART/PC Tester will then display the clutch pedal calibration page.
C L U T C H P E D A L
Fully depress the clutch pedal and press “B”.
- - - - - - - - - - - - - - - -
- P r e s s t h e p e d a l
a l l t h e w a y
- P r e s s [ B ]
- R e l e a s e i t
- P r e s s [ A ]

S w i t c h C l u t c h OF F

Mi n . P o s . 1 . 7 4 7
C u r r e n t 1 . 7 3 7
Ma x . P o s . 3 . 2 5 3
- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 265

20-43
 Calibrations and electronic
diagnosis
6. If the clutch pedal travel limit switch is not operated when “B” is pressed, the
C L U T C H P E D A L
ECU will display an error message.
- - - - - - - - - - - - - - - -
Press “B” to save the value and continue with calibration. - P r e s s t h e p e d a l
a l l t h e w a y
- P r e s s [ B ]
- R e l e a s e i t
- P r e s s [ A ]
S w i t c h C l u t c h O F F
E r r o r : S w i t c h O F F
[ B ] I g n o r e e r r o r
M i n . P o s . 1 . 7 4 7
C u r r e n t 1 . 7 3 7
M a x . P o s . 3 . 2 5 3
- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 266
7. Fully release the clutch pedal and then press “A”.
C L U T C H P E D A L
- - - - - - - - - - - - - - - -
- P r e s s t h e p e d a l
a l l t h e w a y
- P r e s s [ B ]
- R e l e a s e i t
- P r e s s [ A ]

S w i t c h C l u t c h OF F

Mi n . P o s . 1 . 7 4 7
C u r r e n t 1 . 7 3 7
Ma x . P o s . 3 . 2 5 3
- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 266
8. If the clutch pedal travel limit switch is operated when key “A” is pressed,
C L U T C H P E D A L
the control unit will display an error message.
- - - - - - - - - - - - - - - -
Press “A” to save the value and continue with the calibration. - P r e s s t h e p e d a l
Press “E” to go to the next screen page. a l l t h e w a y
- P r e s s [ B ]
- R e l e a s e i t
- P r e s s [ A ]
S w i t c h C l u t c h O N
E r r o r : S w i t c h O N
[ A ] I g n o r e e r r o r
M i n . P o s . 1 . 7 4 7
C u r r e n t 1 . 7 3 7
M a x . P o s . 3 . 2 5 3
- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 267

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Calibrations and electronic
diagnosis
20.3.10 - Renewal of the engine ECU - Introduction
The engine ECU is supplied as a replacement part in two versions:
l ECU with software but without DATASET;
Important
It is necessary to provide the engine serial number indicated on the ECU data plate and on the engine data
plate.

l ECU with software and with DATASET.

The DATASET is the complete set of engine data that is specific to the engine serial number.
If an engine control unit without DATASET is ordered, before changing the control unit, it is necessary to read all the engine data
(DATASET) from the old control unit and save them to a file, which is subsequently to be loaded onto the new control unit. In this
case no calibration is required.
If the ECU is faulty and it is not possible to read the complete DATASET, it will be necessary to order an ECU with DATASET (provide
the engine serial number indicated on the name plate of the control unit plate and the engine data plate) or, if you already have an
ECU without DATASET, request SAT to supply the DATASET for the engine in question.
In this case it will only be necessary carry out the procedures to set the engine operating hours and calibrate the accelerator pedal
and hand throttle.
NOTE
The accelerator pedal and hand throttle calibration procedures can be carried out using the ART connected to the
shuttle ECU.

20.3.11 - Renewal of the engine ECU - Calibration of the accelerator pedal

1. To perform these operations, connect the ART/PC to the connector on the
A V A I L A B L E T E S T
left-hand side of the instrument panel, select the shuttle ECU (SMART
M E N U
LEVER) from the “AVAILABLE TESTS” menu and proceed as described
below.
DANGER 1 - S M A R T L E V E R
2 - C L U S T E R
The accelerator pedal calibration operation must be carried
out with the engine off, the main gear and range gear levers
in neutral and the parking brake applied.
IMPORTANT
This procedure must be carried out each time the shuttle
ECU is renewed. C H O I C E
[ E ] E x i t

Fig. 268
2. From the “Main Menu” select “6 - Engine”.
M A I N M E N U
- - - - - - - - - - - - - - - -
1 - M o n i t o r s
2 - P a r a m e t e r s
3 - C a l i b r a t i o n s
4 - A l a r m s
5 - T e s t
6 - E n g i n e

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 269

20-45
 Calibrations and electronic
diagnosis
3. Select “3 - Params” / Parameters
E N G I N E
- - - - - - - - - - - - - - - -

1 - M o n i t o r
2 - T e s t s
3 - P a r a m s

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 270
4. Select “1 - Gas Pedal” / Accelerator pedal.
E N G I N E
- - - - - - - - - - - - - - - -

1 - G a s P e d a l
2 - H a n d g a s

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 271
5. The ART/PC Tester will then display the accelerator pedal calibration page.
P E D A L C A L I B R .
Release the accelerator pedal and, when the value has stabilised, press
- - - - - - - - - - - - - - - -
“C” to confirm the parameter and proceed to the next calibration.

R e l e a s e
a c c e l e r a t o r
p e d a l t o m i n a n d
t h e n p r e s s [ C ]

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 272

20-46
Calibrations and electronic
diagnosis
6. Fully depress the accelerator pedal and, when the value has stabilised,
P E D A L C A L I B R .
press “C” to confirm the parameter and terminate the calibration procedure.
- - - - - - - - - - - - - - - -

P r e s s
a c c e l e r a t o r
p e d a l t o m a x a n d
t h e n p r e s s [ C ]

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 273
7. If the calibration was successful, the following message will be displayed:
P E D A L C A L I B R .
“Calibration ok”.
- - - - - - - - - - - - - - - -
Press “E” to go to the next screen page.

C A L I B R A T I O N
O K

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 274

20-47
 Calibrations and electronic
diagnosis
20.3.12 - Renewal of the engine ECU - Calibration of the hand throttle lever
1. To perform these operations, connect the ART/PC to the connector on the
H A N D G A S C A L I B R .
left-hand side of the instrument panel, select the shuttle ECU (SMART
- - - - - - - - - - - - - - - -
LEVER) from the “AVAILABLE TESTS” menu and proceed as described
below.
DANGER C A L I B R A T I O N
O K
The hand throttle calibration operation must be carried out
with the engine off, the main gear and range gear levers in
neutral and the parking brake applied.
IMPORTANT
This procedure must be carried out each time the shuttle
ECU is renewed. - - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 275
2. From the “Main Menu” select “6 - Engine”.
M A I N M E N U
- - - - - - - - - - - - - - - -
1 - M o n i t o r s
2 - P a r a m e t e r s
3 - C a l i b r a t i o n s
4 - A l a r m s
5 - T e s t
6 - E n g i n e

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 276
3. Select “3 - Params” / Parameters
E N G I N E
- - - - - - - - - - - - - - - -

1 - M o n i t o r
2 - T e s t s
3 - P a r a m s

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 277

20-48
Calibrations and electronic
diagnosis
4. Select “2 - Handgas” / Hand throttle lever.
E N G I N E
- - - - - - - - - - - - - - - -

1 - G a s P e d a l
2 - H a n d g a s

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 278
5. The ART/PC Tester will then display the hand throttle calibration page.
H A N D G A S C A L I B R .
Move the throttle lever towards the front of the tractor (MAX position) and
- - - - - - - - - - - - - - - -
press “C” to confirm the parameter.

P u s h h a n d g a s
t o m a x a n d
t h e n
p r e s s [ C ]

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 279
6. Move the throttle lever back towards the rear of the tractor (MIN position)
H A N D G A S C A L I B R .
and press “C” to confirm the parameter and terminate the calibration pro-
- - - - - - - - - - - - - - - -
cedure.

P u l l h a n d g a s
t o m i n a n d
t h e n
p r e s s [ C ]

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 280

20-49
 Calibrations and electronic
diagnosis
7. If the calibration was successful, the following message will be displayed:
H A N D G A S C A L I B R .
“Calibration ok”.
- - - - - - - - - - - - - - - -
Press “E” to go to the next screen page.

C A L I B R A T I O N
O K

- - - - - - - - - - - - - - - -
[ E ] E x i t

Fig. 280

20-50
Calibrations and electronic
diagnosis
20.4 - ECU alarms
20.4.1 - Key to the “ECU alarms” tables
ART code
l SPN (Suspect Parameter Number): indicates the faulty component.
l FMI (Failure Mode Identifier): indicates the type of fault affecting the component.
Display on instrument cluster
In the event of a fault, the relative alarm generated is indicated by a letter and a
number displayed at the top right of the instrument panel. 1 2
Indicates the type of fault displayed directly on the instrument panel.
1. Electronic control unit generating alarm.
2. Alarm code.
Table 53

Displayed letter Electronic control unit

T lubrication
Fig. 283
M Engine
L Lift
U User Controller (Services)
I Instrument

Alarms relative to the transmission are signalled according to their priority level.
Table 54

Priority Indicator light Buzzer

High On

STOP

Fig. 281
Medium Intermittent beep

Fig. 282
Low None OFF
Severity
Indicates the severity level of the fault.
Component
Description of the component that has generated the error.
Fault
Description of the fault.
Controls
Description of checks to be performed.
Link to system
Hard copy version: page of the relative system.
Electronic version: link to relative system.

20-51
 Calibrations and electronic
diagnosis
20.4.2 - FMI code
Key to FMI codes
Table 55
FMI code Description
0 Signal too high
1 Signal too low
2 Signal not valid
3 Short to +12V
4 Short to earth
5 Not connected
6 Short circuit
7 Mechanical fault
8 Incorrect frequency
9 Update error
10 Variation outside limits
11 Unidentified fault
12 Device faulty
13 Not calibrated
14 FMI 14
31 Fault not available

20.4.3 - Engine alarms

Alarms - Engine alarms list (R3 EVO 85 -> 16001)
Table 56
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
91 2 M5 MEDIUM K006 - Acceler- Accelerator pedal poten- Check sensor cable. 40-261
ator pedal posi- tiometer faulty Check and if necessary 40-269
tion sensor replace sensor.
91 11 M67 MEDIUM K006 - Acceler- Connection error with po- Check sensor cable. 40-261
ator pedal posi- sition sensor of accelera- Check and if necessary 40-269
tion sensor tor pedal replace sensor.
102 2 M7 MEDIUM K028 - Turbo Intake air pressure sen- Check sensor cable. 40-261
air temperature/ sor Check and if necessary 40-269
pressure sensor replace sensor.
105 2 M10 MEDIUM K028 - Turbo Air supply temperature Check sensor cable. 40-261
air temperature/ sensor Check and if necessary 40-269
pressure sensor replace sensor.
108 12 M87 LOW Atmospheric pressure is Check power supply.
outside admissible limits. Switch off and switch on
again.
Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.
110 0 M31 MEDIUM K026 - Engine The coolant temperature Check coolant. 40-261
coolant temper- has exceeded the warn- Check temperature sen- 40-269
ature sensor ing threshold. sor and cables.
110 0 M41 HIGH K026 - Engine The coolant temperature Check the coolant. 40-261
coolant temper- has exceeded the stop Check coolant tempera- 40-269
ature sensor threshold ture sensor and cables.
Check engine stop limit.
110 2 M9 MEDIUM K026 - Engine Engine coolant tempera- Check sensor cable. 40-261
coolant temper- ture sensor Check and if necessary 40-269
ature sensor replace sensor.

20-52
Calibrations and electronic
diagnosis
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
171 12 M86 LOW Excessive temperature Check power supply. 40-261
inside control unit. Switch off and switch on 40-269
again.
Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.
174 0 M36 MEDIUM K032 - Fuel tem- The fuel temperature has Check fuel. 40-261
perature sensor exceeded the warning Check fuel temperature 40-269
threshold. sensor and cables.
174 2 M11 MEDIUM K032 - Fuel tem- Fuel temperature sensor Check sensor cable. 40-261
perature sensor Check and if necessary 40-269
replace sensor.
190 8 M1 HIGH K031 - Cam- Engine rpm sensor faulty Check distance 40-261
shaft rotation Inspect wiring connec- 40-269
speed sensor tions.
Check and if necessary
replace sensor.
201 2 M6 MEDIUM K005 - Hand Hand throttle faulty Check sensor cable. 40-261
throttle position Check and if necessary 40-269
sensor replace sensor.

Table 57
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
535 7 M53 HIGH N007 - Actuator Mechanical faultwith Check and replace alter- 40-261
governor nator if necessary.
Check cables. 40-269
536 12 M50 HIGH N007 - Actuator Actuator faulty Check and replace alter- 40-261
nator if necessary.
Check cables. 40-269
536 13 M52 HIGH N007 - Actuator Actuator not calibrated Check and replace alter- 40-261
nator if necessary.
Check cables. 40-269
702 14 M35 MEDIUM Engine overspeed Check parameter (21).
Check speed control.
Check speed sensor
743 9 M71 MEDIUM CANBUS transmission Check CAN connection, 40-1012
error. terminal resistor.
Check control unit. 40-1008
743 12 M70 MEDIUM CANBUS line controller Check CAN connection, 40-1012
damaged terminal resistor.
Check control unit. 40-1008
743 14 M74 MEDIUM CANBUS transmission Check CAN connection, 40-1012
error. terminal resistor.
Check control unit. 40-1008

20-53
 Calibrations and electronic
diagnosis
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
752 2 M93 HIGH “Stack Overflow” error Switch off and switch on
during program execu- again.
tion. Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.
752 12 M77 HIGH The ECU has detected Switch off and switch on
an error in reading the again.
program memory during Re-check.
the normal control cycle. In the case of a fault, in-
form the DEUTZ Service
Organisation.
765 2 M90 HIGH Inconsistent parameters Check correct data set-
written in EEPROM ting.
memory. Save parameters, switch
off and then switch on
again.
Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.
765 12 M76 HIGH Detection of error during Switch off and switch on 40-1012
writing of parameters on again.
control unit Re-check. 40-1008
In the case of a fault, in-
form the DEUTZ Service
Organisation.
766 2 M78 HIGH The ECU has detected Switch off and switch on
an error in reading the again.
program memory during Re-check.
the normal control cycle. In the case of a fault, in-
form the DEUTZ Service
Organisation.

20-54
Calibrations and electronic
diagnosis
Table 58
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
766 2 M80 LOW Supply of actuator is not Switch off and switch on 40-261
within admissible param- again.
eters. Re-check. 40-269
In the case of a fault, in-
form the DEUTZ Service
Organisation.
766 2 M83 LOW The power supply to the Check power supply. 40-261
accelerator pedal posi- Switch off and switch on 40-269
tion sensor is not present again. Re-check.
or incorrect. In the case of a fault, in-
form the DEUTZ Service
Organisation.
766 2 M84 LOW Power supply of the en- Check power supply. 40-261
gine boost sensor is Switch off and switch on 40-269
missing or incorrect. again.
Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.
766 2 M94 HIGH Internal error Check power supply.
Switch off and switch on
again.
898 2 M68 MEDIUM Connection to CANBUS Check CAN connection, 40-1012
error terminal resistor.
Check control unit. 40-1008
Alarms - Engine alarms list (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001)
Table 59
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
91 2 M5 MEDIUM K006 - Acceler- Accelerator pedal poten- Check sensor cable. 40-283
ator pedal posi- tiometer faulty Check and if necessary 40-276
tion sensor replace sensor.
91 11 M67 MEDIUM K006 - Acceler- Connection error with po- Check sensor cable. 40-283
ator pedal posi- sition sensor of accelera- Check and if necessary 40-276
tion sensor tor pedal replace sensor.
102 2 M7 MEDIUM K028 - Turbo Intake air pressure sen- Check sensor cable. 40-283
air temperature/ sor Check and if necessary 40-276
pressure sensor replace sensor.
105 2 M10 MEDIUM K028 - Turbo Air supply temperature Check sensor cable. 40-283
air temperature/ sensor Check and if necessary 40-276
pressure sensor replace sensor.
108 12 M87 LOW Atmospheric pressure is Check power supply.
outside admissible limits. Switch off and switch on
again.
Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.

20-55
 Calibrations and electronic
diagnosis
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
110 0 M31 MEDIUM K026 - Engine The coolant temperature Check coolant. 40-283
coolant temper- has exceeded the warn- Check temperature sen- 40-276
ature sensor ing threshold. sor and cables.
110 0 M41 HIGH K026 - Engine The coolant temperature Check the coolant. 40-283
coolant temper- has exceeded the stop Check coolant tempera- 40-276
ature sensor threshold ture sensor and cables.
Check engine stop limit.
110 2 M9 MEDIUM K026 - Engine Engine coolant tempera- Check sensor cable. 40-283
coolant temper- ture sensor Check and if necessary 40-276
ature sensor replace sensor.
171 12 M86 LOW Excessive temperature Check power supply. 40-283
inside control unit. Switch off and switch on 40-276
again.
Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.
174 0 M36 MEDIUM K032 - Fuel tem- The fuel temperature has Check fuel. 40-283
perature sensor exceeded the warning Check fuel temperature 40-276
threshold. sensor and cables.
174 2 M11 MEDIUM K032 - Fuel tem- Fuel temperature sensor Check sensor cable. 40-283
perature sensor Check and if necessary 40-276
replace sensor.
190 8 M1 HIGH K031 - Cam- Engine rpm sensor faulty Check distance 40-283
shaft rotation Inspect wiring connec- 40-276
speed sensor tions.
Check and if necessary
replace sensor.
201 2 M6 MEDIUM K005 - Hand Hand throttle faulty Check sensor cable. 40-283
throttle position Check and if necessary 40-276
sensor replace sensor.

20-56
Calibrations and electronic
diagnosis
Table 60
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
535 7 M53 HIGH N007 - Actuator Mechanical fault with Check and replace alter- 40-283
governor nator if necessary.
Check cables. 40-276
536 12 M50 HIGH N007 - Actuator Actuator faulty Check and replace alter- 40-283
nator if necessary.
Check cables. 40-276
536 13 M52 HIGH N007 - Actuator Actuator not calibrated Check and replace alter- 40-283
nator if necessary.
Check cables. 40-276
702 14 M35 MEDIUM Engine overspeed Check parameter (21).
Check speed control.
Check speed sensor
743 9 M71 MEDIUM CANBUS transmission Check CAN connection, 40-1012
error. terminal resistor.
Check control unit. 40-1008
743 12 M70 MEDIUM CANBUS line controller Check CAN connection, 40-1012
damaged terminal resistor.
Check control unit. 40-1008
743 14 M74 MEDIUM CANBUS transmission Check CAN connection, 40-1012
error. terminal resistor.
Check control unit. 40-1008
752 2 M93 HIGH “Stack Overflow” error Switch off and switch on
during program execu- again.
tion. Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.
752 12 M77 HIGH The ECU has detected Switch off and switch on
an error in reading the again.
program memory during Re-check.
the normal control cycle. In the case of a fault, in-
form the DEUTZ Service
Organisation.
765 2 M90 HIGH Inconsistent parameters Check correct data set-
written in EEPROM ting.
memory. Save parameters, switch
off and then switch on
again.
Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.
765 12 M76 HIGH Detection of error during Switch off and switch on 40-1012
writing of parameters on again.
control unit Re-check. 40-1008
In the case of a fault, in-
form the DEUTZ Service
Organisation.
766 2 M78 HIGH The ECU has detected Switch off and switch on
an error in reading the again.
program memory during Re-check.
the normal control cycle. In the case of a fault, in-
form the DEUTZ Service
Organisation.

20-57
 Calibrations and electronic
diagnosis
Table 61
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
766 2 M80 LOW Supply of actuator is not Switch off and switch on 40-283
within admissible param- again.
eters. Re-check. 40-276
In the case of a fault, in-
form the DEUTZ Service
Organisation.
766 2 M83 LOW The power supply to the Check power supply. 40-283
accelerator pedal posi- Switch off and switch on 40-276
tion sensor is not present again. Re-check.
or incorrect. In the case of a fault, in-
form the DEUTZ Service
Organisation.
766 2 M84 LOW Power supply of the en- Check power supply. 40-283
gine boost sensor is Switch off and switch on 40-276
missing or incorrect. again.
Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.
766 2 M94 HIGH Internal error Check power supply.
Switch off and switch on
again.
898 2 M68 MEDIUM Connection to CANBUS Check CAN connection, 40-1012
error terminal resistor.
Check control unit. 40-1008
Alarms - Engine alarms list (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
Table 62
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
91 2 M5 MEDIUM K006 - Acceler- Accelerator pedal poten- Check sensor cable. 40-254
ator pedal posi- tiometer faulty Check and if necessary
replace sensor.
91 11 M67 MEDIUM K006 - Acceler- Connection error with po- Check sensor cable. 40-254
ator pedal posi- sition sensor of accelera- Check and if necessary
replace sensor.
102 2 M7 MEDIUM K028 - Turbo Intake air pressure sen- Check sensor cable. 40-254
air temperature/ sor Check and if necessary
replace sensor.
105 2 M10 MEDIUM K028 - Turbo Air supply temperature Check sensor cable. 40-254
air temperature/ sensor Check and if necessary
replace sensor.
108 12 M87 LOW Atmospheric pressure is Check power supply.
outside admissible limits. Switch off and switch on
again.
Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.

20-58
Calibrations and electronic
diagnosis
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
110 0 M31 MEDIUM K026 - Engine The coolant temperature Check coolant. 40-254
coolant temper- has exceeded the warn- Check temperature sen-
sor and cables.
110 0 M41 HIGH K026 - Engine The coolant temperature Check the coolant. 40-254
coolant temper- has exceeded the stop Check coolant tempera-
ature sensor threshold ture sensor and cables.
Check engine stop limit.
110 2 M9 MEDIUM K026 - Engine Engine coolant tempera- Check sensor cable. 40-254
coolant temper- ture sensor Check and if necessary
replace sensor.
171 12 M86 LOW Excessive temperature Check power supply. 40-254
inside control unit. Switch off and switch on
again.
Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.
174 0 M36 MEDIUM K032 - Fuel tem- The fuel temperature has Check fuel. 40-254
perature sensor exceeded the warning Check fuel temperature
sensor and cables.
174 2 M11 MEDIUM K032 - Fuel tem- Fuel temperature sensor Check sensor cable. 40-254
perature sensor Check and if necessary
replace sensor.
190 8 M1 HIGH K031 - Cam- Engine rpm sensor faulty Check distance 40-254
shaft rotation Inspect wiring connec-
speed sensor tions.
Check and if necessary
replace sensor.

20-59
 Calibrations and electronic
diagnosis
Table 63
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
201 2 M6 MEDIUM K005 - Hand Hand throttle faulty Check sensor cable. 40-254
throttle position Check and if necessary
replace sensor.
535 7 M53 HIGH N007 - Actuator Mechanical fault with Check and replace alter- 40-254
governor nator if necessary.
Check cables.
536 12 M50 HIGH N007 - Actuator Actuator faulty Check and replace alter- 40-254
nator if necessary.
Check cables.
536 13 M52 HIGH N007 - Actuator Actuator not calibrated Check and replace alter- 40-254
nator if necessary.
Check cables.
702 14 M35 MEDIUM Engine overspeed Check parameter (21).
Check speed control.
Check speed sensor
743 9 M71 MEDIUM CANBUS transmission Check CAN connection, 40-1003
error. terminal resistor.
Check control unit.
743 12 M70 MEDIUM CANBUS line controller Check CAN connection, 40-1003
damaged terminal resistor.
Check control unit.
743 14 M74 MEDIUM CANBUS transmission Check CAN connection, 40-1003
error. terminal resistor.
Check control unit.
752 2 M93 HIGH “Stack Overflow” error Switch off and switch on
during program execu- again.
tion. Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.
752 12 M77 HIGH The ECU has detected Switch off and switch on
an error in reading the again.
program memory during Re-check.
the normal control cycle. In the case of a fault, in-
form the DEUTZ Service
Organisation.
765 2 M90 HIGH Inconsistent parameters Check correct data set-
written in EEPROM ting.
memory. Save parameters, switch
off and then switch on
again.
Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.
765 12 M76 HIGH Detection of error during Switch off and switch on 40-1003
writing of parameters on again.
control unit Re-check.
In the case of a fault, in-
form the DEUTZ Service
Organisation.

20-60
Calibrations and electronic
diagnosis
Table 64
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
766 2 M78 HIGH The ECU has detected Switch off and switch on
an error in reading the again.
program memory during Re-check.
the normal control cycle. In the case of a fault, in-
form the DEUTZ Service
Organisation.
766 2 M80 LOW Supply of actuator is not Switch off and switch on 40-254
within admissible param- again.
eters. Re-check.
In the case of a fault, in-
form the DEUTZ Service
Organisation.
766 2 M83 LOW The power supply to the Check power supply. 40-254
accelerator pedal posi- Switch off and switch on
tion sensor is not present again. Re-check.
or incorrect. In the case of a fault, in-
form the DEUTZ Service
Organisation.
766 2 M84 LOW Power supply of the en- Check power supply. 40-254
gine boost sensor is Switch off and switch on
missing or incorrect. again.
Re-check. In the case of
a fault, inform the DEUTZ
Service Organisation.
766 2 M94 HIGH Internal error Check power supply.
Switch off and switch on
again.
898 2 M68 MEDIUM Connection to CANBUS Check CAN connection, 40-1003
error terminal resistor.
Check control unit.

20.4.4 - Transmission alarms

Alarms - Transmission alarms list (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
Table 65
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
T42 Fault related to the CAN Check wiring
network between instru- Check TCU fuse
ment and transmission
control unit
51 12 T141 LOW K006 - Acceler- Accelerator pedal poten- Check accelerator pedal 40-593
ator pedal posi- tiometer faulty or discon-potentiometer wiring
Check the potentiometer
123 2 T19 LOW K018 - Clutch oil Proportional valve pres- Check accelerator pedal 40-934
pressure switch sure switch plausibility potentiometer wiring
Check the potentiometer

20-61
 Calibrations and electronic
diagnosis
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
123 3 T20 LOW K018 - Clutch oil Proportional valve pres- Check the 4 Bar pressure 40-934
pressure switch sure switch plausibility switch wiring
error (valve off but pres- Check the 4 bar pressure
sure present) switch
Check for possible me-
chanical jamming of pro-
portional valve
127 2 T18 LOW K011 - Services Services pressure Check the 4 Bar pressure 40-369
circuit alarm switch, plausibility error switch wiring
pressure switch (engine off and service Check the 4 bar pressure
switch
160 2 T52 LOW Plausibility error on Check the 4 Bar pressure
shuttle output speed sen- switch wiring
sor (valve controlled but Check the 4 bar pressure
speed zero) switch
160 3 T51 LOW K016 - Shuttle Shuttle output speed Check wiring 40-934
sensor sensor short circuit to Check the sensor
GND or 12V Check the sensor power
supply
160 12 T50 LOW K016 - Shuttle Shuttle output speed Check wiring 40-934
sensor sensor disconnected Check the sensor
Check the sensor power
supply
161 2 T103 LOW K015 - Engine Engine rpm sensor faulty Check wiring 40-934
Check the sensor
168 2 T93 HIGH 12V power supply fault Ignition switch off/on,
check power supply to
pins 1, 2 and 15
Check wiring
177 3 T12 MEDIUM K017 - Oil tem- Temperature sensor dis- Check wiring 40-934
perature sensor connected or short circuit Check the sensor
to 12V Check the sensor power
supply
Check the sensor power
stage
177 4 T13 MEDIUM K017 - Oil tem- Temperature sensor Check wiring 40-934
perature sensor short circuit to earth Check the sensor
Check the sensor power
supply
Check the sensor power
stage

20-62
Calibrations and electronic
diagnosis
Table 66
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
191 3 T48 LOW K010 - Wheel Wheel speed sensor Check wiring 40-934
speed sensor short circuit to 12V Check the sensor
Check the sensor power
supply
191 12 T47 LOW K010 - Wheel Wheel speed sensor dis- Check wiring 40-934
speed sensor connected Check the sensor
Check the sensor power
supply
520 3 T86 LOW H003 - Shuttle Error Hard-Soft control Check control using the 40-934
lever blocked or shorted ART
Check the sensor
520 4 T87 LOW H003 - Shuttle Error Hard-Soft control Check control using the 40-934
lever blocked or disconnected ART
Check the sensor
561 12 T142 LOW K005 - Hand Hand throttle potenti- Check hand throttle po- 40-934
throttle position ometer faulty or discon- tentiometer wiring
Check the potentiometer
598 2 T64 LOW K020 - Clutch Plausibility error on clutch Check wiring 40-934
pedal position pedal potentiometer Check the sensor
sensor Check the sensor power
supply
Check sensor installation
1079 2 T67 HIGH 5V sensor power fault Check power supply to
pin 14
Check wiring and con-
nections of sensors fed
with 5V
1504 2 T17 LOW K007 - Operator Seat sensor (signal level Check wiring 40-934
present sensor invalid) Check the sensor
Check the sensor power
supply
Check the sensor power
stage
1504 3 T16 LOW K007 - Operator Seat sensor short circuit Check wiring 40-934
present sensor to 12V Check the sensor
Check the sensor power
supply
Check the sensor power
stage
1504 4 T15 LOW K007 - Operator Seat sensor disconnect- Check wiring 40-934
present sensor ed or short circuit to earth Check the sensor
Check the sensor power
supply
Check the sensor power
stage

20-63
 Calibrations and electronic
diagnosis
Table 67
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
5110 3 T66 HIGH K020 - Clutch Clutch pedal potentiom- Check wiring 40-934
pedal position eter short circuit to +12V Check the sensor
sensor Check the sensor power
supply
Check sensor installation
5110 4 T65 HIGH K020 - Clutch Clutch pedal potentiome- Check wiring 40-934
pedal position ter disconnected or short Check the sensor
sensor circuit to GND Check the sensor power
supply
Check sensor installation
5110 13 T70 HIGH K020 - Clutch Clutch pedal potentiom- Ignition switch off/on then 40-934
pedal position eter incorrect calibration repeat the pedal calibra-
sensor data tion procedure
Check the sensor
5130 4 T73 LOW H002 - Main Plausibility error on Com- Check wiring 40-934
Check the pushbutton
5140 2 T85 HIGH H003 - Shuttle Plausibility error on shut- Ignition switch off/on, 40-934
lever tle lever if alarm persists renew
shuttle lever
Check the pushbutton
5221 2 T100 LOW On/Off valves connection Check connection of On/
error Off valves – could be re-
versed.
Check the pushbutton
5222 2 T24 HIGH Excessive clutch slipping Check cause of clutch
slippage
Check the pushbutton
5223 2 T25 LOW Alternator belt slipping Check cause of clutch
slippage
Check the pushbutton
5350 3 T94 HIGH L008 - Propor- Proportional SV short cir- Check wiring 40-934
tional solenoid cuit to +12V Check the valve
valve Check the valve power
supply
5350 4 T77 HIGH L008 - Propor- Proportional SV short cir- Check wiring 40-934
tional solenoid cuit to earth Check the valve
valve Check the valve power
supply
5350 5 T76 HIGH L008 - Propor- Proportional SV discon- Check wiring 40-934
tional solenoid nected Check the valve
valve Check the valve power
supply

20-64
Calibrations and electronic
diagnosis
Table 68
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
5370 3 T95 HIGH L006 - Forward FORWARD drive SV Check wiring 40-934
gear selection short circuit to +12V Check the valve
solenoid valve Check the valve power
supply
5370 4 T80 HIGH L006 - Forward FORWARD drive SV Check wiring 40-934
gear selection short circuit to GND Check the valve
solenoid valve Check the valve power
supply
5370 5 T79 HIGH L006 - Forward FORWARD drive SV dis- Check wiring 40-934
gear selection connected Check the valve
solenoid valve Check the valve power
supply
5380 3 T96 HIGH L007 - Reverse REVERSE drive SV Check wiring 40-934
gear selection short circuit to +12V Check the valve
solenoid valve Check the valve power
supply
5380 4 T83 HIGH L007 - Reverse REVERSE direction SV Check wiring 40-934
gear selection short circuit to GND Check the valve
solenoid valve Check the valve power
supply
5380 5 T82 HIGH L007 - Reverse REVERSE drive SV dis- Check wiring 40-934
gear selection connected Check the valve
solenoid valve Check the valve power
supply
5512 2 T99 HIGH EEPROM checksum er- Repeat commissioning
ror procedure
Replace TCU
5560 13 T10 LOW Uncalibrated clutches or Calibrate the shuttle
Stop&Go Replace TCU
Table 69
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
5561 13 T9 HIGH Commissioning not com- Commission the tractor
pleted Replace TCU
5562 13 T11 LOW K006 - Acceler- Accelerator pedal and Calibrate the accelera- 40-254
ator pedal posi- hand throttle not cali- tors
Replace TCU
5562 13 T8 LOW Gear configuration error Check the correct gear-
box configuration
Replace TCU
5910 9 T101 LOW Timeout of CAN mes- Check wiring 40-1003
Check instrument panel
5920 9 T102 LOW CAN or TCU network Check wiring 40-1003
Check instrument panel

20-65
 Calibrations and electronic
diagnosis
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
5930 9 T143 LOW Failure of bus CAN sig- Check CAN bus connec- 40-1003
nals from engine tion between engine and
transmission ECU
Check instrument panel

20.4.5 - Instrument panel alarms

Alarms - Instrument panel alarms list (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
Table 70
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
I20 Low K014 - Fuel lev- Fuel level sensor short 40-397
el sensor circuit to battery 40-382
L43 Low Timeout of CAN mes- 40-1012
sage “System controller 40-1008
MSG#2” sent by lift ECU
M41 Low Timeout of CAN mes- 40-1012
sage “Measured Data1” 40-1008
sent by engine ECU
T42 Low Timeout of CAN mes- 40-1012
sage “FPS transmission 40-1008
controller” sent by trans-
mission ECU
U44 Low Timeout of CAN mes- 40-1012
sage “HLHP Control” 40-1008
sent by User Controller
ECU
Alarms - Instrument panel alarms list (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
Table 71
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
I20 Low K014 - Fuel lev- Fuel level sensor short 40-369
el sensor circuit to battery
L43 Low Timeout of CAN mes- 40-1003
sage “System controller
MSG#2” sent by lift ECU
M41 Low Timeout of CAN mes- 40-1003
sage “Measured Data1”
sent by engine ECU

20-66
Calibrations and electronic
diagnosis
ART code In- Severity Component Fault Checks Link to sys-
SPN FMI stru- tem
ment
panel
dis-
play
error
T42 Low Timeout of CAN mes- 40-1003
sage “FPS transmission
controller” sent by trans-
mission ECU
U44 Low Timeout of CAN mes- 40-1003
sage “HLHP Control”
sent by User Controller
ECU
P.T.O. selfdiagnosis indicator light.
The light integrated in the instrument panel (1) also serves to indicate the type of
fault on the control by means of intermittent flashes.

Fig. 284

When the tractor engine is started, the indicator light will flash to show that the control system has been activated.
Table 72
Code (number of flashes) Description
2 Solenoid valve disconnected
3 Pushbutton control continuously activated
4* Speed sensor faulty
5 Solenoid control output signal shorted to earth or in overcurrent
6* Speed excessive
7 Internal ECU fault in power stage
8 Sensor presence detected in configuration where not required
*: Alarms present in U.S.A. configuration only.
If a fault occurs on the control, the electronic control unit inhibits operation of the P.T.O.

20-67
 Calibrations and electronic
diagnosis

PAGE LEFT INTENTIONALLY BLANK

20-68
30 - Method of intervention

30-1
 Method of intervention
30.1 - Tools for engine disassembly and reassembly
30.1.1 - Commercially available tools
Deutz 2012 2V UPS engines
Table 73
No. Figure Code, description & function Q.ty
1 Code 01899031 (8002) 1
Pressing pump: Check the seal of the cooling system.

© 35409-2

Fig. 285
2 Code 01899034 (8005) 1
Compression value test for diesel engines. (10 - 40 bar) Check of the
compression value.

© 35410-3

Fig. 286
3 Code 01899035 (8008) 1
Injector control equipment: With nebulised spray collection container.
Check the injectors.

© 35411-2

Fig. 287
4 Code 01899037 (8011) 1
Pliers for hose clips: Loosen and fix the hose clips. (e.g. fuel return line)

© 39426-1

Fig. 288
5 Code 01899038 (8012) 1
Box spanner insert: SW15, long.

© 35412-3

Fig. 289

30-2
Method of intervention
No. Figure Code, description & function Q.ty
6 Code 01899050 (8024) 1
Assembly pliers: Removal of the valve stem gaskets.

© 37509-2

Fig. 290
7 Code 01899054 (8035) 1
Box spanner insert: Reinforced, SW 22. Removal and refitting of the
main bearing.

© 37504-2

Fig. 291
8 Code 01899060 (8113) 1
Box spanner insert: Torx - E 14.

© 43022-0

Fig. 292
9 Code 01899061 (8114) 1
Box spanner insert: Torx - E 20.

© 35415-1

Fig. 293
10 Code 01899062 (8115) 1
V-belt tension tester from 150 to 600 N. Checking the V-belt tension.

© 35416-3

Fig. 294
11 Code 01899064 (8117) 1
Toothed box spanner insert: For rotating the injection pump.

© 46422-0

Fig. 295

30-3
 Method of intervention
No. Figure Code, description & function Q.ty
12 Code 01899092 (8189) 1
Torx tool set. Case content: • Double ring wrench E6/E8, • Double ring
wrench E10/E12, • Box spanner inserts E8 and E10 (1/4 inch), • Box
spanner inserts E10 and E12 (3/8 inch), • Box spanner inserts E18 (1/2
inch).

© 39432-1

Fig. 296
13 Code 01899093 (8190) 1
Rotation angle gauge with magnet. Adjustment of valve clearance.

© 43528-0

Fig. 297
14 Code 01899094 (8191) 1
Screwdriver insert for slot head screw. Valve clearance adjustment.

© 43060-0

Fig. 298
15 Code 01899095 (8192) 1
Bowlen wrench: Fuel prefilter (Racor).

© 43193-1

Fig. 299
16 Code 01899096 (8193) 1
Screwdriver insert with hexagonal pin pressure inserted (5 mm), 1/2
inch, long version (in combination with the rotation angle gauge 8190)

© 43183-0

Fig. 300
17 Code 01899097 (8194) 1
Screwdriver insert with hexagonal pin pressure inserted (4 mm), 3/8
inch, long version (in combination with the rotation angle gauge 8190
and 1/2 to 3/8 inch reducer)

© 43183-0

Fig. 301

30-4
Method of intervention
No. Figure Code, description & function Q.ty
18 Code 01899099 (8196) 1
Open-ended wrench: SW 13, for the torque wrench. Tighten the check
nuts of the valve clearance adjustment screw.

© 43019-0

Fig. 302
19 Code (...) 8198 1
Bradawl: Disassembly of the shaft seal ring.

© 43206-0

Fig. 303
20 Code 01899100 (8199) 1
Crow’s foot wrench: SW 15. 3/4 inch (in combination with the rotation
angle gauge 8190)

© 44309-0

Fig. 304
21 Code 01899110 (9017) 1
Assembly lever. (e.g. valve assembly and disassembly)

© 37511-2

Fig. 305
22 Code 01899112 (9090) 1
Circlip pliers: 320 mm. Tension the circlip.

© 00000-0

Fig. 306

30-5
 Method of intervention
30.2 - Workshop tools for engine disassembly and reassembly
30.2.1 - Workshop tools for engine disassembly and reassembly
Deutz 2012 2V UPS engines
Table 74
No. Figure Code, description & function Q.ty
1 Code 02992019 (100190) 1
Dummy injector: In combination with the compression value tester code
01899034 (8005)

© 42524-1

Fig. 307
2 Code ... (100320) 1
Rotation device. On the flywheel side.

Fig. 308
3 Code ... (100330) 1
Rotation device: V-belt pulley. Turn the crankshaft on the torsional vibra-
tion damper.

© 35423-1

Fig. 309
4 Code 01899126 (100400) 1
Dial gauge with stop wheel. Measurement interval: 0 - 10 mm / 0.01 mm.

© 35424-1

Fig. 310
5 Code 01899127 (100410) 1
Digital dial gauge. Measurement interval: 0 - 30 mm / 0.01 mm.

© 43205-0

Fig. 311

30-6
Method of intervention
No. Figure Code, description & function Q.ty
6 Code 02992041 (100750) 1
Measurement device: Sliding vernier scale with two spacer discs. In com-
bination with code 01899126 (100400) and code 01899127 (100410).
Valve retraction check. Piston protrusion check.

© 39402-2

Fig. 312
7 Code 02992045 (100800) 1
Regulation device. For measuring the stroke and blocking the adjust-
ment rod.

© 46441-0

Fig. 313
8 Code 02992046 (100810) 1
Centring pin. For mass compensation shafts.

© 46439-0

Fig. 314
9 Code 02992047 (100830) 1
Pressure device for the adjustment rod.

© 46443-0

Fig. 315
10 Code 01899131 (103050) 1
Box spanner insert SW 15, 3/4 inch. In combination with the rotation
angle gauge code 01899093 (8190).

© 43023-0

Fig. 316
11 Code 02992079 (103210) 1
Measurement device for measuring the base circle. (in engines with an
injection advance variator)

© 46444-0

Fig. 317

30-7
 Method of intervention
No. Figure Code, description & function Q.ty
12 Code ... (103220) 1
Special pliers for extracting the roller tappet. Measurement device com-
ponent, code 02992079 (103210)

© 43175-0

Fig. 318
13 Code 02992084 (110030) 1
Extractor for disassembly of the injection valve. In combination with the
slide hammer extractor code 02992294 (150800).

© 35433-2

Fig. 319
14 Code 02992089 (110110) 1
SW11 support for tightening the injection valve in the screw clamp.

© 35434-2

Fig. 320
15 Code 02992112 (110500) 1
Special wrench SW 17 for disassembly and assembly of the high pres-
sure lines.

© 35436-1

Fig. 321
16 Code 01899132 (110700) 1
Long box spanner insert for the assembly and disassembly of pressure
sensors. (Rail pressure, oil pressure, fuel pressure)

© 43198-2

Fig. 322
17 Code 02992127 (110901) 1
Tool for the disassembly and assembly of the O-rings. Assembly kit com-
ponent, code 02992126 (110900)

© 45950-1

Fig. 323

30-8
Method of intervention
No. Figure Code, description & function Q.ty
18 Code ... (120430) 1
Spark plug assembly and disassembly tool.

© 40333-1

Fig. 324
19 Code 02992136 (120660) 1
Extraction device. Disassembly of the injection valve. In combination
with the slide hammer extractor code 02992294 (150800)

© 45111-0

Fig. 325
20 Code 02992139 (120900) 1
Adjustable support stand. Tightening the cylinder head.

© 35438-3

Fig. 326
21 Code 02992140 (120910) 1
Base plate. In combination with support stand code 02992139 (120900),
if the support stand is not screwed on fixed.

© 35439-3

Fig. 327
22 Code 02992145 (121410) 1
Valve stem gasket assembly tool.

© 37614-2

Fig. 328
23 Code ... (121420) 1
Assembly bushes. Set of assembly bushes for the valve stem gasket.

© 43210-0

Fig. 329

30-9
 Method of intervention
No. Figure Code, description & function Q.ty
24 Code 02992155 (130300) 1
Universal pliers for piston rings. Disassembly and assembly of piston
rings.

© 43021-0

Fig. 330
25 Code 02992165 (130440) 1
Trapezoidal groove wear gauge. Piston diameter 101 mm. Check piston
ring groove.

© 36461-2

Fig. 331
26 Code 02992181 (130670) 1
Piston ring compression collar for piston assembly: Piston Ø mm. 101.

© 39408-1

Fig. 332
27 Code 02992187 (131200) 1
Base plate for press-fit and removal of the connecting rod small end
bush. In combination with assembly tool set code 02992188 (131210)

© 37616-1

Fig. 333
28 Code 02992189 (131220) 1
Set of assembly tools for press-fit and removal of the connecting rod
small end bush. In combination with the base plate code 02992187
(131200)

© 37617-1

Fig. 334
29 Code 02992213 (142670) 1
Assembly device for the crankshaft O-ring. (opposite end to flywheel)

© 35445-1

Fig. 335

30-10
Method of intervention
No. Figure Code, description & function Q.ty
30 Code 02992223 (142830) 1
Assembly device for the crankshaft O-ring. (flywheel side)

© 35446-1

Fig. 336
31 Code 02992251 (143840) 1
Camshaft bearings assembly and disassembly tool.

© 46440-0

Fig. 337
32 Code 02992275 (144800) 1
Counterhead for the torsional vibration damper.

© 35453-1

Fig. 338
33 Code 02992294 (150800) 1
Slide hammer extractor for the disassembly of the injection valve.

© 35449-2

Fig. 339
34 Code 02992301 (151500) 1
Tool for truncation. For removal of the lubricant oil sump pan in plate from
the crankcase.

© 45974-0

Fig. 340
35 Code 01899142 (170050) 1
Special wrench for the removal of the filter cartridges.

© 37629-2

Fig. 341

30-11
 Method of intervention
No. Figure Code, description & function Q.ty
36 Code ... (170160) 1
Plugs and caps: 1 set of different sized plugs and caps. For closing the
holes in the fuel distribution system.

© 43663-0

Fig. 342
37 Code 01899000 (6066) 1
Assembly stand for tightening the engine on two sides.

© 35451-2

Fig. 343
38 Code ... (6066/158) 1
Clamping support, consisting of: 1 support code 01899010 (6066/158-1)
rear right; 1 support 01899011 (6066/158-2) rear left; 1 support 01899012
(6066/158-3) front right; 1 support 01899013 (6066/158-4) front left. In
combination with the assembly stand code 01899000 (6066). Tightening
the engine on two sides.

© 35452-1

Fig. 344
39 Code 01899028 (6068) 1
Suspension device: Maximum load ( 2 tonnes), 3-point suspension,
screw tensioners, crosspiece, chain and hooks.

© 43184-0

Fig. 345

30-12
Method of intervention
30.3 - B0 - Engine
30.3.1 - Air conditioning compressor drive belt
REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Loosen nut (1) and unscrew tie rod (2) to slacken off drive belt (3).

Fig. 346
3. For versions with front PTO
Using a pin punch, remove pin (4) and withdraw PTO engagement shaft (5)
towards the front of the tractor.

Fig. 347
4. For all versions
Remove drive belt (3).
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 2
l Adjust the tension of the fan drive belt.

30.3.2 - Tension adjustment of the fan and air conditioning compressor drive belt
Tension adjustment
1. m Before adjusting the tension, carefully examine the drive belt for signs of wear. The belt must be renewed immediately
at the first sign of cracking, fraying or separation of the plies.
m Always replace both drivebelts at the same time.
DANGER
If new drivebelts are fitted, re-adjust the tension after approx. 50 operating hours.

30-13
 Method of intervention
2. Loosen nuts (1) and screws (2).

Fig. 348
3. Tighten tie-rod (3) forcing it gradually until obtaining belt deflection of 10-15
mm (0.4-0.6 in.) when applying a load of 10 kg (22 lb.) on the long section
of the belt.
mIn the case of a new belt, deflection should be 7-9 mm (0.276 - 0.355
in.).
Secure compressor (4) in place and re-check belt tension.

Fig. 349

30.3.3 - Alternator, fuel pump and water pump drive belt

REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Loosen screws (1) and (2) securing the fuel pump, disengage alternator
drive belt (3) and remove it by passing it between the bottom of the crank-
shaft pulley and the front axle support.

Fig. 350

Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 2
l Adjust drive belt tension.

30-14
Method of intervention
30.3.4 - Tension adjustment of the alternator, fuel pump and water pump drive belt
Tension adjustment
1. Tension the belt using a “T” bar with a 3/4” drive extension, or a 3/4” angle
drive bar inserted in the aperture in the support of fuel pump (1).
Tension the drive belt by turning the bar clockwise and then tighten down
screws (2) and (3).

Fig. 351
2. To check that the tension is correct, use the tool and procedure indicated
in the engine manual.
Static deflection “A” on first fitting
m 13 mm belt: 450±50 N
Static deflection “A” after 15 minutes
m 13 mm belt: 300±50 N
DANGER
This check should be carried out with the engine cold.
Fig. 352

30.3.5 - Compression test

Commercially available tools:
l Compression value test: 8005
l Torx tool set: 8189
Special tools:
l Pipe union: 100130
Compression test
1. m Adjust valve clearance.
See para. 30.3.7 - Adjustment of valve cl... - page 30-22
m Disassemble the injection valves.
See para. 30.3.50 - Fitting and removing i... - page 30-188
m Fit seal (1)
m Fit union (2).
2

© 46377-1

Fig. 353

30-15
 Method of intervention

30-16
Method of intervention
5. Note
The pressure reading will depend on the number of starter No.
Kompression in bar
revolutions during the testing process and on the altitude at Compression value in bar
Pression en bar
which the test is performed. The limit values therefore can- Dat. _________
10 15 20 25 30 35 40
not be defined with precision. We recommend that the read-

Zyl.
ings obtained are used solely for comparison between the 1
different cylinders. A difference between cylinders of over 2
3
15% should be investigated by dismantling the cylinder giv- 4
5
ing the low reading. 6
7
8
DBGM Made in German y
MOTOMETER
© 33771-5

Fig. 357
6. m Remove the compression tester and adapter (1).

© 46308-1

Fig. 358
7. m Remove screw (1).
m Remove retaining bracket (2).
m Remove the union.
m Remove the seal.
m Assemble the injection valves.
See para. 30.3.50 - Fitting and removing i... - page 30-188

© 46378-1

Fig. 359

30-17
 Method of intervention
30.3.6 - Assembly and disassembly of the engine on the assembly stand
Commercially available tools:
l Lifting device
l Loading rope
Special tools:
l Assembly stand with adapter plates: 6066
l Clamping support: 6066/158
l Suspension device: 6068
NOTE
The repair process shown does not take specific customer equipment into account; components not included in the
standard equipment are not shown.

Assembly of the engine on the stand

1. m Hook the suspension device with the support chain to the transport
slats (arrows).
n 4-cylinder: 410 kg

m Hang the engine from the workshop crane.

NOTE
Disassemble all the feet.

m Fit the engine on the assembly stand.

© 46446-0

Fig. 360
2. m Fit the clamping support 6066/158-1 (1) on the support.
m Tighten the screws (2) and the check nuts: 70 Nm.
m Tighten the screws (3) and the check nuts: 90 Nm.

3 2

© 46448-0

Fig. 361

30-18
Method of intervention
3. m Fit the clamping support 6066/158-2 (1) on the support.
m Tighten the screws (2) and the check nuts: 70 Nm.
m Tighten the screws (3) and the check nuts: 90 Nm.
1
2

© 46449-0

Fig. 362
4. m Fit the clamping support 6066/158-3 (1) on the crankcase.
m Tighten the screw (2): 70 Nm.
m Tighten the screws (3) and the check nuts: 90 Nm.
2

3
1

© 46447-0

Fig. 363
5. m Fit the clamping support 6066/158-4 (1) on the crankcase.
m Tighten the screws (2): 70 Nm.
m Tighten the screws (3) and the check nuts: 90 Nm.

3
© 46450-0

Fig. 364

30-19
 Method of intervention
6. m Align the engine on the assembly stand.
m Tighten all the screws (1).
m Hang the engine from the workshop crane.

1
© 46459-0

Fig. 365

Disassembly of the engine from the assembly stand

1. m Hook the suspension device with the support chain to the transport
slats (arrows).
n 4-cylinder: 410 kg

m Hang the engine from the workshop crane.

© 46446-0

Fig. 366
2. m Unscrew the check nuts.
m Remove the screws (3) and the check nuts.
m Remove screws (2).
m Withdraw the clamping support (1).
2

3
© 46450-0

Fig. 367

30-20
Method of intervention
3. m Unscrew the check nuts.
m Remove the screws (3) and the check nuts.
m Withdraw the clamping support (1).
1
3

© 46449-1

Fig. 368
4. m Unscrew the check nuts.
m Remove the screws (3) and the check nuts.
m Withdraw the clamping support (1).

3 3

© 46448-1

Fig. 369
5. m Unscrew the check nuts.
m Unscrew screw (2)
m Remove the screws (3) and the check nuts.
m Remove the clamping support (1). 2
NOTE
Fit all the feet.
3
1
m Deposit the engine.
m Hang the engine from the workshop crane.
3

© 46447-0

Fig. 370

30-21
 Method of intervention
30.3.7 - Adjustment of valve clearance
Commercially available tools:
l Rotation angle gauge: 8190
l Open-ended wrench SW13: 8196
l Screwdriver insert for slot head screws: 8191
l Screwdriver insert for hexagonal pins (5 mm): 8193
Special tools:
l Rotation device: 100320
NOTE
Leave the engine to cool for at least 30 minutes before adjusting valve clearance, .
Engine oil temperature < 80°C.

Bring the engine to valve overlap position

1. m Fit the rotation device.
See para. 30.3.39 - Removal and refitting ... - page 30-144
m Remove the cylinder head cover.
See para. 30.3.10 - Disassembly and assemb... - page 30-32
m Turn the crankshaft with the rotation tool into the valve overlap posi-
tion for cylinder 1.

© 46461-0

Fig. 371
2. Positions of the intake and exhaust valves:
IN = intake valve. EX = exhaust valve
EX IN

© 46381-0

Fig. 372

30-22
Method of intervention
3. 4 cylinders. Firing order:
1–3–4–2

Table 75

Valves Cylinders
at overlap 1 3 4 2
angle
set 4 2 1 3

Valve overlap means that: © 46380-0

Fig. 373
the intake valve starts to open and the exhaust valve starts
to close.

Adjustment of the intake valve clearance

1. m Loosen locknut (1).
m Turn adjustment screw (2) to take up the clearance.
NOTE 2
The rocker arm should rest on the thrust washer of
the collet (arrowed) with no clearance.

WARNING 1
Pay attention to the version of the adjustment screws (slot,
hexagon, internal hexagon).

© 46382-0

Fig. 374
2. m Position rotation angle disc with screwdriver insert on adjuster screw.
m Fix the magnet of the rotation angle gauge to the cylinder head.
m Turn the rotation angle gauge in the direction of the arrow to “0”.
NOTE
Do not move the adjustment screw.

© 46462-0

Fig. 375

30-23
 Method of intervention
3. m Turn the adjustment screw in the direction of the arrow.
n Intake: 75°.

© 46463-0

Fig. 376
4. m Hold the adjustment screw in this position.
m Tighten the check nut (1) using the open-ended wrench: 20 Nm.
m Remove the rotation angle gauge.

© 46464-0

Fig. 377

Adjustment of the exhaust valve clearance

1. m Loosen locknut (1).
m Turn adjustment screw (2) to take up the clearance.
NOTE
The rocker arm should rest on the thrust washer of
the collet (arrowed) with no clearance.
2

© 46387-0

Fig. 378

30-24
Method of intervention
2. m Locate the rotation angle gauge with the slot head screwdriver insert
on the adjustment screw.
m Fix the magnet of the rotation angle gauge to the cylinder head.
m Turn the rotation angle gauge in the direction of the arrow to “0”.
NOTE
Do not move the adjustment screw.

© 46465-0

Fig. 379
3. m Turn the adjustment screw in the direction of the arrow.
n Exhaust: 120°.

© 46466-0

Fig. 380
4. m Hold the adjustment screw in this position.
m Tighten the check nut (1) using the open-ended wrench: 20 Nm.
m Remove the rotation angle gauge.
m Fit the cylinder head cover.
See para. 30.3.10 - Disassembly and assemb... - page 30-32
m Remove the rotation device.
See para. 30.3.39 - Removal and refitting ... - page 30-144

© 46467-0

Fig. 381

30-25
 Method of intervention
30.3.8 - Removal and refitting of the rocker arms and pedestals
Commercially available tools:
l Box spanner insert Torx E14: 8113
l Rotation angle gauge: 8190
Removal of the rocker arms and pedestals
1. m Remove the cylinder head cover.
See para. 30.3.10 - Disassembly and assemb... - page 30-32
m Undo the cylindrical head screw (1) using the socket wrench insert.
m Unscrew screw (2)
m Remove the rocker mount. 2
NOTE
Put the components to one side in the order in which
they were removed.

© 46451-2

Fig. 382
2. m Withdraw pushrods (1).
NOTE
Put the components to one side in the order in which
they were removed.

© 46452-0

Fig. 383
3. m Carry out a visual inspection of the components.

© 46453-0

Fig. 384

30-26
Method of intervention
Refitting the rocker arms and pedestals
1. m Insert pushrods (1).
NOTE
Take care to insert the pushrods in their original posi-
tions. The ball ends of the pushrods must locate in
the cups of the tappets.

© 46452-0

Fig. 385
2. m Fit rocker pedestal (1).
NOTE
The ball heads (2) must be in the pivots of the push-
1
rods.

© 46454-0

Fig. 386
3. m Screw in the screw (1).
NOTE
Do not tighten the screw at this stage.
1

© 46455-0

Fig. 387

30-27
 Method of intervention
4. WARNING
In the case of written certification, the cylindrical head
screws can be used a maximum of 3 times, otherwise re- 1
place them each time they are removed.
m Lightly oil the cylindrical head screw (1).
m Screw the cylindrical head screw (1).

© 46456-0

Fig. 388
5. m Orient the rocker pedestals symmetrically about the axes of the
valves
m Tighten the cylindrical head screws using the box spanner insert.
n Pretightening value: 30 Nm.

WARNING
Before tightening the screw, check that the pushrods are not
under load due to valve overlap.

© 46457-0

Fig. 389
6. m Tighten (1) the screw: 21 Nm.

© 46451-1

Fig. 390

30-28
Method of intervention
7. m Tighten the cylindrical head screws using the box spanner insert.
n Retightening value: + 80 Nm + 90°.

m Adjust valve clearance.

See para. 30.3.7 - Adjustment of valve cl... - page 30-22

© 46457-0

Fig. 391

30.3.9 - Disassemble and complete the rocker and support, check

Commercially available tools:
l Internal bore meter
l Palmer
l Circlip pliers
Special tools:
l Dial gauge: 100400
Disassembly of the rocker support
1. m Disassemble the rocker and the support.
See para. 30.3.8 - Removal and refitting ... - page 30-26
m Remove the circlip with the specific plier.

© 46389-0

Fig. 392
2. m Remove the rocker.
NOTE
Put the components to one side in the order in which
they were removed.

© 46390-0

Fig. 393

30-29
 Method of intervention
Rocker check
1. m Measure the rocker hole.
n Exhaust: 21.02 (+0.033,- 0) mm.

n Intake: 21.02 (+0.033,- 0) mm.

NOTE
The rocker wear limit was reached, replace it.

© 39032-1

Fig. 394
2. m Unscrew the check nut (1).
m Unscrew the adjustment screw (2).
WARNING
Pay attention to the version of the adjustment screws (slot,
hexagon, internal hexagon).

NOTE 2

Put the components to one side in the order in which they

were removed.

1
© 46393-0

Fig. 395
3. m Visually check the wear of the components.
m Check that the oil channels (arrow) are completely free.

© 46392-0

Fig. 396

30-30
Method of intervention
4. m Tighten the adjustment screws (1).
m Tighten the check nuts (2). 2

© 46468-0

Fig. 397

Check the rocker pins

1. m Measure the diameter of the main journals with the palmer: 21 (+0,-
0.052) mm.
NOTE
The rocker support wear limit was reached, replace
it.

© 46469-0

Fig. 398

Completion of the rocker support

1. m Lightly oil the rocker pins.
m Push the rockers (1) on the pins.
2
m Push the rockers (2) on the pins.
NOTE
1
The rocker must be turned with the contact surface
facing (3) facing towards the threaded hole (arrow).
Fit the rockers (1) on the exhaust side. Fit the rockers
(2) on the intake side.

3
© 46471-0

Fig. 399

30-31
 Method of intervention
2. m Fit the new circlips (1).
m Assemble the rockers and support.
See para. 30.3.8 - Removal and refitting ... - page 30-26

© 46453-1

Fig. 400

30.3.10 - Disassembly and assembly of the cylinder head

Commercially available tools:
l Box spanner insert Torx E14: 8113
Removal of the cylinder head cover
1. m Remove all the screws (1).
m Remove cylinder head cover (2).
2

© 46471-1

Fig. 401
2. m Cut the gasket at the ribs (1).
m Remove the gasket.
m Carry out a visual inspection of the components.

© 46587-0

Fig. 402

30-32
Method of intervention
3. m Disassemble the fan support.
See para. 30.3.63 - Removal and refitting ... - page 30-230
m Disassemble the exhaust pipe.
See para. 30.4.3 - Removal and refitting ... - page 30-239

© 46590-0

Fig. 403
4. m Disassemble the injection valves.
See para. 30.3.50 - Fitting and removing i... - page 30-188
m Disassemble the rocker support.
See para. 30.3.8 - Removal and refitting ... - page 30-26
m Disassemble the turbocharging air duct.
See para. 30.3.44 - Removal and refitting ... - page 30-159
m Remove screws (1).
2
m Remove support (2).

© 46331-0

Fig. 404
5. m Unscrew all the screws (1) using the long reach socket.
m Remove the cylinder head. 1
m Remove the gasket.
m Clean the mating surfaces.

© 46334-0

Fig. 405

30-33
 Method of intervention
Assembly of the cylinder head
1. NOTE
Measure the protrusion of all pistons. Select the cylinder
head seal based on the greatest measured piston protru-
sion.
m Measure the piston protrusion.
See para. 30.3.12 - Measuring piston protr... - page 30-42

© 42565-0

Fig. 406
2. m Select the cylinder head seal based on the greatest measured pis-
ton protrusion.
Table 76

Piston protrusion Hole

0.33 - 0.55 mm 1
0.56 - 0.65 mm 2
0.66 - 0.76 mm 3

Example:
piston protrusion = 0.7 mm corresponds to a cylinder head
seal with 3 holes (arrow). © 44154-0

Fig. 407
3. NOTE
Check that tightening bush (1) is present.

© 46335-0

Fig. 408

30-34
Method of intervention

30-35
 Method of intervention
7. m Fit rocker pedestal (1).
NOTE
The ball heads (2) must be in the pivots of the push-
1
rods.

© 46454-0

Fig. 412
8. m Screw in the screw (1).
NOTE
Do not tighten the screw at this stage.
1

© 46455-0

Fig. 413
9. WARNING
In the case of written certification, the cylindrical head
screws can be used a maximum of 3 times, otherwise re- 1
place them each time they are removed.
m Lightly oil the cylindrical head screw (1).
m Screw the cylindrical head screw (1).

© 46456-0

Fig. 414

30-36
Method of intervention
10. m Orient the rocker pedestals symmetrically about the axes of the
valves
m Tighten the cylindrical head screws with the socket wrench insert.
30 Nm.
WARNING
Before tightening the screw, check that the pushrods are not
under load due to valve overlap.

© 46457-0

Fig. 415
11. m Tighten (1) the screw: 21 Nm.

© 46451-1

Fig. 416
12. m Tighten all the cylindrical head screws according to the tightening
sequence.
n Retightening value: 30 Nm + 80 Nm + 90°.

NOTE
14 6 4 12
Use the box spanner insert.
18 10 2 8 16

17 9 1 7 15
13 5 3 11

© 45131-0

Fig. 417

30-37
 Method of intervention
13. m Fit support (2).
m Tighten (1) the screws.
m Assemble the turbocharging air duct.
See para. 30.3.44 - Removal and refitting ... - page 30-159
m Assemble the rocker support.
See para. 30.3.8 - Removal and refitting ... - page 30-26
m Adjust valve clearance.
2
See para. 30.3.7 - Adjustment of valve cl... - page 30-22
m Assemble the injection valves.
See para. 30.3.50 - Fitting and removing i... - page 30-188 1

© 46331-0

Fig. 418
14. m Assemble the exhaust pipe.
See para. 30.4.3 - Removal and refitting ... - page 30-239
m Assemble the fan support.
See para. 30.3.63 - Removal and refitting ... - page 30-230

© 46590-0

Fig. 419

Refitting the cylinder head cover

1. m Cut the new gasket at the ribs (1).
WARNING
Do not bend the flat gasket with metal ribbing. Sand the cut
areas.

© 46587-0

Fig. 420

30-38
Method of intervention
2. m Clean the mating surfaces.
m Fit a new gasket.
NOTE
Check the installation position is correct.

m Fit the cylinder head cover.

m Tighten all screws (1) alternately: 11 Nm.

© 46474-2

Fig. 421
3. NOTE
Make sure the assembly position is correct (arrow).

© 46473-2

Fig. 422

30.3.11 - Grinding the cylinder head seal surface

Commercially available tools:
l Flattener
l Roughness gauge
l Depth gauge
NOTE
When the flattener is used, following the specific instructions of the manufacturer.

Preparation of the cylinder head

1. m Disassemble the valves.
See para. 30.3.13 - Valve assembly and dis... - page 30-45
m Deburr the top of the cylinder head.
NOTE
To ensure a correct fit, the cylinder head surface
must be free of burr or gasket residue.

© 36627-1

Fig. 423

30-39
 Method of intervention
Flattening the cylinder head
1. m Tighten the cylinder head on the flattener.
m Align the cylinder head.
m Flattener tool for aligning the cylinder head.

© 39731-1

Fig. 424
2. m Flattening the sealing surface of the cylinder head.
NOTE
The lapping procedure must be repeated if the seal
surface of the cylinder head is not perfectly flat (rec-
ognisable by variations in colour in the ground sur-
face). The tool supply dimension is maximum 0.2 mm
for the flattening process.

© 39730-1

Fig. 425

Check of the sealing surface of the cylinder head

1. m Visual inspection of the sealing surface of the cylinder head.
m Visually inspect the surface of the combustion chamber.
m Fit the cylinder head gasket.
m Mark the surface of the combustion chamber (arrow).
NOTE
Do not mark with a pointed implement as this may
damage to the cylinder head seal surface.

© 36645-1

Fig. 426

30-40
Method of intervention
2. m Remove the cylinder head seal.
m Visual inspection of the sealing surface of the cylinder head.
NOTE
Minor damage to the combustion chamber surface
is permitted (as indicated by arrow). The lapping
procedure for the cylinder head must be repeated,
however, even if minor damage to the cylinder head
surface is visible. The cylinder head wear limit was
reached, replace it.

© 39732-1

Fig. 427
3. m Measure the roughness of the cylinder head seal surface with the
roughness gauge: Rz 25.
NOTE
If the value measured is not within the permissible
range, the cylinder head seal surface must be lapped
again using different settings for the lapping machine.

© 36647-1

Fig. 428
4. m Measure the height of the cylinder head with a depth gauge.
n Standard: 90 mm.

n Undersizing value: 89.4 mm.

NOTE
The cylinder head wear limit was reached, replace it.

© 36646-1

Fig. 429

30-41
 Method of intervention
5. m Remove the cylinder head from the flattener.
m Apply the repair date and factory mark on the cylinder head.
WARNING
Do not apply the label to a sealing surface.

NOTE
Mark the cylinder head after each repair.

m Assemble the valves.

See para. 30.3.13 - Valve assembly and dis... - page 30-45 © 39731-1

Fig. 430

30.3.12 - Measuring piston protrusion

Special tools:
l Rotation device: 100330
l Dial gauge: 100400
l Measurement device: 100750
Measuring piston protrusion
1. m Fit the rotation device.
See para. 30.3.39 - Removal and refitting ... - page 30-144
m Disassemble the cylinder head.
See para. 30.3.10 - Disassembly and assemb... - page 30-32

© 46474-0

Fig. 431
2. m Turn the crankshaft until the respective piston is positioned just be-
fore the top dead centre (arrow).

© 46333-0

Fig. 432

30-42
Method of intervention

30-43
 Method of intervention
6. m Move the sliding vernier scale.
m Position the preloaded probe on the required measurement points.
m Continue to uniformly rotate the crankshaft until the return point of
the dial gauge pointer is reached.
NOTE
Do not place the dial gauge probe on the markings
on the piston. Note the maximum value measured.

© 43514-1

Fig. 436
7. m Select the cylinder head seal based on the greatest measured pis-
ton protrusion.
Table 77

Piston protrusion Hole

0.33 - 0.55 mm 1
0.56 - 0.65 mm 2
0.66 - 0.76 mm 3

NOTE
Example: piston protrusion = 0.7 mm corresponds to a cylin-
der head seal with 3 holes (arrow). © 44154-0

Fig. 437
8. m Assemble the cylinder head.
See para. 30.3.10 - Disassembly and assemb... - page 30-32
m Remove the rotation device.
See para. 30.3.39 - Removal and refitting ... - page 30-144

© 46474-0

Fig. 438

30-44
Method of intervention
30.3.13 - Valve assembly and disassembly
Commercially available tools:
l Sliding gauge
l Assembly pliers: 8024
l Assembly lever: 9017
Special tools:
l Support stand: 120900
l base plate: 120910
l Assembly tool: 121410
l Assembly bushes: 121420
Valve disassembly
1. m Disassemble the cylinder head.
See para. 30.3.10 - Disassembly and assemb... - page 30-32
m Assemble the support stand (1) on the base plate (2).
m Assemble the cylinder head on the support stand. 1

2
© 42583-0

Fig. 439
2. m Remove the circlip (1).
DANGER
Risk of injury! The circlip jumps away.

© 42584-0

Fig. 440
3. m Remove the thrust washer (1).

© 42585-0

Fig. 441

30-45
 Method of intervention

30-46
Method of intervention
7. m Assemble the valves.
m Measure the length of the valve spring with a vernier scale: 59 mm.
NOTE
If the valve spring wear limit was reached, replace it.

© 35856-2

Fig. 445
8. m Lightly oil the valve stem.
m Insert and retain the valve.
m Push the assembly bush (1) through the valve key seats.

© 42589-0

Fig. 446
9. m Push a new valve stem gasket (1) on the assembly bush.
m Remove the assembly bush.

© 42590-1

Fig. 447

30-47
 Method of intervention
10. m Push the valve stem gasket with the assembly tool (1) to the stop.

© 42591-0

Fig. 448
11. m Insert the valve spring (1).
m Insert the collet (2).
2

© 42592-0

Fig. 449
12. m Apply the assembly lever.
m Fit the assembly lever on the valve collet.
m Push the valve spring downwards with the assembly lever and insert
two retaining tapered rings (1).
NOTE
Make sure the position of the retaining tapered rings
in the valve key seats is correct.

© 42593-0

Fig. 450

30-48
Method of intervention
13. m Disassemble the assembly lever.
m Insert the thrust washer (1).

© 42585-0

Fig. 451
14. m Insert the circlip (1).
NOTE
Make sure that the circlip is inserted correctly in the
1
groove.

© 42594-0

Fig. 452
15. m Disassemble the cylinder head from the support stand (1).
m Disassemble the base plate support stand (2).
m Assemble the cylinder head.
See para. 30.3.10 - Disassembly and assemb... - page 30-32 1

2
© 42583-0

Fig. 453

30-49
 Method of intervention
30.3.14 - Valve check
Commercially available tools:
l Palmer
l Sliding gauge
NOTE
Clean all the valves. If the valve wear limit was reached, replace it.

Check the diameter of the valve stem

1. m Disassemble the valves.
See para. 30.3.13 - Valve assembly and dis... - page 30-45
m Use the palmer to measure the diameter of the valve stem.
n Intake valve: 7.98 (+0, -0.015) mm
n Exhaust valve: 7.96 (+0, -0.015) mm

© 42182-1

Fig. 454

Check the thickness of the valve edge

1. m Use the sliding gauge to measure the thickness of the valve edge.
n Intake valve: 2.3 mm
n Exhaust valve: 1.61 mm

© 42183-1

Fig. 455

30-50
Method of intervention
Check the diameter of the valve head
1. m Use the sliding gauge to measure the diameter of the valve head.
n Intake valve: 41.7 (+0.1, -0.1) mm
n Exhaust valve: 35.9 (+0.1, -0.1) mm

m Assemble the valves.

See para. 30.3.13 - Valve assembly and dis... - page 30-45

© 42184-1

Fig. 456

30.3.15 - Check the valve guide

Commercially available tools:
l Magnetic stand for measurements
Special tools:
l Dial gauge: 100400
NOTE
New valves are used for the check. The valve guide wear limit was reached, replace it.

Check the valve guide

1. m Disassemble the valves.
See para. 30.3.13 - Valve assembly and dis... - page 30-45
m Visually check the wear of the valve guide.
m Apply the magnetic stand for measurements.
m Insert the dial gauge.
m Insert a new valve.
m Apply the preloaded probe on the valve stem (arrow).
m Adjust the dial gauge to “0”.

© 42595-0

Fig. 457

30-51
 Method of intervention
Measure the valve stem clearance
1. m Move the valve forward and backward in the direction of the arrow.
n Intake valve: 0.028 - 0.068 (+0 -0.015) mm
n Exhaust valve: 0.048 - 0.088 (+0 -0.015) mm

NOTE
Take the entire overturning stroke into consideration.

© 42597-0

Fig. 458
2. m Remove the magnetic stand for measurements.
m Disassemble the dial gauge.
m Assemble the valves.
See para. 30.3.13 - Valve assembly and dis... - page 30-45

© 42596-0

Fig. 459

30.3.16 - Replacing the valve guide (oversized - cast)

Commercially available tools:
l Reamers
l Limit plug gauges
l Machine for working the cylinder heads
l Press
l Industrial aspirator
l Helical drill bit
Special tools:
l Spacer bush
l Nitrogen (liquid)
DANGER
Risk of accident, do not touch super cooled components or liquid nitrogen!
Wear protective gloves and safety goggles!

WARNING
The process of pressure fitting must be carried out quickly due to the thermal shock between the cylinder head and
the inserted valve seat.
The necessary work steps must be carried out before pressure fitting.

30-52
Method of intervention
NOTE
When using the machine to process the cylinder heads, following the specific instructions provided by the manufac-
turer.

Check the valve guide

1. m Check the valve guide.
See para. 30.3.15 - Check the valve guide - page 30-51
m Check the valve guide with a limit plug gauge (1).
n Intake valve: 8.008 (+0.025, -0) mm
n Exhaust valve: 8.008 (+0.025, -0) mm
1
NOTE
The reference side of the limit plug gauge must be
able to move up and down with slight shrinkage.

© 39737-1

Fig. 460

Make the housing hole for the valve guide (increased dimension)
1. m Close the coolant channels.
m Tighten the cylinder head on the machine for processing the cylinder
heads.
m Align the cylinder head.

© 36644-1

Fig. 461
2. m With the guide bolt (1) align the drilling unit with respect to the hous-
ing hole.
NOTE
The housing holes may have different diameters,
therefore select a guide bolt suitable for aligning the 1

drilling units. The guide bolt must move easily without

noticing resistance in the housing hole.

© 36629-1

Fig. 462

30-53
 Method of intervention
3. m Drill the valve guide with a helical drill bit (1).
m Remove the swarf with an industrial vacuum.

© 36628-1

Fig. 463
4. m Grind the seat hole to the standard size: 15.000 (+0.011,-0) mm.
WARNING
The reamer twists in an anticlockwise direction and there-
fore must always be turned clockwise. Never turn the ream-
er anticlockwise. The shavings that form when removing
material can block and destroy the cutting edges.
m Blow compressed air through the housing hole.

© 36637-1

Fig. 464
5. m Check the housing hole for the valve guide using the limit plug
gauge (1).
n Standard: 15.000 (+0.011, -0) mm
n Interference: 15.250 (+0.011, -0) mm
n Interference: 15.500 (+0.011, -0) mm
1
NOTE
The reference side of the limit plug gauge must be
able to move up and down with slight shrinkage.
The no-go end of the go-no-go gauge must not pass
through the seat hole. If the no-go end of the gauge
fits in the hole, grind the hole to the next highest inter-
ference size. If the wear limit reached the 2nd degree
of oversizing, replace the cylinder head. © 36634-1

Fig. 465

30-54
Method of intervention
6. m Release the cylinder head.
m Blow compressed air on the cylinder head.

© 36644-1

Fig. 466

Pressure insertion of the valve guide

1. m Apply the cylinder head.
m Select a valve guide suitable for the housing hole.
n Standard: 15.000 (+0.034, +0.023) mm
n Interference: 15.250 (+0.034, +0.023) mm
n Interference: 15.500 (+0.034, +0.023) mm

© 36642-1

Fig. 467
2. m Supercool the valve guide with liquid nitrogen.
NOTE
Use containers suitable for liquid nitrogen and a tool
suitable for the component insertion and removal op-
erations. When starting to cool the metal, the liquid
nitrogen will boil intensely, the effervescence pro-
cess is maintained until the metal components reach
the temperature of the liquid nitrogen (-196 °C). The
guide valve will have the correct temperature once
the effervescence process of the nitrogen is con-
cluded.

© 36636-1

Fig. 468

30-55
 Method of intervention
3. m Fit the valve guide with the spacer bush (1).
NOTE
Be careful to fit the guide valve the right way round.
The valve seal groove must face upwards.

© 36635-1

Fig. 469
4. m Press-fit the valve guide flush in the respective surface using the
spacer bush (arrow).
m Remove the spacer bush.
NOTE
The new valve guide will protrude further than the
original valve guideIl .

m Remove the cylinder head.

m Assemble the valves.
See para. 30.3.13 - Valve assembly and dis... - page 30-45

© 36618-1

Fig. 470

30.3.17 - Check the valve residual

Commercially available tools:
l Depth gauge
Special tools:
l Support stand: 120900
l base plate: 120910
WARNING
If the wear limit of the inserted valve seat and/or the valve is reached, replace them.

30-56
Method of intervention
Check the valve residual
1. m Disassemble the cylinder head.
See para. 30.3.10 - Disassembly and assemb... - page 30-32 1
m Assemble the support stand (1) on the base plate (2).

© 44178-0

Fig. 471
2. m Fasten the cylinder head onto the mounting stand (1) and the base
plate (2).
1

© 46588-0

Fig. 472
3. m Measure the valve residual from the centre of the valve head with
respect to the sealing surface of the cylinder head.
n Intake valve: 0.9 (+0.15, -0.1) mm
n Exhaust valve: 0.9 (+0.15, -0.1) mm

© 42598-0

Fig. 473

30-57
 Method of intervention
4. m Disassemble the cylinder head from the support stand (1).
m Disassemble the base plate support stand (2).
m Assemble the cylinder head.
See para. 30.3.10 - Disassembly and assemb... - page 30-32 1

© 46588-0

Fig. 474

30.3.18 - Replacing the lined valve seat (oversized)

1. Commercially available tools:
m Pin milling cutter, 10 mm
m Internal bore meter
m Sliding gauge
m Machine for working the cylinder heads
m Press
m Industrial aspirator
m Presser
m Vertical drill

m Nitrogen (liquid)
DANGER
Risk of accident, do not touch super cooled components or liquid nitrogen!
Wear protective gloves and safety goggles!

WARNING
The process of pressure fitting must be carried out quickly due to the thermal shock between the cylinder head
and the inserted valve seat.
The necessary work steps must be carried out before pressure fitting.
NOTE
When using the machine to process the cylinder heads, following the specific instructions provided by the
manufacturer. To replace an inserted valve seat, the respective valve guide must be present.

2. m Check the valve residual.

See para. 30.3.17 - Check the valve residual - page 30-56
m Disassemble the valves.
See para. 30.3.13 - Valve assembly and dis... - page 30-45

© 42598-0

Fig. 475

30-58
Method of intervention
Checking the inserted valve seat
1. m Check the inserted valve seat (1).
NOTE
Check the installation position is correct. 1

© 36638-1

Fig. 476

Disassembly of the inserted valve seat

1. m Close the coolant channels.
m Tighten the cylinder head.
m Align the inserted valve seat with the pin milling cutter.

© 36632-1

Fig. 477
2. m Laterally cut the inserted valve seat (arrow) until it can be removed
without tension.
WARNING
Do not damage the cylinder head.

© 36639-1

Fig. 478

30-59
 Method of intervention
3. m Apply a protective sublayer (arrow).
m Remove the inserted valve seat by applying leverage.
WARNING
Do not damage the cylinder head.

m Release the cylinder head.

© 36631-1

Fig. 479

Check the hole of the housing for the inserted valve seat
1. NOTE
Measurement diagram hole of the housing in points “a and
b”, central in surface “1”. 1

© 36640-1

Fig. 480
2. m Measure the hole of the housing with an internal bore meter.
NOTE
Measurement points, see diagram.

m Read the value measured.

n Intake: 42.7 (+0.025, -0) mm
n 2 degrees of oversizing for: + 0.2 mm
n Exhaust: 36.9 (+0.025, -0) mm
n 2 degrees of oversizing for: + 0.2 mm

© 36621-1

Fig. 481

30-60
Method of intervention
3. NOTE
If the wear limit reached the 2nd degree of oversizing, re-
place the cylinder head. Alternatively, determine the diam-
eter of the seat hole with a measuring ring (1).
For example, a lined valve seat lathed to half its height may
be used as a measurement ring, which is then inserted in
the hole to measure the diameter.

© 36641-1

Fig. 482

Make the housing hole for the inserted valve seat (interference)
1. m Set the cutting tool.

© 36620-1

Fig. 483
2. m Tighten the cylinder head on the machine for processing the cylinder
heads.
m Close the coolant channels.
m Align the cylinder head.

© 36619-1

Fig. 484

30-61
 Method of intervention
3. NOTE
The valve guides may have different diameters, therefore
select a guide bolt suitable for aligning the drilling units. The
guide bolt must move easily without noticing resistance in
the valve guide.
1
m With the guide bolt (1) align the drilling unit with respect to the hous-
ing hole.

© 39738-1

Fig. 485
4. m Enlarge the housing hole based on the degree of oversizing.
WARNING
The inserted valve seat support (arrow) must not be ma-
chined with a cutting tool.

m Remove the shavings from the bottom.

© 36624-1

Fig. 486
5. m Measure the hole of the housing with an internal bore meter.

© 36621-1

Fig. 487

30-62
Method of intervention
Pressure insertion of the inserted valve seat
1. m Apply the cylinder head.
m Select a inserted valve seat suitable for the housing hole.
n Intake: 42.79 (+0, -0.02) mm
n Degree of oversizing: 42.99 mm
n Degree of oversizing: 43.19 mm
n Exhaust: 36.99 (+0, -0.02) mm
n Degree of oversizing: 37.19 (+0, -0.02) mm
n Degree of oversizing: 37.39 (+0, -0.02) mm

© 36626-1

Fig. 488
2. m Supercool the inserted valve seat in liquid nitrogen.
NOTE
Use containers suitable for liquid nitrogen and a tool
suitable for the component insertion and removal op-
erations. When starting to cool the metal, the liquid
nitrogen will boil intensely, the effervescence process
is maintained until the metal components reach the
temperature of the liquid nitrogen (-196 °C). The in-
serted valve seat will have the correct temperature
once the effervescence process of the nitrogen is
concluded.

© 36623-1

Fig. 489
3. m Position the inserted valve seat (1) on the presser (2).
NOTE
2
Observe the installation position. The valve seat sur-
face must face towards the presser tool.

© 36643-1

Fig. 490

30-63
 Method of intervention
4. m Insert the inserted valve seat (1) with the presser (2) in the housing
hole (3) to the stop (arrow).
m Remove the cylinder head. 2
m Machining the inserted valve seat.
m Assemble the valves.
See para. 30.3.13 - Valve assembly and dis... - page 30-45 1
m Check the valve residual.
See para. 30.3.17 - Check the valve residual - page 30-56
3

© 36633-1

Fig. 491

30.3.19 - Check the endfloat of the crankshaft

1. Commercially available tools:
m Magnetic stand for measurements
m Palmer
m Internal bore meter
m Box spanner insert: 8035

Special tools:
m Dial gauge: 100400

2. m Disassemble the front cover.

See para. 30.3.33 - Removal and refitting ... - page 30-123
m Disassemble the gear case cover.
See para. 30.3.36 - Disassembly and assemb... - page 30-135
m Apply the magnetic stand for measurements.
m Insert the dial gauge.
m Apply the preloaded probe on the end of the crankshaft.
m Press the crankshaft towards the arrow.
m Adjust the dial gauge to “0”.

© 44179-0

Fig. 492
3. m Press the crankshaft towards the arrow.
m Read the value measured: 0.1 - 0.3 mm
NOTE
If there is a difference in the endfloat, set the permit-
ted value by replacing the halves of the thrust ring.

© 44180-0

Fig. 493

30-64
Method of intervention
4. m Remove screws (1).
NOTE
Use the box spanner insert. 1

m Remove flanged bearing cover (2).

m Remove the lower bearing shell. 2
m Remove the two halves of the thrust ring (arrows).

© 44181-0

Fig. 494
5. m Remove the two halves of the thrust ring (arrows).

© 44182-0

Fig. 495
6. m Measure the thickness of the halves of the thrust ring.
n Standard: 2.00 (+0.05, -0) mm
n Interference: 2.20 (+0.05, -0) mm

m Select the thrust ring halves based on the measured value.

© 43504-0

Fig. 496

30-65
 Method of intervention
7. m Disassemble the crankshaft.
See para. 30.3.25 - Assembly and disassemb... - page 30-93
m Adjust the palmer to 32 mm.
m Push the internal bore meter between the test surfaces of the palm-
er and bring to “0”.

© 35825-2

Fig. 497
8. m Measure the width of the flanged bearing.
m Make a note of dimension (a).

© 42606-0

Fig. 498
9. m Apply the thrust ring halves on the flanged bearing cover (arrows).
m Measure the width with the palmer.
m Make a note of dimension (b).

© 35827-2

Fig. 499
10. m Calculate the endfloat: 0.1 - 0.3 mm
Table 78

Calculation example:
Target: Endfloat
Data: -
Measured value: (a) = 32.8 mm, (b) = 32.7 mm
Calculation: Dimension (a) - dimension (b)
The results of all this are: = 0.1 mm
m Assemble the crankshaft.
See para. 30.3.25 - Assembly and disassemb... - page 30-93

30-66
Method of intervention

30-67
 Method of intervention
14. m Insert the flanged bearing cover (1).
NOTE
The riser (arrow) of the flanged bearing cover is fac-
ing the manifold side.

1
© 44185-0

Fig. 503
15. m Tighten the screws (1) with the socket wrench insert. 50 Nm + 90°
+ 90°.
WARNING
In the case of written certification, the screws can be used
a maximum of 3 times. Otherwise, replace the screws each
time after being removed.

© 44186-1

Fig. 504
16. m Measure the endfloat of the crankshaft: 0.1 - 0.3 mm
m Remove the magnetic stand for measurements.
m Disassemble the dial gauge.
m Fitting the front cover.
See para. 30.3.33 - Removal and refitting ... - page 30-123
m Disassemble the gear case cover.
See para. 30.3.36 - Disassembly and assemb... - page 30-135

© 44187-0

Fig. 505

30-68
Method of intervention
30.3.20 - Check the crankshaft
Commercially available tools:
l Magnetic stand for measurements
l Palmer
l Internal bore meter
l Prisms
l Hardness tester
Special tools:
l Dial gauge: 100400
Check the hardness of the main journal
1. m Disassemble the crankshaft.
See para. 30.3.25 - Assembly and disassemb... - page 30-93
m Rest the crankshaft on the prisms.

© 42602-0

Fig. 506
2. m Apply the hardness tester on the bearing pins.

© 30560-1

Fig. 507
3. m Lift (1) the probe and press the release device (2).
NOTE
1
The probe (1) falls downward, briefly hits the surface
and goes up to the measurement value.

© 43499-0

Fig. 508

30-69
 Method of intervention
4. m Read the value indicated (arrow) by the hardness tester.
n Nominal, minimum value: 55 (+6) HRc

NOTE
The measurement values must be converted using
the tester table.

© 43515-0

Fig. 509
5. NOTE
Measurement diagram of the main journals on points 1 and
2 in surfaces a and b.

© 36424-2

Fig. 510

Check the diameter of the main bearing pins

1. m Measure the main bearing pins with the palmer.
n Standard: 84 (+0, -0.02) mm
n Degree of undersizing: 0.25 mm

NOTE
Measurement points, see diagram.

© 42603-0

Fig. 511

30-70
Method of intervention
Check the diameter of the connecting rod pins
1. m Measure the main journal with the palmer: 62.994 (+0, -0.02) mm
m Degree of undersizing: 0.25 mm
NOTE
Measurement points, see diagram.

© 42604-0

Fig. 512

Check the coaxiality

1. m Apply the magnetic stand for measurements.
m Insert the dial gauge.
m Apply the preloaded probe on the main bearing pins (arrow) and
adjust the dial gauge to “0”.
m Rotate the crankshaft at uniform speed and measure concencitrity:
0.1 mm
m Remove the magnetic stand for measurements.
m Disassemble the dial gauge.

© 42605-0

Fig. 513

Measuring the length of the flanged bearing

1. m Adjust the palmer to 32 mm.
m Push the internal bore meter between the test surfaces of the palm-
er and bring to “0”.

© 35825-2

Fig. 514

30-71
 Method of intervention
2. m Measure the width of the flanged bearing, placing the bore gauge
between the contact surfaces of the thrust rings: 32.2 (+0.04,-0) mm.
n Degree of undersizing: 0.4 mm

© 42606-0

Fig. 515

Visual inspection
1. m Inspect the sliding surfaces (1) of the crankshaft O-rings.
m Inspect the ring gear (2).
m Assemble the crankshaft.
See para. 30.3.25 - Assembly and disassemb... - page 30-93 1
1 2

© 42607-0

Fig. 516

30.3.21 - Replace the crankshaft O-ring (flywheel end)

Commercially available tools:
l Bradawl: 8198
l Assembly lever: 9017
Special tools:
l Assembly tool: 142830
l Self-tapping screw
l Washer

30-72
Method of intervention
Removal of the crankshaft oil seal
1. m Remove the flywheel.
See para. 30.3.64 - Removal and refitting ... - page 30-232
m Using a bradawl, make a hole about 3 mm in diameter in the old
crankshaft oil seal.
WARNING
Do not damage the gearbox cover or the crankshaft.

© 46472-0

Fig. 517
2. m Insert a self-tapping screw (1) with washer.

© 46561-0

Fig. 518
3. m Extract the crankshaft O-ring using the assembly lever.
m Carefully examine the crankshaft O-ring sliding surfaces.

© 46562-0

Fig. 519

30-73
 Method of intervention
Assembly of the crankshaft O-ring
1. m Fit guide bush (1).
m Tighten screws (2).
NOTE
The holes in the guide bush must be aligned with the
1
threaded holes in the crankshaft flange.

© 46563-0

Fig. 520
2. m Lightly oil the lip of the crankshaft O-ring.
m Carefully place the crankshaft O-ring on the sliding surface.
NOTE
The seal lip should be facing the engine crankcase.

© 46564-0

Fig. 521
3. m Fit spacer (1).
NOTE
If the crankshaft flange has an entry groove, the O-
ring can be installed at three different depths:
- First assembly = 2 washers. - 1. repair - assembly
level = 1 washer
- 2. repair - assembly level = 0 washers.

© 46565-0

Fig. 522

30-74
Method of intervention
4. m Fit installation bush (1).
m Push the crankshaft O-ring to the support.

© 46566-0

Fig. 523
5. m Insert bearing (1).
m Screw in nut (2);

2
© 46567-0

Fig. 524
6. m Screw in the nut until it seats against installation bush (1).
NOTE
The crankshaft oil seal is now installed at the correct
depth.
1
m Remove the installation tool.
m Fit the flywheel.
See para. 30.3.64 - Removal and refitting ... - page 30-232

© 44197-0

Fig. 525

30-75
 Method of intervention
30.3.22 - Replacing the crankshaft O-ring (opposite end to flywheel)
Commercially available tools:
l Bradawl: 8198
l Assembly lever: 9017
Special tools:
l Assembly tool: 142670
l Self-tapping screw
l Washer
Removal of the crankshaft oil seal
1. m Remove the V-belt pulley.
See para. 30.3.40 - Removing and fitting t... - page 30-146
m Using a bradawl, make a hole about 3 mm in diameter in the old
crankshaft oil seal.
WARNING
Be careful not to damage the front cover or the crankshaft.

© 43643-0

Fig. 526
2. m Insert a self-tapping screw (1) with washer.

© 44872-0

Fig. 527
3. m Extract the crankshaft O-ring using the assembly lever.
m Carefully examine the crankshaft O-ring sliding surfaces.

© 44873-0

Fig. 528

30-76
Method of intervention
Assembly of the crankshaft O-ring
1. m Remove tightening bush (1).

© 44875-0

Fig. 529
2. m Fit guide bush (1).
NOTE
Check that locating dowel (2) is aligned with hole (3). 1

© 42623-0

Fig. 530
3. m Tighten (1) the screws.

© 44877-0

Fig. 531

30-77
 Method of intervention
4. m Lightly oil the lip of the crankshaft O-ring.
m Carefully place the crankshaft O-ring on the sliding surface.
NOTE
The seal lip should be facing the engine crankcase.

© 44878-0

Fig. 532
5. m Fit spacer (1).
m Observe the assembly depth of the crankshaft O-ring and select a
suitable spacer disc.
n First installation depth = 2 shims
n Repair assembly depth = 1 spacer disc
n Maximum assembly depth = no washers

© 44879-0

Fig. 533
6. m Fit installation bush (1).
m Push the crankshaft O-ring to the support.

© 44880-0

Fig. 534

30-78
Method of intervention
7. m Insert bearing (1).
m Mutter (2) anschrauben.

2
1

© 44881-0

Fig. 535
8. m Screw in the nut until it seats against installation bush (1).
NOTE
The crankshaft oil seal is now installed at the correct 1
depth.

m Remove the installation tool.

© 44882-1

Fig. 536
9. m Insert bush (1) fully.
m Assemble the V-belt pulley.
See para. 30.3.40 - Removing and fitting t... - page 30-146

© 42622-0

Fig. 537

30-79
 Method of intervention
30.3.23 - Check the connecting rod drum
1. Commercially available tools:
m Palmer
m Internal bore meter
m Rotation angle gauge: 8190
m Connecting rod tester

Special tools:
m Dial gauge: 100400

2. m Disassemble the piston and connecting rod drum.

See para. 30.3.27 - Disassembly and assemb... - page 30-107
m Disassemble the piston from the connecting rod drum.

© 40592-1

Fig. 538

Check of the piston pin bush

1. m Prepare the internal bore meter:
n Fit the probes for the corresponding measurement interval in

an internal bore meter.

n Fit the dial gauge with a preload of approx. 1 mm in the inter-

nal bore meter.

n Adjust the palmer to 38 mm.
n Apply the internal bore meter between the test surfaces of

the palmer and in the return point of the pointer, bring the dial
gauge to “0”.

© 34768-2

Fig. 539
2. NOTE
Measurement diagram of the piston pin bush in points “a”
and “b” in surfaces “1” and “2”.

© 37239-1

Fig. 540

30-80
Method of intervention
3. m Insert the internal bore meter.
m Apply the internal bore meter to the measurement points required
occasionally and read the value measured in the return point of the
pointer: 38.025 (+0.010) mm.
NOTE
Measurement points, see diagram.

m Make a note of the measured value, dimension A.

NOTE
Dimension A is used to determine the piston pin
clearance.
© 34770-2

Fig. 541

Check the diameter of the piston pin

1. m Measure the piston pin with the palmer: 38 (+0,-0.006) mm.
m Make a note of the measured value, dimension B.
NOTE
Dimension B is used to determine the piston pin
clearance.

© 35908-2

Fig. 542

Calculate the piston pin clearance

1. NOTE
The piston pin free play is determined by the difference between the inner diameter of the piston pin bearing
shell (a) and the diameter of the piston pin (b): 0.025 - 0.041 mm

Table 79

Calculation example:
Target: Piston pin clearance
Data: -
Measured value: Inner diameter of piston pin bush (a), (a) = 38.025 mm. Diam-
eter of piston pin (b), (b) = 38.000 mm
Calculation: Measurement (a) - measurement (b), 38.025 mm - 38.000 mm
The results of all this are: = 0.025 mm

30-81
 Method of intervention
Check the connecting rod bearing hole
1. m Apply the flanged bearing cover.
WARNING

26519
Pay attention to coupling the flanged bearing cover. The nu- 1
meric marks (1) on the connecting rod drum and on the con-

26519
necting rod bearing cover must be identical and positioned
in front of each other during assembly.

© 44212-0

Fig. 543
2. m Alternatively tighten the screws with the rotation angle gauge and
the box spanner insert: 30 Nm + 60° + 30°

© 44213-0

Fig. 544
3. m Prepare the internal bore meter:
n Fit the probes for the corresponding measurement interval in

an internal bore meter.

n Fit the dial gauge with a preload of approx. 1 mm in the inter-

nal bore meter.

n Adjust the palmer to 66 mm.
n Apply the internal bore meter between the test surfaces of

the palmer and in the return point of the pointer, bring the dial
gauge to “0”.

© 36094-1

Fig. 545

30-82
Method of intervention
4. NOTE
Measurement diagram of the connecting rod bearing hole in
points “a” and “b” in surfaces “1” and “2”.

© 37239-1

Fig. 546
5. m Insert the internal bore meter.
m Apply the bore gauge to each of the measurement positions indicat-
ed and read the maximum value indicated by the dial: 66.6 (+0.019)
mm.
NOTE
If the measured values diverse minimally, take addi-
tional measurements with new bearing shells.

© 44214-0

Fig. 547

Check the internal diameter of the connecting rod bearing shells

1. m Unscrew the screws.
m Remove the flanged bearing cover.
NOTE
Check that tightening bush (1) is present.

© 44440-0

Fig. 548

30-83
 Method of intervention
2. m Insert the connecting rod bearing shell into the connecting rod drum.
WARNING
Take care to couple the bearing shells. The anti-twist safety
(1) must enter the groove (2).

1
© 44215-0

Fig. 549
3. m Insert the connecting rod bearing shell into the relative flanged bear-
ing cover.
WARNING
1
Take care to couple the bearing shells. The anti-twist safety
(1) must enter the groove (2).

© 44216-0

Fig. 550
4. m Apply the flanged bearing cover.
WARNING
2651

The numeric marks (1) on the connecting rod drum and on 1

9

the connecting rod bearing cover must be identical and po-

2651

sitioned in front of each other during assembly.

9

© 44217-0

Fig. 551

30-84
Method of intervention
5. m Alternatively tighten the screws with the rotation angle gauge and
the box spanner insert: 30 Nm + 60° + 30°.

© 44218-0

Fig. 552
6. m Prepare the internal bore meter:
n Fit the probes for the corresponding measurement interval in

an internal bore meter.

n Fit the dial gauge with a preload of approx. 1 mm in the inter-

nal bore meter.

n Adjust the palmer to 63 mm.
n Apply the internal bore meter between the test surfaces of

the palmer and in the return point of the pointer, bring the dial
gauge to “0”.

© 36094-1

Fig. 553
7. NOTE
Measurement diagram of the internal diameter of the con-
necting rod bearing shells in points “a” and “b” in surfaces
“1” and “2”.

© 37239-1

Fig. 554

30-85
 Method of intervention
8. m Insert the internal bore meter.
m Apply the internal bore meter to the measurement points required
occasionally and read the value measured in the return point of the
pointer.
NOTE
See diagram for measurement points: 63.026 -
63.065 mm.

m Make a note of dimension (a).

NOTE
The connecting rod drum wear limit was reached,
replace it.
© 44219-0

Fig. 555

Check the diameter of the connecting rod pins

1. NOTE
Measurement diagram of the main journals on points 1 and
2 in surfaces a and b.

© 36424-2

Fig. 556
2. m Measure the main journal with the palmer: 62.994 (+0,-0.02) mm.
n Degree of undersizing: 0.25 mm.

NOTE
Measurement points, see diagram.

m Make a note of dimension (b).

© 36424-2

Fig. 557

30-86
Method of intervention
Determine the clearance of the connecting rod bearing
1. NOTE
The big end bearing free play is determined by the difference between the inner diameter of the big end bearing
shell (a) and the diameter of the crankpin (b): 0.032 - 0.073 mm.

Table 80

Calculation example:
Target: Clearance of the connecting rod bearing
Data: -
Measured value: Inner diameter of big end bearing shell (a), (a) = 63.026 mm.
Diameter of crankpins (b), (b) = 62.992 mm
Calculation: Dimension (a) - dimension (b)
The results of all this are: = 0.034 mm
m n Wear limit: 0.12 mm
2. m Unscrew the screws.
m Remove the flanged bearing cover.

© 44218-0

Fig. 558

Check the connecting rod drum

1. m Assemble the connecting rod drum without bearing shells on the
tester. A
WARNING
It is not permitted to straighten the connecting rod drum. B

m Move the test fork towards the arrow.

m Check the parallelism of the connecting rod drum.
m Difference permitted from (A) to (B): 0.04 mm.
NOTE
Distance between “A“ and “B“ = 100 mm.
© 30579-1

Fig. 559

30-87
 Method of intervention
2. m Move the test fork towards the arrow.
m Check the angulation of the connecting rod drum.
m Difference permitted from (C) to (D): 0.04 mm.
NOTE
Distance between “C“ and “D“ = 100 mm. C

D
m Complete the piston and the connecting rod drum.
m Assemble the piston and the connecting rod drum.
See para. 30.3.27 - Disassembly and assemb... - page 30-107

© 30580-1

Fig. 560

30.3.24 - Fitting and removing piston pin bush

Commercially available tools:
l Press or threaded pin
Special tools:
l base plate: 131200
l Set of assembly tools: 131220
l Nitrogen (liquid)
l Degreaser/detergent
l Compressed air
l Heating device
DANGER
Risk of accident, do not touch hot components! Risk of accident, do not touch super cooled components or liquid
nitrogen! Wear protective gloves and safety goggles!

WARNING
The process of pressure fitting must be carried out quickly due to the thermal shock between the bush of the piston pin
and the connecting rod drum. The necessary work steps must be carried out before pressure fitting.

NOTE
The extraction of the piston pin bush is illustrated with a pneumatic press. Alternatively, also a threaded pin can be
used.

30-88
Method of intervention
Disassembly of the piston pin bush
1. WARNING
3
Never force the piston pin bush!

1
m Insert the housing of the connecting rod bearing (3) in the base plate
(2).
m Insert the disassembly gauge (1) in the base plate.
WARNING
Do not mix up the disassembly gauge and the assembly
gauge! 2

NOTE © 40404-1

The groove (arrow) must face the housing of the connect- Fig. 561
ing rod bearing. Make sure that the disassembly gauge is
perfectly levelled.
2. m Insert the lower part of the assembly tool (3) from below in the disas-
sembly gauge. 1 2
m Position the connecting rod drum (1) on the base plate.
NOTE
The flat side (arrow) of the connecting rod drum must
face downwards.

m Rotate the lower part (3) in the upper part (2) of the assembly tool.

© 40403-1

Fig. 562
3. m Align the upper part (1) of the assembly tool with the disassembly
gauge (2).
NOTE
The upper part of the assembly tool and the disas-
sembly gauge are flush with the angular surfaces (ar-
1
row) of the connecting rod bearing.
2

© 40401-1

Fig. 563

30-89
 Method of intervention
4. m Tighten the upper part (1) and the lower part (2) of the assembly
tool.

© 40402-1

Fig. 564
5. m Align the pneumatic press horizontally with the base plate.
NOTE
The extractor punch must be situated in the centre
above the top of the assembly tool.

© 36284-3

Fig. 565
6. m Remove the piston pin bush with slight pressure.
m Clean the hole in the bush.
NOTE
The hole in the bush must be free of grease and dirt.

© 36285-3

Fig. 566

30-90
Method of intervention
Assembly of the piston pin bush
1. m Insert the housing of the connecting rod bearing (3) in the base plate
(2). 3
m Insert the assembly gauge (1) in the base plate.
NOTE
1
The groove (arrow) must face the housing of the con-
necting rod bearing. Make sure that the assembly
gauge is perfectly levelled.

© 40405-1

Fig. 567
2. m Heat the connecting rod shank (1): 220 °C.
m Position the connecting rod drum on the base plate (2).
NOTE 1
The flat side (arrow) of the connecting rod drum must
face downwards.

© 40406-1

Fig. 568
3. m Chill the piston pin bush (1) in liquid nitrogen to approximately -40
°C.

© 36288-2

Fig. 569

30-91
 Method of intervention
4. m Position the supercooled bush of the piston pin (1) on the assembly
bolt (3). 1
NOTE
The index (2) must be situated in the groove (indi-
cated by arrow) in the piston pin bush.

2
3

© 40407-1

Fig. 570
5. m Insert the assembly bolt (1) with the piston pin bush (2) in the hole
of the connecting rod.
NOTE
The piston pin bush must be inserted without force 1
into the connecting rod hole. Pay attention to the as-
sembly position of the piston pin bush.
m Remove the assembly bolt. 2
NOTE
The piston pin bush must not slip any more.

© 36290-4

Fig. 571
6. m Check the assembly position.
NOTE
Position of bush separation line (indicated by arrow)
as seen when looking towards the flat side of the
connecting rod shank.

© 40968-1

Fig. 572

30-92
Method of intervention
7. NOTE
After the assembly operation, mechanically adjust the piston
pin bush.

m Turn the piston pin bush to dimension A.

Table 81

Dimension Maximum dimension Minimum dimension

Hole of the piston pin 38.035 mm 38.025 mm
bush, dimension A
Piston pin diameter 38.000 mm 37.994 mm
Theoretical clearance 0.041 mm 0.025 mm © 39730-2

Fig. 573

30.3.25 - Assembly and disassembly of the crankshaft

Special tools:
l Box spanner insert: 8035
l Rotation device: 100330
Disassembly of the piston pin bush
1. m Disassemble the front cover.
See para. 30.3.33 - Removal and refitting ... - page 30-123
m Disassemble the gear case cover.
See para. 30.3.36 - Disassembly and assemb... - page 30-135

© 42647-2

Fig. 574
2. m Tighten screws (1).
m Disassemble all the connecting rod bearing covers.
m Remove the connecting rod bearing shells.
See para. 30.3.27 - Disassembly and assemb... - page 30-107

© 42648-1

Fig. 575

30-93
 Method of intervention
3. m Place the mark of reference (1) on the ring gear of the camshaft.
NOTE 2

The reference mark must be located on a line be-

tween the marking (2) and the mid point (3) of the
camshaft. 1

© 42651-0

Fig. 576
4. m Uniformly rotate the crankshaft until the mark (1) on the flange of the
shaft coincides with the auxiliary mark (2) on the camshaft ring gear.
NOTE
If the crankshaft flange is aligned, the mark on the 1
camshaft ring gear will be covered.

WARNING
2
Do not bend the connecting rod drums while rotating the
crankshaft.

© 42652-0

Fig. 577

Disassembly of the main bearing cover

1. m Unscrew all the screws (1) using the long reach socket.

© 42653-1

Fig. 578

30-94
Method of intervention
2. m Remove flanged bearing cover (1).
m Remove the bearing shell.
m Remove the two halves of the thrust ring (arrows).
m Remove all the main bearing covers (2).
m Remove the bearing shells.
1
NOTE
Put the components to one side in the order in which
they were removed. Note the cylinder order.
2

© 44228-1

Fig. 579
3. m Delicately extract the connecting rod drums from the relative pins.
m Extract the crankshaft by applying leverage.

© 42655-1

Fig. 580
4. m Remove the two halves of the thrust ring (arrows).
m Remove all the main bearing shells (1).
NOTE
Put the components to one side in the order in which
they were removed. Note the cylinder order.
1
m Carry out a visual inspection of the components.
m Check the endfloat of the crankshaft (disassembled crankshaft).
See para. 30.3.19 - Check the endfloat of ... - page 30-64
See para. 30.3.20 - Check the crankshaft - page 30-69

© 44231-2

Fig. 581

30-95
 Method of intervention
Assembly of the crankshaft
1. m Insert the upper shells of the main bearings.
NOTE
Take care to couple the bearing shells. The anti-twist
safety (1) must enter the groove (2).
1

© 42658-0

Fig. 582
2. m Insert the lower shells of the main bearings in the relative main bear-
ing covers.
NOTE
1
Take care to couple the bearing shells. The anti-twist
safety (1) must enter the groove (2).

© 44233-0

Fig. 583
3. NOTE
Make sure all the tightening bushes are present (arrows).

© 44231-1

Fig. 584

30-96
Method of intervention
4. m Position the camshaft.
NOTE
Align the hole (1) in the direction of the cylinder head.

m Oil the surfaces of the bearings.

© 42661-0

Fig. 585
5. m Delicately insert the crankshaft in the crankcase.
WARNING
Do not bend the connecting rod drums while inserting the
crankshaft!

m Move the crankshaft in correspondence of the camshaft.

NOTE
Make sure the marks line up.

© 44238-2

Fig. 586
6. m Check the control times.
NOTE
The mark (1) on the flange of the crankshaft must line
up with the reference mark (2). 1

© 42652-0

Fig. 587

30-97
 Method of intervention
7. m Assemble the upper thrust ring halves based on the measured end-
float.
NOTE
Thrust ring halves without the key, between the
crankshaft and crankcase (arrows). The oil grooves 2
(1) in the thrust ring halves face towards the thrust
discs (2) of the crankshaft (arrows).
1

© 42662-0

Fig. 588
8. m Fix the two thrust ring halves with a small amount of grease on the
flanged bearing cover.
NOTE
Flanged bearing cover marked with “2”. Use the
halves of the thrust ring with the key (arrow). The

2
oil grooves (1) face towards the shoulder disc of the
crankshaft.

© 42663-0

Fig. 589

Assembly of the main bearing cover

1. m Insert the flanged bearing cover (1).
m Insert the main bearing cover (2) based on the numbering.
Pay attention to the attribution and assembly po-
sition:
Insert the main bearing cover with number 1 on the 1
flywheel side. The end (arrow) of the bearing cover is
facing the curve side. 7 6 5 4 3 2 1

© 44240-1

Fig. 590

30-98
Method of intervention
2. m Main bearing cover with socket wrench insert and rotation angle
gauge: 50 Nm + 90° + 90°.
WARNING
In the case of written certification, the screws can be used
a maximum of 3 times. Otherwise, replace the screws each
time after being removed.
m Assemble the flanged bearing cover.
See para. 30.3.27 - Disassembly and assemb... - page 30-107

© 44241-1

Fig. 591
3. m Remove screws (1).

© 42648-1

Fig. 592
4. m Assemble the gear case cover.
See para. 30.3.36 - Disassembly and assemb... - page 30-135
m Fitting the front cover.
See para. 30.3.33 - Removal and refitting ... - page 30-123

© 42647-2

Fig. 593

30-99
 Method of intervention
30.3.26 - Fitting and removing counterweight shafts, checking
Commercially available tools:
l Palmer
l Torque wrench
Special tools:
l Alignment pins (q.ty 2): 100810
l Plaster
l DEUTZ DW 72 mastic
Removing counterweight shafts
1. m Disassemble the gear case cover.
See para. 30.3.36 - Disassembly and assemb... - page 30-135
m Bring cylinder piston 1 to top dead centre.
NOTE
The mark (1) on the flange of the crankshaft must line
up with the reference mark (2).

© 36652-2

Fig. 594
2. m Remove screw (1).
m Remove washer (2).
m Remove the intermediate wheel (3).
m Remove the bearing pin.

3
2

© 46605-0

Fig. 595
3. m Remove screw (1).
m Remove lube oil pipe (2).
m Remove the intermediate wheel (3).
m Remove the bearing pin.
1

© 46606-0

Fig. 596

30-100
Method of intervention
4. m Remove screws (1).
m Remove the shims (2).

1
1

2
2

© 46607-0

Fig. 597
5. m Remove the counterweight shafts in the direction indicated by the
arrow.
WARNING
Take care not to damage the counterweight shafts.

© 36666-3

Fig. 598

Checking counterweight shafts

1. m Visually check the wear of the components.

© 36664-1

Fig. 599

30-101
 Method of intervention
2. m Measure the diameter of the main journals with the palmer: 54
(-0.02) mm.

© 36665-1

Fig. 600

Fitting counterweight shafts

1. m Oil the bearing pins slightly.
m Fit the counterweight shafts in the direction indicated by the arrow.
NOTE
The weight (1) must face towards the lubricant oil
sump pan.

1
© 36666-4

Fig. 601
2. m Undo the screw plugs (1).

© 36651-2

Fig. 602

30-102
Method of intervention
3. m Insert the centring pins (1).
m Fasten the counterweight shafts with the alignment pins (1).
WARNING 1

Stop rotating the mass compensation shaft.

© 36659-2

Fig. 603
4. m Fit the shims (2).
m Tighten screws (1).
NOTE
Do not tighten the screw at this stage.

1
1

2
2

© 46607-0

Fig. 604
5. m Assemble the B side intermediate wheel.
NOTE
2
Centre the intermediate wheel (1) with respect to the
threaded hole (2). If the sides of the teeth do not co-
incide with the crankshaft, it can be rotated easily.

WARNING
Stop rotating the mass compensation shaft.

© 36669-1

Fig. 605

30-103
 Method of intervention
6. m Lightly oil the bearing pins (1).
m Insert the bearing pins (1).
m Fit washer (2).
m Screw in the screw (3).
NOTE
Insert the screw with DEUTZ DW 72 sealant. Do not 1
tighten the screw at this stage.

2
© 36670-2

Fig. 606
7. m Apply the reference marks (1) and (2).
m Unscrew the centring pins (side A).
m Turn the mass compensation shaft of the two teeth in the direction
of the arrow. 1

© 36656-2

Fig. 607
8. m From above, engage the intermediate wheel (1) in the toothing.
NOTE
Turn the mass compensation shaft in the direction of
the arrow until the reference marks coincide. Centre
the intermediate wheel (1) with respect to the thread- 1

ed hole (2).

© 36657-2

Fig. 608

30-104
Method of intervention
9. m Lightly oil the bearing pins (1).
m Insert the bearing pins (1).

© 36667-2

Fig. 609
10. m Fit new O-ring (1).

© 36668-2

Fig. 610
11. m Fit lube oil pipe (1).
m Tighten screws (2).
NOTE
Fit the screw, applying DEUTZ DW 72 thread lock 1
compound. Do not tighten.

© 36658-2

Fig. 611

30-105
 Method of intervention
12. m Remove all the alignment pins (1).

© 36659-2

Fig. 612
13. m Insert the new O-rings.
m Tighten the screw plugs (1). 9 Nm.

© 36651-2

Fig. 613
14. m Tighten the screws (1): 29 Nm.
m Tighten the screws (2): 22 Nm.
m Assemble the gear case cover.
See para. 30.3.36 - Disassembly and assemb... - page 30-135

1
2

© 36660-2

Fig. 614

30-106
Method of intervention
30.3.27 - Disassembly and assembly of the piston and connecting rod drum
Commercially available tools:
l Rotation angle gauge: 8190
Special tools:
l Piston ring compression collar 130670
NOTE
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
The lubricant oil and the coolant must be added according to the user manual.

Disassembly of the piston and connecting rod drum

1. m Disassemble the cylinder head.
See para. 30.3.10 - Disassembly and assemb... - page 30-32
m Remove the oil suction pipe.
See para. 30.3.53 - Removal and refitting ... - page 30-198
m Withdraw the oil level dipstick.

© 46477-0

Fig. 615

Disassembly of the flanged bearing cover

1. m Rotate the crankshaft using the rotation device.
m Move the connecting rod pins to the bottom dead centre.
m Remove screws (1).
m Remove flanged bearing cover (2).
NOTE
Put the components to one side in the order in which
2
they were removed. Note the cylinder order. 1

m Remove the bearing shell.

© 46480-0

Fig. 616

30-107
 Method of intervention
2. m Disassemble the piston and connecting rod drum.
NOTE
Put the components to one side in the order in which
they were removed. Note the cylinder order.

© 46478-0

Fig. 617
3. m Remove the connecting rod bearing shells (1).
m Carry out a visual inspection of the components.

1
© 44250-0

Fig. 618
4. m Remove the circlip.
m Pressure remove the piston pin.
m Carry out a visual inspection of the components.

© 44251-0

Fig. 619

30-108
Method of intervention
Completion of the piston and connecting rod drum
1. m Insert a new circlip.
NOTE
Check the installation position is correct.

© 44252-0

Fig. 620
2. m Insert the connecting rod drum.
NOTE

26519
2
The flywheel/crankshaft symbol (1), on the bottom of
the piston, must face towards the right and numeric
code (2) on the connecting rod drum must face up-
wards.

© 44253-0

Fig. 621
3. m Lightly oil the piston pin.
m Pressure insert the piston pin.
m Insert a new circlip.
NOTE
Check the installation position is correct.

© 44254-0

Fig. 622

30-109
 Method of intervention
Assembly of the piston and connecting rod drum
1. NOTE
Check that tightening bush (1) is present.

1
1
© 46296-0

Fig. 623
2. m Insert the connecting rod bearing shell into the connecting rod drum.
NOTE
Take care to couple the bearing shells. The anti-twist
safety (1) must enter the groove (2).
2

1
© 46295-0

Fig. 624
3. m Insert the connecting rod bearing shell into the relative flanged bear-
ing cover.
WARNING
1
Take care to couple the bearing shells. The anti-twist safety
(1) must enter the groove (2).

© 44216-0

Fig. 625

30-110
Method of intervention
4. m Offset the piston ring joints by approx. 120°.
m Check the piston rings and grooves.
See para. 30.3.29 - Check the piston rings... - page 30-115

© 42380-1

Fig. 626
5. m Lightly oil the cylinder sliding surface, piston, piston rings and con-
necting rod pins.
m Tighten the piston rings with a compression collar (1).
NOTE
Never rotate the piston rings.

© 44255-0

Fig. 627
6. m Move the connecting rod pins to the bottom dead centre.
m Insert the piston and connecting rod drum in the cylinder liner.
NOTE
Pay attention to the piston cylinder allocation. Mark
the assembly position on the bottom of the piston. 1
The flywheel/crankshaft symbol (1) must be facing
the flywheel. The piston ring compression collar must
rest lightly on the cylinder liner.

© 45004-1

Fig. 628

30-111
 Method of intervention
7. m Delicately press the connecting rod drum against the connecting rod
pins.
WARNING
Do not bend the connecting rod drum with the crankshaft.

© 46481-0

Fig. 629

Assembly of the flanged bearing cover

1. m Apply the flanged bearing cover.

© 46482-0

Fig. 630
2. m Tighten the new screws using the rotation angle gauge> 30 Nm +
60° + 30°.
WARNING
The screws must be renewed after being removed.

© 46483-0

Fig. 631

30-112
Method of intervention
3. m Insert the oil level dipstick.
m Fit the oil suction pipe.
See para. 30.3.53 - Removal and refitting ... - page 30-198
m Assemble the cylinder head.
See para. 30.3.10 - Disassembly and assemb... - page 30-32

© 46479-0

Fig. 632

30.3.28 - Check the piston

Commercially available tools:
l Palmer
l Internal bore meter
Special tools:
l Dial gauge: 100400
NOTE
If the piston wear limit was reached, replace it.

Check of the piston pin hole

1. m Disassemble the piston from the connecting rod drum.
See para. 30.3.27 - Disassembly and assemb... - page 30-107

© 44262-0

Fig. 633

30-113
 Method of intervention
2. m Prepare the internal bore meter:
n Fit the probes for the corresponding measurement interval in

an internal bore meter.

n Fit the dial gauge with a preload of approx. 1 mm in the inter-

nal bore meter.

n Adjust the palmer to 38 mm.
n Apply the internal bore meter between the test surfaces of

the palmer and in the return point of the pointer, bring the dial
gauge to “0”.

© 34768-2

Fig. 634
3. NOTE
Measurement diagram of the piston pin hole in points “a”
and “b” in surfaces “1” and “2”.

© 37239-1

Fig. 635
4. m Insert the internal bore meter in the piston pin hole.
m Apply the internal bore meter to the measurement points required
occasionally and read the value measured in the return point of the
pointer: 38 (+0.009,-0.004) mm.
NOTE
Measurement points, see diagram.

© 43483-0

Fig. 636

30-114
Method of intervention
Check the piston diameter
1. NOTE
Measurement diagram of the piston diameter in points “1, 2
and 3”, transversal to the piston pin hole.

© 37244-1

Fig. 637
2. m Measure the clearance of the piston pin with the palmer.
Table 82

Diameter
Measurement height Standard Interference:
16 mm 100.820 (+0.009, 101.320 (+0.009,
-0.009) mm -0.009) mm
50 mm 100.588 (+0.007, 101.088 (+0.007,
-0.007) mm -0.007) mm
78.5 mm 100.270 (+0.012, 100.770 (+0.012,
-0.012) mm -0.012) mm

© 43427-0
NOTE
Fig. 638
Measurement points, see diagram.

m Complete the connecting rod drum and piston.

See para. 30.3.27 - Disassembly and assemb... - page 30-107

30.3.29 - Check the piston rings and piston grooves

Commercially available tools:
l Feeler gauges
Special tools:
l Universal pliers for piston rings: 130300
l Trapezoidal groove wear gauge: 130440

30-115
 Method of intervention
Check the piston rings and piston grooves
1. m Remove the piston from the connecting rod shank
See para. 30.3.27 - Disassembly and assemb... - page 30-107
m Set the universal piston ring tool for the piston diameter: 101 mm.
m Disassemble the piston ring with universal pliers.

Fig. 639
2. m Clean the piston.
m Inspect the piston.
m Visually inspect the piston grooves.

Fig. 640
3. m Measure the race of the first piston ring using a trapezoidal race
wear gauge.

© 33866-3

Fig. 641

30-116
Method of intervention
4. m
NOTE:
If there is a distance “S” between the trapezoidal S
race wear gauge and the piston, the piston can still
be used.

© 33867-3

Fig. 642
5. m
NOTE:
If the trapezoidal race wear gauge rests on the piston
(arrow) the latter must be replaced.

© 33868-3

Fig. 643

Check the coupling clearance of the piston rings

1. m Insert the piston ring (1) in the cylinder.
m Align the rings, pushing the piston into the cylinder.

© 45011-1

Fig. 644

30-117
 Method of intervention
2. m Measure the coupling clearance of the piston rings with the feeler
gauge.
n Piston ring = dual trapezoid section rings: 0.20 - 0.35 mm
n Piston ring = conical section ring: 1.5 - 2.0 mm
n Piston ring = oil scraper ring: 0.3 - 0.55 mm

m
NOTE
The piston ring wear limit was reached, replace it.

© 45012-1

Fig. 645
3. m Assemble the piston rings.
m Sequence and position of the piston rings viewed from the bottom
of the piston:
n Double trapezoidal ring (1)
1
n tapered ring (2)
2
n Oil scraper ring with tubular spring (3)
n
NOTE: 3

The mark “Top” faces towards the combustion

chamber.

© 44267-0

Fig. 646
4. m Assemble the piston ring with universal pliers.
NOTE:
Offset the flexible coupling of the oil scraper ring by
180° with respect to the ring coupling.

Fig. 647

30-118
Method of intervention
Check the endfloat of the piston ring
1. m
NOTE:
Perform the check with new piston rings.

m Check the endfloat between the piston and the groove of the piston
ring using the feeler gauge.
n Piston ring: 0.06 - 0.08 mm
n Piston ring: 0.02 - 0.04 mm

m
NOTE:
If the piston wear limit was reached, replace it.

Fig. 648
2. m Complete the connecting rod drum and piston.
See para. 30.3.27 - Disassembly and assemb... - page 30-107

Fig. 649

30.3.30 - Assembly and disassembly of piston cooling nozzles

Disassembly of the piston cooling nozzles
1. m Disassemble the crankshaft.
See para. 30.3.25 - Assembly and disassemb... - page 30-93
m Delicately tighten the self-tapping screw (1) into the piston cooling
nozzle.

Fig. 650

30-119
 Method of intervention
2. m Remove the piston cooling nozzle (1) with the pliers.

Fig. 651

Assembly of the piston cooling nozzles

1. m Clean the holes for the piston cooling nozzles in the crankcase.
m With the bolt, insert a new piston cooling nozzle (1) to the stop.
m Assemble the crankshaft.
See para. 30.3.25 - Assembly and disassemb... - page 30-93

Fig. 652

30.3.31 - Removal and refitting of the crankcase breather

Commercially available tools:
l Circlip pliers: 9090
Removal of the crankcase breather
1. m Loosen the circlip using the specific pliers and remove it towards
the bottom.
m Remove the flexible hose (1).
m Remove screws (2). 3
m Remove the crankcase breather (3). 2

© 46473-3

Fig. 653

30-120
Method of intervention
2. m Visually inspect the component.
m Clean the mating surfaces.
m Fit a new gasket (1)
1

© 46475-0

Fig. 654
3. m Fit the crankcase breather (1).
NOTE:
Make sure the assembly position is correct (arrow).
1

© 46476-0

Fig. 655
4. m Tighten the screws (1): 21 Nm
m Position the flexible pipe (2).
m Position the circlip with the specific pliers.

© 46473-4

Fig. 656

30-121
 Method of intervention
30.3.32 - Check the cylinder
Commercially available tools:
l Palmer
l Internal bore meter
l Depth gauge
Special tools:
l Dial gauge: 100400
NOTE
To measure the cylinder, the crankshaft bearing covers must be assembled regularly.

Check the cylinder

1. m Disassemble the piston and connecting rod drum.
See para. 30.3.27 - Disassembly and assemb... - page 30-107
m Visually check the wear of the cylinder.

Fig. 657
2. m Prepare the internal bore meter:
n Fit the probes for the corresponding measurement interval in

an internal bore meter.

n Fit the dial gauge with a preload of approx. 1 mm in the inter-

nal bore meter.

n Adjust the palmer to 101 mm.
n Apply the internal bore meter between the test surfaces of

the palmer and in the return point of the pointer, bring the dial
gauge to “0”.

Fig. 658

30-122
Method of intervention
3. NOTE
Measuring diagram of the cylinder liner in points “a” and “b”
in surfaces “1” -
“3”.

Fig. 659
4. m Insert the internal bore meter in the cylinder.
m Apply the internal bore meter to the measurement points required
occasionally and read the value measured in the return point of the
pointer.
m Compare the value measured with the nominal value. 101 (+0.02,
-0) mm
NOTE
Measurement points, see diagram.

m Assemble the piston and the connecting rod drum.

See para. 30.3.27 - Disassembly and assemb... - page 30-107

Fig. 660

30.3.33 - Removal and refitting of the front cover (opposite end to flywheel)
Removal of the front cover
1. m Remove the torsional vibration damper
See para. 30.3.40 - Removing and fitting t... - page 30-146
m Remove the oil suction pipe.
See para. 30.3.53 - Removal and refitting ... - page 30-198

Fig. 661

30-123
 Method of intervention
2. m Turn the engine on the assembly stand.
m Remove all the screws (1).
m Remove the front cover.
m Remove the gasket.

Fig. 662
3. m Visually inspect the components.

© 42996-0

Fig. 663

Refitting the front cover.

1. m Remove crankshaft seal (1).
WARNING
Be careful not to damage the mating surfaces when remov-
ing the front cover.

© 42997-0

Fig. 664

30-124
Method of intervention
2. NOTE
Check that tightening bush (1) is present.

m Fit a new gasket.

© 44545-1

Fig. 665
3. m Position the internal rotor relative to the crankshaft.
NOTE
The machining on the crankshaft and the rotor guides
must coincide. The internal rotor can only be fitted to
the crankshaft in one position.

© 44547-1

Fig. 666
4. m Fit the front cover.
m Fit the screws.
NOTE
Do not tighten the screws at this stage.

m Position the front cover flush with the mating surface of the oil sump
pan.

© 44548-1

Fig. 667

30-125
 Method of intervention
5. m Trim any protruding gasket (arrowed) flush with the mating surface
of the oil sump pan.

© 44551-1

Fig. 668
6. m Tighten the screws in the sequence indicated.
n Pretightening value: 3 Nm.
n Retightening value: 21 Nm.

Fig. 669
7. m Fill the oil pump housing with lubricating oil.

Fig. 670

30-126
Method of intervention
8. m Fit the oil suction pipe.
See para. 30.3.53 - Removal and refitting ... - page 30-198

Fig. 671
9. m Turn the engine on the assembly stand.
m Fit the front crankshaft oil seal (opposite end to flywheel)
See para. 30.3.22 - Replacing the cranksha... - page 30-76

Fig. 672
10. m Fit the torsional vibration damper.
See para. 30.3.40 - Removing and fitting t... - page 30-146

Fig. 673

30-127
 Method of intervention
30.3.34 - Disassembly and assembly of the connector box
Commercially available tools:
l Box spanner insert: 8113
l Box spanner insert: 8114
Disassembly of the connector box
1. m Remove screws (1).
m Remove cover (2)

1
© 42698-1

Fig. 674
2. m Remove screws (1).
m Remove the connector box.
NOTE
1
Use the box spanner insert.
1

m Visually inspect the components. 1

1 1

1
© 42699-1

Fig. 675

Assembly of the connector box

1. m Clean the support surfaces.
1
NOTE
Check that tightening bush (1) is present.
1

© 44083-1

Fig. 676

30-128
Method of intervention
2. m Apply the connector box.
m Centre the connector box above the tightening bushes. 1
m Fit the screws.
NOTE 2
1
Note that the screws are of different lengths M12 =
2
(1). M16 = (2) 1
1

2
© 42703-1
44083-1

Fig. 677
3. m Tighten the screws in the sequence indicated.
NOTE 4 2

Tightening sequence, see graph. Use the box span-

ner insert. 1
6

m Tighten the screw (1) manually.

m Pretension in order screws (2), (3) (4) and (5).
n Pretightening value: 99 Nm.

m Tighten screws (1) and (6). 99 Nm.

m Tightening alternatively screws (2), (3), (4) and (5). 3 5
n Retightening value: 243 Nm.

© 44085-0

Fig. 678
4. m Push the casing to the support.
m Tighten the screws (2): 9 Nm. 1

NOTE
2
The slot (1) is facing the oil sump.

© 42704-1

Fig. 679

30-129
 Method of intervention
30.3.35 - Fitting and removing the camshaft bearings, checking
Commercially available tools:
l Palmer
l Internal bore meter
Special tools:
l Dial gauge: 100400
l Assembly tool: 143840
Check the camshaft bearings
1. m Disassemble the crankshaft.
See para. 30.3.25 - Assembly and disassemb... - page 30-93
m Disassemble the camshaft.
See para. 30.3.37 - Assembly and disassemb... - page 30-139

Fig. 680
2. m Prepare the internal bore meter:
n Fit the probes for the corresponding measurement interval in

an internal bore meter.

n Fit the dial gauge with a preload of approx. 1 mm in the inter-

nal bore meter.

n Adjust the palmer to 70 mm.
n Apply the internal bore meter between the test surfaces of

the palmer and in the return point of the pointer, bring the dial
gauge to “0”.

Fig. 681
3. NOTE
Measurement diagram of the camshaft bearing in points “a”
and “b” in surfaces “1” and “2”.

© 37239-1

Fig. 682

30-130
Method of intervention
4. m Insert the internal bore meter.
m Apply the internal bore meter to the measurement points required
occasionally and read the value measured in the return point of the
pointer: 63 (+0.054) mm
n Wear limit: 63.080 mm

NOTE
Measurement points, see diagram. If the camshaft
bearing wear limit was reached, replace it.

© 46337-0

Fig. 683

Disassembly of the camshaft bearings

1. m Insert the pin (1).
m Fit the guide (2).
m Fit the counterhead (3).

2 1

© 45259-0

Fig. 684
2. m Fit the thrust cap (1).
m Screw in nut (2);

© 45266-1

Fig. 685

30-131
 Method of intervention
3. m Hold the threaded shaft (1)
m Tighten nut (2).
NOTE
Tighten the nut further until the bearing bush falls out.

m Remove the bearing shell.

m Remove the installation tool.

2
1

© 46338-0

Fig. 686

Assembly of the camshaft bearings

1. NOTE
Mark the position of the lubrication oil orifice.

© 45268-0

Fig. 687
2. m Check the alignment of the lubricant oil holes (1).

© 45269-0

Fig. 688

30-132
Method of intervention
3. m Insert the pin (1).
m Fit the counterhead (2).
m Fit the new bearing shell on the thrust cap.
WARNING
3
2 1
Ensure that the lubrication oil orifices are aligned correctly.

m Fit the thrust cap (3).

© 45267-1

Fig. 689
4. m Use the installation tool to install the bearing shell flush with the
surface.
NOTE
Press the bearing shell into the crankcase using the
thrust cap.

© 46338-1

Fig. 690
5. m Check the alignment of the lubricant oil holes (1).
NOTE
If the lubricant oil hole is not aligned, assemble and
disassemble the camshaft bearing one more time.

Fig. 691

30-133
 Method of intervention
6. m Assemble the camshaft.
See para. 30.3.37 - Assembly and disassemb... - page 30-139
m Assemble the crankshaft.
See para. 30.3.25 - Assembly and disassemb... - page 30-93

Fig. 692
7. m Push the casing to the support.
m Tighten the screws (2): 9 Nm. 1

NOTE
2
The slot (1) is facing the oil sump.

© 42704-1

Fig. 692
8. m Push the casing to the support.
m Tighten the screws (2): 9 Nm. 1

NOTE
2
The slot (1) is facing the oil sump.

© 42704-1

Fig. 692

30-134
Method of intervention
9. m Push the casing to the support.
m Tighten the screws (2): 9 Nm. 1

NOTE
2
The slot (1) is facing the oil sump.

© 42704-1

Fig. 692

30.3.36 - Disassembly and assembly of the gear case cover

l DEUTZ DW 67 sealant
Disassembly of the gear case cover
1. m Disassemble the starter.
See para. 30.4.8 - Disassembly and assemb... - page 30-251
m Disassemble the connector box.
See para. 30.3.34 - Disassembly and assemb... - page 30-128
m Remove the flywheel.
See para. 30.3.64 - Removal and refitting ... - page 30-232
m Disassemble the speed regulator.
See para. 30.4.2 - Removing and fitting t... - page 30-237

Fig. 693
2. m Remove the oil sump pan.
See para. 30.3.54 - Removing and fitting t... - page 30-199
m Turn the engine on the assembly stand.
m Remove screws (1).
m Remove cover (2).

Fig. 694

30-135
 Method of intervention
3. m Remove screws (1).

1
1

© 46596-0

Fig. 695
4. m Remove screws (1).
m Remove the gear case cover.

1
1
© 46599-0

Fig. 696
5. m Remove crankshaft seal (1).
WARNING 1
Be careful not to damage the mating surfaces when remov-
ing the front cover.

© 42750-0

Fig. 697

30-136
Method of intervention
Assembly of the gear case cover
1. m Clean the mating surfaces.
NOTE
The sealing surfaces must be clean, dry and free of
grease or other contaminants.

m Apply mastic (arrowed).

WARNING
Assembly must be completed within a maximum of 1 hour.

NOTE
Use DEUTZ DW 67 sealant. Sealing edge thickness, ap- © 42525-0

Fig. 698
prox. 1.4 mm.

2. m Align the gear box cover.

m Apply the gear box cover.
NOTE 1

After applying it, do not move the gear box cover.

m Tighten screws (1).

NOTE
Do not tighten the screws at this stage.

1
1
© 46598-0

Fig. 699
3. m Fit the screws.
NOTE
Note that the screws are of different lengths M8 x
45 mm screws (1). M8 x 35 mm screws (2). Do not
tighten the screws at this stage. 1

2
2

© 46596-1

Fig. 700

30-137
 Method of intervention
4. m Push up the gear box cover and align it flush with the sealing surface
of the oil sump (arrows).
NOTE
The oil sump sealing surface in correspondence of
the crankcase must face downwards.

© 46597-0

Fig. 701
5. m Tighten the screws in the sequence indicated: 30 Nm.
5 6 7
4 1
3 2
12 8

13 11

10
14 9

© 36520-3

Fig. 702
6. m Clean the mating surfaces.
NOTE
The mating surfaces must be clean, dry and free of
grease or other contaminants.

m Fit a new O-ring (1).

m Lightly lubricate the O-ring.

© 46460-0

Fig. 703

30-138
Method of intervention
7. m Push the closing cover (2) to the stop.
m Tighten (1) the screws.
NOTE
Use M8 x 45 mm screws: 21 Nm.

m Assemble a new crankshaft O-ring (flywheel side).

See para. 30.3.21 - Replace the crankshaft... - page 30-72

Fig. 704
8. m Assemble the connector box.
See para. 30.3.34 - Disassembly and assemb... - page 30-128
m Fit the flywheel.
See para. 30.3.64 - Removal and refitting ... - page 30-232
m Assemble the speed regulator.
See para. 30.4.2 - Removing and fitting t... - page 30-237
m Assemble the starter.
See para. 30.4.8 - Disassembly and assemb... - page 30-251
m Turn the engine on the assembly stand.
m Fit the oil sump pan.
See para. 30.3.54 - Removing and fitting t... - page 30-199
See para. 30.3.55 - Disassembly and assemb... - page 30-203

Fig. 705

30.3.37 - Assembly and disassembly of the camshaft

Commercially available tools:
l Lifting device
Disassembly of the camshaft
1. m Disassemble the injection pump.
See para. 30.3.45 - Fitting and removing i... - page 30-163
m Disassemble the injection valves.
See para. 30.3.50 - Fitting and removing i... - page 30-188
m Disassemble the rocker and the support.
See para. 30.3.8 - Removal and refitting ... - page 30-26
m Disassemble the crankshaft.
See para. 30.3.25 - Assembly and disassemb... - page 30-93

Fig. 706

30-139
 Method of intervention
2. m Remove screws (1).
m Hang the crankcase from a suitable workshop crane.

Fig. 707
3. m Disassemble the clamping support (1) from the adapter plates (2).

1
1

2
2

© 42708-0

Fig. 708
4. m Move the assembly stand to the flywheel side.

© 42709-0

Fig. 709

30-140
Method of intervention
5. m Push back all the tappets.
m Carefully remove the camshaft (1) on the flywheel side.

© 42710-0

Fig. 710
6. m Remove all the tappets (arrow).
NOTE
Put the components to one side in the order in which
they were removed. Note the cylinder order.

m Carry out a visual inspection of the components.

© 42711-0

Fig. 711

Assembly of the camshaft

1. m Lightly oil all the tappets.
m Insert all the tappets.
NOTE
Pay attention to couple the tappets.

© 42711-0

Fig. 712

30-141
 Method of intervention
2. m Lightly oil the camshaft bearings.
m Lightly oil the camshaft pins.
m Delicately insert the camshaft.
NOTE
Align the hole (1) in the direction of the cylinder head.

© 42712-0

Fig. 713
3. m Bring closer and orient the assembly stand on the flywheel side.
m Fit the fastener mount (1) onto the adapter plate (2): 90 Nm.

Fig. 714
4. m Hang the crankcase from the workshop crane.
m Remove screws (1).

Fig. 715

30-142
Method of intervention
5. m Assemble the crankshaft.
See para. 30.3.25 - Assembly and disassemb... - page 30-93
m Assemble the rockers and support.
See para. 30.3.8 - Removal and refitting ... - page 30-26
m Assemble the injection valves.
See para. 30.3.50 - Fitting and removing i... - page 30-188
m Assemble the injection pump.
See para. 30.3.45 - Fitting and removing i... - page 30-163

Fig. 716

30.3.38 - Check the camshaft

Commercially available tools:
l Palmer
l Prisms
Check the camshaft
1. m Disassemble the camshaft.
See para. 30.3.37 - Assembly and disassemb... - page 30-139
m Visually check the wear of the cams and main journal.

Fig. 717
2. NOTE
Measurement diagram of the main journals on points 1 and
2 in surfaces a and b.

Fig. 718

30-143
 Method of intervention
3. m Measure the main journals: 63 (-0.05, -0.07) mm
NOTE
Measurement points, see diagram. If the limit value
has been reached, replace the camshaft.

Fig. 719
4. m Visually check the wear of the camshaft ring gear.
m Assemble the camshaft.
See para. 30.3.37 - Assembly and disassemb... - page 30-139

Fig. 720

30.3.39 - Removal and refitting of the rotation device

Special tools:
l Rotation device: 100320
NOTE
Depending on the number of gear teeth, the rotation tool 100330 may also be used.

Removal
1. m Remove screws (1).
m Remove cover (2).
1

1
© 46419-0

Fig. 721

30-144
Method of intervention
Fitting the rotation device
1. m Insert rotation device (1).
NOTE
2
The toothed wheel of the rotation device must mesh
with the teeth of the camshaft gear.
1
m Tighten screws (2).

2
© 46420-0

Fig. 722

Removal of the rotation device

1. m Remove screws (2).
m Remove rotation device (1).
2

2
© 46420-0

Fig. 723
2. m Clean the mating surfaces of the cover plate and the gearbox cover.
m Fit a new O-ring (1).
m Lightly lubricate the O-ring.

© 46460-0

Fig. 724

30-145
 Method of intervention
3. m Fully press down the cover (3).
m Tighten the screw (2): 30 Nm.
m Tighten the screws (1): 21 Nm. 1

1
© 46419-1

Fig. 725

30.3.40 - Removing and fitting the V-belt pulley

Commercially available tools:
l Torque wrench
l Rotation angle gauge: 8189
l Box spanner insert Torx E20: 8114
Removing the V-belt pulley
1. m Loosen screws (1).
m Remove the V-belt.

Fig. 726
2. m Fit the rotation device.
See para. 30.3.39 - Removal and refitting ... - page 30-144
m Fastening flywheel with rotation tool.
m Unscrew the screws (1) using the box spanner insert.
m Remove the V-belt pulley.

Fig. 727

30-146
Method of intervention
3. m Visually inspect the component.

© 46
Fig. 728

Fitting the V-belt pulley

1. m
NOTE:
Check that bush (1) is present.

© 46
Fig. 729
2. m Fit the V-belt pulley.
NOTE:
The hole (1) must be aligned with the hole (2).

© 46
Fig. 730

30-147
 Method of intervention
3. WARNING
The screws must be renewed after being removed.

NOTE:
Screws: M16 x 1.5

m Tighten the new screws using the socket wrench insert and the rota-
tion angle gauge: 40 Nm + 60° + 60°
m Remove the rotation device.
See para. 30.3.39 - Removal and refitting ... - page 30-144
m Fit the V-belt.
Fig. 731
See para. 30.4.7 - Removal and refitting ... - page 30-247

30.3.41 - Fitting, removing, checking and setting adjuster rod

Commercially available tools:
l Sliding gauge
Special tools:
l Adjustment tool: 100800
Remove the adjuster rod
1. m Disassemble the speed regulator.
See para. 30.4.2 - Removing and fitting t... - page 30-237
m Disassemble the gear case cover.
See para. 30.3.36 - Disassembly and assemb... - page 30-135
m Disassemble the injection pump.
See para. 30.3.45 - Fitting and removing i... - page 30-163
m Remove screw (1).

Fig. 732
2. m Remove the adjuster rod

Fig. 733

30-148
Method of intervention
3. m Inspect the adjuster rod
m Measure the width of the groove (1): 5 (+0.03,-0.06) mm.

Fig. 734

Fitting the adjuster rod

1. m Fit the adjuster rod

Fig. 735
2. m Fit and tighten the new screw (1): 10 Nm.
WARNING
Self-locking screw!

m Assemble the gear case cover.

See para. 30.3.36 - Disassembly and assemb... - page 30-135

Fig. 736

30-149
 Method of intervention
3. m Lowly push the adjustment rod towards the arrow.
NOTE
Stop position! There must not be irregular resistance.

m Release the adjustment rod.

NOTE
The adjuster rod must be returned to its initial posi-
tion from any other position by spring force. Starting
position!

© 46344-1

Fig. 737

Measuring the travel of the adjuster rod (with injection pumps removed)
1. m Assemble the adjustment device (1).

© 46340-1

Fig. 738
2. m Move the adjustment rod to the stop position.
m Measure the distance between the adjustment rod and the adjust-
ment device.

© 46341-0

Fig. 739

30-150
Method of intervention
3. m Release the adjustment rod.
NOTE
Starting position!

m Measure the distance between the adjustment rod and the adjust-
ment device.
n The difference between the start and stop position indicates

the stroke of the adjustment rod.

Table 83

Calculation example:
Target: Adjustment rod stroke Fig. 740
Data: -
Measured value: Stop position (a), (a) = 30.7 mm.
Start position (b), (b) = 13.4 mm
Calculation: Dimension (a) - dimension (b)
The results of all this are: = 17.3 mm
Nominal dimension = 17.0 mm - 17.5 mm
4. m Rotate the adjustment tool.
m Turn the knurled screw (1) as far as the stop position.
m Assemble the injection pump.
See para. 30.3.45 - Fitting and removing i... - page 30-163

Fig. 741

30-151
 Method of intervention
Measuring the travel of the adjuster rod (with injection pumps installed)
1. m Assemble the adjustment device (1).

Fig. 742
2. m Move the adjustment rod to the stop position.
m Measure the distance between the adjustment rod and the adjust-
ment device.

Fig. 743
3. m Release the adjustment rod.
NOTE
Starting position!

m Measure the distance between the adjustment rod and the adjust-
ment device.
n The difference between the start and stop position indicates

the stroke of the adjustment rod.

Table 84

Calculation example:
Target: Adjustment rod stroke Fig. 744
Data: -
Measured value: Stop position (a), (a) = 30.5 mm.
Start position (b), (b) = 13.4 mm
Calculation: Dimension (a) - dimension (b)
The results of all this are: = 17.1 mm
Nominal dimension = >16.8 mm

30-152
Method of intervention
4. m Leichtgängigkeit der Regelstange prüfen.
m Lowly push the adjustment rod towards the arrow.
NOTE
There must not be irregular resistance.

m Release the adjustment rod.

NOTE
The adjuster rod must be returned to its initial posi-
tion from any other position by spring force. Starting
position!

Fig. 745

Measuring the residual play of adjuster rod for setting the governor correctly
1. m Measure the residual value between the gearbox and the stop posi-
tion.
WARNING
The value measured must be indicated precisely when re-
placing or repairing the adjuster.

m Assemble the speed regulator.

See para. 30.4.2 - Removing and fitting t... - page 30-237

Fig. 746

30.3.42 - Removal and refitting of the heater

Removal of the heater
1. m Disconnect the wiring connectors.
WARNING 1

Remove the screws, leaving only the positive terminal screw

in place to support the heater.

m Remove screws (1). 1

© 46360-0

Fig. 747

30-153
 Method of intervention
2. m Undo hose union (1).
m Remove seal (2)
m Remove the heater.
m Remove seal (3).

3 2

© 44360-1

Fig. 748
3. m Carry out a visual inspection of the component.

© 44831-0

Fig. 749

Refitting the heater

1. m Fit a new O-ring (3).
m Fit the heater.
m Fit a new O-ring (2).
m Reconnect hose union (1).

3 2

© 44360-1

Fig. 750

30-154
Method of intervention
2. m Tighten screws (1).
m Tighten the screws in alternate sequence: 3 Nm + 30°. 1
m Connect the wiring connector: 20 Nm.
WARNING
Remove the screws, leaving only the positive terminal screw
in place to support the heater. 1

© 46360-0

Fig. 751

30.3.43 - Removal and refitting of the turbocharger

Special tools:
l Disassembly tool: 110901
l DEUTZ S1 assembly product
NOTE
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
The draining and replenishing of engine fluids and lubricants must be carried out in accordance with the instructions
given in the documentation provided by the manufacturer of the vehicle/appliance.
Removal of the turbocharger
1. m Keep the nut (2).
m Remove screw (1).
2

© 46499-0

Fig. 752
2. m Unscrew hollow screws (1)
m Remove the seals. 1
m Remove lube oil pipe (2).

© 46500-0

Fig. 753

30-155
 Method of intervention
3. m Remove screw (1).
m Remove the support.

© 46501-0

Fig. 754
4. m Remove the oil return pipe (1).

© 46502-0

Fig. 755
5. m Unscrew nuts (1).
m Remove exhaust gas turbocharger (2).
m Remove the gasket.
m Unscrew the stud bolts.
m Carry out a visual inspection of the components. 1 1

2
© 46503-0

Fig. 756

30-156
Method of intervention
Refitting the turbocharger
1. m Clean the mating surfaces.
m Insert the new stud bolts with the assembly product.
m Fit the new stud bolts.
m Fit a new O-ring (1).

© 46504-0

Fig. 757
2. m Fit new O-ring (1).
m Lightly lubricate the O-ring. 1

© 46437-0

Fig. 758
3. m Fit turbocharger (2).
m Tighten the nuts (1): 22 Nm.

1 1

2
© 46503-0

Fig. 759

30-157
 Method of intervention
4. m Fit lube oil pipe (2).
m Fit banjo bolts (1) with new seals, but do not tighten: 18 Nm. 1
m Fit banjo bolts (3) with new seals, but do not tighten: 34 Nm.

© 46500-1

Fig. 760
5. m Fit new O-ring (1).
m Lightly lubricate the O-ring.
1

© 46438-0

Fig. 761
6. m Fit the oil return pipe (2) as indicated by the arrow.

© 46507-0

Fig. 762

30-158
Method of intervention
7. m Insert oil return pipe (1) in the engine block (arrow)
m Fit the mount.
m Tighten the screw (2): 21 Nm.

© 46501-1

Fig. 763
8. m Keep the nut (2).
m Tighten (1) the screw: 13 Nm.
2

© 46499-0

Fig. 764

30.3.44 - Removal and refitting of the charge air duct

l DEUTZ DW 72 mastic
Removal of the charge air duct
1. m Unscrew hollow screws (1)
m Remove the seals.

Fig. 765

30-159
 Method of intervention
2. m Disconnect the wiring connectors.
m Remove screws (1).
m Remove charge air manifold (2).
m Remove the gasket.
m Remove the connector element.

Fig. 766
3. m Remove the cylinder head cover.
See para. 30.3.10 - Disassembly and assemb... - page 30-32
m Remove all the screws (1).
m Remove the charge air duct (2).
m Remove the gaskets.
m Carry out a visual inspection of the component.

Fig. 767

Refitting the charge air duct

1. m Clean the mating surfaces.
m Fit new gaskets (1).
NOTE
Check the installation position is correct.

Fig. 768

30-160
Method of intervention
2. m Fit the charge air duct.

Fig. 769
3. m Fit the screws.
NOTE
Do not disturb the gaskets.

m Tighten the screws: 11 Nm.

NOTE
Tightening sequence Start from centre working out-
wards.

Fig. 770
4. m Fit the cylinder head cover.
See para. 30.3.10 - Disassembly and assemb... - page 30-32
m Clean the mating surfaces.
m Fit the new gasket (1).

Fig. 771

30-161
 Method of intervention
5. m Tighten the new O-rings (1).

Fig. 772
6. m Apply assembly product to connection fitting (1).
m Install the connection fitting (1).

© 46498-0

Fig. 773
7. m Fit the charge air duct.
m Fit screws (1) using thread locking agent.
m Fit screws (2) using thread locking agent.
3
m Fit the screws.
NOTE
Note that the screws are of different lengths M8 x 30
mm (1). M8 x 95 mm (2). M8 x 80 mm (3). 2

m Tighten the screws: 30 Nm.

m Reconnect the wiring connector
1

© 46491-1

Fig. 774

30-162
Method of intervention
8. m Tighten the hollow screw (1): 18 Nm.
NOTE
Use new seals.

© 46490-0

Fig. 775

30.3.45 - Fitting and removing injection pump

1. Commercially available tools:
m Socket wrench insert, 10 mm, twelve-sided
m Toothed insert for socket wrench 8117
m Rotation angle gauge: 8190

Special tools:
m Rotation device: 100320
m Presser tool: 100830
m Special pliers: 103220
m Extractor: 110030
m Special wrench: 110500
m Slide hammer extractor: 150800
m Plugs and caps: 170160

m DEUTZ AP1908 assembly product

WARNING
During work on the fuel system always maintain conditions of the maximum cleanliness.
Before proceeding with removal, remove any paint residue or debris. Thoroughly clean the area around the
components to be worked on. Dry any wet areas with a compressed air jet.
When handling fuel observe the safety directives and specific local regulations. All fuel lines and unions should
be closed immediately after opening using new, clean plugs or caps. Remove plugs and caps only immediately
prior to assembly. Collect auxiliary materials in suitable containers and dispose of them in compliance with the
applicable regulations.
NOTE
If replacing the injection pump, remeasure the thickness of the shim. The EP code must be changed on the
factory plate. In the event of replacement of the crankcase, camshaft or roller tappets, determine the correct
assembly measurement of the injection pump “EK” and the relative part number EP, and modify accordingly
on the identification plate.

30-163
 Method of intervention
Disassembly of the injection pump
1. m Remove the hollow connector from the engine block.
m Disassemble the cylinder head case (1).
See para. 30.3.10 - Disassembly and assemb... - page 30-32

Fig. 776
2. m Remove screws (1).

Fig. 777
3. m Withdraw the engine block (1).

Fig. 778

30-164
Method of intervention
4. m Fit the presser tool (1).

© 46365-0

Fig. 779
5. m Tighten (1) the screws.

© 46372-0

Fig. 780
6. m Turn the knurled screw (1).
NOTE
Turn the knurled screw until it stops (adjuster rod end 1

stop)

© 46373-0

Fig. 781

30-165
 Method of intervention
7. m Remove screws (1).
m Remove cover (2).
1

1
© 46419-0

Fig. 782
8. m Insert rotation device (1).
NOTE
2
The toothed wheel of the rotation device must mesh
with the teeth of the camshaft gear.
1
m Tighten screws (2).

2
© 00000-0

Fig. 783
9. m Turn the crankshaft in the correct direction of rotation of the engine
to align the injector pump actuator cam for the respective cylinder
with the base disc.
Example:
The intake valve of cylinder 1 is open.

© 35356-1

Fig. 784

30-166
Method of intervention
10. m Remove the injection pipe with a special wrench.

© 46424-1

Fig. 785
11. m Remove screws (1).

© 46425-0

Fig. 786
12. m Remove the flange

© 46426-0

Fig. 787

30-167
 Method of intervention
13. NOTE
If the injection pump is seized:

1
m Assemble the slide hammer extractor (1) and extractor (2).
m Tighten the check nut (3).
2

© 40958-0

Fig. 788
14. m Fit the slide hammer extractor onto the injection pump.
m Screw the sleeve nuts (1).
m Remove the seized injection pump.

© 46427-0

Fig. 789
15. m Remove the injection pump.
m Carry out a visual inspection of the component.

© 46418-0

Fig. 790

30-168
Method of intervention
16. m Withdraw roller tappet (1) using the special pliers
m Remove the shim washer.
m Carry out a visual inspection of the components.

Fig. 791

Assembly of the injection pump

1. NOTE
If replacing the injection pump, remeasure the thickness
of the shim. The EP code must be changed on the factory
plate.
m Calculating the thickness of the shim washer (engine without vari-
able injection timing adjuster).
[LNK]
[LNK]
m Calculating the thickness of the shim washer (engine with variable
injection timing adjuster).
[LNK]
[LNK]
m Insert the roller tappet (1) using the special pliers.
NOTE Fig. 792

In the event of replacement of the crankcase, cam-

shaft or roller tappets, determine the correct assem-
bly measurement of the injection pump “EK” and the
relative part number EP, and modify accordingly on
the identification plate.
m Determination of the overall dimensions of the injection pump (en-
gine without the injection advance variator)
[LNK]
[LNK]
m Determination of the overall dimensions of the injection pump (en-
gine with the injection advance variator)
[LNK]
[LNK]

30-169
 Method of intervention
2. m Fit the new O-rings (1).

© 39865-1

Fig. 793
3. m Rotate the injection pump actuator arm into approximately the cen-
tral position.

© 46369-0

Fig. 794
4. m Apply assembly sealant to the seat hole in the crankcase and to the
injection pump O-ring.
m Place the roller tappet for the respective cylinder on the base disc.
m Assemble the injection pump.
m Connect the injection pump actuator arm (1) to the adjuster rod.

© 46418-1

Fig. 795

30-170
Method of intervention
5. m Fit the flange.
NOTE
The bevelled side must face towards the injection
pump body.

© 46426-0

Fig. 796
6. NOTE
Start each time with the screw (2).

m Lightly oil screws (2).

m Lightly oil screws (1).
m Tighten the screws evenly with the socket wrench insert. 5 Nm +
80°.
WARNING 1 2

The flange must sit evenly against the respective surface.

© 46430-0

Fig. 797
7. m Turn all the screws (1) by 190° in the direction indicated by the ar-
row.

1 1

© 46366-0

Fig. 798

30-171
 Method of intervention
8. m Using the toothed socket wrench insert, carefully rotate the injection
pump in the direction indicated by the arrow until it stops.

© 46429-0

Fig. 799
9. NOTE
Start each time with the screw (2).

m Tighten screws (1) and (2). 5 Nm + 150°.

m Fasten the new injection pipes with the special wrench: 25 Nm.

1 2

© 46430-0

Fig. 800
10. m Remove screws (1).
m Remove the presser tool (2).

© 46372-1

Fig. 801

30-172
Method of intervention
11. m Remove screws (2).
m Remove rotation device (1).
2

2
© 00000-0

Fig. 802
12. m Clean the mating surfaces of the cover plate and the gearbox cover.
m Fit a new O-ring (1).
m Lightly lubricate the O-ring.

© 46460-0

Fig. 803
13. m Fully press down the cover (3).
m Tighten the screw (2): 30 Nm.
m Tighten the screws (1): 21 Nm. 1

1
© 46419-1

Fig. 804

30-173
 Method of intervention
14. WARNING
Check the mobility of the adjustment rod.

m Operate the stop lever between the start and stop position.
m Fit a new O-ring (1).
m Lightly lubricate the O-ring.

© 46417-0

Fig. 805
15. m Press and hold down the adjustment rod in the stop position, using
the stop lever.
m Insert the engine block (1).
1

© 46364-0

Fig. 806
16. m Tighten the screws (1): 21 Nm.

© 46371-0

Fig. 807

30-174
Method of intervention
17. m Fit the cylinder head cover (1).
See para. 30.3.10 - Disassembly and assemb... - page 30-32
m Fit the hollow connector on the engine block.

Fig. 808

30.3.46 - Determine the thickness of the shim (engine without injection advance variator)
1. Commercially available tools:
m Torque wrench

NOTE
Let the engine cool down for at least one hour. Lubricant oil temperature < 40 °C. In order to exclude measure-
ment errors, all the support and measurement surfaces must be completely clean!

2. NOTE
The following description, by way of an example, makes
reference to an injection pump. If carrying out the work
procedure on another injection pump, proceed in the same
manner.
m Disassemble the injection pump.
See para. 30.3.45 - Fitting and removing i... - page 30-163

Fig. 809
3. m Read the EP code on the factory plate for the corresponding cylin-
der. Example: P/N EP 295 for cylinder 1 (1).
m Read and write down the correct assembly dimension for the EK
injection pump based on the EP code. Example: EK = 120.875 mm.
NOTE
Table 3 - see the technical specifications

Fig. 810

30-175
 Method of intervention
4. m Read the code for the (new) injection pump for the length of the in-
jection pump (dimension A). Example: Measurement A = 42.
m Write down dimension A in order to calculate the theoretical thick-
ness of the TS shim.
m Read and write down the base dimension L0 of the injection pump.
Example: 117.5 mm.
NOTE
Table 1 - see the technical specifications

m Calculate the thickness of the shim.

NOTE
Tables 1, 2, 3 - see the technical specifications
Fig. 811

Table 85

Calculation example:
Target: Theoretical thickness of shim wash-
er TS
Effective thickness of shim washer
SS
Data: Injection pump length code A. Base
size of injection pump L0 from table
1, e.g. 117.15 mm. EP part number
(from factory identification plate)
e.g. 295. Correct assembly mea-
surement of injection pump EK from
table according to EP part number,
e.g. 120.875 mm
Calculation: TS = EK - (L0 + A/100), TS =
120.875 mm - (117.5 mm + 42/100
mm), TS = 120.875 mm - 117.92 mm
The results of all this are: TS= 2.955 mm. Select SS referring
to table 2, SS = 3.0 mm.
5. m Place the calculated shim on the roller tappet.
m Assemble the injection pump.
See para. 30.3.45 - Fitting and removing i... - page 30-163

Fig. 812

30-176
Method of intervention
30.3.47 - Determine the thickness of the shim (engine with injection advance variator)
1. NOTE
Let the engine cool down for at least one hour. Lubricant oil temperature < 40 °C. In order to exclude measure-
ment errors, all the support and measurement surfaces must be completely clean!

2. NOTE
The following description, by way of an example, makes
reference to an injection pump. If carrying out the work
procedure on another injection pump, proceed in the same
manner.
m Disassemble the injection pump.
See para. 30.3.45 - Fitting and removing i... - page 30-163

Fig. 813
3. m Read the EP code on the factory plate for the corresponding cylin-
der. Example: P/N EP 670 for cylinder 1 (1).
m Read and write down the correct assembly dimension for the EK
injection pump based on the EP code. Example: EK = 117.65 mm.
NOTE
Table 3.1 - see the technical specifications

Fig. 814

30-177
 Method of intervention
4. m Read the code for the (new) injection pump for the length of the in-
jection pump (dimension A). Example: Measurement A = 23.
m Write down dimension A in order to calculate the theoretical thick-
ness of the TS shim.
m Read and write down the base dimension L0 of the injection pump.
Example: 111.15 mm.
NOTE
Table 1.1 - see the technical specifications

m Calculate the thickness of the shim.

NOTE
Tables 1.1, 2.1, 3.1 - see the technical specifications
Fig. 815

Table 86

Calculation example:
Target: Theoretical thickness of shim wash-
er TS Effective thickness of shim
washer SS
Data: Injection pump length code A. Base
size of injection pump L0 from table
1.1, e.g. 111.15 mm. EP part num-
ber (from factory identification plate)
e.g. 670. Correct assembly mea-
surement of injection pump EK from
table according to EP part number,
e.g. 117.65 mm
Calculation: TS = EK - (L0 + A/100). TS = 117.65
mm - (111.15 mm + 23/100 mm). TS
= 117.65 mm - 111.38 mm
The results of all this are: TS= 6.27 mm. Select SS referring to
table 2.1. SS = 6.25 mm.
5. m Place the calculated shim on the roller tappet.
m Assemble the injection pump.
See para. 30.3.45 - Fitting and removing i... - page 30-163

Fig. 816

30-178
Method of intervention
30.3.48 - Determination of the overall dimensions of the injection pump (engine without
the injection advance variator)
1. Special tools:
m Digital dial gauge: 100410
m Measurement device: 103210

NOTE
Let the engine cool down for at least one hour. Lubricant oil temperature < 40 °C. In order to exclude measure-
ment errors, all the support and measurement surfaces must be completely clean!

2. NOTE
The following description, by way of an example, makes
reference to an injection pump. If carrying out the work
procedure on another injection pump, proceed in the same
manner.
m Disassemble the injection pump.
See para. 30.3.45 - Fitting and removing i... - page 30-163

Fig. 817
3. NOTE
Residuals of lubricant oil on the roller tappet surface could
falsify the measurement result.

m Clean the roller tappet interface.

m Fit the spacer disc (5 mm) on the roller tappet.
m Insert the roller tappet using the special pliers in the sump of the
injection pump.

Fig. 818
4. m Turn the crankshaft in the engine rotation direction using the rotation
device until the cam for activating the injection pump of cylinder 1 is
located on the base circle position.
NOTE
The intake valve of cylinder 1 is open.

© 35356-1

Fig. 819

30-179
 Method of intervention

30-180
Method of intervention
8. m Insert the dial gauge support in the master group.
m Set the dial gauge with preload to “0”.
NOTE
Pay attention to the unit of measurement. The depth
of the master group measures: Le = 122.25 mm

© 39861-0

Fig. 823
9. m Clean the support and measurement surface on the crankcase.
m Delicately insert the dial gauge support in the injection pump sump.
m Align the dial gauge support.
m Tighten the screws (1) with the spacer bushes (2).
m Tighten the screws (1): 15 Nm.

1 1

2 2
© 46422-0

Fig. 824
10. NOTE
The dial gauge now indicates a value more or less within
the interval.

m Calculate dimension “L”.

Table 87 "L"

Calculation example:
Target: Dimension L
Data: Master group depth Le = 122.25
mm. Spacer disc thickness (d) = 5
mm © 46423-2

Measured value: Dial gauge reading X = + 2.20 mm Fig. 825

Calculation: L = Le - X + d, L = 122.25 mm - 2.20
mm + 5.0 mm
The results of all this are: L=125.05 mm

m Write down dimension “L”.

30-181
 Method of intervention
11. m Disassemble the dial gauge support.
m Calculate the correct assembly dimension of the “EK” injection
pump.
NOTE
Table 1 - see the technical specifications

Table 88

Calculation example:
Target: Correct assembly dimension for the
EK injection pump © 39870-0
Data: Dimension L. Start of delivery (fac- Fig. 826
tory plate). Camshaft type W (from
factory identification plate). Maxi-
mum valve aperture Vh Nominal
value from table 1
Calculation: EK = L - Vh nominal value. EK =
125.05 mm - 5.337 mm
The results of all this are: EK = 119.713 mm

m Write down the correct assembly dimension for the “EK” injection
pump.
12. m Read the code for the injection pump for the length of the injection
pump (dimension A).
m Write down dimension A in order to calculate the theoretical thick-
ness of the TS shim.
n Example: Measurement A = 42.

© 30095-3

Fig. 827
13. m Calculate the thickness of the shim.
NOTE
Tables 1, 2, 3 - see the technical specifications

Table 89

Calculation example:
Target: Theoretic thickness of the TS shim. Thickness of the SS shim
Data: Correct assembly dimension for the EK injection pump (recal-
culated, see calculation above). Injection pump length code A.
Base size of injection pump L0 from table 1, e.g. 117.15 mm.
Calculation: TS = EK - (L0 + A/100). TS = 119.713 mm - (117.5 mm +
42/100 mm). TS = 119.713 mm - 117.92 mm
The results of all this are: TS= 1.793 mm. Select SS referring to table 2. SS = 1.8 mm.

30-182
Method of intervention
14. m Place the calculated shim on the roller tappet.
m Assemble the injection pump.
See para. 30.3.45 - Fitting and removing i... - page 30-163
NOTE
Perform the measurement for each injection pump.
If replacing the crankcase, camshaft or roller tap-
pet, for the correct assembly dimension of the “EK”
injection pump, determine the relative EP code and
change it on the data plate.
m Determine the EP code.
NOTE
Table 3 - see the technical specifications
Fig. 828

Table 90

Calculation example:
Target: EP code
Data: Correct assembly dimension for
the EK injection pump (recalcu-
lated, see calculation above). EK =
119.713 mm. EK rounded equally =
119.725 mm
Calculation: Select EP part number referring to
table 3
The results of all this are: EP P/N = 249

30.3.49 - Determination of the overall dimensions of the injection pump (engine with the
injection advance variator)
1. Commercially available tools:
m Torque wrench

Special tools:
m Rotation device: 100320
m Digital dial gauge: 100410
m Measurement device: 103210

NOTE
Let the engine cool down for at least one hour. Lubricant oil temperature < 40 °C. In order to exclude measure-
ment errors, all the support and measurement surfaces must be completely clean!

2. NOTE
The following description, by way of an example, makes
reference to an injection pump. If carrying out the work
procedure on another injection pump, proceed in the same
manner.
m Disassemble the injection pump.
See para. 30.3.45 - Fitting and removing i... - page 30-163

Fig. 829

30-183
 Method of intervention

30-184
Method of intervention
6. m Insert the dial gauge into the relative support.
m Tighten the knurled screw on the dial gauge support.

© 39859-0

Fig. 833
7. m Insert the spacer using the special pliers in the master group.

© 39860-0

Fig. 834
8. m Insert the dial gauge support in the master group.
m Set the dial gauge with preload to “0”.
NOTE
Pay attention to the unit of measurement. The depth
of the master group measures: Le = 122.25 mm

© 39861-0

Fig. 835

30-185
 Method of intervention
9. m Clean the support and measurement surface on the crankcase.
m Delicately insert the dial gauge support in the injection pump sump.
m Align the dial gauge support.
m Tighten the screws (1) with the spacer bushes (2).
m Tighten the screws (1): 15 Nm.

1 1

2 2
© 46422-0

Fig. 836
10. NOTE
The dial gauge now indicates a value more or less within
the interval. Add 1 mm to the stroke of the variable injection
timing adjuster actuator piston (see example calculation).
m Calculate dimension “L”.
Table 91 "L"

Calculation example:
Target: Dimension L
Data: Master group depth Le = 122.25
mm. Actuator piston stroke = + 1 mm
Measured value: Dial gauge reading X = + 0.45 mm © 46423-2

Calculation: L = (Le + 1 mm) - X. L = (122.25 mm Fig. 837

+ 1 mm) - (+ 0.45 mm). L = 123.25
mm - 0.45 mm
The results of all this are: L=122.80 mm

m Write down dimension “L”.

30-186
Method of intervention
11. m Disassemble the dial gauge support.
m Calculate the correct assembly dimension of the “EK” injection
pump.
NOTE
Table 1 - see the technical specifications

Table 92

Calculation example:
Target: Correct assembly dimension for the
EK injection pump © 39870-0
Data: Dimension L. Start of delivery (fac- Fig. 838
tory plate).
Camshaft type W. Maximum valve
aperture Vh Nominal value from
table 1.1
Calculation: EK = L - Vh nominal value. EK =
122.80 mm - 5.337 mm
The results of all this are: EK = 117.463 mm

m Write down the correct assembly dimension for the “EK” injection
pump.
12. m Read the code for the injection pump for the length of the injection
pump (dimension A).
m Write down dimension A in order to calculate the theoretical thick-
ness of the TS shim.
n Example: Measurement A = 23.

23

© 39865-0

Fig. 839
13. m Calculate the thickness of the shim.
NOTE
Tables 1.1, 2.1, 3.1 - see the technical specifications

Table 93

Calculation example:
Target: Theoretic thickness of the TS shim. Thickness of the SS shim
Data: Correct assembly dimension for the EK injection pump (recal-
culated, see calculation above). Injection pump length code A.
Base size of injection pump L0 from table 1.1, e.g. 111.15 mm.
Calculation: TS = EK - (L0 + A/100). TS = 117.463 mm - (111.15 mm +
23/100 mm). TS = 117.463 mm - 111.38 mm
The results of all this are: TS= 6.083 mm. Select SS referring to table 2.1 SS = 6.1 mm.

30-187
 Method of intervention
14. m Place the calculated shim on the roller tappet.
m Assemble the injection pump.
See para. 30.3.45 - Fitting and removing i... - page 30-163
NOTE
Perform the measurement for each injection pump.
If replacing the crankcase, camshaft or roller tap-
pet, for the correct assembly dimension of the “EK”
injection pump, determine the relative EP code and
change it on the data plate.
m Determine the EP code.
NOTE
Table 3.1 - see the technical specifications
Fig. 840

Table 94

Calculation example:
Target: EP code
Data: Correct assembly dimension for
the EK injection pump (recalcu-
lated, see calculation above). EK =
117.463 mm. EK rounded equally =
117.475 mm
Calculation: Select EP part number referring to
table 3.1
The results of all this are: EP P/N = 663

30.3.50 - Fitting and removing injection valves

Special tools:
l Extractor: 110030
l Extraction device: 120660
l Special wrench: 110500
l Slide hammer extractor: 150800
l DEUTZ AP1908 assembly product
DANGER
After switching off the engine, wait at least 30 seconds before carrying out any work on the fuel system!

WARNING
During work on the fuel system always maintain conditions of the maximum cleanliness.
Thoroughly clean the area around the components to be worked on. Dry any wet areas with a compressed air jet.
When handling fuel observe the safety directives and specific local regulations.
All lines and unions should be closed immediately after opening using new, clean plugs or caps. Remove plugs and
caps only immediately prior to assembly. Collect operating materials in suitable containers and dispose of them in
compliance with the applicable regulations.
NOTE
The following operating procedure is for the installation and removal of a single injection valve. Repeat the procedure
as necessary if more injection valves must be removed.

30-188
Method of intervention
Disassembly of the injection valve
1. m Remove the cylinder head cover.
See para. 30.3.10 - Disassembly and assemb... - page 30-32
m Unscrew the sleeve nuts (1) using the special wrench.

Fig. 841
2. m Unscrew the sleeve nuts (1) using the special wrench.
m Remove the injection pipe.
m Remove the rubber seal from the injection pipe.

© 46570-0

Fig. 842
3. m Remove screw (1).
m Remove retaining bracket (2).
m Remove the injection valve (3).

© 46571-0

Fig. 843

30-189
 Method of intervention
Disassembly of the blocked injection valve
1. m Assemble the slide hammer extractor (1) and extractor (2).
m Tighten the check nut (3).

© 46571-0

Fig. 844
2. m Fit the slide hammer extractor on the injection valve.
m Screw the sleeve nuts (1).
m Withdraw the blocked injection valve.
m Remove the O-ring fastened into the cylinder head with an extractor
tool.

Fig. 845
3. m Carry out a visual inspection of the components.
m Check the injection valve.
See para. 30.3.51 - Checking the injection... - page 30-192

Fig. 846

30-190
Method of intervention
Assembly of the injection valve
1. m Fit a new O-ring (1).
m Fit a new O-ring (2).

Fig. 847
2. WARNING
Observe the installation position. The flange (1) of the injec-
tion valve must face away from the fastener bracket.

Fig. 848
3. m Fit the injection valve (3).
m Fit retaining bracket (2).
m Tighten (1) the screw: 16 Nm.

Fig. 849

30-191
 Method of intervention
4. m Fit a new injection pipe (1).
m Fasten the sleeve nuts (2) with the special wrench: 25 Nm.
m Fit the rubber seal (3).
m Fit the cylinder head cover.
See para. 30.3.10 - Disassembly and assemb... - page 30-32

Fig. 850

30.3.51 - Checking the injection valves

1. Commercially available tools:
m Box spanner insert SW15: 8012
m Injector control equipment: 8008

Special tools:
m Support: 110110

DANGER
Risk of accident when handling the nozzle tester. The injector jet causes the fuel to penetrate deep under the
skin! Risk of septicaemia!

NOTE
After operating the manual lever three or four times, the spring chamber fills with diesel fuel/test oil to above the
injection valve needle. Afterwards, it is not possible to operate the manual lever. Before every test procedure,
carefully loosen the nozzle fastener nut to release pressure from the spring chamber. To check the injection
valves, use only pure ISO 4113 standard test oil or clean diesel fuel.
2. m Disassemble the injection valves.
See para. 30.3.50 - Fitting and removing i... - page 30-188

Fig. 851

30-192
Method of intervention
Assembly of the injection valve on the injector tester
1. m Insert the injection valve in the support.
m Loosen the nozzle tightening nut by approx. 180° using the box
spanner insert (pressure reduction) and then retighten it: 35 Nm.

© 36271-2

Fig. 852
2. m Fit the injection valve on the injector tester.

© 35889-2

Fig. 853

Check the opening pressure

1. m Slightly push the injector tester lever down with the pressure gauge
inserted.
m Read the value measured.
NOTE
The pressure at which the pointer stops or goes
down suddenly is the opening pressure. Repeat the
check 3 times.

© 36293-2

Fig. 854

30-193
 Method of intervention
2. m Compare the values measured: 220 bar.
NOTE
The measurement values of the three tests must co-
incide with the control value.

m Replace the injection valve if the value measured deviates from the
specified value.

© 36293-2

Fig. 855

Check the air-tightness

1. m Dry the injectors and injector holders with a jet of air.
m Press down lightly on the manual tester lever until arriving at approx.
20 bar below the opening pressure read previously.

© 36293-2

Fig. 856
2. NOTE
The injector is air sealed if it does not drip within 10 seconds.

© 36294-2

Fig. 857

30-194
Method of intervention
3. m Replace the injection valve if fuel drips from the injector.
WARNING
Retouch work is not permitted!

© 36295-2

Fig. 858

Checking the mobility of the jet needle

1. m Turn off the tester pressure gauge.
m Perform the noise and needle jet test.
NOTE
Check the mobility of the jet needle in the body of the
injector by means of an acoustic noise test. Due to
the increasing wear in the seat of the injection valve
needle, the acoustic behaviour of the injectors will
change. Quickly operating the lever of a worn injec-
tion valve emits a sound that can be heard and the
fuel is finely pulverised. The jet is quite different than
that from a new injection valve.

© 36296-2

Fig. 859
2. m Replace the injection valve if the injector makes no audible sound.

© 36296-2

Fig. 860

30-195
 Method of intervention
Disassembly of the injection valve from the injector tester
1. m Loosen the nozzle tightening nut by approx. 180° using the box
spanner insert (pressure reduction) and then retighten it: 35 Nm.
NOTE
Before installing the injection valves, reduce the pressure in
the spring chamber.

m Assemble the injection valves.

See para. 30.3.50 - Fitting and removing i... - page 30-188

Fig. 861

30.3.52 - Removal and refitting of the fuel lift pump

Special tools:
l Plugs and caps: 170160
DANGER
After switching off the engine, wait at least 30 seconds before carrying out any work on the fuel system!

WARNING
If working on the fuel system, make sure it is completely clean. From time to time, carefully clean the area surrounding
the concerned component . Dry any wet areas with compressed air. When handling fuel observe the safety directives
and specific local regulations. After opening, immediately close all the connections with new and clean plugs/caps.
Remove plugs/caps only immediately prior to assembly. Collect the exiting technical fluids in suitable containers and
dispose of them in accordance with current regulations. Only check/re-tension/change the V-belt while the engine is
stationary.
Removal of the fuel lift pump
1. DANGER
After switching off the engine, wait at least 30 seconds be-
fore carrying out any work on the fuel system!

m Unscrew banjo bolt (1)

NOTE
Collect any leaked fuel and dispose of it properly.

Fig. 862

30-196
Method of intervention
2. m Remove screws (1).
m Remove the fuel lift pump.
1
m Remove the V-belt.
m Carry out a visual inspection of the components.

© 46573-0

Fig. 863

Refitting the fuel lift pump

1. m Fit the fuel lift pump.
m Tighten screws (1).

© 46574-0

Fig. 864
2. m Fit the V-belt.
m Using a suitable tool, push bracket (1) in the direction of the arrow.

© 46375-1

Fig. 865

30-197
 Method of intervention
3. m Preload the screws (1).
m Check the V-belt tension.
See para. 30.4.7 - Removal and refitting ... - page 30-247

Fig. 866
4. m Tighten the hollow screw (1): 39 Nm (M12x1.5).
NOTE
Use new seals. Bleed the fuel system as indicated in
the instruction manual, using the hand pump on the
fuel pre-filter.

Fig. 867

30.3.53 - Removal and refitting of the oil pickup pipe

Removal of the oil pickup pipe
1. m Remove the oil sump pan.
See para. 30.3.54 - Removing and fitting t... - page 30-199
See para. 30.3.55 - Disassembly and assemb... - page 30-203
m Remove screws (1).
m Remove oil pickup pipe (2).
m Remove the gasket.
m Carry out a visual inspection of the components.

Fig. 868

30-198
Method of intervention
Refitting the oil pickup pipe
1. m Clean the mating surfaces.
m Fit a new gasket.
m Fit the oil pickup pipe.
m Fit the screws.
NOTE
Observe the installation position. Note that the
screws are of different lengths M8 x 25 mm (1).
M8 x 16 mm (2)

Fig. 869
2. m Tighten the screws (1): 21 Nm.
m Fit the oil sump pan.
See para. 30.3.54 - Removing and fitting t... - page 30-199
See para. 30.3.55 - Disassembly and assemb... - page 30-203

Fig. 870

30.3.54 - Removing and fitting the lubricant oil sump pan (cast iron lubricant oil sump)
l DEUTZ DW 74 sealant
NOTE
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
The draining and replenishing of engine fluids and lubricants must be carried out in accordance with the instructions
given in the documentation provided by the manufacturer of the vehicle/appliance.
Removal of the oil sump pan.
1. m Do not fully unscrew drain plug (1).
m Remove the seal.
m Drain, collect and dispose of used oil in accordance with the appli-
cable regulations.

© 46593-0

Fig. 871

30-199
 Method of intervention
2. m Remove screws (1).
m Remove the washer.
m Remove oil filler neck (2).
m Remove the gasket.

1
© 46592-0

Fig. 872
3. m Remove all the screws (1).
m Remove the sump pan. 1

© 46594-3

Fig. 873
4. m Carry out a visual inspection of the components.

© 44948-0

Fig. 874

30-200
Method of intervention
Refitting the oil sump pan.
1. m Clean the mating surfaces.
NOTE
The mating surfaces must be free of grease and dirt.

m Apply sealant evenly to the sealing surface.

NOTE
Apply the sealant in a bead approx. 3.5 mm thick.
The illustration shows only a detail of where the seal-
ant is to be applied.

© 43451-0

Fig. 875
2. m Fit the oil sump pan.
1
NOTE
Be careful not to dislodge the sealant when fitting the
oil sump pan.
2
m Fit the screws.
Screw length:
2
M8 x 130 mm (1). M8 x 110 mm (2).

1
© 46594-2

Fig. 876
3. m Screw in all the screws (1).
1
Screw length:
M8 x 35 mm

© 46594-3

Fig. 877

30-201
 Method of intervention
4. m Orient the oil sump pan on the crankcase.

© 44951-0

Fig. 878
5. m Tighten the screws in the sequence indicated.
20 18 12
NOTE 22
8
21 4
See figure for the correct tightening sequence: 30 19
1
5
Nm 9
13

11

7 15
3 17
2 14 16
6
10

© 45133-0

Fig. 879
6. m Clean the mating surfaces.
m Fit a new seal.
m Fit oil filler neck (1).
m Tighten screws (3).
m Fit the washer.
m Tighten screws (2).
m Tighten the screw (3): 30 Nm.
1
m Tighten the screw (2): 30 Nm.

3
© 46592-1

Fig. 880

30-202
Method of intervention
7. m Fit a new seal.
m Tighten the screw plug (1): 55 Nm (M18 x 1.5).
m Top up the engine oil following the instructions provided.

© 46593-0

Fig. 881

30.3.55 - Disassembly and assembly of the lubricant oil sump (lubricant oil sump-plate)
Commercially available tools:
l Wire brush
l Four M8 x 70 stud bolts
Special tools:
l Tool for truncation: 151500
l DEUTZ DW 74 sealant
WARNING
Make sure that no sealant residue enters the engine crankcase! Close all holes.

NOTE
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
The draining and replenishing of engine fluids and lubricants must be carried out in accordance with the instructions
given in the documentation provided by the manufacturer of the vehicle/appliance.
Removal of the oil sump pan.
1. m Do not fully unscrew drain plug (1).
m Remove the seal.
m Drain, collect and dispose of used oil in accordance with the appli-
cable regulations.

© 44480-0

Fig. 882

30-203
 Method of intervention
2. m Remove all the screws (1).

© 45971-0

Fig. 883
3. m Insert lever (1) up to shoulder (2).
WARNING
The lever may only be used on the engine crankcase. Do
not use it to apply leverage on aluminium castings. Do not 2

damage the mating surfaces.

© 45969-0

Fig. 884
4. m Insert the second lever (1) up to shoulder (2).
WARNING
The lever may only be used on the engine crankcase. Do
2
not use it to apply leverage on aluminium castings. Do not
damage the mating surfaces. 1

© 45970-0

Fig. 885

30-204
Method of intervention
5. m Prise the sump pan off the crankcase.
m Remove the sump pan.

© 45968-0

Fig. 886
6. m Carry out a visual inspection of the component.

© 43450-1

Fig. 887

Refitting the oil sump pan.

1. m Remove the old sealant using the lever.

© 45973-0

Fig. 888

30-205
 Method of intervention
2. WARNING
Wear eye protection.

m Clean the mating surfaces with a wire brush.

NOTE
The mating surfaces must be clean, dry and free of
grease or other contaminants.

© 45967-1

Fig. 889
3. WARNING
Wear eye protection.

m Clean the mating surfaces with a wire brush.

NOTE
The mating surfaces must be clean, dry and free of
grease or other contaminants.

© 45972-0

Fig. 890
4. m Apply an even bead of sealant to the mating surfaces and the ribs
of the oil sump pan.
NOTE
Apply the sealant in a bead approx. 3.5 mm thick.
The illustration shows only a detail of where the seal-
ant is to be applied.

© 43451-0

Fig. 891

30-206
Method of intervention
5. m To align the oil sump pan with crankcase, screw four stud bolts (1)
into the crankcase as shown. 1
m Line the oil sump pan up using the stud bolts as guides.
m Fit the oil sump pan.
WARNING
Allow the time specified for the sealant to set, taking care
not to move the lubricant oil sump pan.

m Unscrew the stud bolts.

© 45678-0

Fig. 892
6. m Screw in all the screws (1).
NOTE
Note that the screws are of different lengths

© 45971-0

Fig. 893
7. m Tighten the screws in the sequence indicated: 30 Nm.
NOTE
24 20 16 12 8 4 1 5 9 13 17 21 25 29
Representation: 6 cylinder tightening sequence

28 32
31 34
27 33

23 19 15 11 7 3 2 6 10 14 18 22 26 30

© 43414-0

Fig. 894

30-207
 Method of intervention
8. NOTE
Representation: 4 cylinder tightening sequence
20 16 12 8 4 1 5 9 13 17

24 21

26 25

23 22

19 15 11 7 3 2 6 10 14 18

© 43413-0

Fig. 895
9. m Fit a new seal.
m Tighten the screw plug (1): 55 Nm (M18x1.5).
m Top up the engine oil following the instructions provided.

© 44480-0

Fig. 896

30.3.56 - Removal and refitting of the oil cooler

l DEUTZ AP1908 assembly product
NOTE
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
The draining and replenishing of engine fluids and lubricants must be carried out in accordance with the instructions
given in the documentation provided by the manufacturer of the vehicle/appliance.
Removal of the oil cooler
1. m Remove the oil cooler housing.
See para. 30.3.57 - Disassembly and assemb... - page 30-211

Fig. 897

30-208
Method of intervention
2. m Remove the retainer plate (1).

Fig. 898
3. m Remove screws (1).
m Remove the seals.

1
1

© 46511-0

Fig. 899
4. m Remove oil cooler (2)
m Carry out a visual inspection of the components.

© 46512-0

Fig. 900

30-209
 Method of intervention
Refitting the oil cooler
1. m Clean the mating surfaces.
m Apply the assembly product on the O-rings.
m Fit new O-rings (1).
1 1

© 46513-0

Fig. 901
2. m Align the oil radiator.
NOTE
Use new seals.

m Insert the screws.

Fig. 902
3. m Tighten the screws in alternate sequence (1).
m Tighten the screws (1): 22 Nm.

Fig. 903

30-210
Method of intervention
4. m Fit the retainer plate (1).
m Assemble the oil radiator housing.
See para. 30.3.57 - Disassembly and assemb... - page 30-211

Fig. 904

30.3.57 - Disassembly and assembly of the oil radiator housing

Commercially available tools:
l Pliers for hose clips: 8011
Special tools:
l Plugs and caps: 170160
l DEUTZ AP1908 assembly product
NOTE
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.
The draining and replenishing of engine fluids and lubricants must be carried out in accordance with the instructions
given in the documentation provided by the manufacturer of the vehicle/appliance.
Disassembly of the oil radiator housing
1. m Disconnect the wiring connectors.

Fig. 905

30-211
 Method of intervention
2. m Do not fully unscrew drain plug (1).
m Empty, collect and dispose of the coolant in compliance with regula-
tions.

Fig. 906
3. m Loosen the hose clips (1).
m Remove the flexible hose (2).

© 46543-0

Fig. 907
4. m Unscrew banjo bolt (1)
m Remove the seals.
m Drain, collect and dispose of used oil in accordance with the appli-
cable regulations.
1

© 46517-0

Fig. 908

30-212
Method of intervention
5. m Remove screws (1).
m Remove fuel filter head (2).

© 46518-0

Fig. 909
6. m Remove screws (1).
m Remove oil radiator body (2). 1 1
m Remove the gasket.

1 2 1

© 46519-0

Fig. 910
7. m Carry out a visual inspection of the component.

© 46534-0

Fig. 911

30-213
 Method of intervention
Assembly of the oil radiator housing
1. m Clean the mating surfaces.
m Fit a new O-ring

© 46521-0

Fig. 912
2. m Fit the oil radiator housing.
m Fit the screws.
3 2
NOTE 1

Note that the screws are of different lengths M8 x 55

mm (1). M8 x 90 mm (2). M8 x 110 mm (3)

m Tighten the screws in alternate sequence: 30 Nm.

1
3 1 2

© 46519-1

Fig. 913
3. m Fit the fuel filter head.
m Fit the nut (1).
m Tighten screws (2).
2

© 46522-0

Fig. 914

30-214
Method of intervention
4. m Fit the nut (1).
m Tighten screws (2). 1
m Tighten the screws: 30 Nm.

© 46523-0

Fig. 915
5. m Tighten the hollow screw (1) with the new O-rings: 39 Nm.
WARNING
Route the flexible pipe without friction or tension points.
1

© 46517-0

Fig. 916
6. m Position the hose clips.
m Fit flexible pipe (1).
m Secure the hose clips with the special pliers.

© 46548-0

Fig. 917

30-215
 Method of intervention
7. m Position the hose clips.
m Fit flexible pipe (1).
m Secure the hose clips with the special pliers.

© 46549-0

Fig. 918
8. m Fit a new seal.
m Fit and tighten plug (1).
m Re-connect the wiring connectors
NOTE
Check that the connection is made correctly. Bleed
the fuel system as indicated in the instruction manu-
al, using the hand pump on the fuel pre-filter.

© 46550-0

Fig. 919

30.3.58 - Removal and refitting of the oil pressure switch

Special tools:
l Long socket wrench insert: 110700
l Plugs and caps: 170160
NOTE:
Maximum cleanliness is essential when working on the lubricating oil system.

NOTE:
Thoroughly clean the area around the components to be worked on. Dry any wet areas with a compressed air jet.

NOTE:
When handling lubricating oils, observe safety standards and all applicable local regulations.

NOTE:
All lines and unions should be closed immediately after opening using new, clean plugs or caps.

30-216
Method of intervention
NOTE:
Remove plugs and caps only immediately prior to assembly.

Removal of the oil pressure switch

1. m Unlock and disconnect wiring connectors (1).

Fig. 920
2. m Remove oil pressure switch (1).
NOTE:
Collect used oil and dispose of it in accordance with
the applicable regulations.
1
m Carry out a visual inspection of the components.

© 42866-0

Fig. 921

Fit the oil pressure switch

1. m Fit and tighten the oil pressure switch (1) with a new O-ring: 40 Nm

© 42866-0

Fig. 922

30-217
 Method of intervention
2. m Reconnect wiring connector (1).
NOTE:
Check that the connection is made correctly.

© 42865-1

Fig. 923

30.3.59 - Removal and refitting of the water pump

NOTE:
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.

NOTE:
The draining and replenishing of engine fluids and lubricants must be carried out in accordance with the instructions
given in the documentation provided by the manufacturer of the vehicle/appliance.

Removal of the water pump

1. m Disassemble the fan support.
See para. 30.3.63 - Removal and refitting ... - page 30-230
m Remove the fuel lift pump.
See para. 30.3.52 - Removal and refitting ... - page 30-196
m Remove screws (1).
NOTE:
Collect any leaked coolant and dispose of it in ac-
cordance with regulations.

Fig. 924

30-218
Method of intervention
2. m Carry out a visual inspection of the components.

Fig. 925

Refitting the water pump

1. m
NOTE
The sealing surfaces must be clean, dry and free of
grease or other contaminants.

m Clean the mating surfaces.

© 46577-0

Fig. 926
2. m Fit a new O-ring
m Fit water pump (1).
WARNING 1

Use new coated screws

m Fit the screws.

© 46575-1

Fig. 927

30-219
 Method of intervention
3. m Tighten the screws in the sequence indicated: 30 Nm.
Tightening sequence
n First tighten screw (1) followed by screw (2) and then the 2
remaining screws in any order.

© 46578-0

Fig. 928
4. m Fit the fuel lift pump.
See para. 30.3.52 - Removal and refitting ... - page 30-196
m Assemble the fan support.
See para. 30.3.63 - Removal and refitting ... - page 30-230

Fig. 929

30.3.60 - Testing the thermostat (after removal)

Commercially available tools:
l Thermometer
WARNING
Risk of injury! Hot water and hot thermostat.

Testing the thermostat

1. m Remove the thermostat.
See para. 30.3.61 - Removal and refitting ... - page 30-222
m Measure dimension (a), with thermostat closed.
m Make a note of dimension (a).

Fig. 930

30-220
Method of intervention
2. m Place the thermostat in water and heat the water.
NOTE:
To ensure an accurate reading, measure the temper-
ature as near to the thermostat as possible.

NOTE:
To ensure that the heat is evenly distributed, the wa-
ter should be in constant motion. The temperature
should not increased at a rate of more than 1°C/min.,
otherwise opening of the thermostat will be delayed.
m Determine the temperature at which the thermostat starts to open:
83 °C.
Fig. 931
3. m Measure dimension (b), with thermostat open.
m Make a note of dimension (b).

Fig. 932
4. m Calculate the stroke of the thermostat valve.
Table 95

Calculation example:
Target: Valve stroke
Data: -
Measured value: Stroke start, dimension (a)
Stroke end, dimension (b)
(b) - (a)
The results of all this are: = Valve stroke

m Compare this value with the nominal value.

n Nominal valve lift: minimum 8 mm
Fig. 933
m Fit the thermostat.
See para. 30.3.61 - Removal and refitting ... - page 30-222

30-221
 Method of intervention
30.3.61 - Removal and refitting of the thermostat
Special tools:
l DEUTZ AP1908
NOTE:
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.

NOTE:
The draining and replenishing of engine fluids and lubricants must be carried out in accordance with the instructions
given in the documentation provided by the manufacturer of the vehicle/appliance.

Removal of the thermostat

1. m Remove screws (1).
m z Remove outlet elbow (2).
1

2
1

© 46294-0

Fig. 934
2. m Remove the coolant thermostat (1).
m Carry out a visual inspection of the components.
1

© 46524-0

Fig. 935

30-222
Method of intervention
Refitting the thermostat
1. m Clean the mating surfaces.
m Use a new seal (1). 1
m Apply assembly product to the new seal.

© 44439-0

Fig. 936
2. m Fit the coolant thermostat.

© 46524-1

Fig. 937
3. m Fit the exhaust aperture (2).
m Tighten the screws (1): 30 Nm.
1

2
1

© 46294-0

Fig. 938

30-223
 Method of intervention
30.3.62 - Removal and assembly of the fan support
Commercially available tools:
l 2-arm extractor
l Internal extractor
l Extension for extractor tool
l Circlip pliers
l Press
Special tools:
l Screw: M10 x 40 mm
l Washer
Removal of the fan support
1. m Remove the fan mount
See para. 30.3.63 - Removal and refitting ... - page 30-230
m Remove screw (1).
m Keep the nut (2).

Fig. 939
2. m Tighten the screw (1) by a few turns.

Fig. 940
3. WARNING
Take care not to damage the components

m Remove the toothed belt pulley with the 2-arm extractor.

© 46527-0

Fig. 941

30-224
Method of intervention
4. m Fit the internal extractor (1).
m Open the internal extractor fully to the stop position.

© 46528-0

Fig. 942
5. m Fit the counterhead.

© 46529-0

Fig. 943
6. m Remove the ball bearings and the hollow shaft.

© 46530-0

Fig. 944

30-225
 Method of intervention
7. m Remove circlip (2).

© 46531-0

Fig. 945
8. m Fit the screws (1) and the washer (2).
NOTE:
Screw length: M10 x 40 mm (1)

© 46532-0

Fig. 946
9. m Turn the extension (1) on the screw (2).

© 46547-0

Fig. 947

30-226
Method of intervention
10. m Fit the counterhead.
m z Remove the ball bearings and nuts.

© 46533-0

Fig. 948
11. m z Push out the nuts.

© 46535-0

Fig. 949
12. m Extract the hollow shaft.
m z Visually inspect the components.

© 46536-0

Fig. 950

30-227
 Method of intervention
Completion of the fan drive
1. m Press-fit the hollow shaft into place.

© 46537-0

Fig. 951
2. m Press-fit the nuts.

© 46538-0

Fig. 952
3. NOTE:
The nuts (1) must face downwards.

m Fit the ball bearings.

1

© 46539-0

Fig. 953

30-228
Method of intervention
4. m z Press-fit the ball bearings into the outer ring.

© 46540-0

Fig. 954
5. m Fit circlip (2).
WARNING
Make sure the assembly position is correct.
2

© 46531-0

Fig. 955
6. m Press-fit the ball bearings into the outer ring.

Fig. 956

30-229
 Method of intervention
7. m Fit V-belt pulley (1).
m Screw in the screw (2).

Fig. 957
8. m Keep the nut (2).
m Tighten screw (1).
n Stage 1: 3 Nm
n Stage 2: 124 Nm

m Fit the fan drive.

See para. 30.3.63 - Removal and refitting ... - page 30-230

Fig. 958

30.3.63 - Removal and refitting of the fan support

Assembly product:
l DEUTZ AP1908
NOTE
The draining and replenishing of engine fluids and lubricants must be carried out in accordance with the instructions
given in the documentation provided by the manufacturer of the vehicle/appliance.

Disassembly of the fan support

1. m Remove screws (1).
m Disassemble the fan support.

1
1

© 46551-0

Fig. 959

30-230
Method of intervention
2. m Remove seal (1).
m Remove the connection fitting (2). 1
m Carry out a visual inspection of the components.

© 46552-1

Fig. 960

Assembly of the fan support

1. m Install a new seal (1).
m Apply assembly product to the new seal.

© 46553-0

Fig. 961
2. m Tighten the new O-rings (1).
m Apply the assembly product on the O-rings.

© 46554-1

Fig. 962

30-231
 Method of intervention
3. m Install the connection fitting (1).
1

© 46555-0

Fig. 963
4. m Fit the fan mount.
WARNING
Make sure the assembly position is correct. 1
1

NOTE:
Note that the screws are of different lengths 1

m Tighten screws (1).

m Tighten the screws (1): 60 Nm
© 46551-0

Fig. 964

30.3.64 - Removal and refitting of the flywheel

Commercially available tools:
l Rotation angle gauge: 8190
l Shop-made guide pin
Removal of the flywheel
1. m Remove the closing plugs (1).

© 31115-2

Fig. 965

30-232
Method of intervention
2. m Counterhold the flywheel using a suitable tool.
m Remove screws (1).
m Remove the flywheel.
m Visually inspect the components.
1

© 42825-1

Fig. 966

Refitting the flywheel

1. m Insert the shop-made guide pin
NOTE:
The holes in the flywheel must coincide with the
threaded hole in the V-belt pulley.

© 34224-2

Fig. 967
2. WARNING
The screws must be renewed after being removed.

m Tighten the screws in alternate sequence.

n M10 x 30: 30 Nm + 60° + 30°
n M10 x 35 - M10 x 85: 30 Nm + 60° + 60°

© 42826-0

Fig. 968

30-233
 Method of intervention
3. m Insert the plugs fully into the threaded holes (arrowed).

© 31115-1

Fig. 969

30.3.65 - Replacing the starter motor ring gear on the flywheel

DANGER
Risk of accident, do not touch hot components!

Disassembly of the starter ring gear

1. m Remove the flywheel.
See para. 30.3.64 - Removal and refitting ... - page 30-232
m Perforate the ring gear.
NOTE:
Counterhold the flywheel using a suitable tool.

Fig. 970
2. m Remove the starter ring gear with a suitable tool.

Fig. 971

30-234
Method of intervention
3. m Clean the flywheel.
m Visually inspect the flywheel.

Fig. 972

Assembly of the starter ring gear

1. m Heat the starter ring gear to 220 °C.
m Position the starter ring gear on the flywheel.
NOTE:
The starter ring gear must rest evenly on the flywheel
support flange.

Fig. 973
2. m Fit the flywheel.
See para. 30.3.64 - Removal and refitting ... - page 30-232

Fig. 974

30-235
 Method of intervention
30.4 - C0 - Engine accessories
30.4.1 - Starter motor
REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Remove nut (1), detach leads (2) from the starter motor (3) and remove
protection (4).

Fig. 975
3. Remove extension (5), detach cable (6) and remove protection (7).

Fig. 976
4. Remove screw and disconnect cable (8).

Fig. 977
5. Remove the three screws (9) and remove the starter motor (3).

Fig. 978

30-236
Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 4
l Screw: 1 to 1.3 Nm (0.74-0.96 lb.ft.)
Procedure 3
l Extension: 16 to 20 Nm (11.76-14.74 lb.ft.)
Procedure 2
l Nut: 16 to 20 Nm (11.76-14.74 lb.ft.)

30.4.2 - Removing and fitting the engine governor

l DEUTZ DW 73 sealant
Removing the engine governor
1. m Disconnect the wiring connectors.
m Unscrew banjo bolt (1)
m Remove the seals.

© 46487-0

Fig. 979
2. m Remove screws (1).
m Remove the engine governor.

1
© 46488-0

Fig. 980

30-237
 Method of intervention
3. m Clean the mating surfaces.
m Carry out a visual inspection of the component.

© 46489-0

Fig. 981

Fitting the engine governor

1. m Apply the sealant evenly on the sealing surfaces of the gear case.
NOTE
The mating surfaces must be clean, dry and free of
grease or other contaminants.

© 46348-1

Fig. 982
2. m Assemble the speed regulator.
m Fit the engine governor.
NOTE 1
If necessary, turn the governor ring gear (1) slightly to
facilitate meshing.

© 46347-1

Fig. 983

30-238
Method of intervention
3. m Tighten the screws in the sequence indicated: 17 Nm.
NOTE
If the governor is replaced with a spare part, the origi- 3 1
nal rod retraction value must be set.

5 2 4

© 46349-0

Fig. 984
4. m Tighten the hollow screw (1): 18 Nm.
NOTE
Use new seals.

m Reconnect the wiring connector

NOTE
Check that the connection is made correctly. 1

© 46487-0

Fig. 985

30.4.3 - Removal and refitting of the exhaust manifold

l DEUTZ S1 assembly product
Removal of the exhaust manifold
1. m Remove the turbocharger.
See para. 30.3.43 - Removal and refitting ... - page 30-155
m Unscrew nuts (1).
m Remove the spacer bushes.
m Remove exhaust manifold (2).

Fig. 986

30-239
 Method of intervention
2. m Remove the gaskets.
m Remove the stud bolts.

Fig. 987
3. m Carry out a visual inspection of the component.

© 46485-0

Fig. 988

Refitting the exhaust manifold

1. m Clean the mating surfaces.
m Apply DEUTZ S1 assembly product to the new stud bolts.
m Fit the new stud bolts.
m Fit the new gaskets.

© 46484-0

Fig. 989

30-240
Method of intervention
2. m Fit exhaust pipe (2).
m Install spacer bushes (1).
1

© 46486-0

Fig. 990
3. m Tighten new nuts (2).

Fig. 991
4. m Tighten all the nuts (1): 25 Nm.
NOTE
Tighten in order from inside out, starting from nut (1).

m Fit the turbocharger.

See para. 30.3.43 - Removal and refitting ... - page 30-155

Fig. 992

30-241
 Method of intervention
30.4.4 - Removal and refitting of the fuel filter head.
Special tools:
l Special wrench: 170050
l Plugs and caps: 170160
DANGER
After switching off the engine, wait at least 30 seconds before carrying out any work on the fuel system!

WARNING
During work on the fuel system always maintain conditions of the maximum cleanliness.
Thoroughly clean the area around the components to be worked on. Dry any wet areas with a compressed air jet.
When handling fuel observe the safety directives and specific local regulations.
All lines and unions should be closed immediately after opening using new, clean plugs or caps. Remove plugs and
caps only immediately prior to assembly. Collect operating materials in suitable containers and dispose of them in
compliance with the applicable regulations.
Removal of the fuel filter head.
1. m Unscrew hollow screws (1)
m Remove the seals.
NOTE
Collect any leaked fuel and dispose of it properly.

Fig. 993
2. m Remove screws (1).
m Remove fuel filter head (2).
1

© 46584-0

Fig. 994

30-242
Method of intervention
3. m Carry out a visual inspection of the component.

© 46585-0

Fig. 995

Refitting the fuel filter head.

1. m Fit the fuel filter head.
m Fit the nut (1).
m Tighten screws (2). 1 2

© 46586-0

Fig. 996
2. m Fit the nut (1).
m Tighten screws (2). 1
m Tighten the screws: 30 Nm.

© 46523-1

Fig. 997

30-243
 Method of intervention
3. m Tighten the hollow screw (1) with the new O-rings: 39 Nm.
m Tighten the hollow screw (2) with the new O-rings: 39 Nm.
WARNING 2

Route the flexible pipe without friction or tension points. 1

NOTE
Bleed the fuel system as indicated in the instruction manual,
using the hand pump on the fuel pre-filter.

© 46583-1

Fig. 998

30.4.5 - Assembly and disassembly of the temperature sender

NOTE:
Collect operating materials in suitable containers and dispose of them in compliance with the applicable regulations.

NOTE:
The draining and replenishing of engine fluids and lubricants must be carried out in accordance with the instructions
given in the documentation provided by the manufacturer of the vehicle/appliance.

Removal of the temperature sender

1. m Unlock and disconnect wiring connectors (1).

© 46353-1

Fig. 999
2. m z Unscrew the temperature sensor (1)

© 46374-0

Fig. 1000

30-244
Method of intervention
3. m Carry out a visual inspection of the component.

© 44084-0

Fig. 1001

Refitting the temperature sender

1. m Tighten the temperature sender (1): 24 Nm.
NOTE:
Check that the seal is present.
1

© 46374-0

Fig. 1002
2. m Reconnect wiring connector (1).
NOTE:
Check that the connection is made correctly.

© 46353-1

Fig. 1003

30-245
 Method of intervention
30.4.6 - Removal and refitting the engine block
Removing the engine block
1. m Remove the hollow connector from the engine block
m Remove screws (1).

© 46432-0

Fig. 1004
2. m Withdraw the engine block (1).
m Carry out a visual inspection of the components.
1

© 46434-0

Fig. 1005

Fitting the engine block

1. WARNING
Check the mobility of the adjustment rod.

m Operate the stop lever between the start and stop position.
m Fit a new O-ring (1).
m Lightly lubricate the O-ring.

© 46417-0

Fig. 1006

30-246
Method of intervention
2. m Press and hold down the adjustment rod in the stop position, using
the stop lever.
m Insert the engine block (1). 1

© 46434-0

Fig. 1007
3. m Tighten the screws (1): 21 Nm
m z Fit the hollow connector on the engine block.

© 46432-0

Fig. 1008

30.4.7 - Removal and refitting of the alternator (with drivebelt)

Commercially available tools:
l V-belt tension tester: 8115
WARNING
Only check/re-tension/change the V-belt while the engine is stationary.

NOTE:
After fitting a new V-belt, check the tension again after running the engine for 15 minutes.

30-247
 Method of intervention
Removal of the alternator
1. m Disconnect the leads from the negative terminal of the battery.
m Disconnect the alternator wiring.
Note the relative connection positions of the wiring!
n (1) = W terminal 1
n (2) = D+ terminal
n (3) = B+ terminal
2

© 46557-0

Fig. 1009
2. m Loosen the screws (1)

© 46375-0

Fig. 1010
3. m Remove the V-belt.
m Loosen screw (1). 2
m Unscrew screws (3) 3
m Remove alternator (2) 1
m Carry out a visual inspection of the components.

© 46558-0

Fig. 1011

30-248
Method of intervention
Refitting the alternator
1. m z Fit the alternator (3)
m Tighten screws (2).
n M8-10.9: 30 Nm

m Tighten screw (1). 1 2 3

n M8-10.9: 30 Nm

m Tighten banjo bolt (4).

n M8-10.9: 40 Nm

4
© 46558-1

Fig. 1012

Fitting the V-belt

1. m Fit the V-belt.
m Using a suitable tool, push bracket (1) in the direction of the arrow.

© 46375-1

Fig. 1013
2. m z Pre-tighten the screws (1).

© 46375-0

Fig. 1014

30-249
 Method of intervention
Check the V-belt tension using the specific tester
1. m Lower the indicator arm (1) of the belt tension gauge.

© 44591-0

Fig. 1015
2. m Apply the tension gauge to the V-belt.
NOTE:
The V-belt must be between the guides on the gauge
(arrowed).

© 46559-0

Fig. 1016
3. m Press the gauge against the V-belt by depressing button (1) until
you hear a click.
m Read off the value at the point where the indicator arm crosses the
numbered scale on the gauge (arrowed).
n After initial assembly: 650 Nm
n Check after 15 minutes of operation under load: 400 Nm
1
NOTE:
Note the two different units of measurement on the
scale.

m If the nominal value is not obtained, repeat the tensioning procedure.

© 46560-0

Fig. 1017

30-250
Method of intervention
4. m Tighten (1) the screws.
n M8-10.9: 30 Nm

© 46375-0

Fig. 1018
5. m Connect the wiring to the alternator terminals.
Note the relative connection positions of the wiring!
n (1) = W terminal
n (2) = D+ terminal 1
n (3) = B+ terminal

m Re-connect the lead to the negative terminal of the battery. 2

© 46557-0

Fig. 1019

30.4.8 - Disassembly and assembly of the starter

Disassembly of the starter
1. m Disconnect the leads from the negative terminal of the battery.
m Disconnect the wiring connectors.
m Remove screws (1). 1
m Remove the starter motor.
m Carry out a visual inspection of the components.

© 46556-0

Fig. 1020

30-251
 Method of intervention
Assembly of the starter
1. m Locate the starter motor.
m Tighten (1) the screws.
n M10x38-10.9: 60 Nm
1
n M8 nut: 40 Nm
n Stud bolt: 10 Nm

m Re-connect the wiring connectors

m Re-connect the lead to the negative terminal of the battery.

© 46556-0

Fig. 1021

30-252
Method of intervention
30.5 - D0 - Transmission
30.5.1 - Changing the transmission oil (D0.00.01) (R3 EVO 110 -> 1001)
WARNING
Accumulators contain gas or oil under pressure. For all repairs, first consult the instructions given in the manufac-
turer’s manual.

IMPORTANT:
Dispose of used oil and filters in compliance with applicable regulations. DO NOT dump oil on the ground, in sewers
or containers that are not sealed. Respect the environment.

IMPORTANT:
Change the filters at the same time as the oil.

Procedure for changing the transmission oil

1. Park the tractor on level ground.
2. Open the plug on top of the lift casing (see “Checking the transmission oil level”).
WARNING
Fuel or oil under pressure may penetrate the skin or eyes, causing serious injury, blindness or even death.
High-pressure fluid leaks may not be visible. Use a piece of cardboard or wood when looking for leaks. NEVER
use your hands. Wear safety goggles to protect your eyes. If any fluid penetrates your skin, seek immediate
attention from medical personnel with experience of this particular problem.
3. Remove the drain plug (1) located under the gearbox, placing a suitable
receptacle under the hole.
DANGER
Use caution when draining off spent: hot oil can cause se-
vere burns.

Fig. 1022
4. m Only for tractors equipped with hydraulic shuttle
Remove drain plug (2) located under the front end of the gearbox after plac-
ing a suitable receptacle under the hole.
DANGER
Use caution when draining off spent: hot oil can cause se-
vere burns.

Fig. 1023

30-253
 Method of intervention
5. For 100-110 hp tractors only
m

Remove the oil plug with dipstick (1).

WARNING
Never top up with oil of a different type (class or viscosity) to
that already present.

Fig. 1024
6. Change the oil filters located on the LH side of the gearbox casing.
7. Fit and tighten the drain plug (1), remove the plug (3) and fill the gearbox
with oil through the hole on top of the lift cover up to the level indicated by
the plug dipstick (4) or the round sight glass.

Fig. 1025
8. After filling, screw in the oil filler plug and run the engine for a few minutes.
9. Check the oil level via the plug dipstick (4) or the sight glass and top up if necessary.
The tractor is equipped with a gearbox oil cooler, for cleaning it see “Cleaning engine front compartment gearbox oil cooler”.

30.5.2 - Range selector assembly (R3 EVO 110 -> 1001)

REMOVAL
1. Remove screw (1) and disconnect range lever (2).

Fig. 1026
2. Remove screws (3) and remove the complete range gear selector assem-
bly (4).

Fig. 1027

30-254
Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 2
l Mating face: Silastic

Fig. 1028

30.5.3 - Disassembly of the range selector (R3 EVO 110 -> 1001)
Disassembly
1. Remove springs (1) and pins (2).

Fig. 1029
2. Remove screw (3).
m Renew the screw on reassembly.

Fig. 1030
3. Remove screws (4) and raise lever support assembly (5) and creeper
range control rod (6) and remove fork (7).

Fig. 1031

30-255
 Method of intervention
4. Remove high speed/low speed range control rod (8).
m Recover interlock pin (9).

Fig. 1032
5. Remove screw (10) and remove fork (11).
m Renew the screw on reassembly.

Fig. 1033
6. Remove rod (6) from lever support (5).

Fig. 1034
7. Remove O-rings (12).

Fig. 1035

30-256
Method of intervention
Assembly
To assemble, follow the disassembly steps in reverse order and carry out the following procedures:
Procedure 3
l Mating face: Silastic
Procedure 2
l Screw: 20 Nm (14.7 lb.ft.)

30.5.4 - Separation of housing from transmission (D0.02.01) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.8.11 - Air conditioning syste... - page 30-439 - (G0.09.01)
See para. 30.8.2 - Front hood and side pa... - page 30-428 - (G0.01.01)
See para. 30.8.5 - Fenders - page 30-431 - (G0.04.01)
See para. 30.8.4 - Cab access steps (R3 E... - page 30-431 - (G0.03.03)
See para. 30.8.1 - Cab (R3 EVO 110 -> 1001) - page 30-422 - (G0.03.01)
See para. 30.7.15 - 4WD shaft (R3 EVO 110 ... - page 30-411 - (F0.04.01)
See para. 30.9.8 - Bleeding the braking c... - page 30-483 - (E0.03.01)
Separation
1. Remove the four lower screws (1).

Fig. 1036
2. Position a trolley jack “A” under the housing and a stand “B” under the
transmission.
Force a stand “C” under the towing hitch to prevent the transmission top-
pling over.

Fig. 1037
3. Remove screws (2) and (3) and remove carrier assembly (4).

Fig. 1038

30-257
 Method of intervention
4. Loosen hose clamps (5) and move hose (6) downwards.

Fig. 1039
5. Remove screw (7).

Fig. 1040
6. Remove union (8) and disconnect pipe (9).

Fig. 1041
7. Loosen nut (10) and remove cover (11).

Fig. 1042
8. Remove screw (12) and remove extension (13).
IMPORTANT
Check the condition of the O-rings and renew them if neces-
sary

Fig. 1043

30-258
Method of intervention
9. Disconnect pipe (14) from resonator (15).
IMPORTANT
Plug the pipe and hole to prevent the ingress of dirt.

Fig. 1044
10. Loosen union (16), remove clamp (17) and disconnect pipe (18).

Fig. 1045
11. Remove nut (19) and screw (20).

Fig. 1046
12. For versions with front lift
Disconnect front lift control pipes (21).

Fig. 1047
13. Loosen unions (22).

Fig. 1048

30-259
 Method of intervention
14. Remove union (23).
IMPORTANT
Renew the copper washers on reassembly

Fig. 1049
15. Loosen the unions and disconnect brakes pipes (24) and differential lock
pipe (25).
IMPORTANT
Plug the pipes and ports to prevent the ingress of dirt.

Fig. 1050
16. Remove the remaining screws (26)

Fig. 1051
17. Separate clutch housing (27) from transmission (28) by pushing on both
front wheels.

Fig. 1052

30-260
Method of intervention
Reconnection
Reconnect the transmission and engine by reversing the separation operation and carry out the following procedures:
Procedures 11-16
l Nut: 78±4 Nm (57.5±3.0 lb.ft.)
l Fixing: 70±3 Nm (51.6±2.2 lb.ft.)

30.5.5 - Shuttle assembly - complete unit (D0.03.01) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.8.11 - Air conditioning syste... - page 30-439 - (G0.09.01)
See para. 30.8.2 - Front hood and side pa... - page 30-428 - (G0.01.01)
See para. 30.5.1 - Changing the transmiss... - page 30-253 - (D0.00.01)
See para. 30.7.15 - 4WD shaft (R3 EVO 110 ... - page 30-411 - (F0.04.01)
See para. 30.9.8 - Bleeding the braking c... - page 30-483 - (E0.03.01)
REMOVAL
1. DANGER
Drain off all the oil from the transmission.

2. Remove all the screws (1).

Fig. 1053
3. Use a slide hammer puller to detach the shuttle unit (2) from the housing
(3).

Fig. 1054
4. Screw in two service stud bolts “B” and remove shuttle unit (2).

Fig. 1055

30-261
 Method of intervention
5. Attach shuttle assembly (2) to a hoist and remove it from the tractor.
IMPORTANT
Check the condition of O-ring (4) and renew if distorted or
damaged.

Fig. 1056
6. Remove screws (5) and remove manifold (6).
IMPORTANT
Check the condition of O-rings (7) and renew them if neces-
sary.

Fig. 1057
7. Remove connection pipes (8)
IMPORTANT
Check the condition of O-rings (9) and renew them if neces-
sary.

Fig. 1058

30-262
Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following
procedures:
Procedure 4
l Apply a thin film of sealant around holes “A” .
m Mating face: Loctite 510
m O-ring: grease

Fig. 1059

30.5.6 - Disassembly of the shuttle unit (R3 EVO 110 -> 1001)
Disassembly
1. Place shuttle unit (1) on a suitable stand and remove the seven screws (2).
IMPORTANT
Mark flange (3) and the support to facilitate assembly opera-
tions.

Fig. 1060
2. Remove flange assembly (3).

Fig. 1061
3. Remove the ten screws (4).

Fig. 1062

30-263
 Method of intervention
4. Remove forward drive clutch assembly (5).

Fig. 1063
5. Recover springs (7) and pins (8) from reverse drive clutch assembly (6).

Fig. 1064
6. Remove O-rings (9).
IMPORTANT
Renew the O-rings on reassembly.

Fig. 1065

30-264
Method of intervention
Assembly
1. Locate springs (7) and pins (8) in clutch assembly (6).

Fig. 1066
2. Make sure that the last friction disc locates correctly on the hub.

Fig. 1067
3. Locate clutch assembly (5), making sure that springs (10) are positioned
in the holes and that locating dowel (11) is aligned with the corresponding
hole in clutch housing (7).

Fig. 1068
4. Tighten screws (4).
m Screws: 20 Nm (29.5 lb.ft.)
m Screws: Loctite 242
IMPORTANT
Tighten the screws in an alternate crosswise sequence.

Fig. 1068
5. Fit new O-rings (9).

Fig. 1068

30-265
 Method of intervention
6. Locate flange (3), taking care to align the marks made during disassembly
or align locating dowel (12).
IMPORTANT
Lubricate the lip of the oil seal with hydraulic oil.

Fig. 1068
7. Tighten screws (2).
m Screws: 40 Nm (29.5 lb.ft.)
m Screws: Loctite 242

Fig. 1069

30.5.7 - Disassembly of the cover unit (R3 EVO 110 -> 1001)
Disassembly
1. Remove seals (1).

Fig. 1070
2. Remove circlip (2) and remove oil seal (3).
IMPORTANT
Renew the oil seal on reassembly.

Fig. 1071

30-266
Method of intervention
3. Remove circlip (4) and, using a suitable puller or drift, remove roller cage
(5).

Fig. 1072

Assembly
To assemble, follow the disassembly steps in reverse order and carry out the following procedures:
Procedure 2
l Make sure that oil seal (3) is installed the right way round.

Fig. 1073

Procedure 1
l Seal rings: hydraulic oil

30-267
 Method of intervention
30.5.8 - Disassembly of the forward drive clutch assembly (R3 EVO 110 -> 1001)

Fig. 1074 - Forward drive clutch assembly

Disassembly
1. Remove the two screws (1) and remove disc (2).
IMPORTANT
Mark the hole in which pin (3) is inserted.

Fig. 1075

30-268
Method of intervention
2. Remove the clutch pack assembly, composed of six corrugated springs (4),
six friction discs (5), five steel discs (6) 3 mm thick and one steel disc (7)
6.5 mm thick.
IMPORTANT
Take care not to alter the assembly sequence of the friction
and steel discs.

Fig. 1076
3. Remove hub (8) and recover Belleville spring (9).

Fig. 1077
4. Blow compressed air at low pressure through the hole in the side of clutch
housing (10) to expel piston (11).
IMPORTANT
Restrain piston (11) as it could be expelled at high speed
and thus damaged.

Fig. 1078
5. Check the condition of O-rings (12) and (13) and renew them if necessary.

Fig. 1079
6. Only if necessary
Remove bearing (14) from hub (8).

Fig. 1080

30-269
 Method of intervention
Installation
1. Only if removed
Using a suitable drift, fit bearing (14) on hub (8).

Fig. 1080
2. Fit O-rings (12) and (13) in clutch housing (10).
IMPORTANT
To facilitate installation of O-ring (13), stretch it slightly at
various points all around the circumference so that it is held
in place in its seating.
m O-ring: hydraulic oil.

Fig. 1081
3. Fit piston (11) in clutch housing (10) and make sure it is properly seated.

Fig. 1082
4. Position Belleville spring (9) in the clutch housing.
IMPORTANT
Take care to install Belleville spring (9) the right way round.

Fig. 1083
5. Fit hub (8) and make sure bearing (14) is firmly seated in Belleville spring
(9).

Fig. 1084

30-270
Method of intervention
6. Fit first steel disc (7), friction disc (5) and corrugated spring (4).
IMPORTANT
Make sure that steel disc (7) is 6.5 mm thick.

m Friction disc ( hydraulic fluid)

Fig. 1085
7. Complete the clutch pack by fitting steel disc (6), friction disc (5) and cor-
rugated spring (4) in sequence.
m Friction discs: hydraulic oil

Fig. 1086
8. Fit disc (2) and secure it in position with screws (1).
IMPORTANT
Orient the disc so pin (3) can be inserted in the hole marked
during disassembly.

Fig. 1086

30-271
 Method of intervention
30.5.9 - Disassembly of the reverse drive clutch assembly (R3 EVO 110 -> 1001)

Fig. 1087 - Reverse drive clutch assembly

30-272
Method of intervention
Disassembly
1. Remove needle roller bearing (1).

Fig. 1088
2. Remove the clutch pack assembly, composed of six corrugated springs (2),
six friction discs (3), five steel discs (4) 3 mm thick and one steel disc (5)
6.5 mm thick.
IMPORTANT
Take care not to alter the assembly sequence of the friction
and plain steel discs.

Fig. 1089
3. Remove hub (6).

Fig. 1090
4. Only if necessary
Using three screws as a driving tool, remove bearing (7) from hub (6).

Fig. 1091
5. Blow compressed air at low pressure through hole “A” of support (8) to
expel piston (9).
IMPORTANT
Restrain piston (9) as it could be expelled at high speed and
thus damaged.

Fig. 1092

30-273
 Method of intervention
6. Check the condition of O-rings (10) and (11) and renew them if necessary.

Fig. 1093
7. Remove circlips (12) and (13).

Fig. 1094
8. Remove circlip (14).

Fig. 1095
9. Remove clutch housing (15) from support (8).

Fig. 1096
10. Remove bearing (16) from clutch housing (15).

Fig. 1097

30-274
Method of intervention
11. Remove rings (17) from support (8).

Fig. 1098

Installation
1. Fit rings (17) on support (8).
m Seal rings: Hydraulic oil

Fig. 1098
2. Insert bearing (16) in clutch housing (15).

Fig. 1098
3. Fit circlips (12) and (13).

Fig. 1098
4. Fit the clutch housing (15) on support (8) and secure it in position with
circlip (14).

Fig. 1099

30-275
 Method of intervention
5. Fit O-rings (10) and (11) in clutch housing (15).
IMPORTANT
To facilitate installation of O-ring (11), stretch it slightly at
various points all around the circumference so that it is held
in place in its seating.
m O-rings: hydraulic oil.

Fig. 1100
6. Fit piston (9) in clutch housing (15) and make sure it is properly seated.

Fig. 1101
7. Using a press and suitable drift, install bearing (7) on hub (6).
Fit hub (6) on clutch housing (15).

Fig. 1102
8. Fit first steel disc (5), friction disc (3) and corrugated spring (2).

Fig. 1103
9. Complete the clutch pack by fitting steel disc (4), friction disc (3) and cor-
rugated spring (2) in sequence.
m Friction discs: hydraulic oil.

Fig. 1104

30-276
Method of intervention
10. Position roller cage (1) on hub (6).

Fig. 1105

30.5.10 - Gearbox and Hi-Lo assembly (R3 EVO 110 -> 1001)
Removal
1. DANGER
Drain off all the oil from the transmission.

2. Remove screws (1) and remove gear lever (2).

Fig. 1106
3. Loosen unions (3) and (4) and remove the pipe (5).
IMPORTANT
Renew the copper washers on reassembly.

Fig. 1107
4. Attach the Hi-Lo unit (6) to a hoist and take up the slack in the lifting rope.

Fig. 1108

30-277
 Method of intervention
5. Remove the three screws (7) on the right-hand side, and screws (8) and the
four nuts (9) on the left-hand side.

Fig. 1109
6. Remove Hi-Lo unit (6) complete with the gearbox.

Fig. 1110

Refitting
Refit by following the removal steps in reverse order and carry out the following procedures:
Procedure 6
l For version with mechanical shuttle
m Mating faces: Loctite 518

Fig. 1111

Procedure 2
l Mating faces: Silastic 738
Procedure 1
l Fill the transmission with the required quantity of oil.
m Transmission oil: max 50 l (13.2 US. gall.)

30.5.11 - Disassembly of the Hi-Lo unit (D0.04.01) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.8.4 - Cab access steps (R3 E... - page 30-431 - (G0.03.03)
See para. 30.8.2 - Front hood and side pa... - page 30-428 - (G0.01.01)
See para. 30.8.1 - Cab (R3 EVO 110 -> 1001) - page 30-422 - (G0.03.01)
See para. 30.7.15 - 4WD shaft (R3 EVO 110 ... - page 30-411 - (F0.04.01)
See para. 30.5.1 - Changing the transmiss... - page 30-253 - (D0.00.01)
See para. 30.5.4 - Separation of housing ... - page 30-257 - (D0.02.01)
See para. 30.9.8 - Bleeding the braking c... - page 30-483 - (E0.03.01)
See para. 30.8.5 - Fenders - page 30-431 - (G0.04.01)

30-278
Method of intervention
Disassembly
1. DANGER
Drain off all the oil from the transmission.

2. Remove plug (1).

Fig. 1112
3. Loosen unions (2) and (3) and remove pipe (4).
IMPORTANT
Renew the copper washers on reassembly.

Fig. 1113
4. Remove screws (5) and remove cover (6).

Fig. 1114
5. Remove circlip (7).

Fig. 1115

30-279
 Method of intervention
6. Remove screws (8) and remove cover (9).

Fig. 1116
7. Remove the six screws (10) and remove the complete Hi gear clutch hous-
ing (11).

Fig. 1117
8. Remove spacer (12) and the first plain steel plate (13).
IMPORTANT
Note that this plate is 5 mm thick.

Fig. 1118
9. Remove the Lo range clutch pack, composed of three friction plates (14)
and three plain steel plates (15).

Fig. 1119
10. Remove circlip (16) and recover shims (17).

Fig. 1120

30-280
Method of intervention
11. Withdraw planet carrier assembly (18) complete with hub (19).

Fig. 1121
12. Remove bolts (20) and nuts (21).

Fig. 1122
13. Remove the Hi-Lo unit housing (22) and remove gasket (23).
IMPORTANT
Renew gasket (23) on reassembly.

Fig. 1123

30-281
 Method of intervention
Installation
To assemble, follow the disassembly steps in reverse order and use caution in relation to the following procedures:
IMPORTANT
If the Hi-Lo unit was removed in order to overhaul the clutches or the piston, refit the unit by following the removal
steps in reverse order. In all other cases, check the end float of the sun gears of the final drive unit. (For details, see
“Adjustment of the planetary reduction gear end float” in this chapter).
Procedure 11
l Before installing the complete planet carrier assembly (18), check that
planet gears are still correctly positioned relative to hub (19), i.e. that the
notches on one tooth of each planet pinion are all converging on the centre
when the hub is in position.

Fig. 1124

Procedure 9
l Install a steel plate (15) followed by a friction plate (14) to complete the
clutch pack.
m Friction plates: transmission oil.

Fig. 1124

l Install the first plain steel plate (13) (thickness 5.0 mm) and spacer (12).

Fig. 1124

Procedure 6
l Fit cover (9) and tighten screws (8).
m Mating face: Loctite 518

Fig. 1124

30-282
Method of intervention
Procedure 5
l Temporarily install cover (6) and secure in position with screws (5).
l Screw a service bolt (A) (M12x45) fully into the hole on the Lo range clutch
housing in order to gain access to the circlip groove.

Fig. 1125

Procedure 5
l Remove cover (6) and fit circlip (7).

Fig. 1125

Procedure 4
l Mating face: Loctite 518
Procedure 1
l Fill the transmission with the required quantity of oil.
m Transmission oil: approx. 50 l (13.2 US. gall.)

Adjustment of the planetary reduction gear end float

1. Fit hub (2) in gearbox (1) and secure in position with circlip (3).

Fig. 1126
2. With a feeler gauge “A”, measure the clearance “R” between hub (2) and
gear (4).

Fig. 1127

30-283
 Method of intervention
3. Calculate the thickness “S” of the shims to be installed between hub (2) and circlip (3) using the formula:
m S = R – F where:

n S = final shim thickness

n R = measured dimension
n F= fixed clearance (0.4±0.2 mm)

m Example:
n R = 1.30
n S = 1.30 – 0.4 = 0.90 mm

30.5.12 - Disassembly of the planet carrier (R3 EVO 110 -> 1001)

Fig. 1128 - Planet carrier

Disassembly
1. Remove hub (1) from the planet carrier.

Fig. 1129
2. Drive out pins (2) and recover balls (3).

Fig. 1130

30-284
Method of intervention
3. Withdraw planet pinions (4) and shims (5).

Fig. 1131
4. Dismantle planet pinions (4) and recover roller cages (6).

Fig. 1132

Installation
To assemble, follow the disassembly steps in reverse order and use caution in
relation to the following procedures:
Procedure 1
l Make sure that planet pinions (4) are correctly positioned relative to the hub
(1), i.e. that the notches present on one tooth of each planet pinion are all
converging on the centre when the hub is in position.

Fig. 1133

30-285
 Method of intervention
30.5.13 - Disassembly of the Hi range clutch housing (R3 EVO 110 -> 1001)

Fig. 1134 - Cross-section view of Hi range clutch housing

Disassembly
1. DANGER
The use of service tool T3 (code 5.9030.676.0) is essential for this procedure.

2. Locate and secure clutch housing (1) on tool T3 (code 5.9030.676.0).

IMPORTANT
If possible, align the slot in shaft (2) with the tab on the tool
T3 (code 5.9030.676.0).

Fig. 1135
3. Relieve the staking and remove nut (3) using special wrench T4 (code
5.9030.603.0).
IMPORTANT
Renew the nut on reassembly

Fig. 1136

30-286
Method of intervention
4. Remove bearing (4).

Fig. 1137
5. Remove shims (5) and spacer (6).
IMPORTANT
Note the dimension “A” of shims (5).

Fig. 1138
6. Remove Belleville springs (7).

Fig. 1139
7. Remove shims (8) and spacer (9).
IMPORTANT
Note the dimension “B” of shims (8).

IMPORTANT
Do not mix up shims (5) with shims (8) and make a note of
their respective positions relative to spacer (6).
Fig. 1140
8. Blow compressed air at low pressure through the upper hole of shaft (2)
and expel piston (10).
IMPORTANT
Restrain piston (10) as it could be expelled at high speed
and thus damaged.

Fig. 1141

30-287
 Method of intervention
9. Remove O-ring seal (11) from piston (10).

Fig. 1142
10. Remove the four friction discs (12) and four plain steel discs (13).

Fig. 1143
11. Remove spacer (14).

Fig. 1144
12. Remove clutch cylinder (15) from the service tool T3 (code 5.9030.676.0).

Fig. 1145
13. Remove O-ring (16).

Fig. 1146

30-288
Method of intervention
14. Remove the complete shaft (2) from clutch cylinder (15) and remove spring
(17).

Fig. 1147
15. Remove O-ring seal (18) and remove lock ring (19).

Fig. 1148
16. Withdraw Lo range piston (20) from clutch cylinder (15).

Fig. 1149
17. Remove O-ring seal (21) from piston (20).

Fig. 1150
18. Make sure that check valve (22) functions correctly and that hole (F) is not
blocked by impurities.

Fig. 1151

30-289
 Method of intervention
Installation
1. Fit O-ring (21) on Lo range piston (20).
m O-ring: transmission oil

Fig. 1151
2. Install piston (20) in clutch cylinder (15) and ensure it is fully seated.

Fig. 1152
3. Install lock ring (19) and O-ring (18) on shaft (2).
m O-ring: transmission oil

Fig. 1153
4. Fit O-ring (16) on clutch cylinder (15).
m O-ring: transmission oil

Fig. 1154
5. Fit spring (17) on shaft (2) and position it on service tool T3 (code
5.9030.676.0) making sure that the tab locates in the slot on the shaft.

Fig. 1155

30-290
Method of intervention
6. Locate clutch cylinder (15) on shaft (2) and secure it to service tool T3
(5.9030.676.0), tightening the screws to seat it.

Fig. 1156
7. Fit spacer (14).

Fig. 1157
8. Assemble the Hi range clutch pack, inserting a friction plate (12) and a plain
steel plate (13). Complete the clutch pack with a friction plate (12).

Fig. 1157
9. Install O-ring (11) on the Hi range piston (10).
m O-ring: transmission oil

Fig. 1157
10. Install complete piston assembly (10) in the clutch housing.

Fig. 1158

30-291
 Method of intervention
11. Fit spacer (9) and shim pack (8) with thickness “A” measured during disas-
sembly or calculated during the Belleville spring preload adjustment pro-
cedure.

Fig. 1158
12. DANGER
If the Belleville springs have been renewed, adjust the spring preload (For details, see “Spring preload adjust-
ment”).

DANGER
If shim packs (5) and (8) have got mixed up and you have not made a note of the dimensions “A” and “B”, fit a
new spring pack and carry out the spring preload adjustment procedure (for details, see “Spring preload adjust-
ment”) and then proceed with the assembly.
13. Fit the Belleville springs (7).
IMPORTANT
Take care to install the Belleville springs the right way round
(7).

Fig. 1159
14. Fit spacer (6) and shim pack (5) with thickness “B” measured during disas-
sembly or calculated during the spring preload adjustment procedure.

Fig. 1159
15. Fit bearing (4) taking care that the groove for the circlip is facing upwards.
IMPORTANT
Using the cover of the Hi-Lo unit, carefully align the tabs of
the plain steel plates (13).

IMPORTANT
If a new bearing is fitted, remove the circlip, which will be
installed at a later stage.
Fig. 1159

30-292
Method of intervention
16. Fit nut (3) and tighten with the special wrench T5 (code 5.9030.503.0).
m Nut: 147 Nm
IMPORTANT
Check that the Belleville springs (7) remain correctly aligned.

Fig. 1160
17. Stake nut (3).

Fig. 1161

Spring preload adjustment

1. DANGER
The adjustment procedure mist be carried out whenever the Belleville springs are renewed or if shim packs (5)
and (8) have got mixed up and the technician has not made a note of dimensions “A” and “B”.
2. Measure and make a note of the dimension “D” of spacer (1).
m Example: D = 21.50

Fig. 1162
3. Form a shim pack (2) of thickness “S”, which, when added to the dimension
“D” of spacer (1), obtains a thickness equal to the fixed dimension “F” of
25.25 mm.
m Example:
n D = 21.50
n F = 25.25
n S = F – D = 25.25 – 21.50 = 3.75

m Form a shim pack of:

n four spacers at 0.50 = 2.00
n five spacers at 0.20 = 1.00 Fig. 1163
n five spacers at 0.15 = 0.75

30-293
 Method of intervention
4. IMPORTANT
After forming the shim pack (2), check that the total thick-
ness of spacer (1) and the shim pack is equal to the fixed
dimension “F”.

Fig. 1164
5. Locate spacer (3) and fit spacer (1) in clutch housing (4).

Fig. 1165
6. While pressing on piston (10), measure dimensions “C” and “L” and deter-
mine the dimension “M” using the formula: M = C – L

Fig. 1166
7. m Example:
n C =20.32
n L = 3.52
n M = 20.32 – 3.52 = 16.80

Fig. 1167
8. Calculate the thickness “A” of the shim pack (5) to be installed under spacer
(1) using the formula: A = 17.70– M where dimension 17.70 is a fixed value.
m Example:
n A = 17.70 – 16.80 = 0.90

Form shim pack (5) of thickness “A” using only those shims used previously
to form shim pack (2).

Fig. 1168

30-294
Method of intervention
9. Install the shim pack (5) and the spacer (1) and check, as described in point
5, that the new dimension C is between 17.65 and 17.75 mm.
IMPORTANT
If dimension C is outside the specified range of values, ad-
just shim pack (5) to obtain an acceptable value.

IMPORTANT
If dimension C is within the specified range, first remove
spacer (1) and then proceed with assembly of the clutch Fig. 1169
housing starting from point (12).
The remaining shims are those that have to be installed above spacer (1).

30.5.14 - Hi-Lo unit output shaft disassembly procedure (R3 EVO 110 -> 1001)

Fig. 1170 - Hi-Lo unit output shaft

Disassembly
1. Remove roller bearing races (1) and spacer (2).

Fig. 1171
2. Remove circlip (3) and remove the thrust washer of bearing (4).

Fig. 1172

30-295
 Method of intervention
3. Using a suitable tool, remove bearing inner ring (4).

Fig. 1173
4. Only if necessary
Remove circlip (6) and roller bearing race (7) from Hi-Lo output shaft (5).

Fig. 1174

Installation
Refitting is the reverse of removal.
30.5.15 - Disassembly of the gearbox input shaft (R3 EVO 110 -> 1001)

Fig. 1175 - Gearbox input shaft

30-296
Method of intervention
Disassembly
1. Remove screws (1) and remove the complete shaft assembly (2).

Fig. 1176
2. Remove circlip (3) and recover spacer (4).

Fig. 1177
3. Withdraw shaft (5) complete with roller bearing (6).

Fig. 1178
4. Remove bearing (7).

Fig. 1179
5. Remove circlip (8) and recover spacer (9).

Fig. 1180

30-297
 Method of intervention
6. Using a press and suitable tool, remove bearing (10) and flange (11) from
shaft (2).

Fig. 1181

Assembly
To assemble, follow the disassembly steps in reverse order and carry out the following procedures:
Procedure 6
l Note which way round flange (11) and bearing (10) are installed relative to
shaft (2).

Fig. 1182

Procedure 3
l Fit bearing (7).

Fig. 1182

l Hold bearing (7) in place with service washers and install bearing (6) on
shaft (5).

Fig. 1183

30-298
Method of intervention
l Using a suitable drift, insert shaft (5) sufficiently to install spacer (4) and
circlip (3).

Fig. 1184

30.5.16 - Torsional spring plate (R3 EVO 110 -> 1001)

Removal
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Remove screws (1).

Fig. 1185
3. Remove torsional spring plate (2).

Fig. 1186

Refitting
Refitting is the reverse of removal.

30-299
 Method of intervention
30.5.17 - Disassembly of the primary shaft - Version with Hi-Lo (R3 EVO 110 -> 1001)

Fig. 1187 - Gearbox assembly - version with Hi-Lo

Disassembly
1. Remove circlip (1) and remove gear (2).

Fig. 1188
2. Using a press, remove bearing (3) and recover circlip (4).

Fig. 1189
3. Remove circlip (5) and remove spacer (6).

Fig. 1190

30-300
Method of intervention
4. Using the puller, remove the bearing (7).

Fig. 1191

Installation
Refitting is the reverse of removal.
30.5.18 - Secondary shaft - Version with Hi-Lo (R3 EVO 110 -> 1001)
REMOVAL
1. Withdraw secondary shaft (1), Hi-Lo output shaft (2) and recover needle
roller bearings (3) and spacer (4).

Fig. 1192
2. Remove circlip (5) and remove gear (6).

Fig. 1193
3. Remove bearing (7).

Fig. 1194

30-301
 Method of intervention
4. Remove disc (8).

Fig. 1195
5. Remove screw (9) and remove 1st speed selector fork (10) and synchro-
nizer assembly (11).
IMPORTANT
Renew screw (9) on reassembly.

IMPORTANT
Note the position of the synchronizer .
Fig. 1196

6. Remove the driven gear (12) of the 1st gear, remove the circlip (13) and
thrust washer(14).
IMPORTANT
Note which way round thrust washer (14) is installed.

Fig. 1197
7. Remove lower plugs (15) and recover springs (16) and (17) and balls (18).
IMPORTANT
Renew the copper washers on reassembly.

Fig. 1198
8. Remove screws (19).

Fig. 1199

30-302
Method of intervention
9. Withdraw selector rod (20) and recover 2nd-3rd speed selector fork (21).

Fig. 1200
10. Withdraw 1st speed selector rod (22).

Fig. 1201
11. Withdraw rod (23) and recover 4th-5th speed selector fork (24).

Fig. 1202
12. Recover spring (25), ball (26) and detents (27) from the gearbox support.

Fig. 1203
13. Remove screws (28) and remove disc (29).

Fig. 1204

30-303
 Method of intervention
14. Remove circlip (30) and recover spacer (31).

Fig. 1205
15. Remove bearing (32) and thrust washer (33).

Fig. 1206
16. Remove the complete secondary shaft assembly (34).

Fig. 1207

30-304
Method of intervention
Installation
To assemble, follow the disassembly steps in reverse order and use caution in relation to the following procedures:
Procedure 7
l Plugs: Loctite 542
Procedure 5
l Fixing: 25 Nm (18.4 lb.ft.)
l Fixing: Loctite 270

30.5.19 - Disassembly of the secondary shaft - Version with Hi-Lo (R3 EVO 110 -> 1001)

Fig. 1208 - Secondary shaft

Key
l To: 2nd gear
l B: 3rd gear
l C: 4th gear
l D: 5th gear

30-305
 Method of intervention
Disassembly
1. Remove circlip (1) and 2nd speed gear (2).

Fig. 1209
2. Remove needle roller bearing (3) and synchonizer ring (4).

Fig. 1210
3. Remove circlip (5) securing synchonizer ring (6).
IMPORTANT
Renew the circlip on reassembly.

Remove synchronizer (6) complete with the second synchonizer ring.

IMPORTANT
Note which way round the synchonizer selector is installed.
Fig. 1211

4. Remove circlip (7) and 3rd speed gear (8).

IMPORTANT
Renew the circlip on reassembly.

Fig. 1212
5. Remove spacer (9) and circlip (10).
IMPORTANT
Note the orientation of the lubrication points.

Fig. 1213

30-306
Method of intervention
6. Remove spacer (11) and remove 4th speed gear (12).
IMPORTANT
Note the orientation of the lubrication points.

Fig. 1214
7. Remove synchonizer ring (13) and remove circlip (14).
IMPORTANT
Renew the circlip on reassembly.

Fig. 1215
8. Remove synchronizer (15) complete with the second synchonizer ring.
IMPORTANT
Note which way round the synchonizer selector is installed.

Remove 5th speed gear (16).

Fig. 1216
9. Remove circlip (17).
IMPORTANT
Renew the circlip on reassembly.

Fig. 1217
10. Only if necessary
Remove circlip (18) and roller bearing race (19).

Fig. 1218

30-307
 Method of intervention
Installation
To assemble, follow the disassembly steps in reverse order and use caution in relation to the following procedures:
Procedure 8
l Take care to install synchronizer (15) the right way round.

Fig. 1219

Procedure 5
l Take care to install thrust washers (9) and (11) the right way round.

Fig. 1220

Procedure 3
l Take care to install synchronizer (6) the right way round.

Fig. 1221

30.5.20 - Range gearbox and differential assembly - complete assembly (R3 EVO 110 ->
1001)
Removal
After having performed the pre-disassembly operations, the assembly will be already disconnected from the tractor.
Refitting
Refitting is the reverse of removal.
30.5.21 - Complete gearbox assembly - Version with Hi-Lo (D0.09.04) (R3 EVO 110 ->
1001)
Previous operations:
See para. 30.8.4 - Cab access steps (R3 E... - page 30-431 - (G0.03.03)
See para. 30.8.2 - Front hood and side pa... - page 30-428 - (G0.01.01)
See para. 30.8.1 - Cab (R3 EVO 110 -> 1001) - page 30-422 - (G0.03.01)
See para. 30.7.15 - 4WD shaft (R3 EVO 110 ... - page 30-411 - (F0.04.01)
See para. 30.5.1 - Changing the transmiss... - page 30-253 - (D0.00.01)
See para. 30.5.4 - Separation of housing ... - page 30-257 - (D0.02.01)
See para. 30.5.11 - Disassembly of the Hi-... - page 30-278 - (D0.04.01)
See para. 30.9.8 - Bleeding the braking c... - page 30-483 - (E0.03.01)

30-308
Method of intervention
REMOVAL
1. Detach connector (1) remove screws (2) and remove gear shift lever (3).

Fig. 1222
2. Remove hose (4) and remove screws (5).

Fig. 1223
3. Remove the complete gearbox assembly (6).

Fig. 1224

Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 3
l Mating face: Silastic 738

Fig. 1225

Procedure 1
l Mating faces: Silastic 738
l Fill the transmission with the required quantity of oil.
m Transmission oil: max 50 l (13.2 US. gall.)

30-309
 Method of intervention
30.5.22 - Adjustment of the differential - Bevel gear pair (R3 EVO 110 -> 1001)

Fig. 1226 - Differential - Bevel gear pair

Preparations for adjustments
1. m All the procedures described in this chapter must be carried out following renewal of the transmission casing, differen-
tial support flanges, bevel gear pair, differential housing or the support bearings of the pinion and differential.

30-310
Method of intervention
2. Install bearing assembly (2) on pinion shaft (1).
IMPORTANT
When handling bearing (2), take care not to invert the inner
races.

IMPORTANT
During assembly of bearing (2) on pinion shaft (1), rotate the
outer race to help seat the rollers.
Fig. 1227

IMPORTANT
Bearing: transmission oil

3. Install a service bush “A” (Ø 65 x Ø 50 x 20) on pinion shaft (1) and provi-
sionally tighten nut (3)

Fig. 1228
4. Remove the outer race of bearing (5) and relative shims (6) from flange (4)
on the crown wheel side.
IMPORTANT
Note the thickness “S” of shim pack (6) (e.g., 0.80 mm).

Fig. 1229
5. Remove the outer race of bearing (8) and shims (9) from flange (7) on the
opposite side to the crown wheel.

Fig. 1230

30-311
 Method of intervention
6. Heat bearing inner race (5) to 80 °C and install it on the crown wheel side
of differential (10).
IMPORTANT
Check that the bearing seats against the shoulder on the
differential.

Install the outer race of bearing (5) in crown wheel side flange (4), with shim
pack (6) approximately 0.5 mm less than the measured dimension “S”.
m Example: Fig. 1231
m Measured dimension = 0.80 mm
Thickness of shim pack (6) to be installed: 0.30 mm
7. Heat the inner race of bearing (8) to approx. 80 °C and install on differential
(10) on the side opposite to the crown wheel.
IMPORTANT
Check that bearing (8) seats against the shoulder on the
differential.

Install the outer race of bearing (8) and a 1.00 mm thick shim pack (9) on
flange (7) on the opposite side to the crown wheel.

Fig. 1232

Adjustment of the differential bearings preload

1. Locate complete differential (10) in the transmission casing.

Fig. 1233
2. Install the flanges (4) and (7) and secure in position with screws (11).
m While tightening screws (11), rotate the differential unit to help seat
the bearings.
Bearings: transmission oil
Screws: 32-40 Nm (23.6-29.5 lb.ft.)

Fig. 1234

30-312
Method of intervention
3. Position a dial gauge with magnetic stand “A” on the crown wheel side of
differential carrier (4) and set it to zero on the end face of the differential
while simultaneously forcing the differential with lever “B” towards the op-
posite side.
Force the differential towards the crown wheel side and measure end float
“G”.
IMPORTANT
If the end float is zero, adjust shim pack (9) on the opposite
side to the crown wheel to 0.70 mm and repeat the proce-
Fig. 1235
dure to measure end float “G”.
4. Add 0.10 mm to the measured end float value “G” and round up to the nearest 0.05 mm to determine the shim thickness to be
added under the outer ring of bearing (8) on the opposite side to the crown wheel.
Example:
m Measured value: 0.28 mm

Nominal value: 0.28 + 0.10 = 0.38 mm

Actual shim thickness to be added: 0.40 mm
5. Remove screws (11) on both sides, leaving just one in position for safety.

Fig. 1235
6. Using a suitable drift made of soft material, separate differential flanges (4)
and (7) from the transmission casing.

Fig. 1236
7. Remove last screw (11) and remove flanges (4) and (7).

Fig. 1237

30-313
 Method of intervention
8. Attach differential (10) to a hoist and remove it.

Fig. 1237

Adjustment of the pinion position

1. Make a note of the value “E” stamped on one of the teeth of pinion (1).
m In this example: + 0.15 mm

Fig. 1238
2. Install pinion (1) without shims (12) in the transmission casing.

Fig. 1239
3. Locate complete differential (10) in the transmission casing

Fig. 1239
4. Install the flanges (4) and (7) and secure in position with screws (11).
m Screws: 32-40 Nm (23.6-29.5 lb.ft.)
While tightening screws (11), check for the presence of clearance
between the differential and pinion (1). If the differential is seated
against the pinion, adjust the shim packs installed under the outer
races of the bearings so as to reduce the thickness of the pack on
the crown wheel side and increase the thickness of the pack on the
opposite side by the same amount.

Fig. 1239

30-314
Method of intervention
5. Use a feeler gauge to measure the distance “D” between the end face of
pinion (1) and the Ø 174 section of differential (10) (in this example 4.85).
Calculate dimension “R” by adding dimension “E” previously read on the
tooth of pinion (1) to the design value of 4.00 mm.
If the value “E” is positive, as in the case reported in the figure, it should
be added to the design value of 4.00 mm:
m R= 4.00 + “E” i.e. R= 4.00 + 0.15 = 4.15
If “E” is negative, subtract it from the design value of 4.00 mm
m R= 4.00 - “E” i.e. R= 4.00 - 0.15 = 3.85
Fig. 1240
If the measured value “D” differs from the calculated value “R”, calculate the
difference between “D” and “R”. The resulting value “S” is the shim thick-
ness to be installed under bearing (2) of pinion (1).
Formula: S = D - R
m which in our example gives: S = 4.85 - 4.15 = 0.70 mm
6. Remove screws (11) on both sides, leaving just one in position for safety.

Fig. 1240
7. Using a suitable drift made of soft material, separate differential flanges (4)
and (7) from the transmission casing.

Fig. 1240
8. Remove last screw (11) and remove flanges (4) and (7).

Fig. 1240

30-315
 Method of intervention
9. Attach differential (10) to a hoist and remove it.

Fig. 1240
10. Using a puller, remove pinion (1) complete with the transmission casing.
Remove nut (3) and service spacer “A” from pinion shaft (1).

Fig. 1241
11. Measure dimension “R” of the shoulder of bearing (2).
Example:
m “R” = 4.96 mm
Install pinion (1) and shim pack (12) of the previously calculated thickness
“S”, reversing the removal procedure.

Fig. 1242
12. Secure pinion (1) in position with suitable circlip (13) selected from the
available sizes.
Select circlip (13) by applying the following formula:
Circlip thickness:
mFixed dimension “K” = 9.5 mm
Shim thickness = “S”
Dimension “R” = 4.96 mm (valid measurements: 4.90-5.00mm)
Formula:
m A = K - S - R which in our example gives:
m A = 9.5 - 0.7 - 4.96 = 3.84 mm Fig. 1243

The circlip to be used is therefore the one with thickness 3.80 mm.

Circlip (13) installed should in any case ensure pinion end

float of less than 0.1 mm.

30-316
Method of intervention
Adjustment of pinion and crown wheel backlash
1. Locate complete differential (10) in the transmission casing.

Fig. 1243
2. Install the flanges (4) and (7) and secure in position with screws (11).
m While tightening screws (11), rotate differential assembly (10) to
help seat the bearings.
Bearings: transmission oil
Screws: 32-40 Nm (23.6-29.5 lb.ft.)

Fig. 1243
3. Position a dial gauge “A” on a magnetic stand with the contact point perpen-
dicular to the side of a tooth on the external diameter of the crown wheel.
Preload the gauge by approx. 3 mm and check the backlash “Z” between
pinion and crown wheel while turning differential (3) in both directions.
m Normal backlash: 0.20-0.28 mm
m Take four measurements 90° apart and calculate the average.

Fig. 1244
4. If backlash “Z” is less than the minimum value, remove a shim from shim
pack (6) (crown wheel side) and add the same shim to shim pack (9) (side
opposite to crown wheel). If backlash “Z” is greater than the maximum val-
ue add a shim to (shim pack (6) (crown wheel side) and remove an identical
shim from shim pack (9) (opposite side to crown wheel).
IMPORTANT
The sum total thickness of shim packs (6) and (9) should not
be different from the calculated value.

Fig. 1245
Recheck backlash “Z” and, if necessary, continue to adjust the shims until
the backlash is within the specified tolerance limits.

30.5.23 - Disassembly of the rear pinion (D0.11.01) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.8.4 - Cab access steps (R3 E... - page 30-431 - (G0.03.03)
See para. 30.8.2 - Front hood and side pa... - page 30-428 - (G0.01.01)
See para. 30.8.1 - Cab (R3 EVO 110 -> 1001) - page 30-422 - (G0.03.01)
See para. 30.5.1 - Changing the transmiss... - page 30-253 - (D0.00.01)
See para. 30.7.15 - 4WD shaft (R3 EVO 110 ... - page 30-411 - (F0.04.01)
See para. 30.13.1 - Lift - Complete assemb... - page 30-526 - (R0.02.03)
See para. 30.15.1 - Towing hitch slide (R3... - page 30-548 - (V0.02.01)
See para. 30.5.29 - PTO output shaft - 4 s... - page 30-336 - (D0.14.01)
See para. 30.6.1 - Right-hand rear axle (... - page 30-350 - (E0.02.01)

30-317
 Method of intervention
See para. 30.6.3 - Left-hand rear axle (R... - page 30-356 - (E0.02.02)
See para. 30.6.5 - Rear differential (R3 ... - page 30-358 - (E0.02.07)
See para. 30.5.4 - Separation of housing ... - page 30-257 - (D0.02.01)
See para. 30.5.21 - Complete gearbox assem... - page 30-308 - (D0.09.04)
See para. 30.9.8 - Bleeding the braking c... - page 30-483 - (E0.03.01)

Fig. 1246 - Rear pinion

Disassembly
1. Loosen union (1) and remove lubrication pipe (2).

Fig. 1247
2. Remove circlips (3) and (4).

Fig. 1248

30-318
Method of intervention
3. Versions with 3 range gears
Using a puller, partially withdraw the pinion shaft (5) in order to gain access
to the nut (6).

Fig. 1249
4. Apply service wrench T (cod. 5.9030.984.0) to the nut and secure in posi-
tion.
Fit a suitable bush on Syncro PTO shaft (7) and loosen nut (6) by turning
the output shaft clockwise.
IMPORTANT
If possible, relieve the staking on nut (6).

Fig. 1250
5. For versions with Syncro PTO
Remove cover (8), fit service tool T11 (code 5.9030.988.0) and loosen nut
(6) by turning it in a clockwise direction.
IMPORTANT
If possible, relieve the staking on nut (6).

Fig. 1251
6. Proceed with removal of pinion (5), removing sleeve (9) and selector (10).

Fig. 1252
7. Remove gear (11) and rotary union (12).

Fig. 1253

30-319
 Method of intervention
8. Remove low or high range selector fork (13).

Fig. 1254
9. Remove nut (6) and gear (14).

Fig. 1255
10. Install a service bush “A” on the pinion shaft (example: Ø65 x Ø50 x 20)
and nut (6).

Fig. 1256
11. Using a puller, remove pinion shaft (5) complete with bearing (15) and
shims (16).

Fig. 1257
12. Only if necessary
Using a press and a suitable puller, remove bearing (15) from pinion shaft
(5).

Fig. 1258

30-320
Method of intervention
Installation
To assemble, follow the disassembly steps in reverse order and carry out the following procedures:
Procedure 11
l Before fitting bearing (15) on pinion shaft (5), lubricate the inner races of
the bearing.
m Bearing: transmission oil

l During assembly of bearing (15), rotate the outer race to bed in the rollers
and ensure smooth rotation.

Fig. 1259

Procedure 5
l Stake nut (6).

Fig. 1260

Procedure 4
l Renew nut (6) on reassembly.
l Tighten the nut by turning the Syncro PTO output shaft counter-clockwise
and using service wrench T (code 5.9030.984.0).
m Nut: Loctite 270
m Nut: Nominal tightening torque: 460±20Nm (339±14.7 lb.ft.)
m Tightening torque using the Syncro PTO output shaft 390±17Nm

287.4±12.5 lb.ft).

Fig. 1261

l If the bevel gear pair, the bearings of the pinion or differential or the transmission casing are renewed, adjust the bevel gear
pair.

30-321
 Method of intervention
30.5.24 - Disassembly of the 4WD output shaft (R3 EVO 110 -> 1001)

Fig. 1262 - 4WD output shaft

Disassembly
1. Remove snap ring (1).

Fig. 1263
2. Remove pin (2) and remove range selector fork (3).
IMPORTANT
Renew the copper washers on reassembly.

Fig. 1264

30-322
Method of intervention
3. Remove circlip (4) and remove spacer (5).

Fig. 1265
4. Remove retaining half rings (6).

Fig. 1266
5. Using a soft metal punch, partially drive out shaft (7) and remove gear (8).

Fig. 1267
6. Continue to withdraw the shaft and remove gear (9) complete with bush
(10) and selector sleeve (11) complete with hub (12).

Fig. 1268
7. For all versions:
Remove gear (13), roller bearing races (14) with bushes and spacer (15).

Fig. 1269

30-323
 Method of intervention
8. Remove circlip (16) and, using a press, remove thrust washer (17) and
bearing (18).

Fig. 1270

Installation
Refitting is the reverse of removal.
30.5.25 - PTO clutch. (D0.12.02) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.9.7 - Rear remote control va... - page 30-481 - (H0.07.01)
See para. 30.13.1 - Lift - Complete assemb... - page 30-526 - (R0.02.03)
See para. 30.5.29 - PTO output shaft - 4 s... - page 30-336 - (D0.14.01)
See para. 30.15.1 - Towing hitch slide (R3... - page 30-548 - (V0.02.01)
REMOVAL
1. Loosen union (1), remove clamp (2) and disconnect pipe (3).

Fig. 1271
2. Disconnect pipe (4), remove screws (5) and remove pipe (6).

Fig. 1272
3. Remove the screws (7) and remove the cover (8).

Fig. 1273

30-324
Method of intervention
4. Loosen the upper and lower unions (9) and disconnect the PTO control
hoses (10).

Fig. 1274
5. Using a slide hammer puller, remove the PTO drive shaft (11).

Fig. 1275
6. Remove the screw and mount (12) and remove manifold (13).
IMPORTANT
Check the condition of O-rings (14) and renew them if nec-
essary.

Fig. 1276
7. Remove extension (15) from the transmission.
IMPORTANT
Check the condition of the O-rings (16) and renew them if
necessary.

Fig. 1277
8. Dislodge circlip (17) from its seat and insert driver sleeve (18) in clutch as-
sembly (19).

Fig. 1278

30-325
 Method of intervention
9. Fully loosen union (20) and disconnect lubrication pipe (21) from clutch
assembly (19).

Fig. 1279
10. Remove complete clutch assembly (19).

Fig. 1280
11. Remove sleeve (17) complete with circlip (18) from clutch assembly (21)
and, if present, remove also spacer (19).

Fig. 1281

30-326
Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 11
l Install driver sleeve (18) in clutch assembly (19) complete with circlip (17)
and spacer (21).
Spacer (21) must always be installed when carrying out the overhaul or
renewal of any of the assemblies or components associated with operation
of the rear PTO.

Fig. 1281

Procedure 5
l Move driver sleeve (18) towards the front of the tractor so that it seats
against O-ring (23).

Fig. 1282

l Using a feeler gauge, measure the residual clearance “G” between spacer
(21) and circlip (17).
If the measured clearance “G” is less than 1.00 mm, remove spacer (21).

Fig. 1283

Procedure 3
l Mating face: Silastic

Fig. 1284

30-327
 Method of intervention
Procedure 2
l Renew gasket (22) after every removal.

Fig. 1285

30.5.26 - Disassembly of the PTO clutch (R3 EVO 110 -> 1001)

Fig. 1286 - PTO clutch

Disassembly
1. Using a suitable wrench T7 remove accumulator (1).
m Renew the copper washers on reassembly.

Fig. 1287

30-328
Method of intervention
2. Remove pressure relief valve (2).
m Renew the copper washers on reassembly.

Fig. 1288
3. Remove circlip (3) and remove spacer (4).

Fig. 1289
4. Remove steel disc (5) and then remove all friction discs (6) and steel discs
(7).

Fig. 1290
5. Remove hub (8) and shim (9).

Fig. 1291
6. Using a press and a suitable tool, lightly compress spring (10) and remove
circlip (11).

Fig. 1292

30-329
 Method of intervention
7. Remove disc (12) and spring (10).

Fig. 1293
8. Turn the assembly over and blow compressed air at low pressure into the
hole on clutch housing (13) to expel piston (14).

Fig. 1294
9. Remove O-ring (15) from piston (14) and remove O-ring (17) from hub (16).

Fig. 1295
10. Remove screws (18) and remove cover (19), friction disc (20) and steel
disc (21).

Fig. 1296
11. Blow compressed air at low pressure through the hole in the side of clutch
housing (13) to expel piston (22).
m Restrain piston (22) as it could be expelled at high speed and thus
damaged.

Fig. 1297

30-330
Method of intervention
12. Remove O-ring (23) from piston (22) and O-ring (24) from clutch housing
(13).

Fig. 1298
13. Remove circlip (25) and thrust washer (26).

Fig. 1299
14. Remove clutch assembly (13) from clutch housing (16).

Fig. 1300
15. Remove retaining rings (27) from clutch housing (16).

Fig. 1301

30-331
 Method of intervention
Assembly
Refitting is the reverse of removal.
Procedure 15
l Rings: Oil
Procedures 9-12
l O-rings: Oil
Procedures 4-10
l Friction discs: Oil
Procedure 3
l Position the clutch assembly vertically and, using a feeler gauge, check that
the clearance “G” between circlip (3) and spacer (4) is within the tolerance
limits. If the clearance exceeds tolerance limits, add another spacer (4).
clearance “G”: 0.6-2.0 mm

Fig. 1302

Procedures 1-2
l Accumulator and pressure relief valve: Loctite 542

30.5.27 - Pump drive PTO - Outer gear (R3 EVO 110 -> 1001)

Fig. 1303

30-332
Method of intervention
Disassembly
1. Remove screws (1) and remove cover (2).

Fig. 1304
2. Remove rear pump drive sleeve (3).

Fig. 1305
3. Remove nuts (4) and remove rear flange (5).
m Renew paper gasket (6) on reassembly.

Fig. 1306
4. Withdraw sleeve (7), bearings (8), spacer (9) and gear (10) from the trans-
mission casing.
m Insert a tie “A” in sleeve (7) to prevent spacer (9) from falling inside
the transmission.

Fig. 1307

Assembly
To assemble, follow the disassembly steps in reverse order and carry out the following procedures:
Procedure 3
l Moisten the paper gasket with Loctite 510

30-333
 Method of intervention
Procedure 1
l Mating face: Silastic 738

Fig. 1308

30.5.28 - Pump drive PTO - Inner gear (R3 EVO 110 -> 1001)

Fig. 1309 - Pump drive PTO

Disassembly
1. Remove circlip (1).

F0085610

Fig. 1310

30-334
Method of intervention
2. Using a soft metal punch, drive out driving gear assembly (2) and spacer
(3). 2
3

F0085620

Fig. 1311
3. Remove bearing (4) from the transmission casing.
4

F0085630

Fig. 1312
4. Using a puller, remove bearing (5) from gear (2).

Fig. 1313
5. Only if necessary:
Remove circlip (6) and withdraw spacer (7) and roller bearing (8).
Remove O-ring (9).

Fig. 1314

30-335
 Method of intervention
Assembly
Refit by following the removal steps in reverse order and carry out the following procedures:
Procedure 4
l For 85 HP versions only:
Install bearing (5) with plastic shield on gear (2).

Fig. 1315

30.5.29 - PTO output shaft - 4 speed version (D0.14.01) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.9.7 - Rear remote control va... - page 30-481 - (H0.07.01)
See para. 30.13.1 - Lift - Complete assemb... - page 30-526 - (R0.02.03)
See para. 30.15.1 - Towing hitch slide (R3... - page 30-548 - (V0.02.01)

Fig. 1316 - PTO output shaft - 4 speed version

REMOVAL
1. Remove the P.T.O. guard (1) and rear hook (2).

Fig. 1317

30-336
Method of intervention
2. Remove the nuts and remove PTO flange (3)

Fig. 1318
3. For version with attached shaft
Remove nuts (4) and remove output shaft (5).

Fig. 1319
4. Remove cover (6).

Fig. 1320
5. Remove screws (7) and remove lubrication manifold (8).

Fig. 1321
6. Loosen and remove screw (9), extract shaft (10) and shoe (11).
Move hose (12) towards the front of the tractor.

Fig. 1322

30-337
 Method of intervention
7. Remove circlip (13) retaining bearing (14) and push gear (15) and the bear-
ing towards the front of the tractor.

Fig. 1323
8. Remove circlip (16) retaining gear (17).

Fig. 1324
9. Keeping gear (17) in place, extract shaft (18) complete with rear bearing
(19) and needle roller bearings (20).

Fig. 1325
10. Remove circlip (21) and hose (22).

Fig. 1326
11. Push shaft (23) towards the front of the tractor and extract gear (15) com-
plete with bearing (14).

Fig. 1327

30-338
Method of intervention
12. Remove needle roller bearings (20) and spacer (24) from the shaft.
Remove the circlip (25), thrust washer (26) and using a puller, remove bear-
ing (19).

Fig. 1328

Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 12
l Take care to install bearing (19) the right way round.
Procedure 7
l Take care to install bearing (14) the right way round.
Procedure 6
l Screw: Loctite 270
Procedures 2-4
l Mating face: Silastic

Fig. 1329

Procedure 2
l Nuts: Loctite 270

30-339
 Method of intervention
30.5.30 - Disassembly of the PTO output shaft - 4 speed version (R3 EVO 110 -> 1001)

Fig. 1330 - PTO output shaft.

Disassembly
1. Version with fitted output shaft
Remove the PTO nuts and flange (1).

Fig. 1331
2. Remove nuts (2) and remove output shaft (3).

Fig. 1332

30-340
Method of intervention
3. Remove cover (4).

Fig. 1333
4. Refit the shaft (3).

Fig. 1334
5. For all versions
Drive out spring pin (5).

Fig. 1335
6. Remove the bracket (6) and the PTO speed selector rod (7).

Fig. 1336
7. Relieve the staking and remove ringnut (8) using a suitable wrench “A”.
IMPORTANT
Renew the nut on each reassembly

Fig. 1337

30-341
 Method of intervention
8. Using a suitable tool, partially withdraw PTO output shaft (9).

Fig. 1338
9. Remove in sequence the spacer (10) and gear (11) complete with roller
races (12) and bushings (13) and spacer (14).

Fig. 1339
10. Remove PTO speed selector fork (15).

Fig. 1340
11. Remove selector sleeve (16) and guide sleeve (17).

Fig. 1341
12. Remove gear (18).

Fig. 1342

30-342
Method of intervention
13. Remove circlip (19) and, using a press, remove thrust washer (20) and
bearing (21).

Fig. 1343
14. Recover bearing (22).

Fig. 1344

Installation
To assemble, follow the disassembly steps in reverse order and use caution in relation to the following procedures:
Procedure 13
l Take care to install bearing (21) the right way round relative to shaft (9).

Fig. 1345

Procedure 7
l Ringnut: 88±1 Nm (64.9±0.74 lb.ft.)
Stake ringnut (8).

Fig. 1346

30-343
 Method of intervention
Procedure 6
l Check the condition of O-ring (23) and renew it if necessary.
O-ring: Grease

Fig. 1347

30.5.31 - Disassembly of the Groundspeed PTO output shaft (R3 EVO 110 -> 1001)

Fig. 1348 - Groundpseed PTO output shaft

Disassembly
1. Remove nuts (1) and remove cover (2).
m Mark the top of cover (2) to avoid error on reassembly. 1

F0084690

Fig. 1349

30-344
Method of intervention
2. Check that the Groundspeed PTO lever (3) is in the “ON” position to pre-
vent the engagement sleeve from falling.

Fig. 1350
3. Withdraw the Groundspeed PTO output shaft (4).

Fig. 1351
4. Remove circlip (5) and spacer (6).

Fig. 1352
5. Using a press remove bearing (7) from shaft (4).
Remove spacer (8) and circlip (9).

Fig. 1353
6. Remove oil seal (10) from cover (2).
2 10

D0024381

Fig. 1354

30-345
 Method of intervention
Assembly
To assemble, follow the disassembly steps in reverse order and use caution in relation to the following procedures:
Procedure 7
l Take care to install oil seal (10) the right way round relative to cover (2). 2 10

D0024381

Fig. 1354

l Mating face: Silastic 738

Oil seal lip: Oil

Fig. 1355

Fill the transmission with the required quantity of oil

30.5.32 - Disassembly of the Groundspeed PTO engagement device (R3 EVO 110 ->
1001)
Disassembly
1. Remove screw (1), withdraw drive shaft (2) and recover lever (3), shoe (4)
and sleeve (5).
m Renew the screw on reassembly.

Fig. 1356

Assembly
Refitting is the reverse of removal.
Procedure 1
l Check the condition of O-ring (6) and renew it if necessary.
l Screw: 20 Nm (14.7 lb.ft.)

Fig. 1357

30-346
Method of intervention
30.5.33 - Disassembly of the 4WD engagement device - Easyshift (R3 EVO 110 -> 1001)

Fig. 1358 - 4WD engagement device

Disassembly
1. Remove oil seal (1) and circlip (2).
IMPORTANT
Renew the gasket every time it is disturbed.

Fig. 1359
2. Remove screws (3) and remove lower plate (4).

Fig. 1360

30-347
 Method of intervention
3. Using a slide hammer puller, remove hub assembly (5 ).

Fig. 1361
4. Remove circlip (6) and remove bearing (7) from hub (5).

Fig. 1362
5. Loosen and remove screw (8).

Fig. 1363
6. Withdraw engagement device (9), spring (10) and disc (11).

Fig. 1364
7. Remove bush (12) from engagement device (9).

Fig. 1365

30-348
Method of intervention
8. Recover manifold (13).

Fig. 1366

Installation
To assemble, follow the disassembly steps in reverse order and use caution in relation to the following procedures:
Procedure 8
l
IMPORTANT
Check the condition of the O-rings (16) and renew them if
necessary.

Fig. 1367

Procedure 7
l
IMPORTANT
Check the condition of the O-rings (15) and renew them if
necessary.

Fig. 1368

Procedure 6
l
IMPORTANT
Check the condition of O-rings (14) and renew them if nec-
essary.

Fig. 1369

Procedure 5
l Screw: Loctite 242
l Screw: 20 Nm
Procedure 2
l Mating face: Silastic 738

30-349
 Method of intervention
30.6 - E0 - Rear axle
30.6.1 - Right-hand rear axle (E0.02.01) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.5.1 - Changing the transmiss... - page 30-253 - (D0.00.01)
REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and depress the parking brake repeatedly to dis-
charge residual pressure.
2. Remove nuts (1) and disconnect bracket (2) from the axle.

Fig. 1370
3. Remove nut (3) and plate (4)

Fig. 1371
4. Using a suitable hoist “A”, raise the cab slightly on the right hand side and
keep in place.

Fig. 1372
5. Remove screws (5) and remove cab support (6).

Fig. 1373

30-350
Method of intervention
6. Disconnect brakes pipes (7) and (8).

Fig. 1374
7. Remove all ten screws (9) and the two nuts (10)

Fig. 1375
8. Attach the axle (11) to a hoist and take up the slack in the lifting rope.

Fig. 1376
9. Remove screw (12) and using a service screw “B” (M10x120 with full-length
thread) or a threaded rod, separate axle (11) from the transmission.
Tighten removed screw (12) and repeat the procedure with the remaining
screws until axle (11) is completely detached from the transmission.

Fig. 1377
10. Remove axle assembly (11).
IMPORTANT
Recover O-ring (13).

Fig. 1378

30-351
 Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 10
l Mating face: Loctite 518
l Carefully check the O-ring, position it and lubricate with oil.

Fig. 1379

Procedure 7
l Screws and nuts: 70±3.5 Nm (51.6±2.6 lb.ft.)
Procedure 6
l Bleed the air from the braking system.
l Fill the transmission with the required quantity of oil.

30.6.2 - Disassembly of LH/RH rear axle (R3 EVO 110 -> 1001)

Fig. 1380 - Rear axle

30-352
Method of intervention
Disassembly
1. Using a puller, remove ring gear (1).

Fig. 1381
2. Remove anti-rotation plate (2).

Fig. 1382
3. Remove screw (3) and remove spacer (4) and shims (5).

Fig. 1383
4. Remove the complete planet carrier assembly (6).

Fig. 1384
5. Using a puller, apply force on axle shaft (7) to remove bearing inner race
(8) from axle shaft (7).
Recover inner bearing race (8).

Fig. 1385

30-353
 Method of intervention
6. Attach axle housing (9) to a hoist and remove it.

Fig. 1386
7. Withdraw bearing outer race (9) and oil seal (8) from axle housing (10).

Fig. 1387
8. Withdraw bearing outer race (11) and disc (12) from axle housing (9).

Fig. 1388
9. Remove bearing inner race (11) from axle half shaft (7).

Fig. 1389
10. Only if necessary:
Remove the back-up ring of oil seal (13).
IMPORTANT
Renew the oil seal on reassembly.

Fig. 1390

30-354
Method of intervention
11. Remove dust seal (13) from axle shaft (7).
IMPORTANT
Renew the oil seal on reassembly.

IMPORTANT
Note which way round oil seal is installed.

Fig. 1391

Installation
To assemble, follow the disassembly steps in reverse order and use caution in relation to the following procedures:
Procedure 9
l Fill the zone outlined in the drawing with grease.

Fig. 1392

Procedures 5-7
l Procedure 5: Lubricate bearing (8) and the lip of oil seal (10).
l Procedure 7: Take care to install oil seal (10) the right way round.

Fig. 1393

Procedure 3
l Provisionally fit spacer (4) and screw (3) without shims and tighten.
Screw: 29.4 Nm (21.7 lb.ft.)

Fig. 1394

l After tightening to the specified torque, rotate the axle housing while holding the axle shaft still to allow the bearings to seat
correctly, then tighten screw (3) again.
l Repeat the procedure until screw (3) no longer turns.

30-355
 Method of intervention
l Remove screw (3) and spacer (4) and, using a depth gauge “F” and cali-
brated shims “G” of approximately 25mm, measure dimensions “A” and “B”.

Fig. 1395

l Calculate thickness “S” of shim pack (7) to be installed under spacer (4)
with the formula: S = A - B (round off the value obtained by ± 0.02 mm):
Calculation example 1:
dimension “A”: 97.44 mm dimension “B”: 95.95 mm S = 97.95 - 50.44 =
1.95 mm thus the final thickness “S” of shims (5) will be 1.49 mm.
Calculation example 2:
dimension “A”: 97.37 mm dimension “B”: 95.95 mm S = 97.37 - 95.95 =
1.42 mm thus the final thickness “S” of shims (7) will be 1.40 mm.

Fig. 1396

l Fit shim pack (5), spacer (4) and secure in positions by tightening screw (3).
Screw: 177±9 Nm (130.5±6.6 lb.ft.)
Screw: Loctite 270

Fig. 1397

Procedure 1
l Mating faces: Loctite 518

Fig. 1398

30.6.3 - Left-hand rear axle (E0.02.02) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.5.1 - Changing the transmiss... - page 30-253 - (D0.00.01)
REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and depress the parking brake repeatedly to dis-
charge residual pressure.
2. Perform the same operations described for the right-hand rear axle.

30-356
Method of intervention
30.6.4 - Disassembly of the planet carrier (R3 EVO 110 -> 1001)

Fig. 1399 - Planet carrier

Disassembly
1. Remove circlip (1) and remove pins (2).

Fig. 1400
2. Remove planet gears (3) with shims (4) and remove roller bearings (5) and
spacer (6).

Fig. 1401

Assembly
To assemble, follow the disassembly steps in reverse order and carry out the following procedures:
Procedure 2
l Lubricate roller bearings (4).
l Roller bearings: oil

30-357
 Method of intervention
30.6.5 - Rear differential (E0.02.07) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.15.1 - Towing hitch slide (R3... - page 30-548 - (V0.02.01)
See para. 30.8.4 - Cab access steps (R3 E... - page 30-431 - (G0.03.03)
See para. 30.5.1 - Changing the transmiss... - page 30-253 - (D0.00.01)
See para. 30.6.1 - Right-hand rear axle (... - page 30-350 - (E0.02.01)
See para. 30.6.3 - Left-hand rear axle (R... - page 30-356 - (E0.02.02)
See para. 30.13.1 - Lift - Complete assemb... - page 30-526 - (R0.02.03)
See para. 30.5.29 - PTO output shaft - 4 s... - page 30-336 - (D0.14.01)
See para. 30.9.8 - Bleeding the braking c... - page 30-483 - (E0.03.01)
REMOVAL
1. Remove plugs (1) and (2).
IMPORTANT
Renew the copper washers on reassembly.

Fig. 1402
2. Drive out spring pin (3).

Fig. 1403
3. Withdraw piston (4) from the transmission casing and partially withdraw
the rod (5).

Fig. 1404
4. Remove spring (6) and spacer (7).

Fig. 1405

30-358
Method of intervention
5. Finally remove rod (5), selector fork (8), spring (9) and spacer (10).

Fig. 1406
6. Using a slide hammer puller, remove the PTO drive shaft (11).

Fig. 1407
7. Remove nuts (12) on both sides and remove the lubrication hose (13).

Fig. 1408
8. Remove screws (14) on both sides, leaving one in place for safety.

Fig. 1409
9. Using a suitable drift made of soft material, separate differential support
flanges (15) from the transmission casing.

Fig. 1410

30-359
 Method of intervention
10. Remove the last screw (14) and remove flanges (15) on both sides.
IMPORTANT
Mark the flanges to avoid exchange on re-assembly.

Fig. 1411
11. Attach differential (16) to a hoist and remove it.

Fig. 1412

Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 8
l Fixing: 32-40 Nm (23.6-29.5 lb.ft.)

30.6.6 - Disassembly of the rear differential (R3 EVO 110 -> 1001)
2

21 3

20

10 16

13 18

15
8

9 5
6 4
7
1

Fig. 1413 - Rear differential

30-360
Method of intervention
Disassembly
1. Using a puller, remove bearing (1).
IMPORTANT
If the bevel gear pair or both bearings are to be renewed,
remove also bearing (2). 1
2

Fig. 1414
2. Remove differential lock flange (3).
3

Fig. 1415
3. Remove screws (4) and remove differential crown wheel (5).

Fig. 1416
4. Remove side gear (6) and its thrust washer (7).

Fig. 1417
5. Remove the spring pins (8).

Fig. 1418

30-361
 Method of intervention
6. Withdraw pins (9) and (10) and remove the planet pinions (11) and (12) and
relative thrust washers (13) and (14). 12
11 14

13

9 10

Fig. 1419
7. Withdraw pin (15) and remove the planet pinions (16) and (17) and relative
thrust washers (18) and (19).

Fig. 1420
8. Remove side gear (20) and its thrust washer (24).

Fig. 1421

30-362
Method of intervention
Installation
To assemble, follow the disassembly steps in reverse order and use caution in relation to the following procedures:
Procedure 4-6-7-8
l Gears and thrust washers: Transmission oil
Procedure 3
l Screws: Engine oil
Screws: 112±5,5 Nm (82.5±4.0 lb.ft.)
Procedure 1
l If the transmission casing, differential or bevel gear pair are renewed, do not fit bearings (1) and (2) in this phase and proceed
as described in the chapter “BEVEL GEAR PAIR”.

30.6.7 - Park Brake assembly

Removal
1. Unscrew retaining screws (1) of brake assembly (2) by one turn at at time.

2
1

F0150350

Fig. 1422
2. Insert an eye-bolt “B” in upper hole “F”, attach the hoist and tension slightly.
Insert half shaft (3) sufficiently to engage the brake discs and remove the
complete brake assembly. F
B

F0150360

Fig. 1423

Refitting
1. Using a hand pump equipped with a shut-off valve, pressurise the parking
brake circuit to approx. 20 bar. Close the shut-off valve to close the circuit.

F0150430

Fig. 1424

30-363
 Method of intervention
2. Using a soft mallet, tap the piston all around its circumference to make it
retract it fully.

F0150440

Fig. 1425
3. Fit friction discs (4) and plain steel disc (5) to the brake assembly.
5

F0150450

Fig. 1426
4. Fit the complete brake assembly (2) and tighten screws (1).
Screws tightening torque: 28÷31 Nm
Mating surface: Loctite 518 2

F0150370

Fig. 1427
5. Install half-shaft (3) before removing the hand pump.

F0150380

Fig. 1428

30-364
Method of intervention
30.6.8 - Park Brake unit disassembly
4

9
1

2 7

11

13

10
12

D0049631

Fig. 1429 - Park Brake assembly

Removal
1. Remove the first friction disc (1), plain steel disc (2) and then the second
friction disc (1); remove half-shaft (3).
1
1 2

3
3
F0147390

Fig. 1430

30-365
 Method of intervention
2. Position brake assembly (4) on a work bench with retaining screws (5) of
flange (6) facing upwards. 4
5
Fit tool “A” (P/N 5.9035.333.0), fully tightening screws (7).

A
7

6
F0150420

Fig. 1431
3. Unscrew and remove screws (8) fixing the reaction ring.

8 8

F0150460

Fig. 1432
4. Loosen tool “A” retainer screws (6) gradually and evenly.
IMPORTANT
Loose screws (7) by approx. 1/4 turn at a time, proceeding
in a circle.
7

F0150470

Fig. 1433
5. Remove tool “A” and reaction ring (9) of the Belleville spring.

F0150480

Fig. 1434
6. Remove Belleville spring (10).
10

F0147441

Fig. 1435

30-366
Method of intervention
7. Upturn the assembly (4) and, using a lever, insert at various points to ex-
4 12
tract piston (11) for the service brake, disengaging it from the backlash
11
recovery units (12).
IMPORTANT
Renew the O-rings on reassembly. 12
12

F0147451

Fig. 1436
8. Using a soft plastic mallet, beat the entire circumference and extract the
piston (13) of the parking brake. 13
IMPORTANT
Renew the O-ring on reassembly.

F0147461

Fig. 1437
9. Only if necessary
Remove the service brake backlash recovery units (12) by using the disas-
sembly wrench on the lower hex nut.
12

F0147471

Fig. 1438

30-367
 Method of intervention
Assembly
Repeat the removal steps in reverse order.
Procedure 9
l Backlash recovery unit: Loctite 243
l Backlash recovery unit: 18-19 Nm
l Lubricate the spring pins on each oil change.
Procedures 8-7
l Lubricate the O-rings with gearbox oil

30-368
Method of intervention
30.7 - F0 - Front axle
30.7.1 - Separation of front support from engine (F0.01.01) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.7.15 - 4WD shaft (R3 EVO 110 ... - page 30-411 - (F0.04.01)
See para. 30.9.8 - Bleeding the braking c... - page 30-483 - (E0.03.01)
Separation
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Close valves (1) turning them clockwise and detach upper pipes (2) .
IMPORTANT
Label the pipes to avoid confusion on reconnection.

IMPORTANT
Activate the rear lift control lever to discharge residual pres-
sure.
Fig. 1439

IMPORTANT
Plug the pipes to prevent the ingress of dirt.

3. Loosen and remove the lower pipe retainer clamps (3) .

Fig. 1440
4. Remove locknuts (4) and tilt the valves (1) towards the front of the tractor.

Fig. 1441

30-369
 Method of intervention
5. Extract pin (5) and disengage the front PTO drive shaft (6).

Fig. 1442
6. Loosen nut (7) and with screw (8) loosen the drive belt (9) of compressor
(10) until it can be released from the engine pulley.

Fig. 1443
7. Loosen screws (11) and detach belt (12) from the engine pulley (13).

Fig. 1444
8. Position a stand “A” under the engine sump.

Fig. 1445
9. Loosen and remove lower nuts (14) (2 per side).

Fig. 1446

30-370
Method of intervention
10. Drive two non-slip “B” wedges between the front support (15) and axle (16)
to prevent the support from tipping.
Connect the hoist and tension slightly.

Fig. 1447
11. Loosen and remove screws (17) and nuts (18).

Fig. 1448
12. Force the front wheels and detach the front support unit complete with axle.

Fig. 1449

30-371
 Method of intervention
Reconnection
Reconnect in reverse of removal.
30.7.2 - Front support (R3 EVO 110 -> 1001)
REMOVAL
1. Position a stand “A” under the engine block.

Fig. 1450
2. Using a pin punch, remove pin (1) and withdraw PTO drive shaft (2) to-
wards the rear of the tractor.

Fig. 1451
3. Detach pipes (3), remove screws (4) and tilt the valve assembly (5) towards
the front.
IMPORTANT
Label the pipes to avoid confusion on refitting.

IMPORTANT
Before disconnecting pipes (3), close valves (5) (turning
counter clockwise) and operate lift control lever to discharge Fig. 1452
all residual pressure in the circuit.
IMPORTANT
Plug the pipes to prevent the ingress of dirt.

4. Loosen and remove lower nuts (6) (2 per side).

Fig. 1453

30-372
Method of intervention
5. Position a jack “B” under the front support (7) and drive two wedges “C”
between axle (8) and front support (7) to prevent the support from tipping.

Fig. 1454
6. Loosen screw (9) to de-tension fuel pump drive belt (10).

Fig. 1455
7. Loosen and remove screws (11) and nuts (12).

Fig. 1456
8. Remove complete front support (7).
IMPORTANT
Recover the shims installed between the front support and
engine sump, making a note of their positions.

IMPORTANT
Keep the left and right shims separate.

Fig. 1457

30-373
 Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 8
l If the engine or engine sump are replaced, or if the shims are no longer
separate or are lost, the shimming procedure must be performed as fol-
lows:
l Before installing the front support, measure the distance “X” between the
underside of the engine block and the face of the sump.

Fig. 1458

l Form a shim pack (13) to obtain alignment within the tolerance of ±0.1 mm
(0.004 in.).

Fig. 1459

Procedure 7
l Nuts and screws: 300±1,5 Nm (221.1±1.1 lb.ft.)
Procedure 6
l Adjust the tension of the fuel pump drive belt.
Procedure 4
l Nuts: 300±1,5 Nm (221.1±1.1 lb.ft.)
l Bleed the front brakes circuit.

30.7.3 - 4WD front axle (F0.03.01) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.7.15 - 4WD shaft (R3 EVO 110 ... - page 30-411 - (F0.04.01)
See para. 30.9.8 - Bleeding the braking c... - page 30-483 - (E0.03.01)
REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Lift the front of the tractor so that the front tyres are clear of the ground and
position a stand “A” under the engine block.

Fig. 1460

30-374
Method of intervention
3. Remove unions (1) and disconnect steering pipes (2).
IMPORTANT
Plug the pipes and ports to prevent the ingress of dirt

IMPORTANT
Renew the copper washers on reassembly

Fig. 1461
4. Position the jack “B” under the front axle.

Fig. 1462
5. Remove the four nuts (3).

Fig. 1463
6. Remove front axle assembly (4).

Fig. 1464

30-375
 Method of intervention
Assembly
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 6
l If the front support, axle body, or axle pivot brackets are renewed, adjust axle end float before proceeding with the final fixing
of the axle.
Procedure 5
l Nuts: 270±13 Nm (199±9.6 lb.ft.)

30.7.4 - Adjusting the front axle end float (R3 EVO 110 -> 1001)
1. Install thrust washer (1) and pivot bracket (2) on the rear of the axle.

Fig. 1465
2. Loosen nuts (3) and remove shim packs (4) on both sides. Re-tighten nuts
(3).

Fig. 1466
3. Fit dust seal (5).
m Take care to install the dust seal the right way round.
m Dust seal: grease

Fig. 1467
4. Fit thrust washer (6) and support (7).

Fig. 1468

30-376
Method of intervention
5. Fit front axle assembly (8) on front support (9).

Fig. 1469
6. Tighten nuts (10) and (11).
m Nuts: 270±13 Nm (199±9.6 lb.ft.)

Fig. 1470
7. Loosen nuts (3) and use two levers to force axle (8) and support (12) apart.

Fig. 1471
8. Using a feeler gauge, measure clearance “A” between axle (8) and support
(12).

Fig. 1472
9. Calculate the thickness “S” of shim packs (4) to obtain a final end float
value “G” between 0.1 and 0.4 mm.
Example calculation:
m measured play “A”: 3.20 mm
calculated value “S”: 3.00 mm
residual end float “G”: 0.20 mm

Fig. 1473

30-377
 Method of intervention
10. Form two shim packs (4) of the same thickness “S” and install them be-
tween axle (8) and support (12) then tighten nuts (3).
m Nuts: 120±6 Nm (88.4±4.4 lb.ft.)

Fig. 1474

30.7.5 - Steering cylinders (R3 EVO 110 -> 1001)

Removal
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Remove unions (1) and disconnect steering control pipes (2).

m Plug the pipes and ports to prevent the ingress of dirt.
m Renew the copper washers on reassembly.

Fig. 1475
3. Remove screw (3) on both sides and remove guard (4).
m Recover spacers (5).

Fig. 1476
4. Loosen nut (6) and remove set screw (7).

Fig. 1477

30-378
Method of intervention
5. Withdraw pin (8).
m If the cylinder is to be removed with the axle installed on the tractor,
remove grease nipple (9) and extract pin (8) downwards.

Fig. 1478
6. Recover oil seals (10) complete with bushes (11).

Fig. 1479
7. Remove screw (12) and withdraw pin (13).

Fig. 1480
8. Recover seals (14) complete with bushes (15) and remove steering cylin-
der (16).

Fig. 1481

30-379
 Method of intervention
Refitting
Refitting is the reverse of removal.
l After installing the steering cylinder, start the engine and repeatedly turn the steering to full lock in both directions to expel any
air from the steering circuit.

30.7.6 - Steering cylinders disassembly (R3 EVO 110 -> 1001)

Disassembly
1. Loosen front ringnut (1) by about 5 turns.

Fig. 1482
2. With a soft mallet, lightly tap front ringnut (1) to drive in end cap (2) by about
3 mm (0.118 in.).

Fig. 1483
3. Remove ringnut (1) and remove circlip (3) fixing head (2).

Fig. 1484
4. Withdraw piston assembly (4).

Fig. 1485

30-380
Method of intervention
5. Unscrew and remove self-locking nut (5) and remove piston (6).
Withdraw end cap (2) from rod (7).

Fig. 1486
6. Remove outer O-ring (8), rod wiper (9) and rod guide ring (10) from end
cap (2).

Fig. 1487
7. Remove outer seal (11) and inner O-ring (12) from piston (6).

Fig. 1488

30-381
 Method of intervention
Installation
1. Fit rod guide (10) and rod wiper (9) in end cap (2).
m Carefully check correct orientation of ring (10).
Fit O-ring (8).

Fig. 1488
2. Fit a suitable installation guide on the piston (6) and fit piston sealing O-ring
(12) by hand.

Fig. 1489
3. Fit the outer piston seal (11) on the installation guide.
Using a suitable installer, drive the seal into its seat (11).

Fig. 1489
4. Using a gauge and suitable support, calibrate the seal passing the gauge
over the entire length of piston (6).

Fig. 1490
5. Fit end cap (2) and piston (6) on rod (7); Secure piston (6) with self-locking
nut (5).
m Cylinder end cap: Gearbox oil.
m Nut: 86÷90 Nm (63.4-66.3 lb.ft.)

Fig. 1490

30-382
Method of intervention
6. Lubricate the seals of the piston and end cap; install the assembly in the
cylinder taking care not to damage the seals.
m Seals: Gearbox oil.
m Insert end cap (2) approx. 2 mm (0.08 in.) beyond the seat of circlip
(3).

Fig. 1491
7. Fit circlip (3) and tighten ringnut (1).
m Nut: 40 Nm (29.5 lb.ft.)
m To tighten the ringnut pressurise the lower side of the cylinder with
compressed air at 5-8 bar.

Fig. 1491

30.7.7 - Steering knuckle housing and half-shaft (R3 EVO 110 -> 1001)

Fig. 1492

30-383
 Method of intervention
REMOVAL
1. Remove split pin (1) and loosen nut (2) without removing it.

Fig. 1493
2. Using a soft mallet, disconnect rod (4) from steering knuckle housing (3).

Fig. 1494
3. Remove screw (5) and withdraw pin (6).

Fig. 1495
4. Recover oil seals (7) complete with bushes (8).

Fig. 1496
5. Remove union (9) and disconnect brake pipe (10).

Fig. 1497

30-384
Method of intervention
6. Remove screws (11).

Fig. 1498
7. Tighten screws (11) into the three threaded holes and withdraw pin (12).
Recover shim (13).

Fig. 1499
8. Remove screws (14).

Fig. 1500
9. Tighten the three screws (14) into the threaded holes and partially withdraw
pin (15).
Recover shims (16).
m Note the quantity of shims (16) installed under pin (15).

Fig. 1501
10. Attach the steering knuckle housing (3) to a hoist, remove pin (15) and lift
steering knuckle housing (3) clear of the tractor.

Fig. 1502

30-385
 Method of intervention
11. Remove seal (17), thrust washer (18), and remove the inner race of bear-
ing (19).

Fig. 1503
12. Remove seal (20) and thrust washer (21) and remove the inner race of
bearing (22).

Fig. 1504
13. Remove axle shaft (23).

Fig. 1505
14. Only if necessary: Remove the outer races of bearings (19) and (22).

Fig. 1506
15. Only if necessary: Remove oil seal (25), circlip (26) and needle roller bear-
ing (27) from axle housing (24).

Fig. 1507

30-386
Method of intervention
16. Remove oil seal (28) from steering knuckle housing (3).
m Take care to install oil seal (28) the right way round.

Fig. 1508

Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 17
l Using a suitable drift, install needle roller bearing (27) in axle housing (24)
and secure with circlip (26).

Fig. 1509

l Using a suitable drift A, install oil seal (25) in the axle housing.

Fig. 1510

Figure showing driving tool A

Fig. 1511
Procedure 16
l Adjust the bearings preload only if bearings (19) and (22) or steering knuckle housing (3) or axle housing (24) are renewed.
Procedure 1

30-387
 Method of intervention
l Nut: 98±5 Nm (72.2±3.7 lb.ft.)
If the notch is not aligned with the hole on the pin, tighten down further until it is aligned.
Bleed the front brakes circuit.
30.7.8 - Adjustment of steering knuckle housing and axle shaft (R3 EVO 110 -> 1001)

Fig. 1512

Adjusting the bearings preload

1. Fit axle shaft (2) in axle housing (1).
1

F0080322

Fig. 1513

30-388
Method of intervention
2. Using a suitable tool, fit the outer races of bearings (3) and (4) in axle hous-
ing (1).
IMPORTANT
Make sure that the thinner outer race is installed in the up-
per hole and the thicker outer race in the the lower hole.

Install, the inner race of bearing (3), shim (5) and seals (6) in axle housing
upper side, and install the inner race of bearing (4), shim (7) and oil seal (8)
on the axle housing lower side.
Fig. 1514
3. Locate the steering knuckle housing (9) and secure it in position with the
upper pin (10) without the shim and tighten the screws (12).
12
9 10

F0080340

Fig. 1515
4. Fit the lower pin (13) and an 0.5 mm shim (14) and secure it in position
with screws (15).
14 15

13

F0080350

Fig. 1516
5. Loosen screws (12), raise upper pin (10) and insert a shim pack (11) ap-
prox. 1.5 mm thick; retighten screws (12).

Fig. 1517
6. Position a dial gauge “A” with a magnetic stand on the axle housing ori-
ented so that the contact point is perpendicular to the lower pin (13) and
preload the gauge by about 2 mm.

13

A
F0080370

Fig. 1518

30-389
 Method of intervention
7. Apply leverage between axle housing (1) and steering knuckle housing (9)
and measure play “G” of the bearings. 9 10
Calculate the thickness of the shim pack to be inserted between the upper
1
pin (10) and the steering knuckle housing (9) in order to preload the bear-
ings between 0.10 and 0.15 mm.
Example 1: Measured play: 0,07
Final shim pack thickness: 1.5 - 0.10 - 0.07=1.33 mm which rounds
m

down to: 1.30 with a bearing preload of 0.13 mm

Example 2: Measured play: 0.18 mm F0080380

Fig. 1519
m Final shim pack thickness: 1.50 - 0.10 - 0.18=1.22 mm which rounds
down to: 1.20 with a preload of 0.12 mm
8. Loosen screws (12), adjust shim pack (11) to the calculated thickness and
fully tighten screws (12).

Fig. 1520

30.7.9 - Differential unit (R3 EVO 110 -> 1001)

Removal
1. Remove plugs (1) and (2) and drain off all the oil from the axle.
m Axle oil: max. 10.5 l (2.77 US.gall.)

Fig. 1521
2. Remove union (3) and disconnect differential lock pipe (4).
m Renew the copper washers on reassembly.

Fig. 1522

30-390
Method of intervention
3. Remove all the nuts (5).
m Note the positions of the thicker washers.

Fig. 1523
4. Using two screws as pullers, separate differential assembly (6) from the
axle housing.

Fig. 1524
5. Attach differential unit (7) to a hoist and lift it clear of the tractor.

Fig. 1525

30-391
 Method of intervention
Refitting
Refit by following the removal steps in reverse order and carry out the following procedures:
Procedure 5
l Mating face: Silastic 738

Fig. 1526

Bleed the front brakes circuit.

30.7.10 - Differential disassembly (R3 EVO 110 -> 1001)
Disassembly
1. Remove screws (1) and remove cover (2) and O-ring (3).

Fig. 1527
2. Remove differential lock control piston (4).
m Check the condition of the O-rings (5) and renew them if necessary.

Fig. 1528
3. Detach spring (6).

Fig. 1529

30-392
Method of intervention
4. Remove split pin (7) and remove pin (8) and washer (9).

Fig. 1530
5. Remove control rod assembly (10).

Fig. 1531
6. Drive out spring pin (11) and remove lever (12) and fork (13) complete with
shoes (14).

Fig. 1532
7. Remove circlip (15), shims (16) and complete differential lock assembly
(17).
m Note the quantity of shims (16).

Fig. 1533
8. Only if necessary: Remove disc (18) and remove the seventeen balls (19)
and shims (20).
m Note the quantity of shims (20).

Fig. 1534

30-393
 Method of intervention
9. Separate quill (21) from sleeve (22).

Fig. 1535

Assembly
To assemble, follow the disassembly steps in reverse order and carry out the following procedures:
Procedure 2
l O-ring: oil

30.7.11 - Differential unit adjustment (R3 EVO 110 -> 1001)

Adjustment
1. Insert quill (2) into sleeve (1).
Position the seventeen balls (3) and disc (4).
m Do not install any shims at this point.

Fig. 1536
2. Install differential lock (6) on differential unit (5) and install a suitable shim
pack (7) to eliminate any play between the sleeve and circlip (8).

Fig. 1537
3. Remove the differential lock and fit some of the shims (7) between disc (4)
and sleeve (2), then reinstall on the differential unit.

Fig. 1538

30-394
Method of intervention
4. Secure the differential lock (6) with the remaining shims (7) and the circlip
(8).

Fig. 1539
5. With sleeve (1) moved towards the differential, check that the flat part “A” of
sleeve (1) is positioned on balls (3) as shown in the figure. 1
A
3
If not, repeat the procedure described in points 4, 5 and 6
until the condition described above is obtained.

D0023460

Fig. 1540
6. Fit fork (9) complete with shoes (10) and lever (11).

Fig. 1541
7. Secure lever (11) in position with spring pin (12).

Fig. 1542
8. Fit the differential lock piston (13).
m O-rings: Oil
13

F0080471

Fig. 1543

30-395
 Method of intervention
9. Fit cover (14) and relative O-ring (15) and tighten screws (16).
16
15

14

F0080560

Fig. 1544
10. Fit complete control rod assembly (17).
Fit pin (18) and washer (19) and secure them in position with split pin (20). 18 19

17
20

F0080570

Fig. 1545
11. Adjust the length “B” of differential lock control rod (13) so that, when sleeve
(1) is in the position shown, shoes (10) are not forced against it.

Fig. 1546
12. Fit spring (21).

21

F0080481

Fig. 1547

30-396
Method of intervention
30.7.12 - Bevel gear pair (R3 EVO 110 -> 1001)

Fig. 1548 - Bevel gear pair

Disassembly
1. Remove screws (1) and detach flange (2) and shims (3).

Fig. 1549
2. Remove screws (4) and detach flange (5) and shims (6).

Fig. 1550

30-397
 Method of intervention
3. Remove the two opposing screws (7) and, using a very slender drift, dis-
lodge the inner ring of bearing (8).

Fig. 1551
4. Using a puller, completely remove the inner ring of bearing (8).

Fig. 1552
5. Remove screw (9) and using a very slender drift remove the inner race of
bearing (10).

Fig. 1553
6. Remove differential assembly (11).

Fig. 1554
7. Remove the remaining screws (9) and remove crown wheel (12).

Fig. 1555

30-398
Method of intervention
8. Relieve the staking and remove ringnut (13).
m To loosen the ringnut turn it clockwise.
Renew ringnut (13) on reassembly.

Fig. 1556
9. Using a soft mallet, drive pinion (14) out from differential carrier (15) and
recover spacer (16).

Fig. 1557
10. Recover shims (17) and spacer (18) from pinion (14).

Fig. 1558
11. Remove the outer ring of bearing (19) and shims (20) from differential car-
rier (15).

Fig. 1559
12. Using a suitable tool, remove oil seal (21) and bearing assembly (22) from
differential carrier (15).
m Renew the oil seal on reassembly.

Fig. 1560

30-399
 Method of intervention
13. Remove the inner race of bearing (19) from pinion (14).
m Dislodge the bearing using a very slender driving tool and then use
a puller to remove it completely.

Fig. 1561

Assembly
Adjust.
Stake ringnut (13) at the two points corresponding to the locations in pinion (14).

Fig. 1562

Using a suitable tool, install oil seal (21) in differential carrier (15).
l Oil seal: grease

Fig. 1563

30-400
Method of intervention
30.7.13 - Adjustment of the bevel gear pair (R3 EVO 110 -> 1001)
Pinion positioning and preload adjustment

Fig. 1564 - Bevel gear pair

Adjustment procedure
1. Note dimension “E” stamped on the crest of a tooth of pinion (1).
m In this example: E = -0.05 mm

Fig. 1565
2. Install bearing inner race (2) on pinion shaft (1).

Fig. 1566

30-401
 Method of intervention
3. Install bearing outer race (2) in differential carrier (3).

F0080730

Fig. 1567
4. Install pinion (1) and flanges (4) and (5) complete with outer bearing races
(6) and (7) in differential carrier (3) and, using a depth gauge “A”, measure
distance “X”.
m Rotate the pinion in both directions to seat the bearing.
Place onto the outer bearing race (7) on the crown wheel side a
cylindrical pin “C” 2.5 mm (code. 2.1651.109.0) in diameter, to make
up the difference between the outside diameters of the bearings (7)
(Ø90) and (6) (Ø85).

Fig. 1568
5. Calculate distance “D” from the differential’s axis of rotation to pinion head
(1) with the following formula:
D=X-R
where: R = 45.00 = radius of bearing (7) on the opposite side to the crown
wheel
Example:

m Dimension “X” = 107.75 mm

Radius “R” = 45.00

D = 107.75 - 45.00 = 62.75 mm

Fig. 1569

30-402
Method of intervention
6. Remove pinion (1), outer bearing race (2) and flanges (4) and (5) and form
a shim pack (8) of thickness “S” calculated using the following formula:
S = D - Theoretical value + E 1

where: S = final shim pack thickness (8)

D = measurement calculated at point 5
2
Theoretical value = 61.00
E = dimension stamped on the crest of a tooth of pinion (1)
Example 1 (negative “E” value)
F0080750

m D = 62.75 mm Fig. 1570

E = - 0.05 mm
Theoretical value = 61.00
S = 62.75 - 61.00 - 0.05 = 1.70 mm
Example 2 (positive “E” value)
m D = 62.75 mm
E = + 0.15 mm
Theoretical value = 61.00
S = 62.75 - 61.00 + 0.15 = 1.90 mm
7. Install shim pack (8) and bearing outer race (2) in differential carrier (3).

3
2 F0080681

Fig. 1571
8. Install pinion assembly (1) in the differential carrier and install spacer (9)
10
and a shim pack (10) approx. 1.50 mm thick.
m Bearing: oil 1
9

F0080760

Fig. 1572
9. Install bearing assembly (11) in differential carrier (3) and seat it using a
suitable driving tool.
m To facilitate installation of the bearing, put the differential carrier in a
vertical position and rest the pinion end face on a spacer.

Fig. 1573

30-403
 Method of intervention
10. Fit spacer (12) on pinion shaft (1) and secure it by tightening nut (13).
1
m Nut: 206-226 Nm (151.8-166.6 lb.ft.)
To tighten the nut, turn it counterclockwise. 12
When tightening the nut, take care not to preload bearings (2) and
(11). If the bearings are preloaded, increase the thickness of the
shim pack(10).
13

F0080780

Fig. 1574
11. Position a dial gauge “F” on a magnetic stand as shown and place the con-
tact point perpendicular to the end face of pinion (1). Preload the gauge by
about 2 mm then apply leverage to the pinion and read play “G” of bearings
(2) and (11).

Fig. 1575
12. Calculate the thickness “P” of shim pack (10) to be installed under spacer
(9) using the following formula, rounding the value down to the nearest
0.05 mm.
“P” = Installed shim thickness - measured play “G”
Example 1: (measured play = 0.17 mm)
P = 1.50 - 0.17 = 1.33 mm which rounds down to 1.30 mm
m

Example 2: (measured play = 0.13 mm)

m P = 1.50 - 0.23 = 1.27 mm which rounds down to 1.25 mm

Fig. 1576
13. Remove nut (13) and withdraw the pinion assembly, spacer (9) and the in-
ner race of bearing (11).
m Loosen the nut by turning it clockwise.

Fig. 1577
14. Alter shim pack (10) to thickness “P” calculated in point 12 and refit the
pinion as described in points 8 - 9 and 10.
m While tightening the nut, rotate the pinion to help seat bearings (2)
and (11).

Fig. 1578

30-404
Method of intervention
15. Rotate the pinion both directions tapping it lightly to help seat bearings (2) and (11) and check as described in point 12 that
there is no pinion end float.
If end float is detected, repeat the procedures described in points 13, 14 and 15.
Adjustment of the differential preload

12
11
8 6

14 2

13 5

9
15

4 7

10

D0049191

Fig. 1579 - Adjustment of the differential preload

Adjustment procedure
1. Fit crown wheel (2) to differential (1) and tighten screws (3).
m Screws: 75±4 Nm (55.3±3 lb.ft.)

Fig. 1580

30-405
 Method of intervention
2. Fit differential assembly (1) in differential carrier (4) and, using a suitable
tool, install the inner race of bearing (5).
m Take care to install bearing (5) and differential (1) the right way
round relative to differential carrier (4). 4
5

F0080830

Fig. 1581
3. Using a suitable tool, install the inner race of bearing (6).

F0080840

Fig. 1582
4. Install the outer race of bearing (5) on the flange of the side opposite the
crown wheel (7).
Fit the outer race of bearing (6) in the crown-wheel side flange (8).

Fig. 1583
5. Install an 0.5 mm thick shim pack (9) and flange (7) in differential carrier (4)
7 9 7
and secure in position by tightening screws (10).

10

4
F0080860

Fig. 1584
6. Install a 1.5 mm thick shim pack (11) and flange (8) in differential carrier (4)
11
and secure in position by tightening screws (12). 8 12

4
F0080870

Fig. 1585

30-406
Method of intervention
7. Position a dial gauge on a magnetic stand “F” as shown, with the contact
point perpendicular to the hub of differential (1). Preload the dial gauge by
approx. 2 mm and set it to zero. F
Use a lever to apply force under differential (1) and measure play “G”.
Example:
m measured play “G” = 0.37 mm

1
F0088280

Fig. 1586
8. Calculate the total thickness of shims “T” to be installed under the flanges
9 11
by subtracting measured play “G” from the thickness of shims (9) and (11)
installed under flanges (7) and (8), rounding down the value obtained to the
nearest 0.05 mm.
Example:
m Thickness of installed shims (9) and (11): 2.00 mm
Measured play “G” = 0.37 mm
Total shim thickness “T”: 2.00 -0.37 = 1.63 mm, which rounds down
7 8
to 1.60 mm F0080890

Remove flanges (7) and (8) and shims (9) and (11). Fig. 1587
9. Change the thickness of shim pack (11) to 1.00 mm, and reinstall it with
11
flange (8). 8 12
m Bearing: oil
Tighten screws (12).

F0080871

Fig. 1588
10. Calculate thickness “H” of shim pack (9) by subtracting the thickness of
7 9 7
shims (11) installed under flange (8) from the value “T”, calculated in point
9.
Example:
10
m H = T - 1.00 = 1.60 -1.00 = 0.60 mm
Form a shim pack (9) of thickness “H”, install it with flange (7) and secure it
by tightening down screws (10).
m While tightening the screws, rotate the differential to ensure that
bearings (5) and (6) turn smoothly.
F0080861

Fig. 1589
m Bearing: oil
11. Rotate the pinion and crown wheel in both directions to help seat bearings
(5) and (6) and check, as described in point 8, that the differential has no
end float.
Using a feeler gauge “A”, check that dimension “D” between the end face
of pinion (13) and differential housing (1) is correct within a tolerance of
±0.10 mm.

Fig. 1590

30-407
 Method of intervention
12. Distance “D” = theoretical distance+ value “E” where:
Theoretical distance = 1.00 mm
Value E = value stamped on pinion tooth.
Example 1 (positive value “E”)
Theoretical distance = 1.00 mm
m

E = + 0.10 mm
D = 1.00 + 0.10 = 1.10 mm
Acceptable values: 1.00 to 1.20 mm
Example 2 (negative value “E”)
m Theoretical distance = 1.00 mm Fig. 1591
E = - 0.05 mm
D = 1.00 - 0.05 = 0.95 mm
Acceptable values: 0.85-1.05 mm

Adjustment of pinion and crown wheel backlash

1. Position a dial gauge “F” on a magnetic stand with the contact point per-
pendicular to a tooth flank on the external diameter of the crown wheel.
Preload the gauge by approx. 2 mm and measure backlash “Z” between
the pinion and crown wheel by turning the differential back and forth in both
directions.
Normal backlash “Z”:
m 100 hp version: 0.15 - 0.20 mm
Take four measurements 90° apart and calculate the average.

Fig. 1592
2. If backlash “Z” is less than 0.15 mm, remove shims from shim pack (11)
(crown wheel side) and add the same number of shims to shim pack (9) 9
(opposite side to crown wheel). If backlash “Z” is greater than 0.20 mm add
shims to shim pack (11) (crown wheel side) and remove the same number 11
of shims from shim pack (9) (opposite side to the crown wheel).
m The sum total thickness of shim packs (11) and (9) should be the
same as the value obtained when checking the preload of the dif-
ferential bearings.
Recheck backlash “Z” and, if necessary, continue to adjust the shims until D0049200

the backlash is within the specified tolerance limits. Fig. 1593

3. Finally tighten down screws (10) and (12) securing flanges (7) and (8).
7
m Screws: 45±2 Nm (33.2±1.5 lb.ft.) 12
Screws: Loctite 242

10
8

F0080910

Fig. 1594

30-408
Method of intervention
30.7.14 - Disassembly of the differential (R3 EVO 110 -> 1001)

Fig. 1595 - Differential

Disassembly
1. Remove screws (1) and remove flange (2).

Fig. 1596
2. Remove shim (3) and side gear (4).

Fig. 1597

30-409
 Method of intervention
3. Drive out spring pins (5) and (6).

Fig. 1598
4. Withdraw pin (7) and remove planet pinion (8) and the relative shim (9).

Fig. 1599
5. Withdraw pin (10) and remove planet pinion (11) and the relative shim (12).

Fig. 1600
6. Partially withdraw pin (13) and remove planet pinion (14) and the relative
shim (15).

Fig. 1601
7. Remove pin (13) and remove locating ring (16).

Fig. 1602

30-410
Method of intervention
8. Remove planet pinion (17) and relative thrust washer (18).
Remove side gear (19) and relative shim (20)

Fig. 1603

Installation
To assemble, follow the disassembly steps in reverse order and carry out the following procedures:
Procedure n° 2-4-5-6-7-8
l Shims: oil

30.7.15 - 4WD shaft (F0.04.01) (R3 EVO 110 -> 1001)

Removal
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Remove screws (1) (3 on the left-hand side and 2 on the right-hand side).

Fig. 1604
3. Remove screws (2) and (3) and remove guard (4).

Fig. 1605
4. Remove clamps (5).

Fig. 1606

30-411
 Method of intervention
5. Disconnect brake pipes (6) and differential lock pipes (7).
m Plug the pipes to prevent the ingress of dirt
Label the hoses to avoid confusion on refitting.

Fig. 1607
6. Disconnect steering control pipes (8).
m Plug the pipes to prevent the ingress of dirt
Label the hoses to avoid confusion on refitting.

Fig. 1608
7. Remove front spring pin (9) and slide sleeve (10) along front axle drive
shaft (11).

Fig. 1609
8. Remove rear pin (12) and slide sleeve (13) along the front axle drive shaft
(11).
Remove 4WD shaft (11).

Fig. 1610

30-412
Method of intervention
Refitting
Refitting is the reverse of removal. Use caution in relation to the following procedures:
Procedure 5
l Bleed the front brakes circuit.

30.7.16 - Planetary reduction gear (F0.06.01) (R3 EVO 110 -> 1001)
Removal
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Remove plugs (1) and (2) and drain off all the oil from steering knuckle
housing (3).
m Oil: ~2.5 l (0.66 US.gall.)

Fig. 1611
3. Remove screw (4), loosen breather valve (5) and remove cover (6).

Fig. 1612
4. Unscrew and remove cover (7).
Remove circlip (8).

Fig. 1613
5. Using a slide hammer, remove cover (9).
Remove circlip (10).

Fig. 1614

30-413
 Method of intervention
6. Remove all the nuts (11) and, using two bolts as pullers, dislodge planetary
reduction gear assembly (12).

Fig. 1615
7. Attach planetary reduction gear assembly (12) to a hoist and lift it clear off
the tractor.

Fig. 1616

Refitting
Refit by following the removal steps in reverse order and carry out the following procedures:
Procedure 7
l Check the condition of O-ring (13) and renew it if necessary.
O-ring: grease.
Procedure 2
l Fill the steering knuckle housing with oil.
Steering knuckle housing: ~2.5 l (0.66 US.gall.)

30.7.17 - Disassembly of the planetary reduction gear (R3 EVO 110 -> 1001)

30-414
Method of intervention

Fig. 1617 - Planetary reduction gear

Disassembly
1. Remove screws (1).

Fig. 1618
2. Remove disc (2).

Fig. 1619

30-415
 Method of intervention
3. Extract pins (3).

Fig. 1620
4. Move planet pinions (5) towards the centre of planet carrier (4).

Fig. 1621
5. Position the assembly under a press and, using a suitable tool, separate
ring gear (6) from planet carrier (4).
m Before starting this operation, make sure planet pinions (5) have not
moved outwards.

Fig. 1622
6. Recover ring (7) and ball cage (8).

Fig. 1623
7. Remove ring gear (6) and recover ball cage (9).

Fig. 1624

30-416
Method of intervention
8. Remove planet pinions (5) and shims (10) from planet carrier (4).
Remove needle roller bearings (11) from planet pinions (5).

Fig. 1625
9. Using a puller, remove oil seal (12).
m Renew oil seal (12) on reassembly.

Fig. 1626
10. Only if necessary: Using a puller, remove ring (13).

Fig. 1627
11. Only if necessary: extract bearing (14), circlip (15) and O-ring (16) from
planet carrier (4).

Fig. 1628

30-417
 Method of intervention
Assembly
1. Remove all traces of paint from face “A” of planet carrier (4) and face “B” of
ring gear (6) to facilitate subsequent installation of oil seal (12).

Fig. 1629
2. Only if removed: Heat ring (13) to around 80 °C (176 °F) and install it on
planet carrier (4).
m Make sure that is seated correctly.

Fig. 1630
3. Fit ball cage (9).

Fig. 1631
4. Install planet pinions (5) complete with needle roller bearings (11) and
shims (10) in planet carrier (4) and secure them with pins (3).

Fig. 1632
5. Fit ring gear (6).

Fig. 1633

30-418
Method of intervention
6. Fit ball cage (8) and ring (7).

Fig. 1634
7. Locate disc (2) and tighten screws (1).
m Screws: 63±3 Nm (46.4±2.2 lb.ft.)

Fig. 1635
8. Place the final drive reduction unit under a press and, using the specific tool
T4 (code 5.9030.980.0), install new oil seal (12).

Fig. 1636

30-419
 Method of intervention
30.7.18 - Front brake discs (R3 EVO 110 -> 1001)
REMOVAL
1. Remove screws (1).

Fig. 1637
2. Remove the reaction flange (2) and retrieve the piston return springs (3).

Fig. 1638
3. Remove friction disc (4) and steel disc (5).

Fig. 1639

Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 3
l Friction disc: Transmission oil
Procedure 1
l Screws: 59-65 Nm (43.5-48.0 lb.ft.)

30.7.19 - Front axle brake piston (R3 EVO 110 -> 1001)
Disassembly
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

30-420
Method of intervention
2. Using a slide hammer puller, remove piston (1).
1
m To facilitate removal of the piston, loosen the bleed screw by a few
turns.

F0085700

Fig. 1640
3. Recover seals (2) and (3).
3

F0085710

Fig. 1641

Assembly
To assemble, follow the disassembly steps in reverse order and use caution in relation to the following procedures:
Procedure 2
l Install piston (1), making sure that the side with the slots is oriented outwards.
Seals: Brake fluid

30-421
 Method of intervention
30.8 - G0 - Bodywork - Cab - Platform
30.8.1 - Cab (G0.03.01) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.8.2 - Front hood and side pa... - page 30-428 - (G0.01.01)
See para. 30.8.4 - Cab access steps (R3 E... - page 30-431 - (G0.03.03)
See para. 30.9.8 - Bleeding the braking c... - page 30-483 - (E0.03.01)
REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-).

2. For versions with air conditioning

Disconnect air conditioning pipes (1) and (2).

Fig. 1642
3. For versions with cab
Remove nuts (3) and disconnect pipes (4) and (5) from bracket (6).
Loosen hose clamps (7) and disconnect heater pipes (8).

Fig. 1643
4. For all versions
Disconnect wiring connectors (9), loosen screw (10) and move brake and
clutch fluid reservoir (11) towards the rear of the tractor.

Fig. 1644
5. Unplug connector (12).

Fig. 1645

30-422
Method of intervention
6. Unplug connector (13)of the shuttle wiring, detach pipe (14) and remove
the hose clamp (15).

Fig. 1646
7. Remove screws (16) (3 on the left-hand side and 2 on the right-hand side).

Fig. 1647
8. Remove screws (17) and (18) and remove guard (19).
IMPORTANT
Recover the spacers

Fig. 1648
9. Disconnect the steering pipes (20).
IMPORTANT
Plug the pipes to prevent the ingress of dirt.

IMPORTANT
Label the pipes to avoid confusion on refitting.

Fig. 1649
10. Remove screw (21) and bracket (22).
Disconnect the supply pipe (23) to the steering valve.

Fig. 1650

30-423
 Method of intervention
11. Disconnect the return pipe (24) from the steering valve.

Fig. 1651
12. Disconnect the Park Brake emergency pipes (25) and (26).

Fig. 1652
13. Disconnect pipes (27) and (28).
IMPORTANT
Label the pipes to avoid confusion on reconnection.

Fig. 1653
14. Disconnect pipes (30) and (31) from valve (29).
IMPORTANT
Label the pipes to avoid confusion on reconnection.

Fig. 1654
15. Mark and disconnect the cables (32) for control of the directional control
valves(33).

Fig. 1655

30-424
Method of intervention
16. Mark and remove split pins (34), and disconnect the lift control cables (35).

Fig. 1656
17. Remove screw (36) and disconnect gear range lever (37).

Fig. 1657
18. Remove screw (38) and disconnect gear engage lever (39).

Fig. 1658
19. Remove circlip (40), fork (41) and disconnect cable (42) from the PTO
speed selector lever (43) .

Fig. 1659
20. Only if fitted
Remove circlip (44) and disconnect groundspeed PTO tie-rod (45).

Fig. 1660

30-425
 Method of intervention
21. Disconnect the earth lead (46) from the axle.

Fig. 1661
22. Detach the cab wiring from the hose clamp and unplug connector (47)

Fig. 1662
23. Unplug the three starter motor supply connectors (48).

Fig. 1663
24. Remove the front hood support (49).

Fig. 1664
25. Remove the rear fender screws (50) and fit two eyebolts retained by nuts.

Fig. 1665

30-426
Method of intervention
26. Connect cab (51) to a hoist and tension the ropes slightly.

Fig. 1666
27. Remove the two front nuts (52) and the two rear nuts (53).

Fig. 1667
28. Lift and remove the cab (51).
IMPORTANT
Lift the cab in a level position and ensure there are no re-
straints.

Fig. 1667

30-427
 Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 27
l Nuts: 170 Nm (125.3 lb.ft.)
Procedures 12-13
l Bleed the air from the brake circuit.
Procedure 2
l Air conditioning pipe fittings:
m Delivery: 13.6-20.3 Nm (10-15 lb.ft.)
m Return: 35.3-42.0 Nm (26-31 lb.ft.)

30.8.2 - Front hood and side panels (G0.01.01) (R3 EVO 110 -> 1001)
Engine hood
REMOVAL
1. IMPORTANT
Remove the key from the starter switch and apply the parking brake.

2. Briefly press the pushbutton and raise hood (1).

Fig. 1668
3. Unplug the light cluster connector (2) .

Fig. 1669
4. Remove the side guards(3).

Fig. 1670

30-428
Method of intervention
5. Loosen and remove three of the four nuts (4) fixing the hood support (5) .
IMPORTANT
Leave one screw for safety.

Fig. 1671
6. Holding the hood (1), disconnect the gas spring (6).
Remove the last nut (4) and hood (1).

Fig. 1672

Installation
Install following the removal procedure in reverse.
Lower hood
REMOVAL
1. Remove the four screws (1) and remove the complete guard (2).

Fig. 1673

Installation
Install following the removal procedure in reverse.
30.8.3 - Battery support (G0.01.04) (R3 EVO 110 -> 1001)
REMOVAL
1. DANGER
Apply the parking brakes and remove the key from the starter switch.

30-429
 Method of intervention
2. Remove the tool box (1) .

Fig. 1674
3. Loosen and remove fixing knobs (2) and remove guard (3) .

Fig. 1675
4. Disconnect the lead from the battery (4) negative terminal (-) (5) and then
from the positive terminal (+) (6).

Fig. 1676
5. Remove the screws (7) and remove the control unit (8) complete with sup-
port (9) and set aside.

Fig. 1677
6. Use a hoist to hold the battery support unit (10) in place.

Fig. 1678

30-430
Method of intervention
7. Loosen and remove screws (11) and (12) and remove the assembly.

Fig. 1679

Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 4
l Connect first the positive terminal (+) and then the negative terminal (-).

30.8.4 - Cab access steps (G0.03.03) (R3 EVO 110 -> 1001)
REMOVAL
1. DANGER
Remove the key from the starter switch and apply the parking brake.

2. Loosen and remove screws (1) and remove the access steps.

Fig. 1680

Installation
Refitting is the reverse of removal.
30.8.5 - Fenders (G0.04.01)
Removal
1. Remove the four screws (1) and remove fender assembly (2).
m Make note of the orientation or the anti-rotation brake (3).

Fig. 1681

30-431
 Method of intervention
Installation
Refitting is the reverse of removal.
30.8.6 - Right-hand console (G0.06.01) (R3 EVO 110 -> 1001)
REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal and apply the parking brake.

2. Remove screws (1) and remove storage compartment (2).

Fig. 1682
3. Remove the bolt (3).

Fig. 1683
4. Remove all knobs (4).

Fig. 1684
5. Remove screws (5) and slightly raise right-hand console (6).

Fig. 1685

30-432
Method of intervention
6. Disconnect wiring connector (7) and remove the console (6).

Fig. 1686

Installation
Refitting is the reverse of removal.
30.8.7 - Left-hand console (G0.06.02) (R3 EVO 110 -> 1001)
REMOVAL
1. DANGER
Disconnect the lead from the negative terminal of the battery.

2. Remove screws (1) and cover (2).

Fig. 1687
3. Remove screw (3) and remove the knob (4).

Fig. 1688
4. Remove pin (5) and remove ECO PTO knob (6) and, if present, of the
groundspeed PTO.

Fig. 1689

30-433
 Method of intervention
5. Remove screws (7) and remove console (8).

Fig. 1690

Installation
Refitting is the reverse of removal.
30.8.8 - Front instrument panel (G0.06.04) (R3 EVO 110 -> 1001)
REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Remove cover (1).

Fig. 1691
3. Remove nut (2) and remove steering wheel (3).

Fig. 1692
4. Remove knob (4), remove screws (5) and remove cover (6).

Fig. 1693

30-434
Method of intervention
5. Remove screws (7) and remove cover (8).

Fig. 1694
6. Remove screws (9) and disconnect wiring connector (10) of the shuttle
lever.

Fig. 1695
7. Remove screws (11) and remove support (12) complete with steering col-
umn switch unit (13).

Fig. 1696
8. Remove panels (14) on both sides.

Fig. 1697
9. Detach instrument (15) from the instrument panel.
IMPORTANT
To avoid damaging the instrument panel, prise off the re-
taining clips of the instrument with a screwdriver inserted
through the lateral openings of the instrument panel.

Fig. 1698

30-435
 Method of intervention
10. Disconnect wiring connectors (16) and remove instrument (15).

Fig. 1699
11. Remove lower screws (17).

Fig. 1700
12. Remove upper screws (18) and move the instrument panel towards the
rear of the tractor.

Fig. 1701
13. Disconnect wiring connectors (19) and (20).

Fig. 1702

30-436
Method of intervention
Installation
Refitting is the reverse of removal.
30.8.9 - Roof lining - Version with high visibility cab (G0.06.07) (R3 EVO 110 -> 1001)
REMOVAL
1. Remove screws (1) and remove the guides (2) of the roller sunblind.

Fig. 1703
2. Loosen and remove the fixing screws (3) of roof lining (4).

Fig. 1704
3. Remove the central screws (5) and lower the roof lining (4).

Fig. 1705
4. Pull out the roof lining (4) towards the rear of the tractor.

Fig. 1706

Installation
Refitting is the reverse of removal.

30-437
 Method of intervention
30.8.10 - Heating fan - Version with high visibility cab (R3 EVO 110 -> 1001)
REMOVAL
1. Remove screw (1) fixing duct (2).

Fig. 1707
2. Remove the duct (3).

Fig. 1708
3. Disconnect the wiring connectors (4) and (5).

Fig. 1709
4. Remove screws (6) and (7).

Fig. 1710
5. Remove the heating fan (8)

Fig. 1711

30-438
Method of intervention
Installation
Refitting is the reverse of removal.
30.8.11 - Air conditioning system controls - High-visibility roof system (G0.09.01) (R3
EVO 110 -> 1001)
2
15 bar
A
20 bar
2,45 bar B
28 bar
C

10
4

1a

3 1

9
D0040790

Fig. 1712 - Operating diagram

KEY
1. Compressor with electromagnetic clutch
2. Condenser
3. Receiver-drier tank
4. 4-level pressure switch for compressor clutch engagement/disengagement and condenser cooling fans control.
5. Expansion valve
6. Evaporator
7. Evaporator electronic minimum temperature sensor
8. Cab air blowers
9. Air cowling
10. Condenser cooling fans.
l To: low pressure gas

30-439
 Method of intervention
l B high pressure gas
l C: high pressure liquid
TECHNICAL DATA
l Minimum safety pressure: 2.45 bar Maximum safety pressure: 28 bars
Refrigerant type: R134a
Refrigerant quantity: 1100 g
Total quantity of moisture-free oil added at 1st charging: 200 g
Oil type: SUN-OIL COMPANY SP20
Operation
The compressor (1) is driven from the crankshaft via a drivebelt and pulley with an electromagnetic clutch (1a), which is controlled by
a switch on the control panel. The system is protected by a safety pressure switch, which performs the following functions:
l Inhibits engagement of the electromagnetic clutch (1a) when the system pressure falls below 2.45 bar as a result of incom-
plete charging or refrigerant leakage.
Disengages the clutch (1a) and thereby stops the compressor when the pressure exceeds the permitted maximum of 28 bar
(406 psi) (generally as a result of overheating).
A further contact controls operation of the cooling fans (10) of the condenser (2) in order to maintain normal operating pressure within
the range of 15 to 20 bar. The refrigerant (in vapour form) is drawn in by the compressor where it is compressed. This compression
causes the temperature of the vapour to rise; the refrigerant flows to the condenser (2) where its heat is transferred to the air flow
generated by cooling fans (10). The refrigerant gas is thus cooled to the point at which it condenses to high-pressure liquid. On lea-
ving the condenser, the liquefied refrigerant flows to the receiver-drier (3) which performs three functions: to filter out any impurities,
absorb any moisture in the circuit, and finally, act as a storage reservoir. The liquid refrigerant is then transferred to the evaporator
(6) through the expansion valve (5), which meters the flow of refrigerant into the evaporator to ensure optimum evaporation. In the
evaporator, the refrigerant expands to the critical evaporation point with an ambient temperature of around -- 8°C (17.6°F). The tem-
perature of the air flow over the evaporator (6) generated by the fans (8) is significantly higher than -- 8°C (17.6°F), and therefore it
gives up its heat to the refrigerant, causing it to boil and evaporate. On leaving evaporator (6), the refrigerant returns to compressor
(1) to repeat the cycle. The removal of heat from the ambient air flowing over the evaporator causes the moisture in the air to conden-
se, and the air is thus dehumidified; the moisture condenses on the fins of the evaporator, where, if it is not maintained at temperature
above 0°C (32°F), it will freeze and impair the efficiency of the evaporator. The task of maintaining the evaporator at a temperature
above 0°C (32°F) (and within the optimum temperature for efficient heat exchange), is performed by an electronic temperature sensor
(7); this sensor disengages the clutch (1a) of the compressor (1) when the temperature falls to the lower limit and engages the clutch
(1a) when the evaporator temperature reaches the upper limit. The condensate that forms on the evaporator fins (6) contains dust,
pollen and other airborne particulates; continuous condensation thus has the effect of purifying the air, and the droplets of conden-
sate are conveyed out of the vehicle via two ducts. A fixed quantity of moisture-free oil is added to the circuit in order to lubricate all
the mechanical components of the system; a certain percentage of this oil continuously circulates in the form of an oil mist, thereby
lubricating the compressor (pistons and bearings) and the expansion valve.
Discharging, flushing and recharging
1. DANGER
Before discharging, flushing and recharging the air conditioning system, check the system for leaks using a
leak detector.
2. In order to carry out the system servicing operations you will require a dedicated A/C servicing station capable of performing
the following tasks:
m Aspiration of the refrigerant fluid.
m Creation of a high vacuum to purge the system of contaminants.
m Filtration of the recovered refrigerant.
m Separation of the antifreeze and lubricating oil from the liquid refrigerant and determination of its quantity by weight.
m Recharging system with the exactly the same amounts of refrigerant and oil as those recovered.
m Measuring the system high side pressure and low side pressure.

Discharging the system

1. DANGER
Remove the key from the starter switch.

30-440
Method of intervention
2. Connect the service machine to high pressure service valve (1) and follow the specific instructions for the service machine to
discharge the system.
3. Disconnect the system component to be renewed or overhauled immediately after the service machine stops; plug the open
ends of the system pipes as quickly as possible.
Flushing and recharging the system
1. Before each recharging, the system must be purged of all air, moisture and contaminants (oxides, deposits). This entails
creating a high vacuum within the system to evaporate any moisture present. The vapour, when extracted, draws with it any
contaminants present in the system.
m For the flushing and recharging operations, the service station must be connected to the high (1) and low (2) pressure

service valves.
DANGER
Maximum vacuum must be maintained for at least 10 minutes.

2. After flushing, the moisture-free oil recovered during the discharging operation must be returned into the system, followed by
the refrigerant.
m Quantity of refrigerant (R134a): 1100 g Oil quantity: the quantity recovered.

DANGER
If the system must be discharged and flushed in order to renew a system component, the quantity of oil in the
replaced component must be measured and the same amount of new oil must added as that recovered with
the refrigerant.
DANGER
For details of the oil and refrigerant recharging procedure, refer to the instructions supplied with the service
machine.

30-441
 Method of intervention
30.8.12 - Air conditioning system - Standard roof version (R3 EVO 110 -> 1001)

Fig. 1713 - Operating diagram

KEY
1. Compressor with electromagnetic clutch
2. Condenser
3. Receiver-drier
4. 3-level pressure switch for compressor clutch engagement/disengagement and condenser cooling fans control.
5. Expansion valve
6. Evaporator
7. Evaporator electronic minimum temperature sensor
8. Cab air blowers
9. Air cowling
10. Condenser cooling fan.
l To: low pressure gas
l B: high pressure gas
l C: high pressure liquid
TECHNICAL DATA

30-442
Method of intervention
l Minimum safety pressure: 2.45 bar Maximum safety pressure: 28 bars
Refrigerant type: R134a
Refrigerant quantity: 1100 g
Total quantity of moisture-free oil added at 1st charging: 200 g
Oil type: SUN-OIL COMPANY SP20
Operation
The compressor (1) is driven from the crankshaft via a drivebelt and pulley with an electromagnetic clutch (1a), which is controlled by
a switch on the control panel. The system is protected by a safety pressure switch, which performs the following functions:
l Inhibits engagement of the electromagnetic clutch (1a) when the system pressure falls below 2.45 bar as a result of incom-
plete charging or refrigerant leakage.
Disengages the clutch (1a) and thereby stops the compressor when the pressure exceeds the permitted maximum of 28 bar
(406 psi) (generally as a result of overheating).
A further contact controls the operation of fan (10) of condenser (2) in order to maintain normal operating pressure within the range
of 11 to 15 bar. The refrigerant (in vapour form) is drawn in by the compressor where it is compressed. This compression causes the
temperature of the vapour to rise; the refrigerant flows to the condenser (2) where its heat is radiated to the air flow generated by
the cooling fans (10). The refrigerant vapour is thus cooled to the point where it condenses to high-pressure liquid. On leaving the
condenser, the liquefied refrigerant flows to the receiver-drier (3) which performs three functions: to filter out any impurities, absorb
any moisture in the circuit, and finally, act as a storage reservoir. The liquid refrigerant is then transferred to the evaporator (6) through
the expansion valve (5), which meters the flow of refrigerant into the evaporator to ensure optimum evaporation. In the evaporator,
the refrigerant expands to the critical evaporation point with an ambient temperature of around -- 8°C (17.6°F). The temperature of
the air flow over the evaporator (6) generated by the fans (8) is significantly higher than -- 8°C (17.6°F), and therefore it gives up its
heat to the refrigerant, causing it to boil and evaporate. On leaving evaporator (6), the refrigerant returns to compressor (1) to repeat
the cycle. The removal of heat from the ambient air flowing over the evaporator causes the moisture in the air to condense, and the
air is thus dehumidified; the moisture condenses on the fins of the evaporator, where, if it is not maintained at temperature above 0°C
(32°F), it will freeze and impair the efficiency of the evaporator. The task of maintaining the evaporator at a temperature above 0°C
(32°F) (and within the optimum temperature for efficient heat exchange), is performed by an electronic temperature sensor (7); this
sensor disengages the clutch (1a) of the compressor (1) when the temperature falls to the lower limit and engages the clutch (1a)
when the evaporator temperature reaches the upper limit. The condensate that forms on the evaporator fins (6) contains dust, pollen
and other airborne particulates; continuous condensation thus has the effect of purifying the air, and the droplets of condensate are
conveyed out of the vehicle via two ducts. A fixed quantity of moisture-free oil is added to the circuit in order to lubricate all the mecha-
nical components of the system; a certain percentage of this oil continuously circulates in the form of an oil mist, thereby lubricating
the compressor (pistons and bearings) and the expansion valve.
Discharging, flushing and recharging
1. DANGER
Before discharging, flushing and recharging the air conditioning system, check the system for leaks using a
leak detector.
2. In order to carry out the system servicing operations you will require a dedicated A/C servicing station capable of performing
the following tasks:
m Aspiration of the refrigerant fluid.
m Creation of a high vacuum to purge the system of contaminants.
m Filtration of the recovered refrigerant.
m Separation of the antifreeze and lubricating oil from the liquid refrigerant and determination of its quantity by weight.
m Recharging system with the exactly the same amounts of refrigerant and oil as those recovered.
m Measuring the system high side pressure and low side pressure.

Discharging the system

1. DANGER
Remove the key from the starter switch.

2. Connect the service machine to high pressure service valve (1) and follow the specific instructions for the service machine to
discharge the system.
3. Disconnect the system component to be renewed or overhauled immediately after the service machine stops; plug the open
ends of the system pipes as quickly as possible.

30-443
 Method of intervention
Flushing and recharging the system
1. Before each recharging, the system must be purged of all air, moisture and contaminants (oxides, deposits). This entails
creating a high vacuum within the system to evaporate any moisture present. The vapour, when extracted, draws with it any
contaminants present in the system.
m For the flushing and recharging operations, the service station must be connected to the high (1) and low (2) pressure

service valves.
DANGER
Maximum vacuum must be maintained for at least 10 minutes.

2. After flushing, the moisture-free oil recovered during the discharging operation must be returned into the system, followed by
the refrigerant.
m Quantity of refrigerant (R134a): 1100 g Oil quantity: the quantity recovered.

DANGER
If the system must be discharged and flushed in order to renew a system component, the quantity of oil in the
replaced component must be measured and the same amount of new oil must added as that recovered with
the refrigerant.
DANGER
For details of the oil and refrigerant recharging procedure, refer to the instructions supplied with the service
machine.

30.8.13 - Heating and air conditioning unit - Version with high visibility cab (G0.09.03)
(R3 EVO 110 -> 1001)
Previous operations:
See para. 30.8.11 - Air conditioning syste... - page 30-439 - (G0.09.01)
See para. 30.8.9 - Roof lining - Version ... - page 30-437 - (G0.06.07)
REMOVAL
1. Remove the ducts (1) on both sides.

Fig. 1714
2. Loosen hose clamps (2) and disconnect the condensate collection pipes
(3).

Fig. 1715

30-444
Method of intervention
3. Disconnect the connectors (4) from the anti-ice sensor(5).

Fig. 1716
4. Loosen clamp (6) and disconnect heater pipe (7).

Fig. 1717
5. Loosen clamp (8) and disconnect heater pipe (9).
Disconnect the air conditioning pipes (10).
IMPORTANT
Retrieve the O-rings from the air conditioning pipes

Fig. 1718
6. Remove screws (11) and remove the heating and air conditioning carrier
assembly (12).

Fig. 1719

30-445
 Method of intervention
Installation
Refitting is the reverse of removal.
30.8.14 - Heating control cable (R3 EVO 110 -> 1001)
REMOVAL
1. Remove screws (1) and lower the switch support assembly (2).

Fig. 1720
2. Recover spacers (3).

Fig. 1721
3. Remove the sheath retainer (4) and detach the heating control cable (5).

Fig. 1722
4. Loosen screw (6), remove the sheath retainer (7) and remove cable (5).

Fig. 1723

Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedures 3-4
l Ensure that when the heating control knob is set to cool, the valve is closed completely. If necessary, adjust the position of the
sheath with respect to the valve until it is completely closed.

30-446
Method of intervention
30.8.15 - Condenser - Version with high-visibility roof (R3 EVO 110 -> 1001)
REMOVAL
1. Remove screw (1) and reposition pipe (2) towards the rear of the tractor.
IMPORTANT
Recover spacer (3).

IMPORTANT
Immediately plug the ends of the pipe to prevent moisture
from getting into the system.
Fig. 1724
2. Disconnect pipe (4) from receiver-drier (5).
Remove screw (6) and remove pipe (4).
IMPORTANT
Recover spacer (7).

IMPORTANT
Immediately plug the opening in the receiver-drier to prevent
moisture from entering. Fig. 1725

3. Turn over the condenser and remove screws (8).

Fig. 1726
4. Remove condenser (9).

Fig. 1727

30-447
 Method of intervention
Installation
To assemble, follow the disassembly steps in reverse order and carry out the fol-
lowing procedures.
Procedures 1-2
l Check the condition of the O-rings and renew them if damaged.
l Flush and recharge the air conditioning system.

Fig. 1728

30.8.16 - Receiver drier - Version with high visibility roof (R3 EVO 110 -> 1001)
Removal
1. Disconnect the pipes (1) and (2).
IMPORTANT
Plug the open ends of the pipes immediately to prevent
moisture getting into the circuit.

Fig. 1729
2. Remove screw (3).

Fig. 1730
3. Remove receiver-drier (4).

Fig. 1731

30-448
Method of intervention
Refitting
Refit by following the removal steps in reverse order and carry out the following
procedures:
Procedure 1
lInspect the seals and renew them if damaged.
Flush and recharge the air conditioning system.

Fig. 1732

30.8.17 - Conditioner evaporator - Version with standard roof (R3 EVO 110 -> 1001)
REMOVAL
1. Remove all fixing screws (1) of cover (2).

Fig. 1733
2. Remove nuts (3), detach the thermostat (4) and fan speed selector (5) from
the heating unit and tilt up the cover (2).
IMPORTANT
Take care when handling the thermostat probe.

Fig. 1734
3. Remove evaporator (6).

Fig. 1735

Installation
Refitting is the reverse of removal.

30-449
 Method of intervention
30.8.18 - Air-conditioning evaporator - Version with high-visibility roof (R3 EVO 110 ->
1001)
Removal
1. Remove evaporator (1).
IMPORTANT
m Recover foam gasket (2).

Fig. 1736

Refitting
Refitting is the reverse of removal.
30.8.19 - Heating valve - Version with high visibility cab (R3 EVO 110 -> 1001)
REMOVAL
1. Remove screw (1) and lower valve (2).

Fig. 1737
2. Loosen screw (3), remove the sheath retainer (4) and withdraw the valve
control cable (5).

Fig. 1738
3. Loosen hose clamps (6), detach pipes (7) and (8) and remove the valve (2).

Fig. 1739

30-450
Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 2
l Ensure that when the heating control knob is set to cool, the valve is closed completely. If necessary, adjust the position of the
sheath with respect to the valve until it is completely closed.

30.8.20 - Heater matrix - Version with high-visibility roof (R3 EVO 110 -> 1001)
Removal
1. Remove all the screws (1), remove spring clips (2) and remove the half
casing (3).
IMPORTANT
Cut gasket (4) in proximity to the joint between the half cas-
ings.

Fig. 1740
2. Remove heater matrix (5).

Fig. 1741

Refitting
Refitting is the reverse of removal.
30.8.21 - Heating radiator - Version with standard roof (R3 EVO 110 -> 1001)
REMOVAL
1. Remove all fixing screws (1) of cover (2).

Fig. 1742

30-451
 Method of intervention
2. Remove nuts (3), detach the thermostat (4) and fan speed selector (5) from
the heating unit and tilt up the cover (2).
IMPORTANT
Take care when handling the thermostat probe.

Fig. 1743
3. Loosen the clamp (6) and disconnect pipe (7).

Fig. 1744
4. Remove the complete radiator assembly (8).

Fig. 1745

30-452
Method of intervention
Installation
Refitting is the reverse of removal.
30.8.22 - Heating and air conditioning unit fan - Version with standard roof (R3 EVO 110
-> 1001)
REMOVAL
1. Remove all fixing screws (1) of cover (2).

Fig. 1746
2. Remove screws (3) and disconnect resistor (4).
Disconnect the four connectors (5) from the fan (6).

Fig. 1747
3. Remove screws (7) and remove half housing (8).

Fig. 1748
4. Detach the retainer (9) and remove the fan assembly (6) .

Fig. 1749

30-453
 Method of intervention
Installation
Refitting is the reverse of removal.
30.8.23 - Expansion valve - Version with high visibility roof (R3 EVO 110 -> 1001)
Removal
1. Remove all the screws (1), remove spring clips (2) and remove the half
casing (3).
IMPORTANT
Cut gasket (4) in proximity to the joint between the half cas-
ings.

Fig. 1750
2. Remove insulating tape (5).
IMPORTANT
Renew the insulating tape on reassembly

Fig. 1751
3. Remove spring clip (6) securing sensor (7).

Fig. 1752
4. Remove screws (8) and remove pipes (9) and expansion valve (10).

Fig. 1753

Refitting
Refit by following the removal steps in reverse order and carry out the following procedures:
Procedure 4
l Check the condition of the O-rings and renew them if damaged.

30-454
Method of intervention
30.8.24 - Expansion valve - Version with standard roof (R3 EVO 110 -> 1001)
REMOVAL
1. Remove insulating tape (1).
IMPORTANT
Renew the insulating tape on reassembly.

Fig. 1754
2. Remove screws (2) and remove pipes (3) and expansion valve (4).

Fig. 1755

Installation
To assemble, follow the disassembly steps in reverse order and carry out the following procedures.
Procedure 2
l Check the condition of the O-rings and renew if damaged.

30.8.25 - Antifreeze sensor - Version with high visibility roof (R3 EVO 110 -> 1001)
Removal
1. Remove all the screws (1), remove spring clips (2) and remove the half
casing (3).
IMPORTANT
m Cut gasket (4) in proximity to the joint between the half casings.

Fig. 1756
2. Remove insulating tape (5).
IMPORTANT
m Renew the insulating tape on reassembly

Fig. 1757

30-455
 Method of intervention
3. Remove spring clip (6) securing sensor (7).

Fig. 1758
4. Remove nut (8) remove antifreeze sensor (7).

Fig. 1759

Refitting
Refitting is the reverse of removal.
30.8.26 - Condenser cooling fans - Version with high-visibility roof (R3 EVO 110 -> 1001)
REMOVAL
1. Disconnect the wiring connector of the fan (1) to be removed, remove
screws (2) and remove fan (1).

Fig. 1760

Installation
Refitting is the reverse of removal.
30.8.27 - Condenser fan control pressure switch - Version with high visibility roof (R3
EVO 110 -> 1001)
REMOVAL
1. Unplug wiring connector (1) and remove pressure switch (2).

Fig. 1761

30-456
Method of intervention
Installation
Refitting is the reverse of removal.
30.8.28 - Air conditioning temperature control thermostat - Version with standard roof
(R3 EVO 110 -> 1001)
REMOVAL
1. Detach connectors (2) from thermostat (1).

Fig. 1762
2. Remove nut (3) and disconnect thermostat (1).

Fig. 1763
3. Withdraw the probe (4) from the heating unit and remove thermostat (1).

Fig. 1764

Installation
Refitting is the reverse of removal.
30.8.29 - Remote valve control cables (R3 EVO 110 -> 1001)
Removal
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

30-457
 Method of intervention
2. Loosen nuts (1) and disconnect remote valve control cables (2).
IMPORTANT
Label the cables to avoid confusion on reconnection.

Fig. 1765
3. Remove screws (3) and remove storage compartment (4).

Fig. 1766
4. Disconnect the relevant control cable (6) from lever (5).
Remove lock ring (7) and remove cable (6).

Fig. 1767

30-458
Method of intervention
Refitting
Refitting is the reverse of removal.
30.8.30 - Adjustment of the control levers (R3 EVO 110 -> 1001)
Adjustment
1.
This procedure should be carried out with the lift unit installed on the transmission and service tool T2 installed
in place of the auxiliary services remote control valve. Furthermore, the level tube installed inside the lift cover
should be replaced with another tube approximately 100 mm long.
2. DANGER
Before starting the tractor, make sure that the yellow lift control lever is in the ‘maximum depth’ position.

3. DANGER
When starting the engine, make sure that the hand throttle lever is in the minimum (idle) position.

4. Remove screws (1) and remove cover (2).

Fig. 1768
5. Connect service tool T2 to the tractor hydraulic system as shown.

Fig. 1769
6. Connection to service tool T2.

Fig. 1770

30-459
 Method of intervention
7. Attach either an implement or a 200 kg weight to the 3-point linkage.
Move yellow lever (3) to the ‘maximum height’ position.

Fig. 1771
8. Check that lever (4) is up against stop (5).
If not, or if lever (4) is restricting the travel of yellow lever (3), adjust the
length of tie rod (6).

Fig. 1772
9. After making the adjustment, move yellow lever (3) to the ‘control’ position
and green lever (7) to position “12”.

Fig. 1773
10. Start the engine and run at idle speed and slowly move yellow lever (3) to
the maximum lift position.

Fig. 1773
11. When the lift stops, check that the end of piston (8) is flush with cylinder (9).

Fig. 1774

30-460
Method of intervention
12. If piston (8) protrudes from the cylinder or stops inside it, adjust the stroke
by way of tie rod (10).
m Shorten the tie-rod to make the piston protrude from the cylinder.
Lengthen the tie rod to cause the piston to retract inside the cylinder.

Fig. 1775
13. Move yellow lever (3) to the ‘control’ position and green lever (7) to position
“0”.
m Take care as the lift arms should still rise a little.

Fig. 1776
14. Check that piston (8) protrudes approximately 5 mm from cylinder (9).

Fig. 1777
15. If piston (8) does not stop in the correct position, adjust the stroke by way
of screw (11).
m Screw in if the piston protrudes too much (7 mm).
Screw out if the piston does not protrude enough (3 mm).
After each adjustment, check by moving green lever (7) to position
“12” and then back to position “0”.

Fig. 1778
16. Move green lever (7) to position “12”.
m The lift should be lowered to maximum depth position.
Slowly move green lever (7) towards position “0” until the lift starts to move.

Fig. 1779

30-461
 Method of intervention
17. The lift should start to move when green lever (7) is in position “4”.

Fig. 1780
18. If the lift starts to move earlier (near positions “5” or “6”) shorten tie-rod (12).
If it starts to move later (near positions “3” or “2”) lengthen tie-rod (12).

Fig. 1781
19. On completion of the adjustments, replace the temporary level tube with the original one, remove special tool T2 and complete
the installation of the lift and the removed components.

30-462
Method of intervention
30.9 - H0 - Hydraulic system
30.9.1 - Pump for hydraulic lift and auxiliary services (R3 EVO 110 -> 1001)
REMOVAL
1. DANGER
Disconnect the battery’s negative terminal lead (-).

2. Remove screws (1) and (2) and remove support assembly (3).

Fig. 1782
3. Loosen union (4) and disconnect the delivery pipe (5).

Fig. 1783
4. Loosen hose clamps (6) and move hose (7) downwards.
Remove screws (8) and remove suction pipe (9).
IMPORTANT
Inspect the O-ring carefully.

Fig. 1784
5. Remove screws (10) (n. 2) and remove the pump (11) complete with its
gasket.
IMPORTANT
Renew the gasket every time it is disturbed.

Fig. 1785

30-463
 Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 4
l Mating face: Silastic

30.9.2 - Power steering valve (H0.02.01) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.8.2 - Front hood and side pa... - page 30-428 - (G0.01.01)
REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Remove screw (1) and place the brake oil tank (2) aside.

Fig. 1786
3. Remove holder (3).

Fig. 1787
4. Remove screws (4) and support (5).

Fig. 1788

30-464
Method of intervention
5. Loosen and remove all unions (6).
IMPORTANT
Renew the copper washers on reassembly.

Fig. 1789
6. Remove screws (7) and remove bulkhead (8).

Fig. 1790
7. Remove screws (9) and remove power steering (10).

Fig. 1791

30-465
 Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 7
l Power steering hole: molybdenum grease

30.9.3 - Power steering disassembly (R3 EVO 110 -> 1001)

26 15
24 18 13

25
25b
27 25a
28 19
29 21
20
22
16
17a

17b
12
10

17

23a
23b

23 23a
8 5a

7 6

11
9
2

5 1

Fig. 1792 - Power steering

30-466
Method of intervention
Disassembly
1. Unscrew and remove screws (1) and (3) and washers (2) securing cover (4)
(6 screws plus one special screw). 3
1 2

F0009470

Fig. 1793
2. Remove cover (4) by sliding it off sideways.
4

F0009480

Fig. 1794
3. Lift rotary spool unit (5) complete with O-rings (6) and spacer (7).
5

6 7

F0009490

Fig. 1795
4. Remove drive shaft (8).

F0009500

Fig. 1796
5. Remove distributor plate (9).

F0009510

Fig. 1797

30-467
 Method of intervention
6. Remove relief valve stop bush (10).

10

F0009520

Fig. 1798
7. Remove O-ring (11).

11

F0009530

Fig. 1799
8. Remove ball (12) of the check valve and pins (13) and balls (15) of the
suction valves.
15

12 13

F0009541

Fig. 1800
9. Checking through the central hole of the spool, position spool-bush as-
sembly cross pin (16) horizontally. Push assembly (17) and the bearing
assembly out of power steering housing (18).
17

18
F0009550

Fig. 1801
10. Remove outer ring (19), inner ring (20) and roller bearing (21) from the
spool; remove also ring (22).
m It may occur that inner ring (20) (thin) remains in the steering valve
22 20
housing; ensure that it is actually removed.

21
19
F0009560

Fig. 1802

30-468
Method of intervention
11. Remove cross pin (16), bush (17b) and spool (17a).
m Use special cover screw (3).

17b

3 16
17a
F0009570

Fig. 1803
12. Slowly withdraw spool (17a) from bush (17b).
17b

17a

F0009580

Fig. 1804
13. Press neutral position springs (23) and remove them from spool (17a).
23

17a

F0009590

Fig. 1805
14. Remove dust seal (24) and composite seal (25) (O-ring + seal).

25

24

F0129940

Fig. 1806
15. Remove plug (26) and its seal.

26

F0129930

Fig. 1807

30-469
 Method of intervention
16. Remove pressure relief adjuster screw (27).

27

F0129950

Fig. 1808
17. Turn over the steering valve housing and remove spring (28) and relief
valve (29).
IMPORTANT 29
The seat of the relief valve is a force fit in the housing and
28
cannot be removed.

F0009681

Fig. 1809

Installation
1. IMPORTANT
Prior to reassembly, lubricate all components with gearbox
23b
oil. 23a

Insert the two flat washers (23a) in the seat and centre them relative to
the diameter of spool (17a). Insert the four curved washers (23b) in pairs
23b 23a 17a
between the two flat washers (23a) and push them fully home.

F0009690

Fig. 1810
2. Align spring assembly (23).

23

F0009700

Fig. 1811
3. Insert spool (17a) in bush (17b).
IMPORTANT 17b

Check that the position between the bush and the spool is 17a
as described in stage 1.

F0009580

Fig. 1811

30-470
Method of intervention
4. Simultaneously push springs (23) and spool (17a) until the springs are
seated in the slots in bush (17b). 23

17a

17b

F0009710

Fig. 1812
5. Align springs (23) and make sure they are positioned centrally in relation to
the diameter of bush (17b). 23

17b
F0009720

Fig. 1813
6. Install ring (22) on its seat on bush (17b).
IMPORTANT
22
Ring (22) must be free to rotate without interfering with
springs (23).

17b
F0009730

Fig. 1814
7. Insert cross pin (16).

16

F0009740

Fig. 1815
8. Install the thrust bearing components in the order indicated in point 9.

20

22 21 F0009751

Fig. 1816

30-471
 Method of intervention
9. Thrust bearing assembly.
20
m 17a - Spool
17b - Bush 21
21- Needle roller bearing 22
20 - Inner ring
22 - Outer ring
17
DANGER
17
The outer ring must be installed with chamfer “X” facing the
shoulder of the spool.
Fig. 1817
10. Position steering valve housing (18) so the hole is horizontal. Insert into the
bush/spool assembly bore the guide of special tool T9 (P/N. 5.9030.480.0).

Fig. 1818
11. Lubricate oil seal (25a) and O-ring (25b) and fit them on the push rod of tool
T9 (P/N. 5.9030.480.0).

Fig. 1819
12. Fit tool T9 (P/N. 5.9030.480.0). and insert it in the guide previously inserted
in the steering valve bore.

Fig. 1819
13. Push seal (25) into its seat in steering valve housing (18) while rotating it
to ease it into position.

18
F0009790

Fig. 1820

30-472
Method of intervention
14. Withdraw tool T9 (P/N 5.9030.480.0). from valve housing (18) and removal
also the guide, leaving the tool push rod in the housing.

Fig. 1821
15. Insert bush/spool assembly (17) in steering valve bore (18). Rotate the
valve slightly while inserting it to ease it into position.
17
IMPORTANT
Keep the cross pin horizontal while inserting the assembly.

18
F0009810

Fig. 1822
16. Push in assembly (17) until fully seated so that it forces out the tool push
rod left in the housing in step 14. 18

17

F0009820

Fig. 1823
17. Rotate steering valve housing (18) until the centre hole is vertical. Insert
ball (12) of the relief valve in the hole indicated by the arrow. 12

18

F0009830

Fig. 1824
18. Screw valve retaining bush (10) into the bore of the relief valve.
IMPORTANT
10
The top of the retaining bush should be set below the face of
steering valve housing (18).

18

F0009521

Fig. 1825

30-473
 Method of intervention
19. Insert the two balls (15) in the holes indicated by the arrows.

15

F0010310

Fig. 1826
20. Insert elements (13) in the same holes.
13

F0009841

Fig. 1827
21. Lubricate O-ring (11) and fit it in its seat.
11
m O-ring: Gearbox oil

F0009850

Fig. 1828
22. Locate distributor plate (9) so that its holes are aligned with the holes in
9
steering valve housing (18).

18

F0009860

Fig. 1829
23. Insert drive shaft (8) in the hole so that it engages the cross pin; check
that the engagement with the cross pin is parallel to the steering column
mounting face.
8

F0009870

Fig. 1830

30-474
Method of intervention
24. Position the drive shaft so that it is vertical and hold it in this position using
a suitable tool.

F0009880

Fig. 1831
25. Lubricate the two O-rings (6) and fit them in the two grooves in rotary spool
unit (5). Fit rotary spool unit (5) to drive shaft (8). 6

m O-rings: Gearbox oil 8

F0009890

Fig. 1832
26. DANGER
Install rotor (5a) on drive shaft (8) so that the valley between
two lobes is aligned with the groove in the end of the drive
shaft. Then turn outer ring (5b) to align the fixing holes. 8

5a

F0009900

Fig. 1833
27. Install spacer (7).
7

F0009910

Fig. 1834
28. Fit cover (4).
4

F0009920

Fig. 1835

30-475
 Method of intervention
29. Insert special screw (3) complete with washer (2) in the hole indicated in
the photo.
3

F0009930

Fig. 1836
30. Insert the six screws (1) complete with washers (2). Tighten screws (1) and
(3) in a crosswise sequence to a torque of 30±6 Nm (22.1±4.4 lb.ft.). 3
1 2

F0009471

Fig. 1837
31. Fit valve (29).

29

F0129960

Fig. 1838
32. Fit spring (28).

28

F0129970

Fig. 1839
33. Fit pressure adjustment screw (27).

27

F0129950

Fig. 1839

30-476
Method of intervention
34. Fit plug (26) complete with seal.
m Plug: 50±10 Nm (36.8±7.4 lb.ft.)

26

F0129930

Fig. 1839
35. Locate dust seal (24) in steering valve housing (18).
24

18

F0009970

Fig. 1840
36. Install dust seal (24) in the steering valve housing using a suitable drift and
a soft faced mallet.

F0009980

Fig. 1841
37. Close off the oil ports with plastic plugs to prevent impurities getting in.
IMPORTANT
Fit the plugs by hand pressure alone; do not hammer.

F0009990

Fig. 1842
38. On completion of the assembly operation, test the operating pressure of the relief valve and calibrate as necessary.

30-477
 Method of intervention
30.9.4 - Pressure relief valve setting (R3 EVO 110 -> 1001)
Checking maximum operating pressure
1. Disconnect the rod side pressure connection from one of the steering cylin-
ders (1) and replace with union “B” connected in turn to a 400 bar full scale
pressure gauge.

Fig. 1843
2. Start the engine and turn the steering to full lock to expel any air from the steering circuit.
3. Force the steering to full lock on the side to which the pressure gauge is connected and read off the maximum continuous
pressure on gauge “A”.
m Maximum permissible pressure: 150 bar (2175.6 psi)

4. If the pressure reading differs from the specified value, adjust the pressure relief valve of the power steering unit.
Pressure relief valve setting
1. IMPORTANT
Remove the power steering to calibrate the relief valve.

2. Remove plug (3) and relative seal (4).

Using a hex key proceed to adjust relief pressure by positioning setscrew
(5).
m To INCREASE the pressure, turn the screw CLOCKWISE
To REDUCE the pressure, turn the screw COUNTERCLOCKWISE.
Refit plug (3), checking that seal (4) is correctly seated.
m Plug: 50÷60 Nm (36.9-44.2 lb.ft.)

Fig. 1844

30.9.5 - Power steering pump (R3 EVO 110 -> 1001)

REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Loosen clamps (1) from hose (2).

Fig. 1845

30-478
Method of intervention
3. Remove the screws (3) and suction pipe (4).
IMPORTANT
Check the condition of the O-ring.

Fig. 1846
4. Disconnect delivery pipe (6) from pump (5).

Fig. 1847
5. Loosen and remove the retainer screws (7) of pump (5) .

Fig. 1848
6. Remove pump (5) complete with gasket.
IMPORTANT
Renew the gasket every time it is disturbed.

Fig. 1849
7. Extract the drive coupling (8) and check the condition of the teeth.

Fig. 1850

30-479
 Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 6
l Mating face: Silastic

30.9.6 - Gearbox oil cooler (R3 EVO 110 -> 1001)

REMOVAL
1. DANGER
Remove the key from the starter switch.

2. Remove lower guard (1).

Fig. 1851
3. Unscrew and remove screws (2).

Fig. 1852
4. Remove the gearbox oil cooler (3).

Fig. 1853

Installation
Refitting is the reverse of removal.
l Take the engine revs to minimum for a few minutes to fill the cooler.
l Stop the engine and restore the gearbox oil levels.

30-480
Method of intervention
30.9.7 - Rear remote control valve (H0.07.01) (R3 EVO 110 -> 1001)
REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Loosen nuts (1) and disconnect remote valve control cables (2).

Fig. 1854
3. For versions with front lift
Disconnect pipes (3).
IMPORTANT
Plug the pipes and ports to prevent the ingress of dirt

Fig. 1855
4. Remove screw (4) and remove clamp (5).

Fig. 1856
5. Remove unions (6) and remove pipes (7).
IMPORTANT
Renew the copper washers on reassembly.

Fig. 1857

30-481
 Method of intervention
6. Remove screws (8) and remove bracket (9).

Fig. 1858
7. Disconnect oil supply pipe (10) to the control valve.
IMPORTANT
Plug the pipes to prevent the ingress of dirt.

Fig. 1859
8. Remove union (11).
IMPORTANT
Renew the copper washers on reassembly.

Fig. 1860
9. Remove the screws (12) to disengage pipe (13).

Fig. 1861
10. Loosen union (14), remove nut (15) and remove clamp (16).

Fig. 1862

30-482
Method of intervention
11. Remove screws (17) and remove remote control valve (18).

Fig. 1863

Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 9
l Screws: Loctite 542

30.9.8 - Bleeding the braking circuit (E0.03.01) (R3 EVO 110 -> 1001)
Bleeding the first part of the circuit
IMPORTANT
During brake bleeding operations, ensure that the fluid in the brake fluid reservoir is always above the minimum level.

l Remove the dust cap and attach a length of transparent tubing “A” to the bleed valve; insert the other end of the tubing in a
container to collect the fluid.
l Ensure that the brake pedals are joined by the connecting latch.
l Fully depress the brake pedal until you feel significant resistance, at which point keep pressing the pedal.
l Slowly open the bleed screw (1) on the distributor valve (2) and allow the fluid and air to flow throughout the entire pedal travel.
l While holding the pedal fully depressed, tighten the bleed screw (1).
l Repeat the previous operations until the fluid flowing from the bleed valve is entirely free of air bubbles.
Bleeding the rear brake circuit
l Disconnect the brake pedals by removing the connecting latch.
l Fully depress the pedal of the pump corresponding to the side of the circuit to be bled until you feel significant resistance, at
which point keep pressing the pedal.
l Slowly open the bleed screw and allow the fluid and air to flow throughout the entire pedal travel.
l While holding the pedal fully depressed, tighten the bleed screw; release the pedal.
l Repeat the sequence of steps until the fluid flowing from the bleed screw is entirely free of air bubbles.
IMPORTANT
After bleeding, fit the dust caps to the bleed screws

Bleeding the front brake circuit

l Disconnect the brake pedals by removing the connecting latch.
l Start the engine and take the revs to minimum.
l Lightly depress the pedal of the circuit to be bled.
l Slowly open the bleed screw and allow the oil to flow out until there are no air bubbles present.
IMPORTANT
After bleeding, fit the dust caps to the bleed screws.

30-483
 Method of intervention
Bleed screw positioning
Braking distributor valve

Fig. 1864

Rear brakes

Fig. 1865

Front brakes

Fig. 1866

30.9.9 - Parking brake control valve (R3 EVO 110 -> 1001)
REMOVAL
1. DANGER
Before disassembly, depress the parking brake repeatedly to discharge residual pressure from the circuit.

2. Disconnect the connectors (1) and (2) from valve (3).

Fig. 1867

30-484
Method of intervention
3. Unscrew and remove screws (4).

Fig. 1868
4. Loosen and remove screws (5) and support plate (6).
IMPORTANT
Note that earth lead (8) is fixed below nut (7).

Fig. 1869
5. Disconnect pipes (9) and remove valve assembly(3).

Fig. 1870

30-485
 Method of intervention
Installation
Refitting is the reverse of removal.
l Bleed the brakes circuit.

30.9.10 - Braking distributor valve (R3 EVO 110 -> 1001)

REMOVAL
1. DANGER
Apply the parking brakes and remove the key from the starter switch

2. Disconnect brake pump connecting pipes (1) and (2).

IMPORTANT
Plug the pipes to prevent the ingress of dirt.

Fig. 1871
3. Disconnect rear and front brakes pipes (3) and (4).
Disconnect pipes (5) and (6).
IMPORTANT
Plug the pipes to prevent the ingress of dirt.

IMPORTANT
Renew the copper washers on reassembly.
Fig. 1872

4. Loosen and remove support fixing nuts (7) and remove valve assembly (8) .

Fig. 1873

Installation
Refitting is the reverse of removal.
l Bleed the brake circuits.

30.9.11 - Services solenoid valve assembly (H0.10.01) (R3 EVO 110 -> 1001)

30-486
Method of intervention
REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Unplug connectors (1), (2) from the solenoid valve set and detach wiring (3)
from the clamps and move upwards.
IMPORTANT
Label the connectors to avoid confusion on refitting.

Fig. 1874
3. Loosen unions (4) and disconnect pipes (5) and (6).

Fig. 1875
4. Loosen clamp (7) and pipe (8) from the solenoid valve set.

Fig. 1876
5. Remove union (9) and disconnect pipes (10), (11) and (12).
IMPORTANT
Renew the copper washers on reassembly.

Fig. 1877

30-487
 Method of intervention
6. Remove rear PTO control pipes (13).

Fig. 1878
7. Remove screws (14).
IMPORTANT
Recover the spacers.

Fig. 1879
8. Remove solenoid valve assembly (15).
IMPORTANT
Recover the spacers installed between the solenoid valve
assembly and the transmission.

Fig. 1880

30-488
Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 8
l Check the condition of O-ring (16) and renew it if necessary.
l O-ring: transmission oil.
l Fill the transmission with the required quantity of oil.

Start the engine and run for a few minutes to allow the coolant to circulate; check
the system for leaks.

Fig. 1881

30.9.12 - Pressure reduction and holding valve disassembly (R3 EVO 110 -> 1001)
Disassembly
1. Loosen and remove screws (1) and separate solenoid valve assembly (2) .
IMPORTANT
Retrieve and check the O-rings.

Fig. 1882
2. Separate the pressure holding unit (3) from the accumulator assembly (4).

Fig. 1883
3. Loosen valve (5) and remove.
IMPORTANT
Check the underhead O-ring and replace if necessary.

Fig. 1884

30-489
 Method of intervention
4. Remove plug (6) and withdraw spool (7) and spring (8).
IMPORTANT
Remove one valve at a time to avoid confusion on subse-
quent reassembly.

IMPORTANT
Check the O-rings and replace if necessary.

Fig. 1885
5. Remove plug (9) and withdraw ball (10).
IMPORTANT
Check the O-ring and replace if necessary.

Fig. 1886

Installation
Refitting is the reverse of removal.
30.9.13 - Shuttle solenoid valves assembly
REMOVAL
1. Disconnect the connectors (1) from the upper solenoid valves.
IMPORTANT
Label the connectors to avoid confusion on refitting.

Fig. 1887
2. Unplug the front connector (2) and lower connector (3).

Fig. 1888

30-490
Method of intervention
3. Disconnect unions (4), (5) and (6).

Fig. 1889
4. Remove screws (7) and remove solenoid valve assembly (8).

Fig. 1890

Installation
To assemble, follow the disassembly steps in reverse order and carry out the fol-
lowing procedures.
Procedure 4
l Check the condition of O-rings (9) and renew them if necessary.

Fig. 1891

30-491
 Method of intervention
30.10 - L0 - Electrical system
30.10.1 - Lateral battery (R3 EVO 110 -> 1001)
REMOVAL
1. DANGER
Apply the parking brakes and remove the key from the starter switch.

2. Remove the tool box (1) .

Fig. 1892
3. Remove the fixing knobs (2) of guard (3).
Remove the guard.

Fig. 1893
4. First disconnect the negative terminal lead (-) from the battery (4) and then
from the positive terminal (+).

Fig. 1894
5. Remove screws (5), battery fixing brackets (6) and then the battery (4).

Fig. 1895

30-492
Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 4
l Always reconnect the positive lead (+) before the negative lead (-).

30.10.2 - Alternator (R3 EVO 110 -> 1001)

REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Loosen screws (1) and (2) of the fuel pump bracket in order to slacken off
drivebelt (3).

Fig. 1896
3. Disconnect wires (5) from alternator (4).

Fig. 1897
4. Remove screw (6) and move bracket (7) downwards.

Fig. 1898
5. Remove upper and lower screws (8) and remove alternator (4).

Fig. 1899

30-493
 Method of intervention
Installation
To assemble, follow the disassembly steps in reverse order and carry out the following procedures.
Procedure 2
l Adjust drivebelt tension.

30.10.3 - Clutch pedal potentiometer (R3 EVO 110 -> 1001)

REMOVAL
1. Remove the four nuts (1) and tilt the fuse box (2) to the right.

Fig. 1900
2. Remove nuts (3).
IMPORTANT
Recover clutch pedal travel stop pins (4) and clutch pedal
return spring (5).

Fig. 1901
3. Remove nuts (6) and remove cover (7).

Fig. 1902
4. Remove tie-rod (8) and disconnect wiring connector (9).

Fig. 1903

30-494
Method of intervention
5. Remove nuts (10) and remove the potentiometer assembly.

Fig. 1904
6. Remove screws (11) and remove potentiometer (12).

Fig. 1905

Installation
To assemble, follow the disassembly steps in reverse order and carry out the fol-
lowing procedures.
Procedure 6
lCheck the condition of retaining spring (13) and renew it if damaged.
Calibrate the clutch pedal

Fig. 1906

30.10.4 - Shuttle output speed sensor (R3 EVO 110 -> 1001)
REMOVAL
1. Remove the front right-hand nut (1) fixing the cab and retrieve the plate (2).

Fig. 1907

30-495
 Method of intervention
2. Using a suitable hoist, apply upward force on the cab.

Fig. 1908
3. Remove screws (3) and nut (4).
IMPORTANT
Remove the stud under nut (4).

Fig. 1909
4. Remove cab support (5).

Fig. 1910
5. Remove screw (6) and remove sensor (7).

Fig. 1911

30-496
Method of intervention
Installation
Refitting is the reverse of removal.
30.10.5 - Accelerator pedal position sensor (R3 EVO 110 -> 1001)
REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Loosen and remove screws (1) and remove cover (2).

Fig. 1912
3. Unplug connector (3), remove screws (4) and remove position sensor (5).

Fig. 1913

Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 1
l Calibrate the accelerator pedal (see “Calibrations and electronic diagnosis” section)

30.10.6 - Hand throttle position sensor (R3 EVO 110 -> 1001)
REMOVAL
1. Loosen and remove screws (1) and lift the lever assembly (2).

Fig. 1914

30-497
 Method of intervention
2. Disconnect the connector (3), remove the bolts (4) and remove the poten-
tiometer (5).

Fig. 1915

Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 2
l Check the condition of retaining spring (6) and renew it if damaged.

Fig. 1916

l Calibrate the hand throttle

30.10.7 - Steering column switch (R3 EVO 110 -> 1001)

Removal
1. DANGER
Disconnect the lead from the battery negative terminal and apply the parking brake.

2. Remove screws (1), knob (2) and remove cover (3).

Fig. 1917
3. Remove screws (4) and remove the cover (5).

Fig. 1918

30-498
Method of intervention
4. Remove screws (6), disconnect wiring connector (7) and remove steering
column switch unit (8).

Fig. 1919

Refitting
Refitting is the reverse of removal.
30.10.8 - Shuttle ECU and forward/reverse selector (R3 EVO 110 -> 1001)
Removal
1. DANGER
Disconnect the lead from the battery negative terminal and apply the parking brake.

2. Remove screws (1), knob (2) and remove cover (3).

Fig. 1919
3. Remove screws (4) and remove cover (5).

Fig. 1919
4. Remove screws (6), disconnect wiring connector (7) and remove the shut-
tle ECU (8).

Fig. 1920

30-499
 Method of intervention
Refitting
Refitting is the reverse of removal.
l Carry out the procedure for putting the tractor into service.

30-500
Method of intervention
30.11 - M0 - Front PTO
30.11.1 - Front PTO
REMOVAL
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Position a stand “A” in the middle of pivot (1).

Fig. 1921
3. Disconnect wiring connectors (2) from air cleaner clogging sensor (3).

Fig. 1922
4. Loosen clamps (4), (5) and (6) and remove air intake hose (7).

Fig. 1923
5. Remove screws (8) and remove filter (9) from support (10).

Fig. 1924

30-501
 Method of intervention
6. Remove screws (11) and remove support assembly (10).

Fig. 1925
7. Remove unions (12) and remove clamps (13) (one per side).
Remove union (14) and move pipe (15) to the side.

Fig. 1926
8. Loosen and remove clamps (16).

Fig. 1927
9. Remove screw (17), support (18) and batteries (19).

Fig. 1928
10. Using a pin punch, remove dowel (20) and withdraw PTO drive shaft (21)
towards the rear of the tractor.

Fig. 1929

30-502
Method of intervention
11. Remove screws (22) and remove cover (23).

Fig. 1930
12. Remove screws (24) and remove hitch assembly (25).

Fig. 1931
13. Attach the PTO assembly (26) to a hoist and take up the slack in the lifting
sling.

Fig. 1932
14. Remove the four fixing screws (27) of assy (26).

Fig. 1933
15. Slowly lift PTO assy (26) causing it to rotate towards the front.
IMPORTANT
Take care not to damage the radiator.

m PTO assembly: 70 kg

Fig. 1934

30-503
 Method of intervention
Installation
Refitting is the reverse of removal.
30.11.2 - PTO assembly.

Fig. 1935 - PTO assembly.

Disassembly
1. Remove screws (1) and remove cover assy (2).

Fig. 1936
2. Remove screws (3) and remove solenoid valve assy (4).

Fig. 1937

30-504
Method of intervention
3. Using a screw as a puller, remove pipes (5).
m Check the condition of O-rings (6) and renew them if necessary.

Fig. 1938
4. Remove nuts (7) and remove cover assy (8).

Fig. 1939
5. Only if necessary
Remove oil seal (9).
m Note which way round oil seal (9) is fitted.

Fig. 1940
6. Remove input shaft (11) retaining screw (10).
m Renew the copper washers on reassembly
Raise oil seal (12).

Fig. 1941
7. Remove input shaft assy (11).

Fig. 1942

30-505
 Method of intervention
8. Use a pry bar to dislodge shaft (13) complete with outer bearing (14).

Fig. 1943
9. Remove output shaft (15) complete with bearing.
m Use a copper hammer, if necessary.

Fig. 1944
10. Remove gear (17) and bearings (18) and (19).

Fig. 1945
11. Remove pin (20) to free clutch assy (21).
m Renew the copper washers on reassembly.

Fig. 1946
12. Remove clutch assy (21) from PTO casing (22).

Fig. 1947

30-506
Method of intervention
13. Remove plug (23) and remove mesh filter (24).

Fig. 1948
14. Withdraw pump assy (25).

Fig. 1949
15. Remove circlip (26) and, using a suitable puller, remove bearing (27).

Fig. 1950
16. Remove oil seal (12).
m Renew the oil seal on reassembly.

Fig. 1951
17. Position shaft (15) under a press and withdraw the inner race of roller bear-
ing (16).

Fig. 1952

30-507
 Method of intervention
18. Using a puller, remove bearing (14) from shaft (13).
Check the condition of O-ring (28) and renew it if necessary.

Fig. 1953
19. Only if necessary
Using an internal puller and slide hammer T1 (P/N. 5.9030.618.4/10), dis-
assemble bush (29) from shaft (13).

Fig. 1954

Assembly
1. Only if removed
Lubricate bush (29) and refit it using a suitable driving tool.
m The bush must be inserted approximately 1 mm (0.04 in.) below the
surface of the shaft (13).

Fig. 1955
2. Heat bearing (14) to approximately 80°C (176°F) and install on shaft (13).
m Ensure the bearing is seated fully home.
Fit O-ring (28).

Fig. 1956
3. Heat the inner race of bearing (16) to approximately 80°C (176°F) and fit
it on shaft (15).
m The thrust washer of the inner race must be facing towards the
splined part of the shaft.

Fig. 1957

30-508
Method of intervention
4. Lubricate shaft (11) and the lip of oil seal (12).
Oil seal and shaft: temperature sensor
Fit ring (12) on shaft (11) and drive it fully home.
m Note the direction of assembly.

Fig. 1958
5. Heat bearing (27) and install on shaft (11), driving it fully home.
Fit circlip (26).

Fig. 1959
6. Fit pump assy (25).

Fig. 1959
7. Fit clutch assy (21) in PTO casing (22).

Fig. 1959
8. Tighten pin (20) taking care to centre the relevant hole in clutch assy (21).
m Renew the copper washers on reassembly.

Fig. 1960

30-509
 Method of intervention
9. Insert complete input shaft (11), turning it to and fro in both directions in
order to mesh the teeth in the pump and clutch assy.

Fig. 1960
10. Tighten screw (10) ensuring it enters the keyway on shaft (11).
m Renew the copper washers on reassembly.

Fig. 1961
11. Fit roller bearing (19) in PTO casing (22).
m The thrust washer of the inner race must be facing the output of the
PTO shaft
Fit ball bearing (18) in PTO casing (22).
Fit gear (17) in PTO casing (22).

Fig. 1962
12. Fit shaft (15), aligning it with gear (17) and bearing (19).
m To fit roller bearing (19), tap lightly with a copper-headed hammer
and rotate shaft (15)

Fig. 1963
13. Fit bearing outer race (16).
m During assembly, tap lightly with a hammer around the entire cir-
cumference.

Fig. 1964

30-510
Method of intervention
14. Fit the shaft complete with outer bearing (14).
m To insert, use a copper-headed hammer to tap lightly on the shaft
and around the outer circumference of the bearing.

Fig. 1965
15. Using a suitable drift, install oil seal (9) in cover (8).
m Note the direction of assembly.

Fig. 1966
16. Apply sealant to the mating surfaces and fit cover (8).
m Sealant: Silastic 738
Tighten nuts (7).
m Tighten the screws in an alternate cross-wise sequence.

Fig. 1967
17. Using a suitable drift T2, seat oil seal (12).

Fig. 1968
18. Fit mesh filter (24) on pump suction pipe.
Smear sealant on the threads of plug (23) and tighten.
m Plug: Silastic 738

Fig. 1969

30-511
 Method of intervention
19. Insert extensions (5) complete with O-rings (6).

Fig. 1969
20. Apply sealant to the mating surfaces of solenoid valve assy (4).
m Surfaces: Loctite 510
Fit solenoid valve (4) and secure it with screws (3).

Fig. 1970
21. Apply sealant to the upper mating surface of PTO housing (22).
m Mating face: Silastic 738
m Check that the sealant forms a continuous film around the holes of
the cover fixing screws.
Fit cover (2) centring the oil delivery and return unions.

Fig. 1971
22. Fit cover (2) and tighten screws (1).

Fig. 1972
23. Fill the PTO with oil.

30-512
Method of intervention
30.11.3 - Pump assembly

Fig. 1973 - Pump assembly

Disassembly
1. Remove screws (1) and remove suction pipe (2).
m Check the condition of the O-rings (3) and (4) and renew them if
necessary.

Fig. 1974
2. Remove screws (5) and remove pump cover (6) from pump body (7).
m Label pump body (7) and cover (6) to avoid confusion on reassem-
bly.

Fig. 1975

30-513
 Method of intervention
3. Remove gears (8) and (9) from pump body (7).

Fig. 1976

Assembly
To assemble, follow the disassembly steps in reverse order and use caution in relation to the following procedures:
Procedure 3
l Lubricate pump body (7) and gears (8) and (9).
Gears lubrication: oil

30.11.4 - Front PTO oil cooler

REMOVAL
1. DANGER
Remove the key from the starter switch and apply the parking brake.

2. Disconnect pipes (1) and (2).

IMPORTANT
Mark the pipe connection positions.

IMPORTANT
Plug the pipes and ports to prevent the ingress of dirt.

Fig. 1977
3. Remove screws (3) and remove the cooler.

Fig. 1978

Installation
Refitting is the reverse of removal.
l Start the engine, engage the front PTO and fill the cooler.
l Disengage the PTO and check the oil level in the casing.

30-514
Method of intervention
30.11.5 - Clutch-brake assembly

Fig. 1979 - Clutch-brake assembly

Disassembly
1. Remove circlip (1) and remove steel plates (2) and (3).

Fig. 1980
2. Remove friction plates (4) and steel plates (5).

Fig. 1981

30-515
 Method of intervention
3. Remove hub (6) and spacer (7).

Fig. 1982
4. Using a puller (or a press) and U frame “A”, compress spring (8) and re-
move circlip (9).

Fig. 1983
5. Release spring (8) and remove in sequence spring guide ring (10) and
spring (8).

Fig. 1984
6. Blow compressed air at low pressure through the upper hole in the direc-
tional control valve body to expel piston (11).
m Restrain piston (11) as it could be expelled at high speed and thus
damaged.

Fig. 1985
7. Remove piston (11) and O-ring (12).

Fig. 1986

30-516
Method of intervention
8. Turn the unit over, remove screws (13) and remove cover (14).

Fig. 1987
9. Remove brake disc (16) and steel plate (17) from clutch assembly (15).

Fig. 1988
10. Blow compressed air at low pressure into clutch assembly (15) to disen-
gage brake piston (18).
m Restrain the piston as it could be expelled at high speed and thus
damaged.

Fig. 1989
11. Withdraw piston (18).

Fig. 1990
12. Check the condition of the O-rings (19) and (20) and renew them if neces-
sary.

Fig. 1991

30-517
 Method of intervention
13. Remove circlip (21) and spacer (22).

Fig. 1992
14. Remove clutch assembly (15) and remove retaining rings (24) from clutch
housing (23).

Fig. 1993
15. Using a suitable wrench T3, remove damper assembly (25).
m Renew the copper washers on reassembly.

Fig. 1994
16. Compress the spring assembly of damper (25) and remove circlip (26).

Fig. 1995
17. Release the assembly and remove disc (28), spring (29) and piston (30)
complete with O-ring (31) from cylinder (27).

Fig. 1996

30-518
Method of intervention
18. Remove plug (32) and remove spring (33) and push rod (34) from clutch
housing (15).
m Renew the copper washers on reassembly.

Fig. 1997
19. Remove O-ring (35) from clutch piston (11).

Fig. 1998

Assembly
To assemble, follow the disassembly steps in reverse order and use caution in relation to the following procedures:
Procedure 17
l Lubricate piston (29) with oil.
Procedure 16
l Damper assembly (24): Loctite 242
Procedure 14
l Lubricate retaining rings (23) with oil.
Procedure 9
l Lubricate O-rings (19) and (20) and piston (18) with oil.
Procedure 8
l Lubricate brake disc (16) with oil
Procedure 7
l Lubricate O-ring (12) and piston (11) with oil.
Procedure 3
l Grease spacer (7) and install it on hub (6).

Fig. 1999

30-519
 Method of intervention
Procedure 2
l Fit steel plates (5) and friction plates (4) in housing (15) starting with a steel
plate (5).
Lubricate friction plates (4) with oil.

Fig. 2000

30.11.6 - Solenoid valve assembly

Disassembly
1. Remove retaining nut (1) and remove solenoid valve (2).
m Recover the O-rings.

Fig. 2001
2. Loosen solenoid valve stem (3) and remove it.

Fig. 2002

Assembly
To assemble, follow the disassembly steps in reverse order and use caution in relation to the following procedures:
Procedure 2
l Valve stem: 15 to 20 Nm (11.06-14.74 lb.ft.)
Valve stem: oil
Procedure 1
l Nut: 5 to 8 Nm (3.69-5.90 lb.ft.)

30-520
Method of intervention
30.12 - N0 - Front lift
30.12.1 - Front lift
Removal of lift cylinders
1. DANGER
Remove any implement or ballast from the front lift and raise the link arms completely.

DANGER
Remove the key from the starter switch and apply the parking brake.

2. Position a stand “A” in the middle of pivot (1).

Fig. 2003
3. Remove screw (2) and pin (3).
m If both cylinders are to be removed, repeat the above steps also on
the cylinder on the other side.

Fig. 2004
4. Start the engine and run at idle speed and retract cylinder (4).
mPull the lever very slowly and retract the cylinder without reaching
the end of its stroke.
m Switch off the engine, remove the key from the ignition and close the

lift control valves.

Recover spacers (5).

Fig. 2005
5. Remove screws (6) and remove surround (7).

Fig. 2006

30-521
 Method of intervention
6. Remove unions (8) and (9).
m Plug the pipes to prevent the ingress of dirt.

Fig. 2007
7. Remove circlip (10) and extract pin (11).
m Support cylinder (4).

Fig. 2008
8. Recover seals (12) and remove the cylinder.

Fig. 2009

30-522
Method of intervention
Installation
Refitting is the reverse of removal.
30.12.2 - Disassembly of front lift cylinders

Fig. 2010 - Lift cylinders

Disassembly
1. Remove circlip (1).

Fig. 2011
2. Using a suitable tool, partially retract end cap (2) and remove circlip (3).

Fig. 2012
3. Withdraw rod (5) complete with end cap (2) and circlips (1) and (3) and
piston (6) from cylinder (4).

Fig. 2013

30-523
 Method of intervention
4. Remove nut (7) and remove piston assembly (6).

Fig. 2014
5. Withdraw end cap (2) and circlips (1) and (3) from rod (5).

Fig. 2015
6. Remove guide rings (8), oil seal (9a) and O-ring (9b) from piston (6).

Fig. 2016
7. Remove rod wiper (10), seal (11) and O-ring (12) from end cap (2).
m Note which way round seal (11) is installed.

Fig. 2017

30-524
Method of intervention
Assembly
To assemble, follow the disassembly steps in reverse order and carry out the following procedures:
Procedure 6
l Fit a suitable installation guide on piston (6) and fit piston O-ring (9b) by
hand.
Fit oil seal (9a) on the installation guide.

Fig. 2018

l Using a suitable installer, drive oil seal (9a) into its seat.

Fig. 2019

l Using a gauge and suitable support, calibrate the seal (9a) passing the
gauge over the entire length of piston (6).

Fig. 2020

Procedure 4
l Nut: 200±10 Nm (147.4±7.4 lb.ft.)

30-525
 Method of intervention
30.13 - R0 - Rear lift
30.13.1 - Lift - Complete assembly (R0.02.03) (R3 EVO 110 -> 1001)
Previous operations:
See para. 30.9.7 - Rear remote control va... - page 30-481 - (H0.07.01)
REMOVAL
1. Remove screw (1) and remove pins (2) on both sides.

Fig. 2021
2. Remove split pin (3) and remove pivot pins (4).
IMPORTANT
Fit new split pins on reassembly.

Fig. 2022
3. Remove terminal (5) and detach all connecting pipes (6) from the remote
control valve.
IMPORTANT
Plug the pipes to prevent the ingress of dirt.

Fig. 2023
4. Disconnect tie rods (7) and (8) from the lift levers.

Fig. 2024

30-526
Method of intervention
5. Remove unions (9) and remove pipe (10).
IMPORTANT
Renew the copper washers on reassembly.

Remove nuts (11) and remove top link mounting (12).

Fig. 2025
6. Disconnect the connector , remove the bolts (13) and detach the support
(14).

Fig. 2026
7. Remove screw (15) and nuts (16) from the right-hand side.

Fig. 2027
8. Remove screw (17) and nut (18).

Fig. 2028
9. Remove screw (19) and place the bracket (20), complete with trailer socket
(21) aside.

Fig. 2029

30-527
 Method of intervention
10. Remove the six nuts (22) of the left-hand side.

Fig. 2030
11. Remove the split pins and detach the control tie-rods (23).

Fig. 2031
12. Attach lift assembly (24) to a hoist and remove it from the tractor.

Fig. 2032

30-528
Method of intervention
Installation
Install by following the removal steps in reverse order and carry out the following procedures:
Procedure 12
l Mating face: Loctite 510

Fig. 2033

Procedures 7-8-10
l Nuts: 78±4 Nm (57.5±3.0 lb.ft.)
l Screws: 70±3.5 Nm (51.6±2.6 lb.ft.)
Procedure 5
l Nuts: 111±5,5 Nm (81.8±4.0 lb.ft.)

30.13.2 - Disassembly of the lift- complete assembly (R3 EVO 110 -> 1001)
Disassembly
1. Remove all screws (1) and remove bracket (2) and cover (3).

Fig. 2034
2. Remove circlips (4) on both sides.

Fig. 2035
3. Remove lift arms (5) and spacers (6) on both sides.

Fig. 2036

30-529
 Method of intervention
4. Remove circlips (7) and (8) and remove tie-rods (9) and (10).

Fig. 2037
5. Loosen nut (11) and remove set screw (12).

Fig. 2038
6. Loosen nut (13) and remove grub screw (14) securing cam (15).

Fig. 2039
7. Remove oil seal (16) on one side and withdraw shaft (17).
m Renew the oil seal on reassembly.

Fig. 2040
8. Remove lever (18) complete with connecting rod (19) and cam (20).

Fig. 2041

30-530
Method of intervention
9. Only if necessary
Drive out spring pin (21) and separate connecting rod (19) from lever (18).

Fig. 2042
10. Remove circlips (22) and (23) and remove tie-rods (24) and (25).
m Label the tie-rods to avoid confusion on reassembly.

Fig. 2043
11. Remove brake cylinder assembly (26).

Fig. 2044
12. Remove the two screws (27).

Fig. 2045
13. Remove lift control valve assembly (28).

Fig. 2046

30-531
 Method of intervention
14. Only if necessary
Renew bushes (29).

Fig. 2047

Assembly
To assemble, follow the disassembly steps in reverse order and carry out the following procedures:
Procedure 13
l Check the condition of the O-rings (30) and renew them if necessary.
Each time the lift control valve is removed from the tractor adjust the control
levers.

Fig. 2048

Procedure 9
l Grease the seating of connecting rod ball joint (19).
Procedures 7-14
l Grease bushes (17) and shaft (29).
Procedure 6
l Grub screw: Loctite 242
Screw grub screw (14) fully into its hole in the shaft and, while holding the
grub screw in position, tighten nut (13).

Fig. 2049

Procedure 5
l Grub screw: Loctite 242
Screw grub screw (12) fully into its hole in the shaft, then back it off by half
a turn. Hold the grub screw in position and secure with nut (11).

Fig. 2049

30-532
Method of intervention
Procedure 1
l Mating face: Loctite 510

Fig. 2050

30.13.3 - Lift cylinder (R3 EVO 110 -> 1001)

Disassembly
1. Remove screws (1) and withdraw cylinder assembly (2).

Fig. 2051
2. Using a low pressure compressed air jet (max. 2.5 bar), blow piston (3) out
of cylinder (4).

Fig. 2052
3. Remove seal (5) from piston (3).
m Note which way round seal (5) is installed.

Fig. 2053

Assembly
To assemble, follow the disassembly steps in reverse order and use caution in relation to the following procedures.

30-533
 Method of intervention
Procedure 3
l Fit seal (5), making sure that is positioned the right way round relative to
piston (3).

Fig. 2053

Procedure 1
l Check the condition of O-rings (6) and (7) and renew them if necessary.

Fig. 2054

30.13.4 - Bushes (R3 EVO 110 -> 1001)

Renewal
1. Position the lift cover under a press and, using a suitable tool, remove
bushes (1).

Fig. 2055
2. Install new bushes (1) making sure that they are inserted flush with the
bores in the lift housing.

Fig. 2056
3.

Install bushes (1) with the split oriented towards the top of
the lift housing.

Fig. 2057

30-534
Method of intervention
30.13.5 - Auxiliary lift cylinders (R3 EVO 110 -> 1001)
Removal
1. Fully lower the rear lift, disconnect the lead from the negative terminal of the battery and apply the parking brake.
2. Remove split pin (1).
IMPORTANT
Fit new split pins on reassembly.

Fig. 2058
3. Remove pin (2) and recover spacer (3).

Fig. 2059
4. Disconnect pipe (4).

Fig. 2060
5. Remove split pin (5) and spacer (6).
IMPORTANT
Always renew the split pin on reassembly

Fig. 2061

30-535
 Method of intervention
6. Remove cylinder (7).

Fig. 2062

Refitting
Refitting is the reverse of removal.
30.13.6 - Disassembly of the lift control valve (R3 EVO 110 -> 1001)
Disassembly
1. Remove spring (1).

Fig. 2063
2. Remove split pin (2) and remove pivot pin (3) and roller (4).
m Renew the split pin every time it is disturbed.

Fig. 2064
3. Remove circlip (5), remove pin (6) and remove control levers assembly (7).

Fig. 2065

30-536
Method of intervention
4. Remove the three screws (8) and remove lever support (9).

Fig. 2066
5. Loosen screw (10) without removing it and turn remote control valve as-
sembly (11) over so that the aluminium body is facing downwards.
Remove screw (10) and separate remote control valve bodies (11) and
(12).

Fig. 2067
6. Remove spring (13).

Fig. 2068
7. Remove spring (14) and rod (15).

Fig. 2069
8. Remove piston (16) and spring (17) from remote control valve body (11).

Fig. 2070

30-537
 Method of intervention
9. Remove spring (18) and spacer (19) from remote control valve body (11).

Fig. 2071
10. Drive out spring pin (20) and withdraw spool (21).

Fig. 2072
11. Remove plug (22) and remove valve (23).
m Renew the copper washers on reassembly.

Fig. 2073
12. Remove plug (24) and withdraw spring (25) and valve (26).
m Renew the copper washers on reassembly.

Fig. 2074
13. Remove O-rings (27) and withdraw piston (28).

Fig. 2075

30-538
Method of intervention
14. Remove union (29) and remove valve (30), pin (31) and spring (32) from
remote control valve body (12).
m Renew the copper washers on reassembly.

Fig. 2076
15. Remove valve (33).
m Renew the copper washers on reassembly.

Fig. 2077

Assembly
To assemble, follow the disassembly steps in reverse order and carry out the following procedures:
Procedure 14
l Check that valve (30) is installed the right way round.
Check that valve (30) slides freely in its seat.
Pipe union: Loctite 542

Fig. 2078

Procedure 13
l Check that piston (28) is installed the right way round.

Fig. 2079

30-539
 Method of intervention
Procedure 12
l Hold ball “A” contained in valve (26) seated against rod (15), and check that
rod (15) protrusion relative to the face of body (11) is within the specified
limits (X = 15.8±0.05 mm).
Plug: Loctite 542

Fig. 2080

Procedure 11
l Check that valve (23) slides freely.
Plug: Loctite 542

Fig. 2081

Procedure 10
l Check that spool (21) slides freely.

Fig. 2082

Procedure 8
l Check that piston (16) slides freely.

Fig. 2083

Procedure 7
l Check that rod (15) is installed the right way round.

Fig. 2084

30-540
Method of intervention
Procedure 5
l While tightening screw (10), check that spool (21) slides freely without
sticking.

Fig. 2085

Procedure 2
l Take care to position roller (34) on the top of spool (21).

Fig. 2086

30.13.7 - Mechanical draft sensor (R3 EVO 110 -> 1001)

Removal
1. Remove split pin (1) and withdraw pivot pin (2).
m Renew split pin (1) on reassembly.

Fig. 2087
2. Remove screw (3), loosen screw (4) and remove draft sensor assembly (5).

Fig. 2088

Refitting
Refitting is the reverse of removal. Use caution in relation to the following procedures:
Procedure 2
l Nuts: 72±7 Nm (53.1±5.2 lb.ft.)

30-541
 Method of intervention
30.13.8 - Mechanical draft sensor disassembly (R3 EVO 110 -> 1001)

Fig. 2089 - Mechanical draft sensor

Disassembly
1. Remove screw (1) and the relative nut and remove plug (2).

Fig. 2090
2. Remove fork (3) and remove spring assembly (4) from sensor body (5).

Fig. 2091
3. Remove nut (6), and remove spacer (7) and disc (8).

Fig. 2092

30-542
Method of intervention
4. Remove spring (9), spacer (10) and washer (11).

Fig. 2093
5. Remove spring (12) and spacer (13) from tie-rod (14).

Fig. 2094

Assembly
To assemble, follow the disassembly steps in reverse order and carry out the following procedures:
Procedure 3
l Screw in nut (6) to take up the play in springs (9) and (12) but without preloading them.
Procedure 2
l Liberally grease spring assembly (4) and insert it in sensor body (5).

30.13.9 - 3-point linkage (R3 EVO 110 -> 1001)

Removal
1. DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.

2. Remove screw (1) and pin (2).

Fig. 2095

30-543
 Method of intervention
3. Remove split pin (3) and remove pin (4) and washer (5).
m Always renew the split pin.

Fig. 2096
4. Remove split pin (6), nut (7) and washer (8).
Remove 3-point linkage assembly (9).

Fig. 2097
5. Recover spacer (10).

Fig. 2098

30-544
Method of intervention
Refitting
Refitting is the reverse of removal. Use caution in relation to the following procedures:
Procedure 5
l Note which way round spacer (10) is installed.

Fig. 2099

Procedure 4
l Tighten nut (7) to the prescribed torque and, if necessary, tighten further to align the slots in nut (7) with the hole in the pin.
Nut: 150 Nm (110.5 lb.ft.)

30-545
 Method of intervention
30.14 - S0 - Wheels
30.14.1 - Front wheels
REMOVAL
1. DANGER
Remove the key from the starter switch and apply the parking brake.

2. Raise the tractor and position two stands “A” under the front axle.
m Drive safety wedges “B” between the axle and the front support.

Fig. 2100
3. Remove all the screws (1) except one for safety.
Remove the last screw and remove wheel (2).

Fig. 2101
4. Repeat the above operations for the other wheel.
Installation
Refitting is the reverse of removal. Use caution in relation to the following procedures:
Procedure 3
l Screws: 350 Nm (258 lb.ft.)

30.14.2 - Rear wheels

Removal
1. Position a jack “A” under the rear gearbox casing.
m Position a jack “A” under the rear gearbox casing.
Raise the tractor sufficiently to eliminate the flexure of the tyre wall.

Fig. 2102

30-546
Method of intervention
2. Remove all the nuts (1) and remove wheel (2).

Fig. 2103
3. Position a stand “B” under the rear axle housing and lower the jack until the
axle housing is resting on the stand.
Check that the stand is in exactly the correct position and then remove the
trolley jack.

Fig. 2104
4. Repeat the above operations to remove the other wheel.

Installation
Refitting is the reverse of removal. Use caution in relation to the following procedures:
Procedure 2
l Nuts: 500 Nm (368.5 lb.ft)

30-547
 Method of intervention
30.15 - V0 - Ballast - towing hitches
30.15.1 - Towing hitch slide (V0.02.01) (R3 EVO 110 -> 1001)
Removal
1. Remove all the screws (1) except two.

Fig. 2105
2. Sling towing hitch (2) to hoist and take up the slack in lifting ropes.
Remove the last two screws (1) and remove the towing hitch assembly.

Fig. 2106

Installation
Refitting is the reverse of removal. Use caution in relation to the following procedures:
Procedure 1
l Screws: 186.4±18 Nm (137.4±13.3 lb.ft.)

30-548
40 - Wiring diagrams

40-1
 Wiring diagrams
40.1 - Introduction
40.1.1 - Introduction
For easier consultation, this unit has been divided into the following chapters:
l Introduction
m Contains a brief description of the terminology used, the procedures to follow for troubleshooting and repairs, and the

instruments required for fault diagnosis.

l Components list
m Contains the components of the electrical systems, organised by type.
m Indicates the system code, the component code and description, the technical data required for functional testing and

a description of the pin-outs of the ECUs.

l Systems
m Contains the wiring diagrams of the tractor’s systems.

l Wiring harnesses
m Contains the layouts, the wiring diagrams and the positions of connectors on the tractor.

Introduction
This section of the workshop manual is intended as a practical guide to fault diagnosis of the tractor’s electrical and electronic
systems. The following pages provide the technician with all the necessary information regarding the tractor’s systems and compo-
nents. Due to the possible time difference between the introduction of technical modifications (in line with our policy of continuous
product improvement) and the corresponding amendment of our printed documentation, the data contained in this document are
subject to modification and as such are not binding.
Definition of components and symbols
To prevent any misunderstanding or ambiguity, definitions for some of the key terms used in this unit are listed below.
Table 96
TERM DESCRIPTION
Connector Element used to connect two components (e.g. wiring-switch, wiring-wiring)
Temperature sensor Electrical component that converts the temperature of a medium (air, water, oil, etc.) into a voltage
or resistance
Pressure sensor Electrical component that converts the pressure of a medium (air, water, etc.) into a voltage or
resistance
Position sensor Electrical component that converts an angular or linear position into a voltage
Pressure switch Switch that changes state (opens or closes a contact) according to the operating pressure in the
circuit in which it is installed
Thermostat Switch that changes state (opens or closes a contact) according to the temperature of the medium
(air, water, etc.) in which it is immersed.
Switch Mechanical component that opens or closes one or more electrical contacts.
Solenoid valve Valve operated by applying electrical current to a coil (or solenoid)
Chapter “Components” shows the wiring diagrams for certain switches and buttons. The following symbols are used for ease of
interpretation:
Contact between pins CLOSED (stable switch position)

Contact between pins CLOSED (unstable switch position)

Indicator LED

Indicator light

40-2
Wiring diagrams
Diode

General rules
The inspection, maintenance, fault diagnosis and repair operations are essential to ensure that the tractor continues to operate cor-
rectly over time and to prevent malfunctions and breakdowns. This paragraph describes repair procedures and aims to help improve
the quality of repairs.
Modification of the tractor’s electrical/electronic circuits
The manufacturer prohibits any modification or alteration of the electrical wiring for the connection of any non-approved electrical
appliances or components. In particular, if the electrical system or a component is altered without the Manufacturer’s authorisation,
the Manufacturer will accept no liability for any damage to the vehicle and the vehicle warranty will be invalidated.
Main wiring faults
Bad contact between connectors
l The main causes of poor contact between connectors are incorrect insertion of the male into the female connector, deforma-
tion of one or both connectors, and corrosion or oxidisation of the pin contact surfaces.
Defective pin soldering or crimping
l The pins of the male and female connectors make good contact in the crimped or soldered area, but the wires are subjected
to excessive strain, leading to breakage of the insulation and a poor connection or breakage of the wire.
Disconnecting wiring
l If connectors are disconnected by pulling on the cables, or if components are removed with the wires still connected, or if the
wiring is subject to impact by a heavy object this could damage the soldering or crimping of wires on the pins and some wires
may break.
Penetration of water inside connectors
l The connectors are designed to prevent penetration of liquids (water, oil etc.); however, when cleaning the tractor with pres-
sure washers or steam washers water could penetrate or condense in the connectors. As the connectors are designed to
prevent liquid penetration, any water that does get in will be unable to drain out, and thus may cause short circuits across the
pins. It is therefore good practice to dry the connectors with a low pressure jet of compressed air after washing the tractor.
Oil or dirt on connectors
l If the connectors or pin contact surfaces show signs of oil or grease contamination, this will prevent the passage of current
(oil and grease are electrical insulators) creating a poor contact. Clean the connectors thoroughly using a dry cloth or a low
pressure jet of compressed air and use specific products (deoxidising sprays, etc.) to degrease the contacts.
Important
Take care not to bend the pins when cleaning them. Use dry oil-free compressed air.

Removal, refitting and drying of connectors and wiring

When disconnecting wiring, pull on the connectors rather than on the wires themselves. For connectors that are held in position with
screws or levers, fully loosen the screws, then pull on the connector. For connectors that are clipped together, fully depress the clip
then pull the connector apart. After disconnecting connectors, apply water proof covers to prevent contamination of the contacts with
dirt or moisture.
Connecting the connectors. Check the condition of the connectors:
l Make sure the pin contact surfaces are free of water, dirt or oil.
l Check that the connectors are not deformed and that the pins are not corroded or oxidised.
l Check that the connector casings are not damaged or split.
l If a connector is contaminated with oil or grease, or if moisture has penetrated the casing, clean it thoroughly.
l If a connector is damaged, deformed or broken, replace it with a new one.
When connecting connectors, make sure they are properly aligned before applying force. For connectors with clips, insert the two
halves until they clip together.
Cleaning and drying wiring

40-3
 Wiring diagrams
l When wiring is dirty or contaminated with oil or grease, clean it with a dry cloth, or, if necessary, with water or steam. If the
wiring must be cleaned with water, avoid directing the water or steam jet on the connectors; if water penetrates the connector,
clean it thoroughly.
l Check that the connector is not short circuited due to the presence of water by testing for continuity across the pins.
l After checking that the connector is good condition, degrease the contacts using a deoxidising product.
Renewal of damaged electrical components.
l When replacing electrical components (fuses, relays, etc.), use only original parts supplied by the manufacturer.
l When replacing fuses, check that the new fuse conforms to DIN 72581 or ISO 8820 standards, and in particular:
m fuse F1 (100A) DIN 72581/2
m bayonet fuse (F2, F3, etc.) DIN 72581/3C
m fuse F51 (100A) and F52 (200A) ISO 8820.

l The fitting of replacement fuses that do not comply with these standards will invalidate the warranty with immediate effect and
release the manufacturer from all liability.
l When replacing relays, make sure that the new relay conforms to the standards marked on the original relay.
Diagnostic instruments
For the correct diagnosis of any faults in the tractor’s electrical system, the following instruments are required:
l Digital multimeter with the following minimum characteristics:
m AC VOLT 0-600
m DC VOLT 0-600
m OHM 0-32M
m AC AMP 0-10
m DC AMP 0-10

l All Round Tester or computer with “PCTESTER” software installed

l SDF Analyzer
Wire colour codes
Table 97
COLOUR CODES
A Light blue
B White
S Orange
G Yellow
H Grey
L Blue
M Brown
N Black
R Red
S Pink
V Green
Z Purple

40.1.2 - Basic electronics for mechanics (1/2)

What is electronics?
The name of this branch of electrical science is derived from the word “ELECTRON”, the name given to a small electrically charged
particle.
The movement of electrons produces electrical current, which we know more about for its effects - heat, light, magnetism, elec-
trolysis, etc. - than for its actual nature.
While electrical engineering is concerned with these external effects of electrical current, electronics deals with way materials react
to the gain or loss of electrons.
Electrons in fact move from (-) to (+), but according to a convention that was established before the emergence of modern atomic
theory, electric current flows in the opposite direction from (+) to (-).
Using electronics it is possible to program complex logical processes, which could not be achieved in other ways.
The various applications of electronics on our tractors can be divided into two groups:
l Invisible electronics, which operate without requiring any intervention of the driver, (voltage regulation, rectification of the cur-
rent produced by the alternator, timing, etc.);

40-4
Wiring diagrams
l Visible electronics, ranging from the visible and audible information to made available to the driver via the vehicle’s instru-
ments and signalling systems, to the control systems that serve to optimise work processes (Performance Monitor, SBA
System, I-Monitor, etc.).
Logical development of the electronics
As mentioned previously, electronics is generally viewed as a branch of electrical science, even though in certain aspects they are
quite independent.
Whereas electrical engineering generally deals with large amounts of current, electronics is more concerned with very low levels of
current.
Electronic applications are based on the movement of electrons and thus exploit the different degrees to which different materials
conduct electrical current:
l Conductors,
l Insulators,
l Semiconductors
We therefore need to know what happens “electrically” inside the material.
All matter is composed of tiny particles called atoms.
The atom can be likened to a planetary system which has at its core a nucleus, comprised of protons and neutrons, around which
rotate the electrons in different orbits, or shells.

Fig. 2107
Under certain conditions, electrons can move from one atom to another.
If the number of electrons in an atom is the same as the number of protons, the atom is neutral (it has no charge).
If the number of electrons exceeds the number of protons, the atom is negatively charged, while if it loses electrons it will become
positively charged.

40-5
 Wiring diagrams
Atomic structure of matter
The atom is the smallest particle of a simple element that can combine with other
atoms to form molecules.

Fig. 2108

The composition of the nucleus and the number of electrons present in an atom
determine which element it belongs to.

Fig. 2109

The structure of an atom can be compared to that of the solar system:

1. Electron (Planet)
2. Nucleus (Sun)

Fig. 2110

Electrical charges of the same sign (1) repel each other while charges of opposite
signs (2) attract.

Fig. 2111

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Wiring diagrams
40.1.3 - Basic electronics for mechanics (2/2)
Conductors, Insulators and Semiconductors
The behaviour exhibited by different materials in response to electricity derives from their atomic structure:
1. In conductors (generally metals), electrons are able to move freely from one atom to another;
2. In insulators (generally metalloids) electron movement is restricted to varying degrees, depending on the type of material.
Their atoms are not able to acquire electrons.
3. Semiconductors (germanium, silicon, selenium, etc.), are materials which in their pure state may act as insulators, but with
the addition of precisely calibrated amounts certain impurities, they can become conductors. Their electrical properties thus
lie somewhere in the range between insulators and conductors. If these materials in their pure state are subjected to a techni-
cal process known as “doping” (the addition of impurities with a certain number of atoms with free electrical charges), they
become positively or negatively charged, depending on the specific process.
Electrical voltage
We have talked about “external causes” that can provoke the movement of electrons in atoms.
One of these external causes is “voltage” or “potential difference”, which exerts a “force” on electrical charges, causing them to start
moving.
This force is known as electromotive force; the force supplied by electrical sources (battery, dynamo, alternator).
The concept of voltage or potential difference is illustrated by the example shown
here.
l The levels in A and B are equal if the valve is open.

Fig. 2112

The concept of voltage or potential difference is illustrated by the example shown

here.
l For water to flow from A to B, there must a difference in level “h” when the
valve closed.
l The difference between the height of water in A and that in B creates a dif-
ference in pressure.

Fig. 2113

When the valve is opened, water flows from A to B until the point where the two
pressures are equalised.
The same happens with electrical current:
l to obtain current flow, there has to be potential difference at one of the
conductor (caused by the presence of electrical charge).

Fig. 2114

40-7
 Wiring diagrams
Resistance
The water model can also be used to explain the concept of electrical resistance. If water encounters obstacles when flowing through
a pipe the the flow rate will slow or the direction of flow will change .
The same applies to electrical current; obstacles of an electrical nature reduce the flow of electrons. Every material offers some de-
gree resistance to the flow of electrons; the level of this resistance will depend on its atomic structure and its dimensions. Obstacles
in a water course will slow down or change the direction of the water flow.
Electrical resistance can be compared to a restriction in the conductor or scaling
on the inside of a water pipe.

Fig. 2115

The electrical resistance of a material can be defined as the opposition it presents to the flow of electrons and varies according to the
nature of the material and its dimensions.
Electrical continuity
Staying with the water analogy, let’s examine how to obtain a continuous flow of water in a circuit. 424For the flow to be continuous,
the water must be returned to basin 1.
In this hydraulic circuit, the function of the pump (2) is to return the water to basin
or tank (1).

Fig. 2116

Similarly, for current to flow continuously in an electrical circuit, the electrons must return from the positively charged terminal to the
negatively charged terminal, in order to maintain a potential difference between the two terminals. This is the job of the electrical
power source.
Electrical power supply
An electrical power source can be defined as a system capable of separating and initiating the motion of a number of electrons.
A battery, for example, has two metal terminals, one positive and one negative.
Inside the battery, a chemical process causes free electrons to flow to the negative terminal to create a negative charge and a corre-
sponding positive charge to build at the positive terminal.
This process will continue inside the battery until the actions which caused it are balanced by the forces of attraction between the
electrons and the positive charges.
If the electrons could flow to the positive terminal, the initial neutral status could be restored, but as there is internal connection betwe-
en the two terminals, this can only be achieved if there is an external connection between B and A.
We can therefore state that a difference in potential, or voltage, has been created between the two terminals A and B.
If we now connect an external load between B and A, the electrons concentrated at terminal A (+) will starting moving towards terminal
B, thereby pushing along the free electrons present in the connecting conductor.
An electrical current is thus created, (which by convention is deemed as flowing from A to B), and this current will continue to flow as
long as there remains a difference in potential between the two terminals.

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Wiring diagrams
Schematic representation of a electrical power source
A = Positive terminal
B = Negative terminal
G = Generator

Fig. 2117

Electromotive force (e.m.f.)

Taking a simple electrical circuit , let’s see what happens to the voltage at the terminals of the power source when the circuit is closed
(in this example, the power source is a battery, but the same result would be obtained with a different source of power, such as an
alternator).
Simple circuit with switch “I “open: no current flow.
The same situation occurs if we replace the battery with an alternator in rotation.
A voltage (e.g. 12V) is present at the terminals of the power source, which can be
measured with a voltmeter. This no-load voltage is known as the electromotive
force.
R = resistance of a load.

Fig. 2118

Simple circuit with switch “I” closed. The battery powers the resistance R. A volt-
age drop occurs between the terminals of the power source, caused by the circula-
tion of current in the source itself, which has its own internal resistance.
Vd = r × A
r = internal resistance of the power source in series with the other elements of the
circuit
A = current flowing through the circuit

Fig. 2119

The following relationship is therefore true for every power source:

Available voltage = Electromotive force - Internal resistance x Current
V=E-(r×I)
Direct Current (DC) and Alternating Current (AC)
Electrical current can be either direct or variable: with direct current, the electrons always flow only one direction; with variable cur-
rent, the direction and intensity of electron flow varies over time in accordance with the laws of trigonometry.
If this change in direction is regular over time, the current is described as “alternating”. Alternating current changes cyclically from
positive values to zero and from zero to negative values and so on.
On a tractor, the battery supplies direct current voltage, and therefore direct current flows through the connected circuits.
The alternator produces alternating current, which, as we shall see, must be converted into direct current by a bridge rectifier before
it can be used.
The graph below illustrates the behaviour of a sinusoidal alternating current. The voltage increases from zero volts up to the maxi-
mum positive value and then decreases to zero volts . The polarity is then inverted and the the voltage rises to the maximum negative

40-9
 Wiring diagrams
value before returning once again to zero. This complete sequence is referred to as one “cycle”.
If a cycle is performed once every second, then the frequency of the alternating current is said to be 1 Hertz. In domestic electrical
supplies, the frequency of the supply is 50 Hz.
Frequency is thus the number of complete cycles performed in one second.
A period is defined as the time required for an alternating sine wave to complete one cycle, i.e. from zero to a positive peak to zero
to a negative peak and back to zero.
This time period is expressed in seconds and is denoted by the letter T.
The alternating current wave form illustrated in the graph is called sinusoidal.
T = 1 period

A = Amplitude

B = Positive voltage

C = Negative voltage

Fig. 2120

The number of cycles per second is the FREQUENCY and is expressed in Hertz and denoted with the letter “f”.
f=1÷T
T=1÷f
An AC current with a frequency of 50 Hertz therefore has a period of 1 ÷ 50 = 0.02 seconds.
Electrical values: Current and Voltage
CURRENT Symbol A
Value: Amount of electrical charge that passes through a conductor in a given unit of time.
Units: amperes.
Instrument: ammeter.
Connection to circuit: In series.
Basic electrical circuit incorporating a voltmeter and an ammeter.
Resistance is present in the conductors (R), in the loads (Ri1) and in the power
source (Ri2).
The inclusion of an ammeter (unlike a voltmeter) requires a modification to the
circuit, in that the circuit must be opened at some point by cutting a conductor and
the instrument must be then connected between the open ends of the conductor.

Fig. 2121

The inclusion of an ammeter (unlike a voltmeter) requires a modification to the

circuit, in that the circuit must be opened at some point by cutting a conductor and
the instrument must be then connected between the open ends of the conductor.

Fig. 2122

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Wiring diagrams
VOLTAGE Symbol V
Voltage: Difference in potential; (emf); force that causes electrons to flow
Units: Volts
Measuring instrument: Voltmeter.
Connection to circuit: in parallel.
Resistance
In an electrical circuit, voltage and current are both dependent on RESISTANCE, i.e. the opposition to the flow of electrons in a
material.
We have already mentioned how the motion of electrons occurs as a result of forces produced by the collision of these minute par-
ticles.
This phenomenon generates heat and is this reason why materials heat up when current passes through them.
The greater the current (the greater the number of electrons in motion) the more heat is produced.
As the temperature increases, the movement of the electrons also increases, and the electrons find it more difficult to move under
the influence of the voltage.
In some materials, this resistance is minimal; these materials are good conductors of current (conductors: copper, aluminium, silver,
etc.). In others, the resistance is so high that it is difficult for electrons to move (insulators: mica, porcelain, glass, paper, etc.)
In addition to the nature of the material, resistance is also affected by its dimensions:
l LENGTH: the greater the length of the conductor the greater the number of collisions between atoms and free electrons.
l CROSS-SECTIONAL AREA; the greater the cross-sectional area, the greater the number of free electrons. Resistance is
inversely proportional to cross-sectional area.
l TEMPERATURE, the motion of atoms and consequently the probability of collision with free atoms increases proportionally
with the temperature, thus increasing also the resistance.
The electrical circuits on the tractor are generally comprised of wire conductors with a cross-sectional area that is negligible in com-
parison with their length.

Fig. 2123 - Load connection cables

1. Single colour.
2. Spiral striping with max. pitch 50 mm
3. Horizontal striping.
4. With narrow-spaced coloured rings.
5. With wide spaced rings.
6. With rings in groups of 2 of same or different colours, depending on use.
7. With coloured rings in groups of 3
RESISTANCE Symbol R ( Omega )
Resistance: Opposition to the flow of electrons.

40-11
 Wiring diagrams
Units: Ohm (Omega ).
Measuring instrument: Ohmmeter (tester), or voltmeter and ammeter when in presence of voltage.
The resistance of different materials - Resistivity
It has been determined experimentally that the resistance of a wire conductor is given by:
R = p × ( l ÷ S ) = ohms
in which:
p = (Greek letter pronounced “rho”) is a proportional coefficient that varies according to the nature of the material and is known as
“resistivity” or “specific resistance”.
l = length, expressed in metres
S = sectional area, expressed in mm²
This formula can also be written:
p=(R×S)÷l
so we can state that the unit of measurement of resistivity (p) represents a resistance of 1 ohm of a conductor of the material in que-
stion, with a length 1 metre, and sectional area of 1 mm², at a temperature of 0°C.
While for conductors resistivity is measured in ohms per mm²/m, for insulators it is almost always expressed in mega ohms/mm,
which is the resistance in millions of ohms of a cube with a side length of 1 m.
Variation of resistance with temperature (temperature coefficient)
For most metals, resistivity increases with the temperature (positive temperature coefficient); this is why when talking about resistivity
there must always be a reference to temperature.
There are exceptions to this rule, such as, for example, chromium and carbon, in which resistivity decreases with the temperature
(negative temperature coefficient) and some alloys in which resistivity does not vary, which have temperature coefficient of 0.
This increase or decrease in the resistance per degree of temperature and per ohm of resistance is termed the “temperature coeffi-
cient” , and is denoted with the Greek letter a (alpha).
If the initial resistance is R0, at a temperature t0 (ambient temperature), and the temperature difference is t = t1 - t0, the variation in
resistance will be:
R×t×a
and the final resistance is:
Rt = R0 + R0 × t × a
Rt = R0 (1 + a × t0)
This formula is of great practical importance as it allows us to calculate the final temperature of a coil or resistor using the resistance
variation method.
The temperature coefficient is used (positive or negative) to characterise thermistors (PTC = Positive Temperature Coefficient and
NTC = Negative Temperature Coefficient)
The interdependence of electrical values
In an electrical circuit, the relationship between current, voltage and resistance is given by the formula:
V=IxR
Volts = ohms x amps
If any of these values is unknown, it can be calculated, providing the other two values are known, simply by applying one of the
following formulae:
R=V÷I
I=V÷R
V=IxR
Power
The power developed or dissipated is given by the formula:
Power = Voltage x Current
Watt (W) = Volts x Amps
In mechanical engineering, power is still commonly expressed in terms of horsepower: hp
The relationship between horsepower and Watts is given in the following equation:

40-12
Wiring diagrams
1 hp = 736 W = 0.736 kW
1 kW = 1.36 hp
Dissipated power, in electrical terms, is power transformed into heat and is given by:
Power = Voltage x Current = Resistance x Current x Current
given that:
W=V×I
V=R×I
then:
W = R × I × I = R × I²
Multiples and submultiples of electrical values
Table 98
Multiples and submultiples of units of measurement
Prefix Multiply by Divide by
Name Symbol
mega- M 1,000,000 -
kilo- k 1000 -
hecto- h 100 -
deca- da 10 -
deci- D - 10
centi- S - 100
milli- M - 1.000
micro- µ - 1,000,000
nano- N - 1,000,000,000
pico- P - 1,000,000,000,000

40.1.4 - Electrical and electronic components (1/2)

Electrical and electronic components
Electronic components are used in circuits to modulate (vary, modify), control and regulate electrical values or to protect other devi-
ces.
In particular, electronic semiconductor components exploit the various reactions of electrons to heat, magnetism, and light in order
to generate small electrical signals. These electrical signals, when suitably modified, can be used by signalling devices or to control
other components.
Components can be classified on the basis of the functions they perform; components used to control or amplify power signals are
deemed ACTIVE; components which neither control nor amplify power are deemed PASSIVE.
Resistors*
Components of various design comprised of a conductor with a known resistivity that when included in a circuit causes a voltage
drop.
They are therefore used to change voltage and current; they come in different shapes and sizes, depending on their type, ohmic
resistance value, tolerance and heat dispersion characteristics.
Table 99
TYPES OF RESISTORS
FIXED VARIABLE THERMALLY SENSITIVE RE- LIGHT SENSITIVE RESIS-
SISTORS TORS
wirewound wirewound Thermistors: LDR
film film NTC -
- Linear or non-linear variation PTC -
All resistors are defined by their dimensions and characteristics: ohmic value, and maximum operating temperature.
* N.B. To avoid confusion, in this manual the term RESISTANCE is used for the value expressed in ohms which represents the op-
position to the flow of electrical current.
The term RESISTOR is used for the component used to introduce “resistance” into an electrical circuit.
Resistors are of two types: fixed or variable.
(the term “resistance” is also often used for the component).

40-13
 Wiring diagrams
Fixed resistors
How to determine the ohmic value of a resistor
In wirewound resistors, the value is printed with decimal point (or comma) and the
omega symbol.
If the value of the resistor is 10.5 ohms, the marking will be: 10.5 ohms
sometimes the letter R is used in place of the decimal separator (point or comma):
10 R5
On resistors with values measured in thousand of ohms, the printed value will
include the letter “k”, which stands for thousand (1000): 10.5 kohms (10,500 ohms)

Fig. 2124

Potentiometers (Variable resistors)

This a resistor with a sliding contact that varies the resistance as it is moved along
the resistor.
The symbols used in schematics for a variable resistor or potentiometer are shown
in the figure on the right:

Fig. 2125

Use of a variable resistor as a voltage divider

Divides the voltage into two or three parts in a specific ratio.
V1 = Applied voltage,
P = Potentiometer,
U = Load,
V2 = Required voltage (obtained by moving the sliding contact) < V1

Fig. 2126

Use of a variable resistor as an electrical resistance of absolute value

All the current flows through the sliding contact.
This means that the sliding contact must be held securely in place, otherwise the
voltage V2 will change.

Fig. 2127

40-14
Wiring diagrams
Preventing arcing between the resistor and sliding contact.
The figure shows a way to prevent the arcing between the resistor and the sliding
contact that may occur in the case of poor contact.
This connection allows some of the current to flow through the full length of the
resistor. The voltage drop between the sliding contact and the resistor is less than
V1, thus reducing the possibility of arcing.
The resistor of the rheostat can be sized so that the resistance can be varied in
both a linear and a non-linear way.

Fig. 2128

Voltage divider
Voltage dividers with fixed resistors or potentiometers are used whenever circuits require electrical power below the standard volta-
ges available on the tractor (12 Volts with engine off and 14.5 Volts with engine running).
Voltage dividers are found in the voltage regulator of the alternator and in the electronic control units.
Thermistors (Thermally Sensitive Resistors)
These are semiconductor resistors in which the resistance decreases as the temperature rises, ranging from just a few ohms at 0 °C
to tens of thousands of ohms at 100 °C; they are used to detect changes in temperature.
They may be either self-heating, if the heat is produced by the current flowing through them, or externally heated, if sensitive to the
temperature of the environment or the component on which they are mounted.
There are two types: PTC (Positive Temperature Coefficient) and NTC (Negative Temperature Coefficient)
With PTC thermistors, resistance increases with the temperature, while with the NTC type, resistance decreases as the temperature
rises.
NTC types are available with resistance values ranging from just a few ohms to several hundred kohms.
Operating characteristics of NTC thermistors

Fig. 2129

Operating characteristics of PTC thermistors

Note the linearity of the variation.

Fig. 2130

Thermistors are used in cab heating and climate control systems.

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 Wiring diagrams
Capacitor
This component consists of a pair of conductors, generally in the form of flat plates, separated by an insulator (dielectric). Its function
to store electrical charge from a power supply.
This charge can then be given as and when required.
Symbol

Fig. 2131

Capacitor in a circuit with a generator.

Fig. 2132

The amount of electrical charge that a capacitor can store is referred to as its “capacitance” (C), and is measured in farads (F). In
practice, however, the farad is too large for general use so the following units are used instead:
mF = millifarad = 1/1,000 F
µF = microfarad = 1/1,000,000 F
nF = nanofarad = 1/1,000,000,000 F
On closing the switch, the electrons start moving but their flow is impeded by the dielectric. Electrons will therefore accumulate in the
plate connected to the negative terminal (-) of the generator, causing negative charge to build up. In the meantime the positive plate
loses electrons, thereby becoming positively charged. A potential difference is thus created across the plates of the capacitor, and
this increases until it equals the potential difference of the generator.
The capacitance of the capacitor is therefore proportional to the applied voltage and to the surface area of the plates and is inversely
proportional to the distance “d” between the plates. It also depends on the type of dielectric used.
The process described above is known as charging the capacitor, and is complete when the capacitor is fully charged. If a resistor
or a load of another type is connected to the capacitor, the latter discharges as electrons flow in opposite direction and the potential
difference between the plates decreases to zero.
Diodes
A diode can be defined simply as a junction between two semiconductors, one made of P-type material and the other made of N-type
material.

40-16
Wiring diagrams
A diode is a junction between two semiconductors, one made of P type material
and the other made of N type material.

Fig. 2133

The contact between the two semiconductors in different situations of electrical charge forms a barrier to electrical current flow at
the junction.
This barrier prevents the current from flowing through the diode.

Fig. 2134

Rectification, isolation, (switch), discharge and protection.

Fig. 2135

The diode symbol and the designations of its terminals.

Fig. 2136

The situation at the junction between the two semiconductors changes when a voltage is applied across the anode and cathode; the
diode is polarised, as shown in the figure.
When a voltage is applied to the diode, it polarises in the two ways indicated.

40-17
 Wiring diagrams
(A) = Direct polarisation (forward biasing)
( - ) = Cathode
( + ) = Anode

Fig. 2137

(B) = Reverse polarisation (reverse biasing)

( - ) = Cathode
( + ) = Anode

Fig. 2138

With forward biasing (positive connected to the anode and negative to the cathode) the resistance to current flow is significantly
reduced and the diode allows current to flow, providing that the applied voltage exceeds the threshold value, i.e. the voltage required
to initiate the process by which the barrier is reduced.
If the polarity of the diode is reversed, there is no electron flow except for the very weak current that crosses the junction. If the rever-
se voltage applied to the diode exceeds a certain value (thousand of Volts) the reverse current flowing through the diode will increase
rapidly to the point where the junction is damaged.
The function of the diode is therefore to allow current flow in one direction only, from the anode (+) to the cathode ( - ).
It this way it acts as an electrical one-way valve.
Forward biased diode allows current flow.
The lamp illuminates,

Fig. 2139

40-18
Wiring diagrams
Reverse biased diode blocks current flow.
The lamp does not illuminate.

Fig. 2140

The main function of the diode is to act as an electrical one-way valve.

Fig. 2141

Zener diode
We have already mentioned how diodes do not tolerate reverse voltage, as when this reaches a certain level, the reverse current flow
will increase significantly to the point where the diode itself is damaged.
The Zener diode is specifically designed to allow a certain amount of reverse current flow without damage to the junction.
It is also possible to make this reverse current flow occurs at a certain reverse voltage, known as “zener voltage”.
A zener diode can therefore be defined as semiconductor with a special PN junction with controlled reverse bias properties.
If forward biased, the Zener diode behaves just like a normal diode, while if reverse biased, it prevents current flow until the voltage
reaches the critical level, which is defined as the “Zener point”.
At this point the current increases rapidly.

40-19
 Wiring diagrams

Fig. 2142
The behaviour of the Zener diode can thus be compared to that of a pressure relief valve in a hydraulic circuit.
a) current and water flow
b) no current or water flow,
c) the water flows when it overcomes the opposing force of the valve spring. Likewise, the current flows when the voltage reaches
the zener point.
LED (light emitting diode)
A LED is a special diode with two terminals; it allows current flow in one direction only and emits light when low-voltage current pas-
ses through it.
The polarity of the terminals is very important, and the cathode is marked to facilitate identification.
The light emitted is monochromatic; the colours red, yellow, green and orange are available.
Operating characteristics of a LED and its symbol.

Fig. 2143

40-20
Wiring diagrams
LED
1. Light beam emitted
2. Diode
3. Transparent plastic cap
4. PIN terminals

Fig. 2144

LEDs are often used for signal lamps as their power consumption is very low, they require only low levels of reverse current and they
are impact resistant.
A typical application is as an indicator lamp, which, unlike a conventional bulb, can be flashed on and off repeatedly without failing.
They are also used to display segmented symbols and alphanumeric digits.
40.1.5 - Electrical and electronic components (2/2)
Transistors
A transistor is semiconductor which has three junctions.
It can be distinguished from a diode by its three leads, whereas a diode only has two.

Fig. 2145 - Schematic diagram and symbol of the transistor.

As you can see from the schematic, there two possible configurations: PNP (with a N semiconductor in the centre) or NPN (with a P
semiconductor in the centre). The central part is known as the “base”.
The lateral parts are doped with impurities and are termed the “collector” and the “emitter”. On the symbol, note that the emitter is
marked with an arrow, which indicates the direction of current flow between the base and the emitter.
Inside the transistor, there are two opposing barriers to current flow: if voltage is applied at one end of the semiconductor (E-C), one if
the barriers is eliminated while the other is strengthened and consequently no current flows; the same result is obtained if the polarity
of the applied voltage is reversed.

40-21
 Wiring diagrams
When voltage is applied across terminals (E) and (C), no current flows through
the transistor.

Fig. 2146

If a weak voltage is applied simultaneously to the base terminal, the transistor becomes a conductor and current flows between the
emitter and collector.
When voltage is also applied to the base terminal, the transistor allows current
flow.

Fig. 2147

When the voltage applied to the base terminal is modified, the current flow between the emitter and collector will also vary proportio-
nally. From this behaviour are derived the two main characteristics of the transistor:
1. Current does not flow through the transistor if the circuit between the emitter and collector is interrupted, i.e. no voltage ap-
plied.
2. The current flowing through the transistor is directly proportional to current that flows through the emitter-base circuit, within
the operating limits of the transistor. This means that the base current (the current that flows between the emitter and base) is
proportional to the collector current (the current flow between the emitter and the collector) and therefore the latter increases.
Given these two characteristics, a transistor can function as a switch (by removing the voltage at the base) or as an amplifier.
With a transistor, a weak current flowing from the emitter E to the base B (PNP transistor) or from the base to the emitter (NPN
transistor), can be used to control a strong current flow from the emitter to the collector (PNP) or from the collector to emitter (NPN).
This is the most useful characteristic of the transistor, which can be summarised in the equation:
a = ( Ic ) ÷ ( Ib )
This parameter, however, varies according to the collector current and voltage, as well as the temperature of the transistor.
The difference between NPN-type and PNP-type transistors lies solely in the direction of the current flow. The operating limits of
transistors are:
l the maximum collector current,
l maximum voltage from collector to emitter.

40-22
Wiring diagrams

Fig. 2148 - Operation schematic

Schematic showing operation of a PNP transistor and an NPN transistor when voltage is applied at the base.
The current Ic can flow from E to C only if it flows from E to B (1) or from B to E (2). Ic is amplified relative to Ib.

Fig. 2149
Typical connection of a transistor. The resistor R limits the current and protects the transistor.

40-23
 Wiring diagrams

Fig. 2150
Typical connection of a transistor. The resistor R limits the current and protects the transistor.

Fig. 2151
The transistor as a current amplifier
Use of a transistor as a switch or relay
Thanks to their amplifying properties, transistors can be used in place of relays (electromagnetic switches) as they can perform the
same function, but with the advantage that they use static components rather than moving parts.
The figure shows two electrical circuits, one controlled by a relay and the other by a transistor.
In the relay circuit, when the switch is closed in the relay control circuit, the contacts close the main circuit (drawn with the thick black
line); i.e. a relatively small current (0.2 A) can be used to control a much larger working current (8A).
The transistor circuit works in exactly the same way. When the switch in the control circuit is closed, the current flows from the positive
pole of the battery through the emitter; the base terminal of the transistor is polarised and the transistor allows current flow (EC) thus
allowing current to flow in the main circuit.

40-24
Wiring diagrams

Fig. 2152
Circuit diagrams show use of an electromagnetic relay (B) and use of a transistor as a relay (A). U = Load in main circuit.

40-25
 Wiring diagrams
40.2 - Components
40.2.1 - A - Starting and charging (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001)
Table 100
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
A001 04258670 Preheating device Power supply: 12V 40-175 40-1194
Total resistance at 20°C: 0.061
Ohms
A002 01183630 Alternator “B+” 40-175 40-1236
40-175 40-1234
A003 01183630 Alternator “D+” 40-1123 40-1236
40-966 40-1236
40-175 40-1236
40-1123 40-1234
40-175 40-1234
40-966 40-1234
A004 01183630 Alternator “W” 40-175 40-1236
40-175 40-1234

40.2.2 - A - Starting and charging (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85
-> 16001)
Table 101
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
A001 04258670 Preheating device Power supply: 12V 40-229 40-1194
Total resistance at 20°C: 0.061
Ohms
Power supply: 12V 40-202 40-1194
Total resistance at 20°C: 0.061
Ohms
A002 01183630 Alternator “B+” 40-229 40-1234
40-202 40-1234
40-229 40-1236
40-202 40-1236
A003 01183630 Alternator “D+” 40-202 40-1234
40-229 40-1234
40-990 40-1234
40-990 40-1236
40-229 40-1236
40-1138 40-1236
40-202 40-1236
40-1138 40-1234
A004 01183630 Alternator “W” 40-202 40-1236
40-229 40-1234
40-202 40-1234
40-229 40-1236

40-26
Wiring diagrams
40.2.3 - B - Fuses (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)

MF5
40A FT1-2-3 B029
MF4
40A START B028

PK1 PK2
+15
START FAN SPEED J008 J009
COMPRESSOR
MU1

MU4

RELAY
B030
COMPRESSOR

30A
MK3
FT 5-6-7-8

FAN SPEED
RELAY

B025

B026

B027
MK1

20 A B032
30A
30A

30A

POWER
B031 B033
MU6
MU3

30A +15
MF1

20 A
MK3 MF3

SOCKET
MK1

+15 +15
HI/LO J002 J003 J004
F14-15 F11-12-13

+15 ROOF +15

FAN SPEED J005 J006 J007
MK4

MK6

FT5.6.7.8 MU6
M11

B006 B016

B010 B020
B011 B021
B005 B015

B009 B019

B012 B022
B013 B023
STOLL SOCKET

B007 B017
B008 B018

B014 B024
RELAY

L R
+15 +15 +15 +15 +15 +15 +15 +15
M20

7.5A 7.5A 7.5 A 10A 3A 15 A 15 A 7.5 A 7.5 A 15 A

COMPRESSOR

STOP(EU)
STOP +30
+15 +30 +30 USA +30 +30 +30
10 A 7.5 A 20 A 15 A 15 A 5A 7.5A 15 A 15 A 15 A
M1

M10

D0063290

Fig. 2153 - Fusebox

Table 102
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B001 Fuse 40-175 40-1198
40-839 40-1198
B002 Fuse 40-839 40-1199
B003 Fuse 40-543 40-1200
40-839 40-1200
B004 Fuse 40-175 40-1194
B005 Fuse (10A) 40-593 40-1221
40-647 40-1209
40-593 40-1209
40-700 40-1209
40-647 40-1221
40-700 40-1221
B006 Fuse (7.5A) 40-1153 40-1221
40-934 40-1221
40-1016 40-1209
40-934 40-1209

40-27
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B007 Fuse (20A) 40-797 40-1209
40-755 40-1209
40-839 40-1209
40-1094 40-1221
40-1064 40-1221
40-839 40-1221
B008 Fuse (15A) 40-290 40-1221
40-839 40-1221
40-327 40-1221
40-290 40-1209
40-327 40-1209
40-839 40-1209
Table 103
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B009 Fuse (15A) 40-839 40-1209
40-1016 40-1209
40-1094 40-1221
40-1064 40-1221
40-839 40-1221
B010 Fuse (5A) 40-1064 40-1221
40-254 40-1221
40-327 40-1221
40-1153 40-1221
40-290 40-1221
40-369 40-1221
40-1094 40-1221
40-175 40-1221
40-934 40-1221
40-1003 40-1221
B010 Fuse (5A) 40-1123 40-1221
40-1016 40-1209
40-797 40-1209
40-369 40-1209
40-934 40-1209
40-327 40-1209
40-966 40-1209
40-755 40-1209
40-254 40-1209
40-1003 40-1209
B010 Fuse (5A) 40-839 40-1209
40-175 40-1209
40-839 40-1221
40-290 40-1209
Table 104
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B011 Fuse (7.5A) 40-327 40-1209
40-839 40-1221
40-327 40-1221
40-290 40-1221
40-1003 40-1221
40-934 40-1221
40-934 40-1209
40-839 40-1209
40-290 40-1209
40-1003 40-1209

40-28
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B012 Fuse (15A) 40-797 40-1209
40-1064 40-1221
40-755 40-1209
40-1094 40-1221
B013 Fuse (15A) 40-797 40-1209
40-755 40-1209
40-1064 40-1221
40-1094 40-1221
B015 Fuse (15A) 40-567 40-1221
40-290 40-1221
40-1094 40-1221
40-543 40-1221
40-700 40-1221
40-898 40-1221
40-1064 40-1221
40-934 40-1221
40-647 40-1221
B015 Fuse (15A) 40-1123 40-1221
40-593 40-1221
Table 105
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B015 Fuse (15A) 40-473 40-1221
40-327 40-1221
40-369 40-1221
40-410 40-1221
40-445 40-1221
40-515 40-1221
40-567 40-1209
40-1153 40-1221
40-1016 40-1209
40-797 40-1209
B015 Fuse (15A) 40-966 40-1209
40-647 40-1209
40-369 40-1209
40-445 40-1209
40-410 40-1209
40-700 40-1209
40-870 40-1209
40-515 40-1209
40-934 40-1209
40-593 40-1209
B015 Fuse (15A) 40-898 40-1209
40-870 40-1221
40-327 40-1209
40-543 40-1209
40-755 40-1209
40-473 40-1209
40-290 40-1209
B016 Fuse (7.5A) 40-290 40-1221
40-327 40-1221
Table 106
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B016 Fuse (7.5A) 40-290 40-1209
40-327 40-1209
40-1064 40-1209
40-1094 40-1209

40-29
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B018 Fuse (15A) 40-445 40-1221
40-410 40-1209
40-410 40-1221
40-515 40-1221
40-515 40-1209
40-445 40-1209
40-473 40-1221
40-473 40-1209
B019 Fuse (15A) 40-410 40-1209
40-473 40-1209
40-410 40-1221
40-473 40-1221
B020 Fuse (3A) 40-864 40-1221
40-473 40-1221
40-445 40-1221
40-369 40-1221
40-898 40-1221
40-1153 40-1221
40-934 40-1221
40-290 40-1221
40-1064 40-1221
40-647 40-1221
B020 Fuse (3A) 40-870 40-1221
40-567 40-1221
40-1094 40-1221

Table 107
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B020 Fuse (3A) 40-543 40-1221
40-327 40-1221
40-410 40-1221
40-515 40-1221
40-1123 40-1221
40-410 40-1209
40-593 40-1221
40-327 40-1209
40-567 40-1209
40-445 40-1209
B020 Fuse (3A) 40-700 40-1221
40-797 40-1209
40-898 40-1209
40-473 40-1209
40-870 40-1209
40-369 40-1209
40-700 40-1209
40-755 40-1209
40-647 40-1209
40-290 40-1209
B020 Fuse (3A) 40-543 40-1209
40-864 40-1209
40-515 40-1209
40-1016 40-1209
40-934 40-1209
40-593 40-1209
40-966 40-1209
B021 Fuse (10A) 40-934 40-1209
40-175 40-1209

40-30
Wiring diagrams
Table 108
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B021 Fuse (10A) 40-290 40-1221
40-254 40-1221
40-369 40-1221
40-369 40-1209
40-327 40-1209
40-327 40-1221
40-755 40-1209
40-1016 40-1209
40-966 40-1209
40-797 40-1209
B021 Fuse (10A) 40-864 40-1221
40-1003 40-1209
40-290 40-1209
40-864 40-1209
40-254 40-1209
40-1064 40-1221
40-934 40-1221
40-1123 40-1221
40-1153 40-1221
40-1003 40-1221
B021 Fuse (10A) 40-175 40-1221
40-1094 40-1221
B022 Fuse (7.5A) 40-290 40-1221
40-1003 40-1221
40-175 40-1221
40-327 40-1221
40-254 40-1221
40-864 40-1221
40-1003 40-1209

Table 109
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B022 Fuse (7.5A) 40-175 40-1209
40-864 40-1209
40-327 40-1209
40-254 40-1209
40-290 40-1209
B023 Fuse (7.5A) 40-797 40-1209
40-755 40-1209
40-1094 40-1221
40-1064 40-1221
B024 Fuse (7.5A) 40-515 40-1221
40-1094 40-1221
40-1123 40-1221
40-898 40-1221
40-327 40-1221
40-473 40-1221
40-1064 40-1221
40-290 40-1221
40-410 40-1221
40-700 40-1221

40-31
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B024 Fuse (7.5A) 40-1153 40-1221
40-369 40-1221
40-934 40-1221
40-445 40-1221
40-445 40-1209
40-369 40-1209
40-515 40-1209
40-934 40-1209
40-290 40-1209
40-473 40-1209
Table 110
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B024 Fuse (7.5A) 40-898 40-1209
40-327 40-1209
40-1016 40-1209
40-700 40-1209
40-755 40-1209
40-966 40-1209
40-410 40-1209
40-797 40-1209
B025 Fuse (30A) 40-1016 40-1209
40-515 40-1221
40-934 40-1221
40-473 40-1221
40-445 40-1221
40-839 40-1221
40-410 40-1221
40-839 40-1209
40-473 40-1209
40-445 40-1209
B025 Fuse (30A) 40-1153 40-1221
40-410 40-1209
40-515 40-1209
40-934 40-1209
B026 Fuse (30A) 40-870 40-1221
40-898 40-1221
40-515 40-1221
40-473 40-1221
40-445 40-1221
40-410 40-1221
40-839 40-1221
Table 111
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B026 Fuse (30A) 40-290 40-1221
40-410 40-1209
40-839 40-1209
40-870 40-1209
40-445 40-1209
40-898 40-1209
40-515 40-1209
40-290 40-1209
40-473 40-1209
B027 Fuse (30A) 40-839 40-1209
40-567 40-1221
40-839 40-1221
40-700 40-1209
40-567 40-1209
40-700 40-1221

40-32
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B028 Fuse (40A) 40-175 40-1209
40-175 40-1221
B029 Fuse (40A) 40-647 40-1209
40-290 40-1221
40-327 40-1221
40-593 40-1221
40-700 40-1221
40-839 40-1221
40-593 40-1209
40-327 40-1209
40-290 40-1209
B029 Fuse (40A) 40-700 40-1209
40-839 40-1209
40-647 40-1221
Table 112
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B030 Fuse (30A) 40-1153 40-1221
40-290 40-1221
40-1064 40-1221
40-327 40-1221
40-543 40-1221
40-870 40-1221
40-369 40-1221
40-515 40-1221
40-934 40-1221
40-410 40-1221
B030 Fuse (30A) 40-898 40-1221
40-567 40-1221
40-934 40-1209
40-445 40-1221
40-473 40-1221
40-1123 40-1221
40-647 40-1221
40-593 40-1221
40-839 40-1221
40-700 40-1221
B030 Fuse (30A) 40-543 40-1209
40-567 40-1209
40-839 40-1209
40-755 40-1209
40-700 40-1209
40-410 40-1209
40-593 40-1209
40-327 40-1209
40-369 40-1209
Table 113
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B030 Fuse (30A) 40-870 40-1209
40-1094 40-1221
40-797 40-1209
40-1016 40-1209
40-473 40-1209
40-445 40-1209
40-966 40-1209
40-898 40-1209
40-290 40-1209
40-515 40-1209

40-33
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B030 Fuse (30A) 40-647 40-1209
40-327 40-1209
40-290 40-1221
40-327 40-1221
40-839 40-1209
40-839 40-1221
40-290 40-1209
B032 Fuse (20A) 40-839 40-1209
40-755 40-1209
40-797 40-1209
40-839 40-1221
40-1094 40-1221
40-1064 40-1221
B033 Fuse (20A) 40-700 40-1209
40-593 40-1221
40-567 40-1221
40-700 40-1221
40-647 40-1209
40-593 40-1209
Table 114
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B033 Fuse (20A) 40-567 40-1209
40-647 40-1221
B034 Fuse (10A) 40-290 40-1226
B034 Fuse (10A) 40-290 40-1244
B034 Fuse (15A) 40-327 40-1204
B035 Fuse (5A) 40-327 40-1204
40-290 40-1226
40-290 40-1244
B036 Fuse (20A) 40-700 40-1204
B036 Fuse (30A) 40-593 40-1226
B036 Fuse (30A) 40-647 40-1244
B037 Fuse (7.5A) 40-870 40-1226
40-870 40-1244
40-898 40-1204
B038 Fuse (7.5A) 40-290 40-1226
40-870 40-1226
40-290 40-1244
40-870 40-1244
40-898 40-1204
B039 Fuse (10A) 40-410 40-1226
40-515 40-1204
40-473 40-1204
40-410 40-1244
40-445 40-1226
40-445 40-1244
B040 Fuse (10A) 40-473 40-1204
40-410 40-1226
40-445 40-1226
40-445 40-1244
40-410 40-1244
40-515 40-1204

40-34
Wiring diagrams
40.2.4 - B - Fuses (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001)

MF5
40A FT1-2-3 B029
MF4
40A START B028

PK1 PK2
+15
START FAN SPEED J008 J009
COMPRESSOR
MU1

MU4

RELAY
B030
COMPRESSOR

30A
MK3
FT 5-6-7-8

FAN SPEED
RELAY

B025

B026

B027
MK1

20 A B032
30A
30A

30A

POWER
B031 B033
MU6
MU3

30A +15
MF1

20 A
MK3 MF3

SOCKET
MK1

+15 +15
HI/LO J002 J003 J004
F14-15 F11-12-13

+15 ROOF +15

FAN SPEED J005 J006 J007
MK4

MK6

FT5.6.7.8 MU6
M11

B006 B016

B010 B020
B011 B021
B005 B015

B009 B019

B012 B022
B013 B023
STOLL SOCKET

B007 B017
B008 B018

B014 B024
RELAY

L R
+15 +15 +15 +15 +15 +15 +15 +15
M20

7.5A 7.5A 7.5 A 10A 3A 15 A 15 A 7.5 A 7.5 A 15 A

COMPRESSOR

STOP(EU)
STOP +30
+15 +30 +30 USA +30 +30 +30
10 A 7.5 A 20 A 15 A 15 A 5A 7.5A 15 A 15 A 15 A
M1

M10

D0063290

Fig. 2154 - Fusebox - version with digital instrument panel

40-35
 Wiring diagrams

MF5
40A FT1-2-3 B029
MF4
40A START B028

PK1 PK2
+15
START FAN SPEED J008 J009
COMPRESSOR
MU1

MU4

30A
RELAY
MK3
COMPRESSOR B030
FT 5-6-7-8

FAN SPEED
RELAY

B025

B026

B027
MK1

20 A B032
30A
30A

30A

POWER
B031 B033
MU6
MU3

30A +15
MF1

20 A
MK3 MF3

SOCKET
MK1

+15 +15
J002 J004
F14-15 F11-12-13

+15 ROOF +15

FAN SPEED J005 J007
MK4

MK6

FT5.6.7.8 MU6
M11

B016

B010 B020
B011 B021
B005 B015

B009 B019

B012 B022
B013 B023
+15 EV STOLL SOCKET

B007 B017
B008 B018

B014 B024
RELAY
EU
L R
+15 +15 +15 +15 +15 +15
M20

7.5A 7.5A 7.5 A 10A 3A 15 A 15 A 7.5 A 7.5 A 15 A

COMPRESSOR

STOP

+30 +30 +30 +30

10 A 20 A 15 A 15 A 15 A 15 A 15 A
M1

M10

D0064740

Fig. 2155 - Fusebox - version with analog instrument panel

Table 115
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B001 Fuse 40-202 40-1198
40-229 40-1198
40-856 40-1198
B002 Fuse 40-848 40-1199
40-856 40-1199
B003 Fuse 40-559 40-1200
40-552 40-1200
40-848 40-1200
40-856 40-1200
B004 Fuse 40-202 40-1194
40-229 40-1194

40-36
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B005 Fuse (10A) 40-682 40-1221
40-664 40-1238
40-611 40-1238
40-629 40-1221
40-737 40-1221
40-682 40-1205
40-737 40-1205
40-629 40-1205
40-719 40-1238
B007 Fuse (20A) 40-856 40-1221
40-812 40-1238
40-770 40-1238
40-1079 40-1221
40-848 40-1238
40-856 40-1205
40-826 40-1205
40-783 40-1205
40-1109 40-1221
Table 116
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B008 Fuse (15A) 40-315 40-1221
40-304 40-1238
40-342 40-1238
40-848 40-1238
40-354 40-1221
40-856 40-1205
40-354 40-1205
40-315 40-1205
40-856 40-1221
B009 Fuse (15A) 40-1109 40-1221
40-856 40-1221
40-848 40-1238
40-1079 40-1221
40-1043 40-1205
40-856 40-1205
40-1030 40-1238
B010 Fuse (5A) 40-1012 40-1221
40-1109 40-1221
40-856 40-1221
40-397 40-1221
40-1079 40-1221
40-283 40-1221
40-1138 40-1221
40-1167 40-1221
40-229 40-1221
B010 Fuse (5A) 40-315 40-1221
40-958 40-1221
Table 117
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B010 Fuse (5A) 40-990 40-1205
40-354 40-1221
40-1012 40-1205
40-826 40-1205
40-283 40-1205
40-958 40-1205
40-315 40-1205
40-856 40-1205

40-37
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B010 Fuse (5A) 40-229 40-1205
40-397 40-1205
40-1043 40-1205
40-783 40-1205
40-354 40-1205
B012 Fuse (15A) 40-783 40-1205
40-770 40-1238
40-1109 40-1221
40-826 40-1205
40-812 40-1238
40-1079 40-1221
B013 Fuse (15A) 40-1109 40-1221
40-770 40-1238
40-812 40-1238
40-826 40-1205
40-1079 40-1221
40-783 40-1205
B015 Fuse (15A) 40-1079 40-1221
40-456 40-1238
40-1167 40-1221
40-535 40-1221

Table 118
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B015 Fuse (15A) 40-922 40-1221
40-682 40-1221
40-890 40-1221
40-1138 40-1221
40-354 40-1221
40-958 40-1221
40-910 40-1238
40-770 40-1238
40-737 40-1221
40-981 40-1238
B015 Fuse (15A) 40-881 40-1238
40-552 40-1238
40-611 40-1238
40-1030 40-1238
40-664 40-1238
40-951 40-1238
40-342 40-1238
40-382 40-1238
40-719 40-1238
40-489 40-1238
B015 Fuse (15A) 40-428 40-1238
40-315 40-1221
40-577 40-1238
40-629 40-1205
40-527 40-1238
40-464 40-1205
40-922 40-1205
40-503 40-1205
40-559 40-1205

40-38
Wiring diagrams
Table 119
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B015 Fuse (15A) 40-990 40-1205
40-783 40-1205
40-737 40-1205
40-629 40-1221
40-890 40-1205
40-535 40-1205
40-585 40-1205
40-354 40-1205
40-1109 40-1221
40-585 40-1221
B015 Fuse (15A) 40-559 40-1221
40-503 40-1221
40-464 40-1221
40-826 40-1205
40-397 40-1221
40-397 40-1205
40-682 40-1205
40-1043 40-1205
B015 Fuse (15A) 40-958 40-1205
40-436 40-1205
40-315 40-1205
40-436 40-1221
B016 Fuse (7.5A) 40-1109 40-1221
40-304 40-1238
40-342 40-1238
40-1079 40-1221
40-354 40-1205
40-354 40-1221
40-315 40-1205
40-315 40-1221

Table 120
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B018 Fuse (15A) 40-951 40-1238
40-981 40-1238
B019 Fuse (15A) 40-503 40-1205
40-503 40-1221
40-489 40-1238
B020 Fuse (3A) 40-304 40-1238
40-382 40-1238
40-456 40-1238
40-342 40-1238
40-436 40-1221
40-682 40-1221
40-354 40-1221
40-981 40-1238
40-1030 40-1238
40-527 40-1238
B020 Fuse (3A) 40-958 40-1221
40-585 40-1221
40-1079 40-1221
40-1109 40-1221
40-719 40-1238
40-552 40-1238
40-812 40-1238
40-489 40-1238
40-951 40-1238
40-664 40-1238

40-39
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B020 Fuse (3A) 40-866 40-1238
40-577 40-1238
40-770 40-1238
40-881 40-1238
40-611 40-1238
Table 121
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B020 Fuse (3A) 40-428 40-1238
40-535 40-1221
40-629 40-1221
40-910 40-1238
40-354 40-1205
40-397 40-1221
40-503 40-1221
40-535 40-1205
40-783 40-1205
40-315 40-1205
B020 Fuse (3A) 40-503 40-1205
40-1043 40-1205
40-922 40-1205
40-826 40-1205
40-464 40-1205
40-436 40-1205
40-890 40-1205
40-737 40-1205
40-585 40-1205
40-1138 40-1221
B020 Fuse (3A) 40-868 40-1221
40-958 40-1205
40-682 40-1205
40-315 40-1221
40-559 40-1221
40-737 40-1221
40-464 40-1221
40-629 40-1205
40-1167 40-1221
Table 122
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B020 Fuse (3A) 40-397 40-1205
40-890 40-1221
40-559 40-1205
40-990 40-1205
40-922 40-1221
40-868 40-1205
B021 Fuse (10A) 40-276 40-1238
40-981 40-1238
40-304 40-1238
40-1079 40-1221
40-315 40-1221
40-229 40-1221
40-951 40-1238
40-397 40-1221
40-1109 40-1221
40-1008 40-1238

40-40
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B021 Fuse (10A) 40-202 40-1238
40-342 40-1238
40-1030 40-1238
40-382 40-1238
40-770 40-1238
40-812 40-1238
B021 Fuse (10A) 40-868 40-1221
40-783 40-1205
40-866 40-1238
40-1012 40-1205
40-826 40-1205
40-1043 40-1205
Table 123
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B021 Fuse (10A) 40-958 40-1205
40-958 40-1221
40-315 40-1205
40-354 40-1205
40-283 40-1205
40-229 40-1205
40-1012 40-1221
40-990 40-1205
B021 Fuse (10A) 40-283 40-1221
40-1138 40-1221
40-1167 40-1221
40-354 40-1221
40-397 40-1205
40-868 40-1205
B022 Fuse (7.5A) 40-868 40-1205
40-229 40-1205
40-354 40-1221
40-315 40-1221
40-868 40-1221
40-354 40-1205
B022 Fuse (7.5A) 40-283 40-1205
40-1012 40-1205
40-229 40-1221
40-315 40-1205
40-283 40-1221
Table 124
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B022 Fuse (7.5A) 40-276 40-1238
40-866 40-1238
40-1008 40-1238
40-342 40-1238
40-202 40-1238
40-304 40-1238
40-1012 40-1221
B023 Fuse (7.5A) 40-826 40-1205
40-770 40-1238
40-812 40-1238
40-1109 40-1221
40-783 40-1205
40-1079 40-1221

40-41
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B024 Fuse (7.5A) 40-981 40-1238
40-1109 40-1221
40-958 40-1221
40-1167 40-1221
40-737 40-1221
40-489 40-1238
40-770 40-1238
B024 Fuse (7.5A) 40-812 40-1238
40-1030 40-1238
40-527 40-1238
40-202 40-1238
40-342 40-1238
40-382 40-1238
40-354 40-1221
40-719 40-1238
Table 125
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B024 Fuse (7.5A) 40-1079 40-1221
40-910 40-1238
40-354 40-1205
40-951 40-1238
40-535 40-1221
40-826 40-1205
40-535 40-1205
40-397 40-1205
40-783 40-1205
40-922 40-1205
B024 Fuse (7.5A) 40-315 40-1205
40-737 40-1205
40-922 40-1221
40-503 40-1221
40-397 40-1221
B024 Fuse (7.5A) 40-1043 40-1205
40-1138 40-1221
40-503 40-1205
40-990 40-1205
40-315 40-1221
40-958 40-1205
B025 Fuse (30A) 40-527 40-1238
40-489 40-1238
40-951 40-1238
40-503 40-1205
40-1030 40-1238
40-848 40-1238
40-981 40-1238
40-1167 40-1221
Table 126
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B025 Fuse (30A) 40-503 40-1221
40-1043 40-1205
40-535 40-1205
40-856 40-1205
40-535 40-1221
40-856 40-1221

40-42
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B026 Fuse (30A) 40-428 40-1238
40-535 40-1221
40-503 40-1221
40-910 40-1238
40-489 40-1238
40-881 40-1238
40-848 40-1238
40-304 40-1238
40-527 40-1238
40-890 40-1221
B026 Fuse (30A) 40-315 40-1221
40-456 40-1238
40-464 40-1205
40-922 40-1221
40-856 40-1205
40-436 40-1205
B026 Fuse (30A) 40-535 40-1205
40-503 40-1205
40-922 40-1205
40-464 40-1221
40-436 40-1221
40-890 40-1205
40-856 40-1221
40-315 40-1205
Table 127
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B027 Fuse (30A) 40-856 40-1221
40-577 40-1238
40-719 40-1238
40-848 40-1238
40-856 40-1205
40-585 40-1205
40-585 40-1221
40-737 40-1221
40-737 40-1205
B028 Fuse (40A) 40-202 40-1238
40-229 40-1205
40-229 40-1221
B029 Fuse (40A) 40-629 40-1221
40-719 40-1238
40-848 40-1238
40-664 40-1238
40-611 40-1238
40-682 40-1221
40-315 40-1221
40-304 40-1238
40-682 40-1205
B029 Fuse (40A) 40-856 40-1221
40-342 40-1238
40-354 40-1205
40-629 40-1205
40-737 40-1205
40-856 40-1205
40-315 40-1205
40-354 40-1221
40-737 40-1221

40-43
 Wiring diagrams
Table 128
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B030 Fuse (30A) 40-737 40-1221
40-489 40-1238
40-456 40-1238
40-848 40-1238
40-910 40-1238
40-304 40-1238
40-315 40-1221
40-629 40-1221
40-1138 40-1221
40-981 40-1238
B030 Fuse (30A) 40-585 40-1221
40-382 40-1238
40-1079 40-1221
40-397 40-1221
40-1109 40-1221
40-527 40-1238
40-719 40-1238
40-611 40-1238
40-552 40-1238
40-577 40-1238
B030 Fuse (30A) 40-664 40-1238
40-342 40-1238
40-1030 40-1238
40-812 40-1238
40-428 40-1238
40-951 40-1238
40-770 40-1238
40-881 40-1238
40-922 40-1205
40-1167 40-1221

Table 129
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B030 Fuse (30A) 40-503 40-1205
40-436 40-1221
40-990 40-1205
40-856 40-1205
40-535 40-1205
40-559 40-1205
40-826 40-1205
40-354 40-1205
40-1043 40-1205
40-783 40-1205
B030 Fuse (30A) 40-629 40-1205
40-585 40-1205
40-397 40-1205
40-436 40-1205
40-682 40-1205
40-958 40-1221
40-737 40-1205
40-503 40-1221
40-464 40-1221
40-535 40-1221
B030 Fuse (30A) 40-958 40-1205
40-682 40-1221
40-354 40-1221
40-559 40-1221

40-44
Wiring diagrams
Table 130
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B030 Fuse (30A) 40-922 40-1221
40-856 40-1221
40-890 40-1205
40-464 40-1205
40-315 40-1205
40-890 40-1221
B031 Fuse (30A) 40-315 40-1221
40-304 40-1238
40-848 40-1238
40-342 40-1238
40-315 40-1205
40-856 40-1205
40-354 40-1205
40-856 40-1221
40-354 40-1221
40-1079 40-1221
B032 Fuse (20A) 40-770 40-1238
40-848 40-1238
40-812 40-1238
40-856 40-1221
40-826 40-1205
40-856 40-1205
40-783 40-1205
40-1109 40-1221
B033 Fuse (20A) 40-611 40-1238
40-629 40-1221
Table 131
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B033 Fuse (20A) 40-664 40-1238
40-577 40-1238
40-682 40-1221
40-585 40-1221
40-629 40-1205
40-682 40-1205
40-585 40-1205
40-737 40-1205
40-719 40-1238
40-737 40-1221
B034 Fuse (10A) 40-304 40-1228
40-354 40-1204
40-342 40-1204
40-304 40-1242
40-315 40-1228
40-315 40-1242
B035 Fuse (5A) 40-342 40-1204
40-304 40-1228
40-354 40-1204
40-304 40-1242
40-315 40-1228
40-315 40-1242
B036 Fuse (30A) 40-611 40-1228
40-629 40-1228
40-664 40-1242
40-682 40-1242
40-737 40-1204
40-719 40-1204

40-45
 Wiring diagrams
Table 132
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B037 Fuse (7.5A) 40-881 40-1242
40-910 40-1204
40-922 40-1204
40-881 40-1228
40-890 40-1228
40-890 40-1242
B038 Fuse (7.5A) 40-315 40-1228
40-315 40-1242
40-304 40-1242
40-922 40-1204
40-910 40-1204
40-304 40-1228
B039 Fuse (10A) 40-436 40-1242
40-489 40-1204
40-535 40-1204
40-503 40-1204
40-464 40-1242
40-456 40-1242
B039 Fuse (10A) 40-436 40-1228
40-456 40-1228
40-464 40-1228
40-428 40-1228
40-428 40-1242
40-527 40-1204
Table 133
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B040 Fuse (10A) 40-436 40-1228
40-535 40-1204
40-527 40-1204
40-489 40-1204
40-456 40-1242
40-436 40-1242
40-464 40-1242
B040 Fuse (10A) 40-428 40-1242
40-464 40-1228
40-456 40-1228
40-503 40-1204
40-428 40-1228

40-46
Wiring diagrams
40.2.5 - B - Fuses (R3 EVO 85 -> 16001)

MF5
40A FT1-2-3 B029
MF4
40A START B028

PK1 PK2
+15
START FAN SPEED J008 J009
COMPRESSOR
MU1

MU4

RELAY
B030
COMPRESSOR

30A
MK3
FT 5-6-7-8

FAN SPEED
RELAY

B025

B026

B027
MK1

20 A B032
30A
30A

30A

POWER
B031 B033
MU6
MU3

30A +15
MF1

20 A
MK3 MF3

SOCKET
MK1

+15 +15
HI/LO J002 J003 J004
F14-15 F11-12-13

+15 ROOF +15

FAN SPEED J005 J006 J007
MK4

MK6

FT5.6.7.8 MU6
M11

B006 B016

B010 B020
B011 B021
B005 B015

B009 B019

B012 B022
B013 B023
STOLL SOCKET

B007 B017
B008 B018

B014 B024
RELAY

L R
+15 +15 +15 +15 +15 +15 +15 +15
M20

7.5A 7.5A 7.5 A 10A 3A 15 A 15 A 7.5 A 7.5 A 15 A

COMPRESSOR

STOP(EU)
STOP +30
+15 +30 +30 USA +30 +30 +30
10 A 7.5 A 20 A 15 A 15 A 5A 7.5A 15 A 15 A 15 A
M1

M10

D0063290

Fig. 2155 - Fusebox - version with digital instrument panel

40-47
 Wiring diagrams

MF5
40A FT1-2-3 B029
MF4
40A START B028

PK1 PK2
+15
START FAN SPEED J008 J009
COMPRESSOR
MU1

MU4

30A
RELAY
MK3
COMPRESSOR B030
FT 5-6-7-8

FAN SPEED
RELAY

B025

B026

B027
MK1

20 A B032
30A
30A

30A

POWER
B031 B033
MU6
MU3

30A +15
MF1

20 A
MK3 MF3

SOCKET
MK1

+15 +15
J002 J004
F14-15 F11-12-13

+15 ROOF +15

FAN SPEED J005 J007
MK4

MK6

FT5.6.7.8 MU6
M11

B016

B010 B020
B011 B021
B005 B015

B009 B019

B012 B022
B013 B023
+15 EV STOLL SOCKET

B007 B017
B008 B018

B014 B024
RELAY
EU
L R
+15 +15 +15 +15 +15 +15
M20

7.5A 7.5A 7.5 A 10A 3A 15 A 15 A 7.5 A 7.5 A 15 A

COMPRESSOR

STOP

+30 +30 +30 +30

10 A 20 A 15 A 15 A 15 A 15 A 15 A
M1

M10

D0064740

Fig. 2155 - Fusebox - version with analog instrument panel

Table 134
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B001 Fuse 40-202 40-1198
40-229 40-1198
40-856 40-1198
B002 Fuse 40-848 40-1199
40-856 40-1199
B003 Fuse 40-559 40-1200
40-552 40-1200
40-848 40-1200
40-856 40-1200
B004 Fuse 40-202 40-1194
40-229 40-1194

40-48
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B005 Fuse (10A) 40-682 40-1221
40-664 40-1238
40-611 40-1238
40-629 40-1221
40-737 40-1221
40-682 40-1205
40-737 40-1205
40-629 40-1205
40-719 40-1238
B007 Fuse (20A) 40-856 40-1221
40-812 40-1238
40-770 40-1238
40-1079 40-1221
40-848 40-1238
40-856 40-1205
40-826 40-1205
40-783 40-1205
40-1109 40-1221
Table 135
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B008 Fuse (15A) 40-315 40-1221
40-304 40-1238
40-342 40-1238
40-848 40-1238
40-354 40-1221
40-856 40-1205
40-354 40-1205
40-315 40-1205
40-856 40-1221
B009 Fuse (15A) 40-1109 40-1221
40-856 40-1221
40-848 40-1238
40-1079 40-1221
40-1043 40-1205
40-856 40-1205
40-1030 40-1238
B010 Fuse (5A) 40-1012 40-1221
40-1109 40-1221
40-856 40-1221
40-397 40-1221
40-1079 40-1221
40-1138 40-1221
40-1167 40-1221
40-229 40-1221
B010 Fuse (5A) 40-315 40-1221
40-269 40-1205
40-269 40-1221
40-958 40-1221
Table 136
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B010 Fuse (5A) 40-990 40-1205
40-354 40-1221
40-1012 40-1205
40-826 40-1205
40-958 40-1205
40-315 40-1205
40-856 40-1205

40-49
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B010 Fuse (5A) 40-229 40-1205
40-397 40-1205
40-1043 40-1205
40-783 40-1205
40-354 40-1205
B012 Fuse (15A) 40-783 40-1205
40-770 40-1238
40-1109 40-1221
40-826 40-1205
40-812 40-1238
40-1079 40-1221
B013 Fuse (15A) 40-1109 40-1221
40-770 40-1238
40-812 40-1238
40-826 40-1205
40-1079 40-1221
40-783 40-1205
B015 Fuse (15A) 40-1079 40-1221
40-456 40-1238
40-1167 40-1221
40-535 40-1221

Table 137
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B015 Fuse (15A) 40-922 40-1221
40-682 40-1221
40-890 40-1221
40-1138 40-1221
40-354 40-1221
40-958 40-1221
40-910 40-1238
40-770 40-1238
40-737 40-1221
40-981 40-1238
B015 Fuse (15A) 40-881 40-1238
40-552 40-1238
40-611 40-1238
40-1030 40-1238
40-664 40-1238
40-951 40-1238
40-342 40-1238
40-382 40-1238
40-719 40-1238
40-489 40-1238
B015 Fuse (15A) 40-428 40-1238
40-315 40-1221
40-577 40-1238
40-629 40-1205
40-527 40-1238
40-464 40-1205
40-922 40-1205
40-503 40-1205
40-559 40-1205

40-50
Wiring diagrams
Table 138
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B015 Fuse (15A) 40-990 40-1205
40-783 40-1205
40-737 40-1205
40-629 40-1221
40-890 40-1205
40-535 40-1205
40-585 40-1205
40-354 40-1205
40-1109 40-1221
40-585 40-1221
B015 Fuse (15A) 40-559 40-1221
40-503 40-1221
40-464 40-1221
40-826 40-1205
40-397 40-1221
40-397 40-1205
40-682 40-1205
40-1043 40-1205
B015 Fuse (15A) 40-958 40-1205
40-436 40-1205
40-315 40-1205
40-436 40-1221
B016 Fuse (7.5A) 40-1109 40-1221
40-304 40-1238
40-342 40-1238
40-1079 40-1221
40-354 40-1205
40-354 40-1221
40-315 40-1205
40-315 40-1221

Table 139
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B018 Fuse (15A) 40-951 40-1238
40-981 40-1238
B019 Fuse (15A) 40-503 40-1205
40-503 40-1221
40-489 40-1238
B020 Fuse (3A) 40-304 40-1238
40-382 40-1238
40-456 40-1238
40-342 40-1238
40-436 40-1221
40-682 40-1221
40-354 40-1221
40-981 40-1238
40-1030 40-1238
40-527 40-1238
B020 Fuse (3A) 40-958 40-1221
40-585 40-1221
40-1079 40-1221
40-1109 40-1221
40-719 40-1238
40-552 40-1238
40-812 40-1238
40-489 40-1238
40-951 40-1238
40-664 40-1238

40-51
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B020 Fuse (3A) 40-866 40-1238
40-577 40-1238
40-770 40-1238
40-881 40-1238
40-611 40-1238
Table 140
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B020 Fuse (3A) 40-428 40-1238
40-535 40-1221
40-629 40-1221
40-910 40-1238
40-354 40-1205
40-397 40-1221
40-503 40-1221
40-535 40-1205
40-783 40-1205
40-315 40-1205
B020 Fuse (3A) 40-503 40-1205
40-1043 40-1205
40-922 40-1205
40-826 40-1205
40-464 40-1205
40-436 40-1205
40-890 40-1205
40-737 40-1205
40-585 40-1205
40-1138 40-1221
B020 Fuse (3A) 40-868 40-1221
40-958 40-1205
40-682 40-1205
40-315 40-1221
40-559 40-1221
40-737 40-1221
40-464 40-1221
40-629 40-1205
40-1167 40-1221
Table 141
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B020 Fuse (3A) 40-397 40-1205
40-890 40-1221
40-559 40-1205
40-990 40-1205
40-922 40-1221
40-868 40-1205
B021 Fuse (10A) 40-981 40-1238
40-304 40-1238
40-1079 40-1221
40-315 40-1221
40-229 40-1221
40-951 40-1238
40-397 40-1221
40-1109 40-1221
40-1008 40-1238

40-52
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B021 Fuse (10A) 40-202 40-1238
40-342 40-1238
40-1030 40-1238
40-382 40-1238
40-770 40-1238
40-812 40-1238
B021 Fuse (10A) 40-261 40-1238
40-868 40-1221
40-783 40-1205
40-866 40-1238
40-1012 40-1205
40-826 40-1205
40-1043 40-1205
Table 142
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B021 Fuse (10A) 40-958 40-1205
40-958 40-1221
40-315 40-1205
40-354 40-1205
40-229 40-1205
40-1012 40-1221
40-269 40-1205
40-990 40-1205
B021 Fuse (10A) 40-1138 40-1221
40-269 40-1221
40-1167 40-1221
40-354 40-1221
40-397 40-1205
40-868 40-1205
B022 Fuse (7.5A) 40-868 40-1205
40-229 40-1205
40-269 40-1221
40-354 40-1221
40-315 40-1221
40-868 40-1221
40-354 40-1205
B022 Fuse (7.5A) 40-269 40-1205
40-1012 40-1205
40-229 40-1221
40-315 40-1205
Table 143
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B022 Fuse (7.5A) 40-866 40-1238
40-1008 40-1238
40-342 40-1238
40-202 40-1238
40-304 40-1238
40-261 40-1238
40-1012 40-1221
B023 Fuse (7.5A) 40-826 40-1205
40-770 40-1238
40-812 40-1238
40-1109 40-1221
40-783 40-1205
40-1079 40-1221

40-53
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B024 Fuse (7.5A) 40-981 40-1238
40-1109 40-1221
40-958 40-1221
40-1167 40-1221
40-737 40-1221
40-489 40-1238
40-770 40-1238
B024 Fuse (7.5A) 40-812 40-1238
40-1030 40-1238
40-527 40-1238
40-202 40-1238
40-342 40-1238
40-382 40-1238
40-354 40-1221
40-719 40-1238
Table 144
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B024 Fuse (7.5A) 40-1079 40-1221
40-910 40-1238
40-354 40-1205
40-951 40-1238
40-535 40-1221
40-826 40-1205
40-535 40-1205
40-397 40-1205
40-783 40-1205
40-922 40-1205
B024 Fuse (7.5A) 40-315 40-1205
40-737 40-1205
40-922 40-1221
40-503 40-1221
40-397 40-1221
B024 Fuse (7.5A) 40-1043 40-1205
40-1138 40-1221
40-503 40-1205
40-990 40-1205
40-315 40-1221
40-958 40-1205
B025 Fuse (30A) 40-527 40-1238
40-489 40-1238
40-951 40-1238
40-503 40-1205
40-1030 40-1238
40-848 40-1238
40-981 40-1238
40-1167 40-1221
Table 145
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B025 Fuse (30A) 40-503 40-1221
40-1043 40-1205
40-535 40-1205
40-856 40-1205
40-535 40-1221
40-856 40-1221

40-54
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B026 Fuse (30A) 40-428 40-1238
40-535 40-1221
40-503 40-1221
40-910 40-1238
40-489 40-1238
40-881 40-1238
40-848 40-1238
40-304 40-1238
40-527 40-1238
40-890 40-1221
B026 Fuse (30A) 40-315 40-1221
40-456 40-1238
40-464 40-1205
40-922 40-1221
40-856 40-1205
40-436 40-1205
B026 Fuse (30A) 40-535 40-1205
40-503 40-1205
40-922 40-1205
40-464 40-1221
40-436 40-1221
40-890 40-1205
40-856 40-1221
40-315 40-1205
Table 146
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B027 Fuse (30A) 40-856 40-1221
40-577 40-1238
40-719 40-1238
40-848 40-1238
40-856 40-1205
40-585 40-1205
40-585 40-1221
40-737 40-1221
40-737 40-1205
B028 Fuse (40A) 40-202 40-1238
40-229 40-1205
40-229 40-1221
B029 Fuse (40A) 40-629 40-1221
40-719 40-1238
40-848 40-1238
40-664 40-1238
40-611 40-1238
40-682 40-1221
40-315 40-1221
40-304 40-1238
40-682 40-1205
B029 Fuse (40A) 40-856 40-1221
40-342 40-1238
40-354 40-1205
40-629 40-1205
40-737 40-1205
40-856 40-1205
40-315 40-1205
40-354 40-1221
40-737 40-1221

40-55
 Wiring diagrams
Table 147
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B030 Fuse (30A) 40-737 40-1221
40-489 40-1238
40-456 40-1238
40-848 40-1238
40-910 40-1238
40-304 40-1238
40-315 40-1221
40-629 40-1221
40-1138 40-1221
40-981 40-1238
B030 Fuse (30A) 40-585 40-1221
40-382 40-1238
40-1079 40-1221
40-397 40-1221
40-1109 40-1221
40-527 40-1238
40-719 40-1238
40-611 40-1238
40-552 40-1238
40-577 40-1238
B030 Fuse (30A) 40-664 40-1238
40-342 40-1238
40-1030 40-1238
40-812 40-1238
40-428 40-1238
40-951 40-1238
40-770 40-1238
40-881 40-1238
40-922 40-1205
40-1167 40-1221

Table 148
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B030 Fuse (30A) 40-503 40-1205
40-436 40-1221
40-990 40-1205
40-856 40-1205
40-535 40-1205
40-559 40-1205
40-826 40-1205
40-354 40-1205
40-1043 40-1205
40-783 40-1205
B030 Fuse (30A) 40-629 40-1205
40-585 40-1205
40-397 40-1205
40-436 40-1205
40-682 40-1205
40-958 40-1221
40-737 40-1205
40-503 40-1221
40-464 40-1221
40-535 40-1221
B030 Fuse (30A) 40-958 40-1205
40-682 40-1221
40-354 40-1221
40-559 40-1221

40-56
Wiring diagrams
Table 149
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B030 Fuse (30A) 40-922 40-1221
40-856 40-1221
40-890 40-1205
40-464 40-1205
40-315 40-1205
40-890 40-1221
B031 Fuse (30A) 40-315 40-1221
40-304 40-1238
40-848 40-1238
40-342 40-1238
40-315 40-1205
40-856 40-1205
40-354 40-1205
40-856 40-1221
40-354 40-1221
40-1079 40-1221
B032 Fuse (20A) 40-770 40-1238
40-848 40-1238
40-812 40-1238
40-856 40-1221
40-826 40-1205
40-856 40-1205
40-783 40-1205
40-1109 40-1221
B033 Fuse (20A) 40-611 40-1238
40-629 40-1221
Table 150
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B033 Fuse (20A) 40-664 40-1238
40-577 40-1238
40-682 40-1221
40-585 40-1221
40-629 40-1205
40-682 40-1205
40-585 40-1205
40-737 40-1205
40-719 40-1238
40-737 40-1221
B034 Fuse (10A) 40-304 40-1228
40-354 40-1204
40-342 40-1204
40-304 40-1242
40-315 40-1228
40-315 40-1242
B035 Fuse (5A) 40-342 40-1204
40-304 40-1228
40-354 40-1204
40-304 40-1242
40-315 40-1228
40-315 40-1242
B036 Fuse (30A) 40-611 40-1228
40-629 40-1228
40-664 40-1242
40-682 40-1242
40-737 40-1204
40-719 40-1204

40-57
 Wiring diagrams
Table 151
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B037 Fuse (7.5A) 40-881 40-1242
40-910 40-1204
40-922 40-1204
40-881 40-1228
40-890 40-1228
40-890 40-1242
B038 Fuse (7.5A) 40-315 40-1228
40-315 40-1242
40-304 40-1242
40-922 40-1204
40-910 40-1204
40-304 40-1228
B039 Fuse (10A) 40-436 40-1242
40-489 40-1204
40-535 40-1204
40-503 40-1204
40-464 40-1242
40-456 40-1242
B039 Fuse (10A) 40-436 40-1228
40-456 40-1228
40-464 40-1228
40-428 40-1228
40-428 40-1242
40-527 40-1204
Table 152
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
B040 Fuse (10A) 40-436 40-1228
40-535 40-1204
40-527 40-1204
40-489 40-1204
40-456 40-1242
40-436 40-1242
40-464 40-1242
B040 Fuse (10A) 40-428 40-1242
40-464 40-1228
40-456 40-1228
40-503 40-1204
40-428 40-1228

40.2.6 - C - Earths (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
C001
Table 153
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C001 Battery negative terminal 40-839 40-1241
40-1056 40-1241
40-175 40-1241
C002
Table 154
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C002 Earthing point 2 40-175 40-1241
40-1056 40-1241
40-839 40-1241

40-58
Wiring diagrams
C003
Table 155
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C003 Earthing point 3 40-934 40-1221
40-1064 40-1221
40-290 40-1221
40-1056 40-1221
40-1094 40-1221
40-1123 40-1221
40-369 40-1221
40-1153 40-1221
40-175 40-1221
40-934 40-1209
C003 Earthing point 3 40-327 40-1209
40-327 40-1221
40-755 40-1209
40-290 40-1209
40-369 40-1209
40-175 40-1209
40-1056 40-1209
40-797 40-1209
40-1016 40-1209
40-966 40-1209
C004
Table 156
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C004 Earthing point 4 40-966 40-1209
40-327 40-1209
40-254 40-1221
40-175 40-1221
40-515 40-1209
40-445 40-1209
40-515 40-1221
40-700 40-1221
40-1056 40-1221
40-1153 40-1221
C004 Earthing point 4 40-1003 40-1221
40-898 40-1221
40-870 40-1221
40-593 40-1221
40-410 40-1209
40-567 40-1209
40-1123 40-1221
40-755 40-1209
40-898 40-1209
40-870 40-1209
C004 Earthing point 4 40-647 40-1209
40-1094 40-1221
40-700 40-1209
40-473 40-1209
40-797 40-1209
40-369 40-1209
40-254 40-1209
40-934 40-1209
40-1003 40-1209
40-1016 40-1209

40-59
 Wiring diagrams
Table 157
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C004 Earthing point 4 40-1056 40-1209
40-175 40-1209
40-593 40-1209
40-543 40-1209
40-290 40-1209
40-543 40-1221
40-1064 40-1221
40-567 40-1221
40-473 40-1221
40-327 40-1221
C004 Earthing point 4 40-445 40-1221
40-410 40-1221
40-369 40-1221
40-290 40-1221
40-934 40-1221
40-647 40-1221
C005
Table 158
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C005 Earthing point 5 40-1056 40-1242
C006
Table 159
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C006 Earthing point 6 40-1056 40-1242
C007
Table 160
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C007 Earthing point 7 40-647 40-1244
40-898 40-1204
40-700 40-1204
40-327 40-1204
40-1056 40-1204
40-473 40-1204
40-410 40-1244
40-290 40-1244
40-543 40-1244
40-445 40-1244
C007 Earthing point 7 40-567 40-1204
40-1056 40-1226
40-515 40-1204
40-410 40-1226
40-593 40-1244
40-870 40-1226
40-290 40-1226
40-445 40-1226
40-647 40-1226
40-593 40-1226
C007 Earthing point 7 40-870 40-1244
40-1056 40-1244
40-543 40-1226

40-60
Wiring diagrams
C008
Table 161
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C008 Earthing point 8 40-254 40-1221
40-327 40-1221
40-175 40-1221
40-290 40-1221
40-1056 40-1221
40-1016 40-1209
40-290 40-1209
40-1056 40-1209
40-327 40-1209
40-254 40-1209
C008 Earthing point 8 40-175 40-1209
40-1153 40-1221
C009
Table 162
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C009 Earthing point 9 40-755 40-1209
40-898 40-1221
40-1123 40-1221
40-1056 40-1221
40-1094 40-1221
40-1003 40-1221
40-1064 40-1221
40-797 40-1209
40-966 40-1209
40-898 40-1209
C009 Earthing point 9 40-1003 40-1209
40-870 40-1209
40-870 40-1221
40-1056 40-1209

40.2.7 - C - Earths (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001)
Table 163
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C001 Battery negative terminal 40-848 40-1241
40-856 40-1241
40-229 40-1241
40-202 40-1241
40-1057 40-1241
40-1061 40-1241
C002 Earthing point 2 40-1057 40-1241
40-229 40-1241
40-1061 40-1241
40-202 40-1241
40-856 40-1241
40-848 40-1241
C003 Earthing point 3 40-202 40-1238
40-1079 40-1221
40-315 40-1221
40-1109 40-1221
40-958 40-1221
40-1030 40-1238
40-342 40-1238

40-61
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C003 Earthing point 3 40-382 40-1238
40-951 40-1238
40-812 40-1238
40-397 40-1221
40-304 40-1238
40-981 40-1238
40-1057 40-1238
Table 164
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C003 Earthing point 3 40-315 40-1205
40-770 40-1238
40-1061 40-1221
40-990 40-1205
40-826 40-1205
40-1043 40-1205
40-397 40-1205
40-1061 40-1205
40-354 40-1205
C003 Earthing point 3 40-958 40-1205
40-1138 40-1221
40-229 40-1221
40-783 40-1205
40-229 40-1205
40-354 40-1221
C004 Earthing point 4 40-464 40-1221
40-922 40-1221
40-890 40-1221
40-958 40-1221
40-354 40-1221
40-315 40-1221
C004 Earthing point 4 40-1167 40-1221
40-1012 40-1221
40-503 40-1221
40-812 40-1238
Table 165
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C004 Earthing point 4 40-535 40-1221
40-559 40-1221
40-737 40-1221
40-283 40-1221
40-1138 40-1221
40-1061 40-1221
40-436 40-1221
40-397 40-1221
C004 Earthing point 4 40-1030 40-1238
40-428 40-1238
40-719 40-1238
40-1057 40-1238
40-382 40-1238
40-304 40-1238
40-456 40-1238
40-585 40-1221

40-62
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C004 Earthing point 4 40-682 40-1205
40-770 40-1238
40-503 40-1205
40-826 40-1205
40-922 40-1205
40-229 40-1205
40-629 40-1205
40-283 40-1205
40-397 40-1205
40-890 40-1205
Table 166
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C004 Earthing point 4 40-990 40-1205
40-342 40-1238
40-1043 40-1205
40-910 40-1238
40-464 40-1205
40-737 40-1205
40-1061 40-1205
40-1109 40-1221
40-783 40-1205
C004 Earthing point 4 40-585 40-1205
40-958 40-1205
40-535 40-1205
40-1012 40-1205
40-354 40-1205
40-436 40-1205
40-315 40-1205
40-1079 40-1221
C004 Earthing point 4 40-229 40-1221
40-682 40-1221
40-629 40-1221
40-559 40-1205
40-664 40-1238
40-881 40-1238
40-527 40-1238
40-202 40-1238
40-951 40-1238
40-276 40-1238
Table 167
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C004 Earthing point 4 40-1008 40-1238
40-981 40-1238
40-489 40-1238
40-552 40-1238
40-577 40-1238
C005 Earthing point 5 40-1057 40-1242
40-1061 40-1242
C006 Earthing point 6 40-1057 40-1242
40-1061 40-1242
C007 Earthing point 7 40-1057 40-1204
40-682 40-1242
40-436 40-1242
40-881 40-1242
40-1061 40-1242
40-304 40-1242
40-464 40-1242
40-428 40-1242

40-63
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C007 Earthing point 7 40-1061 40-1204
40-342 40-1204
40-922 40-1204
40-503 40-1204
40-535 40-1204
40-737 40-1204
40-354 40-1204
40-577 40-1204
Table 168
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C007 Earthing point 7 40-664 40-1242
40-489 40-1204
40-910 40-1204
40-585 40-1204
40-719 40-1204
40-428 40-1228
40-552 40-1242
40-527 40-1204
40-552 40-1228
40-629 40-1228
C007 Earthing point 7 40-436 40-1228
40-559 40-1228
40-910 40-1228
40-456 40-1228
40-1057 40-1228
40-611 40-1228
40-881 40-1228
40-1057 40-1242
C007 Earthing point 7 40-456 40-1242
40-315 40-1242
40-304 40-1228
40-559 40-1242
40-315 40-1228
40-1061 40-1228
40-464 40-1228
40-890 40-1228
Table 169
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C007 Earthing point 7 40-890 40-1242
C008 Earthing point 8 40-283 40-1221
40-315 40-1221
40-354 40-1221
40-229 40-1221
40-1167 40-1221
40-1061 40-1205
40-229 40-1205
C008 Earthing point 8 40-354 40-1205
40-1043 40-1205
40-283 40-1205
40-1061 40-1221
40-315 40-1205
C009 Earthing point 9 40-1030 40-1238
40-276 40-1238
40-1057 40-1238
40-202 40-1238
40-342 40-1238
40-981 40-1238
40-304 40-1238

40-64
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C009 Earthing point 9 40-812 40-1238
40-910 40-1238
40-1109 40-1221
40-881 40-1238
40-1008 40-1238
Table 170
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C009 Earthing point 9 40-770 40-1238
40-922 40-1221
40-1138 40-1221
40-1061 40-1221
40-1012 40-1221
40-890 40-1221
40-783 40-1205
C009 Earthing point 9 40-1061 40-1205
40-922 40-1205
40-890 40-1205
40-826 40-1205
40-1012 40-1205
40-990 40-1205
40-1079 40-1221

40.2.8 - C - Earths (R3 EVO 85 -> 16001)

Table 171
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C001 Battery negative terminal 40-848 40-1241
40-856 40-1241
40-229 40-1241
40-202 40-1241
40-1057 40-1241
40-1061 40-1241
C002 Earthing point 2 40-1057 40-1241
40-229 40-1241
40-1061 40-1241
40-202 40-1241
40-856 40-1241
40-848 40-1241
C003 Earthing point 3 40-202 40-1238
40-1079 40-1221
40-315 40-1221
40-1109 40-1221
40-958 40-1221
40-1030 40-1238
40-342 40-1238
C003 Earthing point 3 40-382 40-1238
40-951 40-1238
40-812 40-1238
40-397 40-1221
40-304 40-1238
40-981 40-1238
40-1057 40-1238

40-65
 Wiring diagrams
Table 172
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C003 Earthing point 3 40-315 40-1205
40-770 40-1238
40-1061 40-1221
40-990 40-1205
40-826 40-1205
40-1043 40-1205
40-397 40-1205
40-1061 40-1205
40-354 40-1205
C003 Earthing point 3 40-958 40-1205
40-1138 40-1221
40-229 40-1221
40-783 40-1205
40-229 40-1205
40-354 40-1221
C004 Earthing point 4 40-464 40-1221
40-922 40-1221
40-890 40-1221
40-958 40-1221
40-354 40-1221
40-315 40-1221
C004 Earthing point 4 40-1167 40-1221
40-1012 40-1221
40-503 40-1221
40-269 40-1221
40-812 40-1238

Table 173
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C004 Earthing point 4 40-535 40-1221
40-559 40-1221
40-737 40-1221
40-1138 40-1221
40-1061 40-1221
40-436 40-1221
40-397 40-1221
C004 Earthing point 4 40-1030 40-1238
40-428 40-1238
40-719 40-1238
40-1057 40-1238
40-382 40-1238
40-304 40-1238
40-456 40-1238
40-585 40-1221
C004 Earthing point 4 40-682 40-1205
40-770 40-1238
40-503 40-1205
40-826 40-1205
40-922 40-1205
40-229 40-1205
40-629 40-1205
40-397 40-1205
40-890 40-1205

40-66
Wiring diagrams
Table 174
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C004 Earthing point 4 40-990 40-1205
40-342 40-1238
40-1043 40-1205
40-910 40-1238
40-464 40-1205
40-737 40-1205
40-1061 40-1205
40-1109 40-1221
40-783 40-1205
C004 Earthing point 4 40-585 40-1205
40-958 40-1205
40-535 40-1205
40-1012 40-1205
40-354 40-1205
40-436 40-1205
40-315 40-1205
40-269 40-1205
40-1079 40-1221
C004 Earthing point 4 40-229 40-1221
40-682 40-1221
40-629 40-1221
40-559 40-1205
40-664 40-1238
40-881 40-1238
40-527 40-1238
40-202 40-1238
40-951 40-1238
Table 175
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C004 Earthing point 4 40-261 40-1238
40-1008 40-1238
40-981 40-1238
40-489 40-1238
40-552 40-1238
40-577 40-1238
C005 Earthing point 5 40-1057 40-1242
40-1061 40-1242
C006 Earthing point 6 40-1057 40-1242
40-1061 40-1242
C007 Earthing point 7 40-1057 40-1204
40-682 40-1242
40-436 40-1242
40-881 40-1242
40-1061 40-1242
40-304 40-1242
40-464 40-1242
40-428 40-1242
C007 Earthing point 7 40-1061 40-1204
40-342 40-1204
40-922 40-1204
40-503 40-1204
40-535 40-1204
40-737 40-1204
40-354 40-1204
40-577 40-1204

40-67
 Wiring diagrams
Table 176
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C007 Earthing point 7 40-664 40-1242
40-489 40-1204
40-910 40-1204
40-585 40-1204
40-719 40-1204
40-428 40-1228
40-552 40-1242
40-527 40-1204
40-552 40-1228
40-629 40-1228
C007 Earthing point 7 40-436 40-1228
40-559 40-1228
40-910 40-1228
40-456 40-1228
40-1057 40-1228
40-611 40-1228
40-881 40-1228
40-1057 40-1242
C007 Earthing point 7 40-456 40-1242
40-315 40-1242
40-304 40-1228
40-559 40-1242
40-315 40-1228
40-1061 40-1228
40-464 40-1228
40-890 40-1228
Table 177
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C007 Earthing point 7 40-890 40-1242
C008 Earthing point 8 40-315 40-1221
40-269 40-1221
40-354 40-1221
40-229 40-1221
40-1167 40-1221
40-1061 40-1205
40-229 40-1205
C008 Earthing point 8 40-354 40-1205
40-1043 40-1205
40-269 40-1205
40-1061 40-1221
40-315 40-1205
C009 Earthing point 9 40-1030 40-1238
40-1057 40-1238
40-202 40-1238
40-342 40-1238
40-981 40-1238
40-304 40-1238
C009 Earthing point 9 40-812 40-1238
40-910 40-1238
40-1109 40-1221
40-881 40-1238
40-1008 40-1238

40-68
Wiring diagrams
Table 178
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
C009 Earthing point 9 40-770 40-1238
40-922 40-1221
40-1138 40-1221
40-1061 40-1221
40-1012 40-1221
40-890 40-1221
40-783 40-1205
C009 Earthing point 9 40-1061 40-1205
40-922 40-1205
40-890 40-1205
40-826 40-1205
40-1012 40-1205
40-990 40-1205
40-261 40-1238
40-1079 40-1221

40.2.9 - D - Intermediate connections (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO
85 -> 20001)
D001
Table 179
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D001 Wiring connector 40-175 40-1198
40-175 40-1209
40-839 40-1209
40-839 40-1221
40-175 40-1221
40-839 40-1198
40-839 40-1198
40-175 40-1198
D002
Table 180
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D002 Wiring connector 40-839 40-1199
40-839 40-1209
40-839 40-1221
40-839 40-1199
D003
Table 181
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D003 Wiring connector 40-543 40-1200
40-543 40-1221
40-839 40-1221
40-543 40-1209
40-839 40-1200
40-839 40-1209
40-543 40-1200
40-839 40-1200

40-69
 Wiring diagrams
D004
Table 182
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D004 Wiring connector 40-797 40-1209
40-755 40-1209
40-410 40-1221
40-1064 40-1221
40-445 40-1221
40-473 40-1221
40-1094 40-1221
40-515 40-1221
40-410 40-1209
40-445 40-1193
D004 Wiring connector 40-473 40-1209
40-445 40-1209
40-755 40-1193
40-410 40-1193
40-473 40-1193
40-797 40-1193
40-515 40-1193
40-515 40-1209
40-473 40-1193
40-1064 40-1193
D004 Wiring connector 40-515 40-1193
40-1094 40-1193
40-445 40-1193
40-410 40-1193
D005
Table 183
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D005 Wiring connector 40-593 40-1221
40-593 40-1209
40-647 40-1209
40-966 40-1209
40-369 40-1209
40-175 40-1209
40-1016 40-1209
40-1123 40-1221
40-700 40-1221
40-369 40-1221
D005 Wiring connector 40-175 40-1221
40-647 40-1221
40-647 40-1236
40-1153 40-1221
40-369 40-1234
40-966 40-1236
40-700 40-1209
40-1016 40-1234
40-647 40-1234
40-175 40-1234
D005 Wiring connector 40-966 40-1234
40-700 40-1234
40-700 40-1236
40-1016 40-1236
40-593 40-1236
40-369 40-1236
40-175 40-1236
40-593 40-1234
40-175 40-1234

40-70
Wiring diagrams
Table 184
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D005 Wiring connector 40-1123 40-1234
40-647 40-1234
40-700 40-1234
40-369 40-1234
40-593 40-1234
40-175 40-1236
40-593 40-1236
40-1153 40-1236
40-700 40-1236
40-369 40-1236
D005 Wiring connector 40-647 40-1221
40-1123 40-1236
40-647 40-1236
40-175 40-1209
40-175 40-1221
40-700 40-1209
40-1153 40-1234
40-593 40-1209
40-647 40-1209
40-966 40-1209
D005 Wiring connector 40-369 40-1209
40-593 40-1221
40-700 40-1221
40-1153 40-1221
40-1123 40-1221
40-369 40-1221
40-1016 40-1209
D006
Table 185
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D006 Wiring connector 40-1123 40-1236
40-966 40-1180
40-966 40-1236
40-1123 40-1180
D007
Table 186
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D007 Wiring connector 40-1003 40-1195
40-934 40-1221
40-327 40-1221
40-290 40-1221
40-1003 40-1221
40-290 40-1195
40-327 40-1195
40-290 40-1209
40-327 40-1209
40-1003 40-1209
D007 Wiring connector 40-934 40-1209
40-934 40-1195
40-327 40-1195
40-934 40-1195
40-290 40-1195
40-1003 40-1195

40-71
 Wiring diagrams
D008
Table 187
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D008 Wiring connector 40-290 40-1221
40-647 40-1221
40-473 40-1220
40-700 40-1220
40-327 40-1220
40-593 40-1221
40-898 40-1221
40-473 40-1221
40-870 40-1221
40-515 40-1221
D008 Wiring connector 40-327 40-1221
40-898 40-1220
40-445 40-1221
40-445 40-1220
40-700 40-1221
40-870 40-1209
40-870 40-1220
40-410 40-1220
40-473 40-1209
40-593 40-1209
D008 Wiring connector 40-647 40-1209
40-700 40-1209
40-410 40-1209
40-445 40-1209
40-290 40-1209
40-327 40-1209
40-593 40-1220
40-515 40-1209
40-647 40-1220
40-290 40-1220
Table 188
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D008 Wiring connector 40-515 40-1220
40-898 40-1209
40-593 40-1220
40-647 40-1220
40-898 40-1220
40-473 40-1220
40-515 40-1220
40-700 40-1220
40-290 40-1220
40-870 40-1220
D008 Wiring connector 40-445 40-1220
40-327 40-1220

40-72
Wiring diagrams
D009
Table 189
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D009 Wiring connector 40-567 40-1220
40-543 40-1221
40-593 40-1209
40-567 40-1221
40-647 40-1221
40-593 40-1221
40-700 40-1221
40-543 40-1220
40-593 40-1220
40-647 40-1220
D009 Wiring connector 40-647 40-1209
40-700 40-1209
40-567 40-1209
40-700 40-1220
40-543 40-1209
40-647 40-1220
40-567 40-1220
40-700 40-1220
40-593 40-1220
40-543 40-1220

D010
Table 190
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D010 0.900.1571.7 Park Brake switch 40-1016 40-1209
40-1153 40-1221
D011
Table 191
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D011 Wiring connector 40-966 40-1214
40-254 40-1221
40-1153 40-1221
40-1094 40-1221
40-1123 40-1221
40-934 40-1221
40-1064 40-1221
40-369 40-1214
40-797 40-1214
40-175 40-1221
D011 Wiring connector 40-254 40-1214
40-369 40-1221
40-934 40-1209
40-175 40-1214
40-934 40-1214
40-369 40-1209
40-755 40-1209
40-175 40-1209
40-1016 40-1209
40-254 40-1209

40-73
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D011 Wiring connector 40-797 40-1209
40-755 40-1214
40-1016 40-1214
40-966 40-1209
40-254 40-1214
40-175 40-1214
40-1153 40-1214
40-369 40-1214
40-1123 40-1214
40-934 40-1214
D011 Wiring connector 40-1094 40-1214
40-1064 40-1214
D012
Table 192
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D012 Configuration connector 40-934 40-1209
40-934 40-1221
Configuration connector 40-934 40-1221
40-934 40-1209
Configuration connector 40-934 40-1209
40-934 40-1221
D013
Table 193
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D013 Wiring connector 40-1123 40-1221
40-934 40-1221
40-254 40-1221
40-934 40-1221
40-254 40-1221
40-1123 40-1221
40-934 40-1209
40-966 40-1209
40-934 40-1209
40-966 40-1209
D013 Wiring connector 40-254 40-1209
40-254 40-1209
D014
Table 194
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D014 Wiring connector 40-797 40-1209
40-410 40-1221
40-1094 40-1221
40-473 40-1221
40-473 40-1224
40-755 40-1224
40-755 40-1209
40-410 40-1224
40-473 40-1209
40-410 40-1209

40-74
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D014 Wiring connector 40-1064 40-1221
40-797 40-1224
40-1094 40-1224
40-410 40-1224
40-473 40-1224
40-1064 40-1224
D015
Table 195
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D015 Wiring connector 40-254 40-1214
40-254 40-1249
D018
Table 196
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D018 Wiring connector 40-1016 40-1214
40-1153 40-1214
40-1153 40-1232
40-1016 40-1232
D019
Table 197
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D019 Wiring connector 40-934 40-1214
40-934 40-1201
D021
Table 198
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D021 Wiring connector 40-1153 40-1191
40-1016 40-1191
40-1016 40-1214
40-1153 40-1214
D022
Table 199
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D022 Wiring connector 40-934 40-1195
40-934 40-1201

40-75
 Wiring diagrams
D023
Table 200
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D023 Wiring connector 40-870 40-1244
40-290 40-1226
40-327 40-1204
40-898 40-1204
40-515 40-1204
40-700 40-1204
40-473 40-1204
40-410 40-1244
40-290 40-1244
40-647 40-1244
D023 Wiring connector 40-593 40-1220
40-410 40-1226
40-593 40-1226
40-870 40-1226
40-445 40-1226
40-445 40-1220
40-410 40-1220
40-290 40-1220
40-870 40-1220
40-445 40-1244
D023 Wiring connector 40-445 40-1220
40-290 40-1220
40-647 40-1220
40-410 40-1220
40-870 40-1220
40-898 40-1220
40-700 40-1220
40-515 40-1220
40-327 40-1220
40-473 40-1220

D024
Table 201
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D024 Wiring connector 40-543 40-1244
40-700 40-1204
40-647 40-1244
40-543 40-1226
40-543 40-1220
40-593 40-1220
40-567 40-1204
40-593 40-1226
40-647 40-1220
40-543 40-1220
D024 Wiring connector 40-700 40-1220
40-567 40-1220
D025
Table 202
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D025 Wiring connector 40-567 40-1220
40-700 40-1220
40-700 40-1204
40-567 40-1204

40-76
Wiring diagrams
D026
Table 203
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D026 Wiring connector 40-593 40-1226
40-647 40-1244
40-593 40-1183
40-647 40-1183
D027
Table 204
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D027 Wiring connector 40-593 40-1226
40-543 40-1226
40-543 40-1244
40-647 40-1244
40-543 40-1182
40-593 40-1182
40-593 40-1183
40-543 40-1183
40-647 40-1244
40-543 40-1244
D027 Wiring connector 40-543 40-1226
40-593 40-1226
40-543 40-1183
40-543 40-1182
40-647 40-1182
40-647 40-1183
D028
Table 205
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D028 Wiring connector 40-593 40-1180
40-647 40-1217
40-700 40-1204
40-647 40-1244
40-593 40-1226
40-700 40-1215
D029
Table 206
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D029 Wiring connector 40-290 40-1226
40-445 40-1230
40-870 40-1230
40-410 40-1230
40-290 40-1230
40-290 40-1244
40-870 40-1244
40-445 40-1244
40-445 40-1226
40-870 40-1226
D029 Wiring connector 40-410 40-1226
40-410 40-1244
40-290 40-1230
40-410 40-1230
40-870 40-1230
40-445 40-1230

40-77
 Wiring diagrams
D030
Table 207
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D030 Wiring connector 40-870 40-1244
40-898 40-1186
40-870 40-1185
40-870 40-1226
40-898 40-1204
40-870 40-1185
D031
Table 208
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D031 Wiring connector 40-327 40-1204
40-290 40-1230
40-327 40-1189
40-290 40-1189
D032
Table 209
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D032 Wiring connector 40-327 40-1204
40-290 40-1230
40-327 40-1190
40-290 40-1190
D034
Table 210
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D034 Wiring connector 40-567 40-1204
40-700 40-1204
40-700 40-1204
40-567 40-1204
D035
Table 211
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D035 Wiring connector 40-700 40-1204
40-567 40-1204
40-700 40-1204
40-567 40-1204
D036
Table 212
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D036 Wiring connector 40-870 40-1230
40-870 40-1203

40-78
Wiring diagrams
D037
Table 213
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D037 Wiring connector 40-755 40-1224
40-473 40-1251
40-797 40-1251
40-410 40-1251
40-755 40-1251
40-1064 40-1251
40-1064 40-1224
40-473 40-1224
40-1094 40-1224
40-797 40-1224
D037 Wiring connector 40-1094 40-1251
40-410 40-1224
D038
Table 214
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D038 Wiring connector 40-410 40-1251
40-1064 40-1251
40-797 40-1251
40-473 40-1251
40-755 40-1251
40-755 40-1224
40-797 40-1224
40-1064 40-1224
40-410 40-1224
40-1094 40-1224
D038 Wiring connector 40-473 40-1224
40-1094 40-1251
D039
Table 215
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D039 Wiring connector 40-473 40-1224
40-797 40-1250
40-410 40-1250
40-473 40-1250
40-1094 40-1224
40-1064 40-1224
40-755 40-1224
40-797 40-1224
40-755 40-1250
40-410 40-1224

40-79
 Wiring diagrams
D040
Table 216
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D040 Wiring connector 40-410 40-1224
40-410 40-1250
40-473 40-1250
40-797 40-1250
40-1094 40-1224
40-1064 40-1224
40-755 40-1224
40-473 40-1224
40-797 40-1224
D041
Table 217
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D041 Wiring connector 40-473 40-1250
40-410 40-1196
40-473 40-1192
40-410 40-1250
D041 2.8039.299.0 Rh front light on arms 40-1094 40-1250
40-797 40-1250
D042
Table 218
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D042 Wiring connector 40-410 40-1251
40-410 40-1197
40-473 40-1192
40-473 40-1251
D042 2.8039.299.0 LH front light on arms 40-1094 40-1251
40-797 40-1251
D043
Table 219
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D043 Wiring connector 40-1094 40-1221
40-1064 40-1221
40-1064 40-1187
40-1094 40-1187
D044
Table 220
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D044 Wiring connector 40-1094 40-1187
40-1094 40-1221
40-1064 40-1221
40-1064 40-1187

40-80
Wiring diagrams
40.2.10 - D - Intermediate connections (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001)
D001
Table 221
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D001 Wiring connector 40-229 40-1198
40-856 40-1205
40-229 40-1205
40-856 40-1221
40-229 40-1221
40-202 40-1238
40-856 40-1198
40-229 40-1198
40-856 40-1198
40-202 40-1198
D002
Table 222
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D002 Wiring connector 40-848 40-1238
40-856 40-1221
40-856 40-1199
40-856 40-1205
40-856 40-1199
40-848 40-1199
D003
Table 223
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D003 Wiring connector 40-559 40-1221
40-848 40-1238
40-552 40-1238
40-856 40-1221
40-856 40-1205
40-559 40-1205
40-856 40-1200
40-559 40-1200
40-856 40-1200
40-559 40-1200
D003 Wiring connector 40-552 40-1200
40-848 40-1200
D004
Table 224
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D004 Wiring connector 40-812 40-1238
40-826 40-1218
40-783 40-1218
40-770 40-1238
40-1109 40-1221
40-826 40-1205
40-783 40-1205
40-1079 40-1221
40-1079 40-1218
40-1109 40-1218
D004 Wiring connector 40-812 40-1218
40-770 40-1218

40-81
 Wiring diagrams
D005
Table 225
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D005 Wiring connector 40-682 40-1221
40-1138 40-1221
40-629 40-1221
40-1167 40-1221
40-229 40-1205
40-664 40-1238
40-682 40-1205
40-229 40-1221
40-737 40-1221
40-397 40-1221
D005 Wiring connector 40-382 40-1238
40-611 40-1238
40-202 40-1238
40-719 40-1238
40-737 40-1234
40-397 40-1205
40-1030 40-1238
40-229 40-1234
40-629 40-1236
40-629 40-1234
D005 Wiring connector 40-737 40-1205
40-990 40-1234
40-682 40-1234
40-1043 40-1234
40-981 40-1238
40-397 40-1234
40-629 40-1205
40-990 40-1236
40-990 40-1205
40-229 40-1236
D005 Wiring connector 40-1043 40-1236
40-737 40-1236
40-682 40-1236
Table 226
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D005 Wiring connector 40-397 40-1236
40-1043 40-1205
40-981 40-1238
40-1167 40-1236
40-1138 40-1234
40-397 40-1236
40-737 40-1234
40-629 40-1236
40-682 40-1236
40-737 40-1236
D005 Wiring connector 40-1138 40-1236
40-229 40-1236
40-202 40-1238
40-1030 40-1238
40-719 40-1238
40-611 40-1238
40-664 40-1238
40-397 40-1234
40-382 40-1238
40-737 40-1205

40-82
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D005 Wiring connector 40-1167 40-1234
40-990 40-1205
40-1043 40-1205
40-629 40-1205
40-397 40-1205
40-682 40-1205
40-229 40-1221
40-1138 40-1221
40-737 40-1221
40-397 40-1221
D005 Wiring connector 40-629 40-1221
40-1167 40-1221
40-682 40-1221

Table 227
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D005 Wiring connector 40-682 40-1234
40-229 40-1234
40-629 40-1234
40-229 40-1205
40-664 40-1236
40-719 40-1236
40-382 40-1236
40-611 40-1236
40-981 40-1236
40-1030 40-1236
D005 Wiring connector 40-382 40-1234
40-1030 40-1234
40-202 40-1234
40-719 40-1234
40-664 40-1234
40-611 40-1234
40-202 40-1236
40-981 40-1234
D006
Table 228
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D006 Wiring connector 40-981 40-1180
40-990 40-1180
40-1138 40-1236
40-981 40-1236
40-990 40-1236
40-1138 40-1180

40-83
 Wiring diagrams
D008
Table 229
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D008 Wiring connector 40-456 40-1238
40-304 40-1238
40-436 40-1221
40-503 40-1221
40-629 40-1221
40-535 40-1221
40-737 40-1221
40-464 40-1221
40-682 40-1221
40-890 40-1221
D008 Wiring connector 40-428 40-1238
40-527 40-1238
40-910 40-1238
40-664 40-1238
40-489 40-1238
40-342 40-1238
40-611 40-1238
40-922 40-1221
40-315 40-1221
40-881 40-1238
D008 Wiring connector 40-503 40-1220
40-629 40-1220
40-922 40-1205
40-315 40-1205
40-436 40-1205
40-890 40-1205
40-682 40-1205
40-535 40-1205
40-503 40-1205
40-629 40-1205
D008 Wiring connector 40-719 40-1238
40-535 40-1220
40-464 40-1220

40-84
Wiring diagrams
Table 230
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D008 Wiring connector 40-315 40-1220
40-464 40-1205
40-737 40-1220
40-922 40-1220
40-682 40-1220
40-354 40-1220
40-890 40-1220
40-737 40-1205
40-436 40-1220
40-315 40-1220
D008 Wiring connector 40-922 40-1220
40-354 40-1220
40-737 40-1220
40-464 40-1220
40-503 40-1220
40-436 40-1220
40-890 40-1220
40-629 40-1220
40-535 40-1220
40-682 40-1220
D008 Wiring connector 40-342 40-1220
40-664 40-1220
40-611 40-1220
40-428 40-1220
40-527 40-1220
40-881 40-1220
40-304 40-1220
40-489 40-1220
40-719 40-1220
40-910 40-1220
D008 Wiring connector 40-456 40-1220
D009
Table 231
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D009 Wiring connector 40-719 40-1238
40-682 40-1221
40-737 40-1221
40-559 40-1221
40-552 40-1238
40-664 40-1238
40-611 40-1238
40-585 40-1221
40-682 40-1205
40-577 40-1238
D009 Wiring connector 40-585 40-1205
40-629 40-1221
40-737 40-1205
40-559 40-1205
40-585 40-1220
40-737 40-1220
40-629 40-1205
40-559 40-1220
40-629 40-1220
40-682 40-1220

40-85
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D009 Wiring connector 40-629 40-1220
40-737 40-1220
40-559 40-1220
40-682 40-1220
40-585 40-1220
40-552 40-1220
40-664 40-1220
40-719 40-1220
40-611 40-1220
40-577 40-1220
D010
Table 232
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D010 0.900.1571.7 Park Brake switch 40-1043 40-1205
40-1167 40-1221
D011
Table 233
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D011 Wiring connector 40-812 40-1233
40-1079 40-1221
40-382 40-1233
40-981 40-1233
40-770 40-1233
40-951 40-1233
40-1030 40-1233
40-1167 40-1221
D011 Wiring connector 40-276 40-1233
40-382 40-1238
40-202 40-1233
40-812 40-1238
40-951 40-1238
40-770 40-1238
40-1030 40-1238
40-981 40-1238
40-276 40-1238
40-202 40-1238
D011 Wiring connector 40-783 40-1205
40-397 40-1221
40-826 40-1212
40-1138 40-1221
40-958 40-1212
40-958 40-1205
40-283 40-1205
40-229 40-1205
40-826 40-1205
D011 Wiring connector 40-990 40-1205
40-397 40-1205

40-86
Wiring diagrams
Table 234
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D011 Wiring connector 40-229 40-1212
40-1043 40-1212
40-1109 40-1221
40-283 40-1221
40-1043 40-1205
40-958 40-1221
40-397 40-1212
40-283 40-1212
40-783 40-1212
D011 Wiring connector 40-990 40-1212
40-229 40-1221
40-1079 40-1212
40-1138 40-1212
40-397 40-1212
40-1167 40-1212
40-958 40-1212
40-229 40-1212
40-1109 40-1212
D013
Table 235
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D013 Wiring connector 40-958 40-1221
40-951 40-1238
40-202 40-1238
40-981 40-1238
40-276 40-1238
40-202 40-1238
40-981 40-1238
40-276 40-1238
D013 Wiring connector 40-951 40-1238
40-283 40-1221
40-990 40-1205
40-283 40-1221
40-1138 40-1221
40-958 40-1221
40-990 40-1205
D013 Wiring connector 40-283 40-1205
40-958 40-1205
40-283 40-1205
40-1138 40-1221
40-958 40-1205
D013a
Table 236
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
Wiring connector 40-276 40-1238
40-276 40-1238

40-87
 Wiring diagrams
D014
Table 237
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D014 Wiring connector 40-783 40-1205
40-503 40-1205
40-826 40-1205
40-783 40-1224
40-503 40-1224
40-826 40-1224
40-1109 40-1221
40-503 40-1221
40-770 40-1238
40-812 40-1238
D014 Wiring connector 40-489 40-1238
40-1079 40-1221
40-503 40-1224
40-1109 40-1224
40-1079 40-1224
40-812 40-1224
40-770 40-1224
40-489 40-1224
D015
Table 238
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D015 Wiring connector 40-283 40-1212
40-283 40-1248
40-276 40-1233
40-276 40-1248
D021
Table 239
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D021 Wiring connector 40-1043 40-1191
40-1030 40-1233
40-1167 40-1212
40-1043 40-1212
40-1167 40-1191
40-1030 40-1191
D023
Table 240
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D023 Wiring connector 40-922 40-1204
40-428 40-1242
40-464 40-1242
40-881 40-1242
40-456 40-1242
40-664 40-1242
40-315 40-1242
40-682 40-1242
40-436 40-1242
40-527 40-1204

40-88
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D023 Wiring connector 40-489 40-1204
40-503 40-1204
40-737 40-1204
40-719 40-1204
40-535 40-1204
40-342 40-1204
40-354 40-1204
40-890 40-1242
40-428 40-1228
40-910 40-1204
D023 Wiring connector 40-611 40-1220
40-456 40-1220
40-629 40-1220
40-304 40-1228
40-436 40-1220
40-304 40-1242
40-890 40-1220
40-464 40-1220
40-304 40-1220
40-881 40-1220
Table 241
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D023 Wiring connector 40-428 40-1220
40-456 40-1228
40-611 40-1228
40-436 40-1228
40-629 40-1228
40-464 40-1228
40-315 40-1228
40-890 40-1228
40-881 40-1228
40-315 40-1220
D023 Wiring connector 40-304 40-1220
40-890 40-1220
40-464 40-1220
40-664 40-1220
40-881 40-1220
40-682 40-1220
40-456 40-1220
40-315 40-1220
40-436 40-1220
40-428 40-1220
D023 Wiring connector 40-342 40-1220
40-737 40-1220
40-527 40-1220
40-922 40-1220
40-489 40-1220
40-535 40-1220
40-503 40-1220
40-354 40-1220
40-719 40-1220
40-910 40-1220

40-89
 Wiring diagrams
D024
Table 242
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D024 Wiring connector 40-577 40-1204
40-737 40-1204
40-585 40-1204
40-552 40-1242
40-664 40-1242
40-682 40-1242
40-559 40-1242
40-629 40-1228
40-559 40-1228
40-552 40-1228
D024 Wiring connector 40-552 40-1220
40-629 40-1220
40-611 40-1220
40-559 40-1220
40-611 40-1228
40-719 40-1204
40-682 40-1220
40-559 40-1220
40-664 40-1220
40-552 40-1220
D024 Wiring connector 40-585 40-1220
40-719 40-1220
40-737 40-1220
40-577 40-1220
D025
Table 243
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D025 Wiring connector 40-737 40-1220
40-577 40-1220
40-719 40-1220
40-585 40-1220
40-577 40-1204
40-585 40-1204
40-737 40-1204
40-719 40-1204
D026
Table 244
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D026 Wiring connector 40-664 40-1242
40-629 40-1183
40-682 40-1242
40-611 40-1228
40-611 40-1183
40-629 40-1228
40-664 40-1183
40-682 40-1183

40-90
Wiring diagrams
D027
Table 245
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D027 Wiring connector 40-682 40-1242
40-611 40-1183
40-629 40-1183
40-552 40-1182
40-664 40-1242
40-629 40-1228
40-611 40-1228
40-559 40-1182
40-552 40-1228
40-552 40-1242
D027 Wiring connector 40-559 40-1242
40-559 40-1228
40-664 40-1183
40-552 40-1182
40-559 40-1182
40-682 40-1183
D028
Table 246
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D028 Wiring connector 40-611 40-1180
40-719 40-1215
40-737 40-1215
40-629 40-1228
40-664 40-1217
40-629 40-1180
40-737 40-1204
40-719 40-1204
40-664 40-1242
40-682 40-1242
D028 Wiring connector 40-611 40-1228
40-682 40-1217
D029
Table 247
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D029 Wiring connector 40-436 40-1242
40-464 40-1230
40-456 40-1230
40-304 40-1230
40-428 40-1230
40-315 40-1230
40-436 40-1230
40-304 40-1242
40-436 40-1228
40-315 40-1242
D029 Wiring connector 40-464 40-1242
40-456 40-1242
40-456 40-1228
40-315 40-1228
40-428 40-1228
40-304 40-1228
40-464 40-1228
40-428 40-1242
40-304 40-1230
40-315 40-1230

40-91
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D029 Wiring connector 40-436 40-1230
40-428 40-1230
40-456 40-1230
40-464 40-1230
D030
Table 248
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D030 Wiring connector 40-922 40-1204
40-922 40-1186
40-910 40-1186
40-881 40-1185
40-910 40-1204
40-881 40-1242
40-890 40-1242
40-890 40-1228
40-881 40-1228
40-890 40-1185
D030 Wiring connector 40-881 40-1185
40-890 40-1185
D031
Table 249
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D031 Wiring connector 40-304 40-1230
40-354 40-1189
40-315 40-1230
40-354 40-1204
40-342 40-1204
40-342 40-1189
40-304 40-1189
40-315 40-1189
D032
Table 250
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D032 Wiring connector 40-354 40-1190
40-354 40-1204
40-342 40-1204
40-315 40-1230
40-304 40-1230
40-342 40-1190
40-304 40-1190
40-315 40-1190
D034
Table 251
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D034 Wiring connector 40-737 40-1204
40-585 40-1204
40-577 40-1204
40-719 40-1204
40-737 40-1204
40-719 40-1204
40-585 40-1204
40-577 40-1204

40-92
Wiring diagrams
D035
Table 252
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D035 Wiring connector 40-737 40-1204
40-585 40-1204
40-719 40-1204
40-577 40-1204
40-585 40-1204
40-719 40-1204
40-577 40-1204
40-737 40-1204
D037
Table 253
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D037 Wiring connector 40-783 40-1251
40-1079 40-1224
40-812 40-1251
40-503 40-1251
40-489 40-1251
40-1079 40-1251
40-826 40-1251
40-1109 40-1251
40-1109 40-1224
40-489 40-1224
D037 Wiring connector 40-826 40-1224
40-503 40-1224
40-783 40-1224
40-770 40-1224
40-770 40-1251
40-812 40-1224
D038
Table 254
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D038 Wiring connector 40-770 40-1251
40-503 40-1251
40-1109 40-1251
40-770 40-1224
40-783 40-1251
40-489 40-1251
40-812 40-1251
40-1079 40-1251
40-503 40-1224
40-826 40-1251
D038 Wiring connector 40-1079 40-1224
40-489 40-1224
40-826 40-1224
40-783 40-1224
40-812 40-1224
40-1109 40-1224

40-93
 Wiring diagrams
D039
Table 255
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D039 Wiring connector 40-826 40-1224
40-826 40-1250
40-489 40-1250
40-1109 40-1250
40-783 40-1250
40-770 40-1250
40-812 40-1250
40-503 40-1250
40-812 40-1224
40-1079 40-1250
D039 Wiring connector 40-783 40-1224
40-489 40-1224
40-503 40-1224
40-1109 40-1224
40-770 40-1224
40-1079 40-1224
D040
Table 256
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D040 Wiring connector 40-826 40-1250
40-783 40-1250
40-1109 40-1250
40-489 40-1250
40-812 40-1250
40-503 40-1250
40-770 40-1250
40-1079 40-1250
40-489 40-1224
40-1109 40-1224
D040 Wiring connector 40-826 40-1224
40-1079 40-1224
40-503 40-1224
40-812 40-1224
40-783 40-1224
40-770 40-1224
D041
Table 257
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D041 Wiring connector 40-1109 40-1192
40-489 40-1250
40-489 40-1192
40-826 40-1192
40-812 40-1192
40-503 40-1250
40-1109 40-1250
40-826 40-1250
40-812 40-1250
40-503 40-1192
D041 2.8039.299.0 Rh front light on arms 40-503 40-1250
40-1109 40-1250
40-826 40-1250
40-489 40-1250
40-812 40-1250

40-94
Wiring diagrams
D042
Table 258
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D042 Wiring connector 40-826 40-1251
40-503 40-1251
40-1109 40-1251
40-489 40-1251
40-812 40-1251
40-489 40-1192
40-826 40-1192
40-503 40-1192
40-812 40-1192
40-1109 40-1192
D042 2.8039.299.0 LH front light on arms 40-503 40-1251
40-812 40-1251
40-489 40-1251
40-1109 40-1251
40-826 40-1251
D043
Table 259
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D043 Wiring connector 40-1109 40-1221
40-1109 40-1187
40-1079 40-1187
40-1079 40-1221
D044
Table 260
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D044 Wiring connector 40-1109 40-1187
40-1079 40-1221
40-1109 40-1221
40-1079 40-1187

40.2.11 - D - Intermediate connections (R3 EVO 85 -> 16001)

D001
Table 261
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D001 Wiring connector 40-229 40-1198
40-856 40-1205
40-229 40-1205
40-856 40-1221
40-229 40-1221
40-202 40-1238
40-856 40-1198
40-229 40-1198
40-856 40-1198
40-202 40-1198

40-95
 Wiring diagrams
D002
Table 262
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D002 Wiring connector 40-848 40-1238
40-856 40-1221
40-856 40-1199
40-856 40-1205
40-856 40-1199
40-848 40-1199
D003
Table 263
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D003 Wiring connector 40-559 40-1221
40-848 40-1238
40-552 40-1238
40-856 40-1221
40-856 40-1205
40-559 40-1205
40-856 40-1200
40-559 40-1200
40-856 40-1200
40-559 40-1200
D003 Wiring connector 40-552 40-1200
40-848 40-1200
D004
Table 264
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D004 Wiring connector 40-812 40-1238
40-826 40-1218
40-783 40-1218
40-770 40-1238
40-1109 40-1221
40-826 40-1205
40-783 40-1205
40-1079 40-1221
40-1079 40-1218
40-1109 40-1218
D004 Wiring connector 40-812 40-1218
40-770 40-1218
D005
Table 265
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D005 Wiring connector 40-682 40-1221
40-1138 40-1221
40-629 40-1221
40-1167 40-1221
40-229 40-1205
40-664 40-1238
40-682 40-1205
40-229 40-1221
40-737 40-1221
40-397 40-1221

40-96
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D005 Wiring connector 40-382 40-1238
40-611 40-1238
40-202 40-1238
40-719 40-1238
40-737 40-1234
40-397 40-1205
40-1030 40-1238
40-229 40-1234
40-629 40-1236
40-629 40-1234
D005 Wiring connector 40-737 40-1205
40-990 40-1234
40-682 40-1234
40-1043 40-1234
40-981 40-1238
40-397 40-1234
40-629 40-1205
40-990 40-1236
40-990 40-1205
40-229 40-1236
D005 Wiring connector 40-1043 40-1236
40-737 40-1236
40-682 40-1236
Table 266
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D005 Wiring connector 40-397 40-1236
40-1043 40-1205
40-981 40-1238
40-1167 40-1236
40-1138 40-1234
40-397 40-1236
40-737 40-1234
40-629 40-1236
40-682 40-1236
40-737 40-1236
D005 Wiring connector 40-1138 40-1236
40-229 40-1236
40-202 40-1238
40-1030 40-1238
40-719 40-1238
40-611 40-1238
40-664 40-1238
40-397 40-1234
40-382 40-1238
40-737 40-1205
D005 Wiring connector 40-1167 40-1234
40-990 40-1205
40-1043 40-1205
40-629 40-1205
40-397 40-1205
40-682 40-1205
40-229 40-1221
40-1138 40-1221
40-737 40-1221
40-397 40-1221
D005 Wiring connector 40-629 40-1221
40-1167 40-1221
40-682 40-1221

40-97
 Wiring diagrams
Table 267
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D005 Wiring connector 40-682 40-1234
40-229 40-1234
40-629 40-1234
40-229 40-1205
40-664 40-1236
40-719 40-1236
40-382 40-1236
40-611 40-1236
40-981 40-1236
40-1030 40-1236
D005 Wiring connector 40-382 40-1234
40-1030 40-1234
40-202 40-1234
40-719 40-1234
40-664 40-1234
40-611 40-1234
40-202 40-1236
40-981 40-1234
D006
Table 268
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D006 Wiring connector 40-981 40-1180
40-990 40-1180
40-1138 40-1236
40-981 40-1236
40-990 40-1236
40-1138 40-1180
D008
Table 269
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D008 Wiring connector 40-456 40-1238
40-304 40-1238
40-436 40-1221
40-503 40-1221
40-629 40-1221
40-535 40-1221
40-737 40-1221
40-464 40-1221
40-682 40-1221
40-890 40-1221
D008 Wiring connector 40-428 40-1238
40-527 40-1238
40-910 40-1238
40-664 40-1238
40-489 40-1238
40-342 40-1238
40-611 40-1238
40-922 40-1221
40-315 40-1221
40-881 40-1238

40-98
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D008 Wiring connector 40-503 40-1220
40-629 40-1220
40-922 40-1205
40-315 40-1205
40-436 40-1205
40-890 40-1205
40-682 40-1205
40-535 40-1205
40-503 40-1205
40-629 40-1205
D008 Wiring connector 40-719 40-1238
40-535 40-1220
40-464 40-1220
Table 270
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D008 Wiring connector 40-315 40-1220
40-464 40-1205
40-737 40-1220
40-922 40-1220
40-682 40-1220
40-354 40-1220
40-890 40-1220
40-737 40-1205
40-436 40-1220
40-315 40-1220
D008 Wiring connector 40-922 40-1220
40-354 40-1220
40-737 40-1220
40-464 40-1220
40-503 40-1220
40-436 40-1220
40-890 40-1220
40-629 40-1220
40-535 40-1220
40-682 40-1220
D008 Wiring connector 40-342 40-1220
40-664 40-1220
40-611 40-1220
40-428 40-1220
40-527 40-1220
40-881 40-1220
40-304 40-1220
40-489 40-1220
40-719 40-1220
40-910 40-1220
D008 Wiring connector 40-456 40-1220

40-99
 Wiring diagrams
D009
Table 271
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D009 Wiring connector 40-719 40-1238
40-682 40-1221
40-737 40-1221
40-559 40-1221
40-552 40-1238
40-664 40-1238
40-611 40-1238
40-585 40-1221
40-682 40-1205
40-577 40-1238
D009 Wiring connector 40-585 40-1205
40-629 40-1221
40-737 40-1205
40-559 40-1205
40-585 40-1220
40-737 40-1220
40-629 40-1205
40-559 40-1220
40-629 40-1220
40-682 40-1220
D009 Wiring connector 40-629 40-1220
40-737 40-1220
40-559 40-1220
40-682 40-1220
40-585 40-1220
40-552 40-1220
40-664 40-1220
40-719 40-1220
40-611 40-1220
40-577 40-1220

D010
Table 272
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D010 0.900.1571.7 Park Brake switch 40-1043 40-1205
40-1167 40-1221
D011
Table 273
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D011 Wiring connector 40-812 40-1233
40-269 40-1221
40-1079 40-1221
40-382 40-1233
40-981 40-1233
40-770 40-1233
40-261 40-1233
40-951 40-1233
40-1030 40-1233
40-1167 40-1221

40-100
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D011 Wiring connector 40-382 40-1238
40-202 40-1233
40-812 40-1238
40-951 40-1238
40-770 40-1238
40-1030 40-1238
40-981 40-1238
40-202 40-1238
D011 Wiring connector 40-783 40-1205
40-397 40-1221
40-261 40-1238
40-826 40-1212
40-1138 40-1221
40-958 40-1212
40-958 40-1205
40-229 40-1205
40-826 40-1205
D011 Wiring connector 40-990 40-1205
40-269 40-1205
40-397 40-1205
Table 274
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D011 Wiring connector 40-229 40-1212
40-1043 40-1212
40-1109 40-1221
40-1043 40-1205
40-958 40-1221
40-397 40-1212
40-269 40-1212
40-783 40-1212
D011 Wiring connector 40-990 40-1212
40-229 40-1221
40-1079 40-1212
40-1138 40-1212
40-397 40-1212
40-1167 40-1212
40-269 40-1212
40-958 40-1212
40-269 40-1212
40-229 40-1212
D011 Wiring connector 40-1109 40-1212
D013
Table 275
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D013 Wiring connector 40-958 40-1221
40-951 40-1238
40-261 40-1238
40-202 40-1238
40-981 40-1238
40-261 40-1238
40-202 40-1238
40-981 40-1238

40-101
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D013 Wiring connector 40-951 40-1238
40-990 40-1205
40-269 40-1221
40-1138 40-1221
40-958 40-1221
40-269 40-1221
40-269 40-1205
40-990 40-1205
D013 Wiring connector 40-269 40-1205
40-958 40-1205
40-1138 40-1221
40-958 40-1205
D013a
Table 276
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
Wiring connector 40-261 40-1238
40-261 40-1238
D014
Table 277
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D014 Wiring connector 40-783 40-1205
40-503 40-1205
40-826 40-1205
40-783 40-1224
40-503 40-1224
40-826 40-1224
40-1109 40-1221
40-503 40-1221
40-770 40-1238
40-812 40-1238
D014 Wiring connector 40-489 40-1238
40-1079 40-1221
40-503 40-1224
40-1109 40-1224
40-1079 40-1224
40-812 40-1224
40-770 40-1224
40-489 40-1224
D015
Table 278
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D015 Wiring connector 40-269 40-1246
40-261 40-1246
40-261 40-1233
40-269 40-1212

40-102
Wiring diagrams
D021
Table 279
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D021 Wiring connector 40-1043 40-1191
40-1030 40-1233
40-1167 40-1212
40-1043 40-1212
40-1167 40-1191
40-1030 40-1191
D023
Table 280
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D023 Wiring connector 40-922 40-1204
40-428 40-1242
40-464 40-1242
40-881 40-1242
40-456 40-1242
40-664 40-1242
40-315 40-1242
40-682 40-1242
40-436 40-1242
40-527 40-1204
D023 Wiring connector 40-489 40-1204
40-503 40-1204
40-737 40-1204
40-719 40-1204
40-535 40-1204
40-342 40-1204
40-354 40-1204
40-890 40-1242
40-428 40-1228
40-910 40-1204
D023 Wiring connector 40-611 40-1220
40-456 40-1220
40-629 40-1220
40-304 40-1228
40-436 40-1220
40-304 40-1242
40-890 40-1220
40-464 40-1220
40-304 40-1220
40-881 40-1220
Table 281
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D023 Wiring connector 40-428 40-1220
40-456 40-1228
40-611 40-1228
40-436 40-1228
40-629 40-1228
40-464 40-1228
40-315 40-1228
40-890 40-1228
40-881 40-1228
40-315 40-1220

40-103
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D023 Wiring connector 40-304 40-1220
40-890 40-1220
40-464 40-1220
40-664 40-1220
40-881 40-1220
40-682 40-1220
40-456 40-1220
40-315 40-1220
40-436 40-1220
40-428 40-1220
D023 Wiring connector 40-342 40-1220
40-737 40-1220
40-527 40-1220
40-922 40-1220
40-489 40-1220
40-535 40-1220
40-503 40-1220
40-354 40-1220
40-719 40-1220
40-910 40-1220

D024
Table 282
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D024 Wiring connector 40-577 40-1204
40-737 40-1204
40-585 40-1204
40-552 40-1242
40-664 40-1242
40-682 40-1242
40-559 40-1242
40-629 40-1228
40-559 40-1228
40-552 40-1228
D024 Wiring connector 40-552 40-1220
40-629 40-1220
40-611 40-1220
40-559 40-1220
40-611 40-1228
40-719 40-1204
40-682 40-1220
40-559 40-1220
40-664 40-1220
40-552 40-1220
D024 Wiring connector 40-585 40-1220
40-719 40-1220
40-737 40-1220
40-577 40-1220

40-104
Wiring diagrams
D025
Table 283
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D025 Wiring connector 40-737 40-1220
40-577 40-1220
40-719 40-1220
40-585 40-1220
40-577 40-1204
40-585 40-1204
40-737 40-1204
40-719 40-1204
D026
Table 284
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D026 Wiring connector 40-664 40-1242
40-629 40-1183
40-682 40-1242
40-611 40-1228
40-611 40-1183
40-629 40-1228
40-664 40-1183
40-682 40-1183
D027
Table 285
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D027 Wiring connector 40-682 40-1242
40-611 40-1183
40-629 40-1183
40-552 40-1182
40-664 40-1242
40-629 40-1228
40-611 40-1228
40-559 40-1182
40-552 40-1228
40-552 40-1242
D027 Wiring connector 40-559 40-1242
40-559 40-1228
40-664 40-1183
40-552 40-1182
40-559 40-1182
40-682 40-1183
D028
Table 286
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D028 Wiring connector 40-611 40-1180
40-719 40-1215
40-737 40-1215
40-629 40-1228
40-664 40-1217
40-629 40-1180
40-737 40-1204
40-719 40-1204
40-664 40-1242
40-682 40-1242

40-105
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D028 Wiring connector 40-611 40-1228
40-682 40-1217
D029
Table 287
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D029 Wiring connector 40-436 40-1242
40-464 40-1230
40-456 40-1230
40-304 40-1230
40-428 40-1230
40-315 40-1230
40-436 40-1230
40-304 40-1242
40-436 40-1228
40-315 40-1242
D029 Wiring connector 40-464 40-1242
40-456 40-1242
40-456 40-1228
40-315 40-1228
40-428 40-1228
40-304 40-1228
40-464 40-1228
40-428 40-1242
40-304 40-1230
40-315 40-1230
D029 Wiring connector 40-436 40-1230
40-428 40-1230
40-456 40-1230
40-464 40-1230
D030
Table 288
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D030 Wiring connector 40-922 40-1204
40-922 40-1186
40-910 40-1186
40-881 40-1185
40-910 40-1204
40-881 40-1242
40-890 40-1242
40-890 40-1228
40-881 40-1228
40-890 40-1185
D030 Wiring connector 40-881 40-1185
40-890 40-1185

40-106
Wiring diagrams
D031
Table 289
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D031 Wiring connector 40-304 40-1230
40-354 40-1189
40-315 40-1230
40-354 40-1204
40-342 40-1204
40-342 40-1189
40-304 40-1189
40-315 40-1189
D032
Table 290
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D032 Wiring connector 40-354 40-1190
40-354 40-1204
40-342 40-1204
40-315 40-1230
40-304 40-1230
40-342 40-1190
40-304 40-1190
40-315 40-1190
D034
Table 291
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D034 Wiring connector 40-737 40-1204
40-585 40-1204
40-577 40-1204
40-719 40-1204
40-737 40-1204
40-719 40-1204
40-585 40-1204
40-577 40-1204
D035
Table 292
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D035 Wiring connector 40-737 40-1204
40-585 40-1204
40-719 40-1204
40-577 40-1204
40-585 40-1204
40-719 40-1204
40-577 40-1204
40-737 40-1204

40-107
 Wiring diagrams
D037
Table 293
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D037 Wiring connector 40-783 40-1251
40-1079 40-1224
40-812 40-1251
40-503 40-1251
40-489 40-1251
40-1079 40-1251
40-826 40-1251
40-1109 40-1251
40-1109 40-1224
40-489 40-1224
D037 Wiring connector 40-826 40-1224
40-503 40-1224
40-783 40-1224
40-770 40-1224
40-770 40-1251
40-812 40-1224

D038
Table 294
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D038 Wiring connector 40-770 40-1251
40-503 40-1251
40-1109 40-1251
40-770 40-1224
40-783 40-1251
40-489 40-1251
40-812 40-1251
40-1079 40-1251
40-503 40-1224
40-826 40-1251
D038 Wiring connector 40-1079 40-1224
40-489 40-1224
40-826 40-1224
40-783 40-1224
40-812 40-1224
40-1109 40-1224
D039
Table 295
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D039 Wiring connector 40-826 40-1224
40-826 40-1250
40-489 40-1250
40-1109 40-1250
40-783 40-1250
40-770 40-1250
40-812 40-1250
40-503 40-1250
40-812 40-1224
40-1079 40-1250
D039 Wiring connector 40-783 40-1224
40-489 40-1224
40-503 40-1224
40-1109 40-1224
40-770 40-1224
40-1079 40-1224

40-108
Wiring diagrams
D040
Table 296
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D040 Wiring connector 40-826 40-1250
40-783 40-1250
40-1109 40-1250
40-489 40-1250
40-812 40-1250
40-503 40-1250
40-770 40-1250
40-1079 40-1250
40-489 40-1224
40-1109 40-1224
D040 Wiring connector 40-826 40-1224
40-1079 40-1224
40-503 40-1224
40-812 40-1224
40-783 40-1224
40-770 40-1224
D041
Table 297
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D041 Wiring connector 40-1109 40-1192
40-489 40-1250
40-489 40-1192
40-826 40-1192
40-812 40-1192
40-503 40-1250
40-1109 40-1250
40-826 40-1250
40-812 40-1250
40-503 40-1192
D041 2.8039.299.0 Rh front light on arms 40-503 40-1250
40-1109 40-1250
40-826 40-1250
40-489 40-1250
40-812 40-1250
D042
Table 298
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D042 Wiring connector 40-826 40-1251
40-503 40-1251
40-1109 40-1251
40-489 40-1251
40-812 40-1251
40-489 40-1192
40-826 40-1192
40-503 40-1192
40-812 40-1192
40-1109 40-1192
D042 2.8039.299.0 LH front light on arms 40-503 40-1251
40-812 40-1251
40-489 40-1251
40-1109 40-1251
40-826 40-1251

40-109
 Wiring diagrams
D043
Table 299
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D043 Wiring connector 40-1109 40-1221
40-1109 40-1187
40-1079 40-1187
40-1079 40-1221
D044
Table 300
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
D044 Wiring connector 40-1109 40-1187
40-1079 40-1221
40-1109 40-1221
40-1079 40-1187

40.2.12 - E - On-board instruments and visual and audible indicators (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
Table 301
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
E001 2.8419.007.0 Horn 40-797 40-1193
40-755 40-1193
40-1094 40-1193
40-1064 40-1193
E002 2.8339.269.0/50 Instrument panel 40-755 40-1209
40-254 40-1221
40-369 40-1221
40-1003 40-1221
40-1094 40-1221
40-934 40-1221
40-1123 40-1221
40-1153 40-1221
40-327 40-1221
40-966 40-1209
E002 2.8339.269.0/50 Instrument panel 40-934 40-1209
40-175 40-1221
40-1003 40-1209
40-290 40-1221
40-254 40-1209
40-1016 40-1209
40-797 40-1209
40-175 40-1209
40-369 40-1209
40-327 40-1209
E002 2.8339.269.0/50 Instrument panel 40-290 40-1209
40-1064 40-1221

40-110
Wiring diagrams
Table 302
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
E003 2.8339.269.0/50 Instrument panel 40-290 40-1221
40-369 40-1221
40-1123 40-1221
40-1153 40-1221
40-1003 40-1221
40-934 40-1221
40-1064 40-1221
40-254 40-1221
40-1016 40-1209
40-175 40-1221
E003 2.8339.269.0/50 Instrument panel 40-1094 40-1221
40-797 40-1209
40-327 40-1221
40-254 40-1209
40-755 40-1209
40-290 40-1209
40-369 40-1209
40-327 40-1209
40-934 40-1209
40-966 40-1209
E003 2.8339.269.0/50 Instrument panel 40-1003 40-1209
40-175 40-1209
E004 0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1016 40-1209
Pin + = 15V power supply
Pin - = earth
E004 0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1153 40-1221
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1016 40-1209
Pin + = 15V power supply
Pin - = earth
Table 303
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1153 40-1221
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1153 40-1221
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1016 40-1209
Pin + = 15V power supply
Pin - = earth
E005 Clock 40-290 40-1244
40-290 40-1226
E006 0.015.5549.4/10 Climate control LED 40-700 40-1204
E007 0.015.5549.4/10 Climate control panel light- 40-700 40-1204
ing

40-111
 Wiring diagrams
40.2.13 - E - On-board instruments and visual and audible indicators (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001)
Table 304
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
E001 2.8419.007.0 Horn 40-1079 40-1218
40-812 40-1218
40-770 40-1218
40-783 40-1218
40-1109 40-1218
40-826 40-1218
E002 2.8339.269.0/50 Instrument panel 40-1079 40-1221
40-229 40-1221
40-1109 40-1221
40-283 40-1221
40-397 40-1221
40-1167 40-1221
40-315 40-1221
E002 2.8339.269.0/50 Instrument panel 40-1012 40-1221
40-354 40-1221
40-1138 40-1221
40-1043 40-1205
40-958 40-1221
40-1012 40-1205
40-826 40-1205
40-283 40-1205
E002 2.8339.269.0/50 Instrument panel 40-783 40-1205
40-315 40-1205
40-354 40-1205
40-958 40-1205
40-990 40-1205
40-229 40-1205
40-397 40-1205
Table 305
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
E003 2.8339.269.0/50 Instrument panel 40-958 40-1205
40-315 40-1205
40-783 40-1205
40-229 40-1205
40-826 40-1205
40-1012 40-1205
40-354 40-1205
E003 2.8339.269.0/50 Instrument panel 40-397 40-1205
40-283 40-1205
40-1043 40-1205
40-283 40-1221
40-229 40-1221
40-990 40-1205
40-315 40-1221
E003 2.8339.269.0/50 Instrument panel 40-354 40-1221
40-1012 40-1221
40-397 40-1221
40-1079 40-1221
40-1167 40-1221
40-1138 40-1221
40-1109 40-1221
40-958 40-1221

40-112
Wiring diagrams
Table 306
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
E004 0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1043 40-1205
Pin + = 15V power supply
Pin - = earth
E004 0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1167 40-1221
Pin + = 15V power supply
Pin - = earth
E004 0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1030 40-1238
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1043 40-1205
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1167 40-1221
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1030 40-1238
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1043 40-1205
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1167 40-1221
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1030 40-1238
Pin + = 15V power supply
Pin - = earth
Table 307
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
E005 Clock 40-304 40-1228
40-304 40-1242
40-315 40-1228
40-315 40-1242
E006 0.015.5549.4/10 Climate control LED 40-719 40-1204
40-737 40-1204
E007 0.015.5549.4/10 Climate control panel light- 40-719 40-1204
ing 40-737 40-1204
E008 2.8339.256.0 Instrument panel 40-812 40-1238
40-951 40-1238
40-276 40-1238
40-382 40-1238
40-1030 40-1238
40-981 40-1238
40-202 40-1238
40-770 40-1238
E009 2.8339.256.0 Instrument panel 40-202 40-1238
40-1030 40-1238
40-382 40-1238
40-951 40-1238
E010 2.8339.256.0 Instrument panel 40-202 40-1238
40-382 40-1238
E011 2.8339.256.0 Instrument panel 40-382 40-1238
E012 2.8339.256.0 Instrument panel 40-382 40-1238

40-113
 Wiring diagrams
40.2.14 - E - On-board instruments and visual and audible indicators (R3 EVO 85 ->
16001)
Table 308
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
E001 2.8419.007.0 Horn 40-1079 40-1218
40-812 40-1218
40-770 40-1218
40-783 40-1218
40-1109 40-1218
40-826 40-1218
E002 2.8339.269.0/50 Instrument panel 40-1079 40-1221
40-229 40-1221
40-1109 40-1221
40-397 40-1221
40-269 40-1221
40-1167 40-1221
40-315 40-1221
E002 2.8339.269.0/50 Instrument panel 40-1012 40-1221
40-354 40-1221
40-1138 40-1221
40-1043 40-1205
40-958 40-1221
40-1012 40-1205
40-826 40-1205
E002 2.8339.269.0/50 Instrument panel 40-783 40-1205
40-315 40-1205
40-354 40-1205
40-269 40-1205
40-958 40-1205
40-990 40-1205
40-229 40-1205
40-397 40-1205
Table 309
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
E003 2.8339.269.0/50 Instrument panel 40-958 40-1205
40-315 40-1205
40-783 40-1205
40-269 40-1205
40-229 40-1205
40-826 40-1205
40-1012 40-1205
40-354 40-1205
E003 2.8339.269.0/50 Instrument panel 40-397 40-1205
40-1043 40-1205
40-229 40-1221
40-990 40-1205
40-269 40-1221
40-315 40-1221
E003 2.8339.269.0/50 Instrument panel 40-354 40-1221
40-1012 40-1221
40-397 40-1221
40-1079 40-1221
40-1167 40-1221
40-1138 40-1221
40-1109 40-1221
40-958 40-1221

40-114
Wiring diagrams
Table 310
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
E004 0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1043 40-1205
Pin + = 15V power supply
Pin - = earth
E004 0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1167 40-1221
Pin + = 15V power supply
Pin - = earth
E004 0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1030 40-1238
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1043 40-1205
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1167 40-1221
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1030 40-1238
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1043 40-1205
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1167 40-1221
Pin + = 15V power supply
Pin - = earth
0.011.9433.0 Trailer pressure indicator Pin S = input from sensor 40-1030 40-1238
Pin + = 15V power supply
Pin - = earth
Table 311
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
E005 Clock 40-304 40-1228
40-304 40-1242
40-315 40-1228
40-315 40-1242
E006 0.015.5549.4/10 Climate control LED 40-719 40-1204
40-737 40-1204
E007 0.015.5549.4/10 Climate control panel light- 40-719 40-1204
ing 40-737 40-1204
E008 2.8339.256.0 Instrument panel 40-812 40-1238
40-951 40-1238
40-261 40-1238
40-382 40-1238
40-1030 40-1238
40-981 40-1238
40-202 40-1238
40-770 40-1238
E009 2.8339.256.0 Instrument panel 40-202 40-1238
40-1030 40-1238
40-382 40-1238
40-951 40-1238
E010 2.8339.256.0 Instrument panel 40-202 40-1238
40-382 40-1238
E011 2.8339.256.0 Instrument panel 40-382 40-1238
E012 2.8339.256.0 Instrument panel 40-382 40-1238

40-115
 Wiring diagrams
40.2.15 - F - External lights (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)
Table 312
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
F001 2.8039.003.0 Rh front worklight (on 40-515 40-1193
hood) 40-410 40-1193
40-445 40-1193
40-473 40-1193
F002 2.8039.005.0 Rh high beam headlight 40-1064 40-1193
40-797 40-1193
40-1094 40-1193
40-755 40-1193
F003 2.8039.004.0 Rh low beam headlight 40-1094 40-1193
40-755 40-1193
40-1064 40-1193
40-797 40-1193
F003 2.8039.008.0 Rh low beam headlight 40-1064 40-1193
40-797 40-1193
40-755 40-1193
40-1094 40-1193
F004 2.8039.004.0 Lh low beam headlight 40-755 40-1193
40-1094 40-1193
40-797 40-1193
40-1064 40-1193
F004 2.8039.008.0 Lh low beam headlight 40-1094 40-1193
40-1064 40-1193
40-755 40-1193
40-797 40-1193
F005 2.8039.005.0 Lh high beam headlight 40-797 40-1193
40-1094 40-1193
40-755 40-1193
40-1064 40-1193
F006 2.8039.003.0 Lh front worklight (on 40-410 40-1193
hood) 40-445 40-1193
40-473 40-1193
40-515 40-1193
Table 313
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
F007 2.8059.526.0 Number plate light 40-1094 40-1221
40-1064 40-1221
40-755 40-1209
40-797 40-1209
2.8059.526.0 Number plate light 40-755 40-1209
40-797 40-1209
40-1094 40-1221
40-1064 40-1221
F008 2.8059.080.0 LH rear light 40-755 40-1209
F008 2.8059.080.0 LH rear light 40-797 40-1209
F008 2.8059.450.0 LH rear sidelight and di- 40-1064 40-1187
rection indicator
F008 2.8059.450.0 LH rear sidelight and di- 40-1094 40-1187
rection indicator
F008 2.8059.080.0 LH rear light 40-1016 40-1209
F009 2.8059.090.0 RH rear light 40-755 40-1209
40-1016 40-1209
40-797 40-1209
F009 2.8059.450.0 RH rear sidelight and di- 40-1094 40-1187
rection indicator 40-1064 40-1187

40-116
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
F010 2.8029.730.0 Rh front worklight (on cab 40-410 40-1230
roof) 40-445 40-1230
F010 2.8039.298.0/20 Rh front worklight (on cab 40-473 40-1204
roof) 40-515 40-1204
F011 2.8039.298.0/20 Lh rear worklight (on cab 40-473 40-1204
roof)
F011 2.8029.730.0 Lh rear worklight (on cab 40-445 40-1230
roof)
F011 2.8029.730.0 Lh rear worklight (on cab 40-410 40-1230
roof)
F011 2.8039.298.0/20 Lh rear worklight (on cab 40-515 40-1204
roof)
F012 2.8039.298.0/20 Rh rear worklight (on cab 40-473 40-1204
roof) 40-515 40-1204
F012 2.8029.730.0 Rh rear worklight (on cab 40-445 40-1230
roof) 40-410 40-1230

Table 314
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
F013 2.8039.298.0/20 Lh front worklight (on cab 40-473 40-1204
roof)
F013 2.8029.730.0 Lh front worklight (on cab 40-410 40-1230
roof)
F013 2.8039.298.0/20 Lh front worklight (on cab 40-515 40-1204
roof)
F013 2.8029.730.0 Lh front worklight (on cab 40-445 40-1230
roof)
F014 04411921.4 Front RH sidelight and di- 40-797 40-1250
rection indicator 40-755 40-1250
40-1064 40-1250
40-1094 40-1250
F015 04411920.4 Front LH sidelight and di- 40-797 40-1251
rection indicator 40-1064 40-1251
40-1094 40-1251
40-755 40-1251
F016 2.8029.730.0 Rh auxiliary worklight 40-410 40-1196
F016 2.8039.299.0 Rh auxiliary worklight 40-473 40-1192
F017 2.8039.299.0 Lh auxiliary worklight 40-473 40-1192
F017 2.8029.730.0 Lh auxiliary worklight 40-410 40-1197
F018 0.013.0868.4 Rotating beacon 40-290 40-1190
40-327 40-1190
F019 0.013.0868.4 Rotating beacon 40-327 40-1189
40-290 40-1189
F020 2.8059.440.0/10 LH rear light (hazard warn- 40-1064 40-1187
ing) 40-1094 40-1187
F021 2.8059.440.0/10 RH rear light (hazard 40-1094 40-1187
warning) 40-1064 40-1187

40-117
 Wiring diagrams
40.2.16 - F - External lights (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)
Table 315
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
F002 2.8039.005.0 Rh high beam headlight 40-812 40-1218
40-1109 40-1218
40-1079 40-1218
40-826 40-1218
40-770 40-1218
40-783 40-1218
F003 2.8039.004.0 Rh low beam headlight 40-770 40-1218
40-826 40-1218
40-812 40-1218
40-783 40-1218
40-1109 40-1218
40-1079 40-1218
F003 2.8039.008.0 Rh low beam headlight 40-1079 40-1218
40-1109 40-1218
40-812 40-1218
40-783 40-1218
40-770 40-1218
40-826 40-1218
F004 2.8039.004.0 Lh low beam headlight 40-1109 40-1218
40-812 40-1218
40-1079 40-1218
40-783 40-1218
40-826 40-1218
40-770 40-1218
F004 2.8039.008.0 Lh low beam headlight 40-1109 40-1218
40-1079 40-1218
40-770 40-1218
40-783 40-1218
40-826 40-1218
40-812 40-1218

Table 316
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
F005 2.8039.005.0 Lh high beam headlight 40-826 40-1218
40-783 40-1218
40-812 40-1218
40-1109 40-1218
40-770 40-1218
40-1079 40-1218
F007 2.8059.526.0 Number plate light 40-783 40-1205
40-826 40-1205
40-1109 40-1221
40-1079 40-1221
40-770 40-1238
40-812 40-1238
2.8059.526.0 Number plate light 40-770 40-1238
40-812 40-1238
40-1109 40-1221
40-783 40-1205
40-826 40-1205
40-1079 40-1221
F008 2.8059.450.0 LH rear sidelight and di- 40-1109 40-1187
rection indicator

40-118
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
F008 2.8059.080.0 LH rear light 40-1030 40-1238
40-783 40-1205
40-812 40-1238
40-1079 40-1187
40-826 40-1205
40-1043 40-1205
40-770 40-1238
Table 317
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
F009 2.8059.090.0 RH rear light 40-770 40-1238
40-1043 40-1205
40-783 40-1205
40-826 40-1205
F009 2.8059.450.0 RH rear sidelight and di- 40-1109 40-1187
rection indicator
F009 2.8059.090.0 RH rear light 40-812 40-1238
40-1030 40-1238
F009 2.8059.450.0 RH rear sidelight and di- 40-1079 40-1187
rection indicator
F010 2.8039.298.0/20 Rh front worklight (on cab 40-503 40-1204
roof) 40-527 40-1204
40-535 40-1204
40-489 40-1204
F010 2.8029.730.0 Rh front worklight (on cab 40-428 40-1230
roof)
F010 2.8029.730.0 Rh front worklight (on cab 40-456 40-1230
roof)
F010 2.8029.730.0 Rh front worklight (on cab 40-464 40-1230
roof)
F010 2.8029.730.0 Rh front worklight (on cab 40-436 40-1230
roof)
F011 2.8039.298.0/20 Lh rear worklight (on cab 40-503 40-1204
roof)
F011 2.8029.730.0 Lh rear worklight (on cab 40-428 40-1230
roof)
F011 2.8029.730.0 Lh rear worklight (on cab 40-456 40-1230
roof)
F011 2.8029.730.0 Lh rear worklight (on cab 40-436 40-1230
roof)
F011 2.8039.298.0/20 Lh rear worklight (on cab 40-527 40-1204
roof)
F011 2.8039.298.0/20 Lh rear worklight (on cab 40-489 40-1204
roof)
F011 2.8039.298.0/20 Lh rear worklight (on cab 40-535 40-1204
roof)
F011 2.8029.730.0 Lh rear worklight (on cab 40-464 40-1230
roof)
Table 318
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
F012 2.8039.298.0/20 Rh rear worklight (on cab 40-489 40-1204
roof)
F012 2.8039.298.0/20 Rh rear worklight (on cab 40-535 40-1204
roof)
F012 2.8039.298.0/20 Rh rear worklight (on cab 40-503 40-1204
roof)

40-119
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
F012 2.8039.298.0/20 Rh rear worklight (on cab 40-527 40-1204
roof)
F012 2.8029.730.0 Rh rear worklight (on cab 40-436 40-1230
roof)
F012 2.8029.730.0 Rh rear worklight (on cab 40-464 40-1230
roof)
F012 2.8029.730.0 Rh rear worklight (on cab 40-428 40-1230
roof)
F012 2.8029.730.0 Rh rear worklight (on cab 40-456 40-1230
roof)
F013 2.8029.730.0 Lh front worklight (on cab 40-464 40-1230
roof)
F013 2.8029.730.0 Lh front worklight (on cab 40-436 40-1230
roof)
F013 2.8029.730.0 Lh front worklight (on cab 40-428 40-1230
roof)
F013 2.8029.730.0 Lh front worklight (on cab 40-456 40-1230
roof)
F013 2.8039.298.0/20 Lh front worklight (on cab 40-503 40-1204
roof)
F013 2.8039.298.0/20 Lh front worklight (on cab 40-489 40-1204
roof)
F013 2.8039.298.0/20 Lh front worklight (on cab 40-527 40-1204
roof)
F013 2.8039.298.0/20 Lh front worklight (on cab 40-535 40-1204
roof)
F014 04411921.4 Front RH sidelight and di- 40-783 40-1250
rection indicator
F014 04411921.4 Front RH sidelight and di- 40-826 40-1250
rection indicator
F014 04411921.4 Front RH sidelight and di- 40-770 40-1250
rection indicator
F014 04411921.4 Front RH sidelight and di- 40-1079 40-1250
rection indicator
F014 04411921.4 Front RH sidelight and di- 40-812 40-1250
rection indicator
F014 04411921.4 Front RH sidelight and di- 40-1109 40-1250
rection indicator
F015 04411920.4 Front LH sidelight and di- 40-783 40-1251
rection indicator
F015 04411920.4 Front LH sidelight and di- 40-770 40-1251
rection indicator
F015 04411920.4 Front LH sidelight and di- 40-1109 40-1251
rection indicator
F015 04411920.4 Front LH sidelight and di- 40-1079 40-1251
rection indicator
F015 04411920.4 Front LH sidelight and di- 40-812 40-1251
rection indicator
F015 04411920.4 Front LH sidelight and di- 40-826 40-1251
rection indicator

40-120
Wiring diagrams
Table 319
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
F016 2.8039.299.0 Rh auxiliary worklight 40-503 40-1192
F016 2.8039.299.0 Rh auxiliary worklight 40-489 40-1192
F017 2.8039.299.0 Lh auxiliary worklight 40-503 40-1192
F017 2.8039.299.0 Lh auxiliary worklight 40-489 40-1192
F018 0.013.0868.4 Rotating beacon 40-354 40-1190
F018 0.013.0868.4 Rotating beacon 40-342 40-1190
F018 0.013.0868.4 Rotating beacon 40-304 40-1190
F018 0.013.0868.4 Rotating beacon 40-315 40-1190
F019 0.013.0868.4 Rotating beacon 40-304 40-1189
F019 0.013.0868.4 Rotating beacon 40-354 40-1189
F019 0.013.0868.4 Rotating beacon 40-315 40-1189
F019 0.013.0868.4 Rotating beacon 40-342 40-1189
F020 2.8059.440.0/10 LH rear light (hazard warn- 40-1109 40-1187
ing)
F020 2.8059.440.0/10 LH rear light (hazard warn- 40-1079 40-1187
ing)
F021 2.8059.440.0/10 RH rear light (hazard 40-1079 40-1187
warning)
F021 2.8059.440.0/10 RH rear light (hazard 40-1109 40-1187
warning)

40.2.17 - G - Interior lights (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)
Table 320
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
G001 2.8339.032.0 Interior roof light 40-327 40-1204
40-290 40-1244
40-290 40-1226
G002 2.8339.074.0 Spot light 40-327 40-1204

40.2.18 - G - Interior lights (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)
Table 321
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
G001 2.8339.032.0 Interior roof light 40-354 40-1204
40-342 40-1204
40-315 40-1242
40-304 40-1242
40-304 40-1228
40-315 40-1228
G002 2.8339.074.0 Spot light 40-342 40-1204
40-354 40-1204

40.2.19 - H - Electrical and manual controls (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001,
R3 EVO 85 -> 20001)
Table 322
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
H001 0.015.0359.4 Lights selector switch 40-797 40-1209
40-1094 40-1221
40-1064 40-1221
40-755 40-1209
H002 0.014.8997.4 Main gear lever - Hi/Lo 40-934 40-1209
buttons and transmission 40-934 40-1221
split

40-121
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
H003 2.8519.103.0 Shuttle lever 40-290 40-1195
40-1003 40-1195
40-327 40-1195
40-934 40-1195
H004 0.015.5549.4/10 Blower speed selector 40-567 40-1204
switch 40-700 40-1204
H004 0.015.5594.4/10 Blower speed selector 40-700 40-1204
switch 40-567 40-1204
H005 0.009.4743.1 Blower speed selector 40-647 40-1183
switch 40-543 40-1182
40-593 40-1183

40.2.20 - H - Electrical and manual controls (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001,
R3 EVO 85 -> 16001)
Table 323
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
H001 0.015.0359.4 Lights selector switch 40-783 40-1205
40-1109 40-1221
40-1079 40-1221
40-770 40-1238
40-812 40-1238
40-826 40-1205
H004 0.015.5549.4/10 Blower speed selector 40-737 40-1204
switch 40-585 40-1204
40-719 40-1204
40-577 40-1204
H004 0.015.5594.4/10 Blower speed selector 40-737 40-1204
switch 40-577 40-1204
40-585 40-1204
40-719 40-1204
H005 0.009.4743.1 Blower speed selector 40-611 40-1183
switch 40-559 40-1182
40-552 40-1182
40-664 40-1183
40-629 40-1183
40-682 40-1183

40.2.21 - I - Circuit breakers (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)
Table 324
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I001 2.7659.203.0/10 Engine speed memory Normally open contact (NO) 40-254 40-1209
button 40-254 40-1221
I002 2.7659.097.0 P.T.O. engagement switch 40-966 40-1209
1
540

Fig. 2156
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)

40-122
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I002 2.7659.097.0 P.T.O. engagement switch 40-1123 40-1221
1
540

Fig. 2156
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I003 2.7659.097.0 P.T.O. engagement switch 40-966 40-1209
1
1.000

Fig. 2156
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I003 2.7659.097.0 P.T.O. engagement switch 40-1123 40-1221
1
1.000

Fig. 2156
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I004 2.7659.277.0 40-966 40-1209
40-1123 40-1221

Fig. 2157
I005 2.7659.278.0 Rear PTO control switch 40-966 40-1209
40-1123 40-1221

Fig. 2157
I006 2.7659.177.0/20 Lh rear PTO control switch Resistance between Pin 1 and 40-966 40-1209
(on fender) Pin 2 with button pressed: 3.9 40-1123 40-1221
Ohms

40-123
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I007 2.7659.177.0/20 Rh rear PTO control switch Resistance between Pin 1 and 40-966 40-1209
(on fender) Pin 2 with button pressed: 3.9 40-1123 40-1221
Ohms
I008 2.7659.271.0 Road lights switch 40-934 40-1209
40-1094 40-1221
40-410 40-1221
40-515 40-1221
40-1123 40-1221
40-445 40-1221
40-934 40-1221
40-1064 40-1221
40-369 40-1221
Fig. 2158

Table 325
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I008 2.7659.271.0 Road lights switch 40-327 40-1221
40-898 40-1221
40-473 40-1221
40-1153 40-1221
40-410 40-1209
40-898 40-1209
40-290 40-1221
40-966 40-1209
40-515 40-1209
Fig. 2158
I008 2.7659.271.0 Road lights switch 40-445 40-1209
40-327 40-1209
40-290 40-1209
40-797 40-1209
40-755 40-1209
40-369 40-1209
40-1016 40-1209
40-473 40-1209

Fig. 2158
I009 2.7659.283.0/10 Upper worklights switch 40-1064 40-1221
40-797 40-1209
40-1094 40-1221
40-755 40-1209
I010 2.7659.152.0/10 Differential lock control 40-934 40-1221
switch 40-934 40-1209

Fig. 2159
I011 2.7659.097.0 Clutch pedal switch 40-934 40-1209
1

Fig. 2159
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)

40-124
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I011 2.7659.097.0 Clutch pedal switch 40-175 40-1209
1

Fig. 2159
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I011 2.7659.097.0 Clutch pedal switch 40-175 40-1221
1

Fig. 2159
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
Table 326
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I011 2.7659.097.0 Clutch pedal switch 40-934 40-1221
1

Fig. 2159
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I012 2.7659.150.0 Lower front worklights 0 40-410 40-1221
switch 1 40-473 40-1209
40-473 40-1221
40-410 40-1209

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2160
I013 2.7659.097.0 Brake pedal switch 40-1016 40-1209
1

Fig. 2160
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)

40-125
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I015 2.7659.151.0/20 4WD control switch 40-934 40-1209
40-934 40-1221

Fig. 2161
I016 2.7659.158.0 Hazard warning lights 0
1
40-1064 40-1221
switch
5 17
18
10
40-1094 40-1221
40-755 40-1209
8 1 2 3
5 1 7 18

Pos

0
Pin 1 2 3 5 8 10 17 18
40-797 40-1209

Fig. 2162
I018 0.015.0485.4 Starter switch 0
1
40-864 40-1209
5 17
18
10
40-175 40-1209
40-864 40-1221
8 1 2 3
5 1 7 18

Pos

0
Pin 1 2 3 5 8 10 17 18
40-175 40-1221

Fig. 2162
I019 2.7659.156.0 Corner lights switch 0 40-515 40-1221
1
40-515 40-1209
7
40-410 40-1209
7 4 5 6
8
2 3
40-473 40-1209
40-410 40-1221
Pin
40-473 40-1221
1 2 3 4 5 6 7 8
Pos
40-445 40-1209
0
40-445 40-1221
1

Fig. 2163
I020 2.7659.343.0/10 Start enable switch (trans- 40-175 40-1214
mission in neutral)
I021 2.7659.096.0/10 P.T.O. engagement switch 40-966 40-1214
ECO
CB A

Fig. 2164
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 2 and pin 3: normally
open contact (NO)

40-126
Wiring diagrams
Table 327
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I021 2.7659.096.0/10 P.T.O. engagement switch 40-1123 40-1214
ECO

CB A
Fig. 2164
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 2 and pin 3: normally
open contact (NO)
I022 4WD engagement control 40-934 40-1214
switch
I023 2.7659.202.0 P.T.O. engagement switch Between pin 2 and pin 3: normally 40-1123 40-1214
ECO closed contact (NC)
Between pin 1 and pin 4: normally
open contact (NO)
With switch free of levers
I023 2.7659.202.0 P.T.O. engagement switch Between pin 2 and pin 3: normally 40-966 40-1214
ECO closed contact (NC)
Between pin 1 and pin 4: normally
open contact (NO)
With switch free of levers
I024 2.7659.078.0 Front worklights switch 0 40-410 40-1226
1

Pin 1 2
Pos

Fig. 2165
I024 2.7659.154.0 Front worklights switch 0 40-473 40-1204
I024 2.7659.154.0 Front worklights switch 1 40-515 40-1204

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2166
I024 2.7659.078.0 Front worklights switch 0 40-410 40-1244
40-445 40-1226
1
40-445 40-1244
1

Pin 1 2
Pos

Fig. 2166

40-127
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I025 2.7659.126.0 Rotating beacon switch 0 40-290 40-1226
40-290 40-1244
1

Pin 1 2
Pos

Fig. 2166
I025 2.7659.159.0 Rotating beacon switch 0 40-327 40-1204
1
7

8
2 3
7 4 5 6

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2166
I026 2.7659.079.0 Rear worklights switch 0 40-410 40-1244
40-445 40-1244
1

Pin 1 2
Pos

Fig. 2166
I026 2.7659.079.0 Rear worklights switch 0 40-410 40-1226
1

Pin 1 2
Pos

Fig. 2166
I026 2.7659.155.0 Rear worklights switch 0 40-473 40-1204
1 40-515 40-1204

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2166

40-128
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I026 2.7659.079.0 Rear worklights switch 0 40-445 40-1226
1

Pin 1 2
Pos

Fig. 2166
I027 2.7659.091.0 Windscreen washer pump 0 40-870 40-1226
switch 1
40-870 40-1244

1
2
4
Pin 1 2
Pos

Fig. 2167
I027 2.7659.223.0/10 Windscreen washer pump 40-898 40-1204
switch

Fig. 2167
I028 2.7659.092.0 Windscreen wiper switch 1
0 40-870 40-1226
2
40-870 40-1244

1 2 3 4

5 6 7 8

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2168
I028 2.7659.192.0/10 Windscreen wiper switch 40-898 40-1204

Fig. 2169

40-129
 Wiring diagrams
Table 328
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I029 2.7659.146.0 Rear screen wiper switch 0 40-870 40-1226
1
2
40-870 40-1244

1 2 3 4

5 6 7 8

Pin 1 2 3 4 5 6
Pos

Fig. 2170
I029 2.7659.224.0/10 Rear screen wiper switch 40-898 40-1204

Fig. 2171
I030 0.015.5549.4/10 A/C activation switch 40-700 40-1204

40.2.22 - I - Circuit breakers (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001)
Table 329
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I001 2.7659.203.0/10 Engine speed memory Normally open contact (NO) 40-276 40-1238
button 40-283 40-1221
40-283 40-1205
I002 2.7659.097.0 540 PTO control switch 40-1138 40-1221
1

Fig. 2172
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I002 2.7659.097.0 540 PTO control switch 40-990 40-1205
1

Fig. 2172
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)

40-130
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I003 2.7659.097.0 1000 PTO control switch 40-990 40-1205
1

Fig. 2172
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I003 2.7659.097.0 1000 PTO control switch 40-1138 40-1221
1

Fig. 2172
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I004 2.7659.277.0 Front PTO control switch 40-990 40-1205
40-1138 40-1221
40-202 40-1238
40-981 40-1238

Fig. 2173
I005 2.7659.274.0 Rear PTO control switch 40-981 40-1238
40-202 40-1238
I005 2.7659.278.0 Rear PTO control switch 40-1138 40-1221
40-990 40-1205

Fig. 2173
I006 2.7659.177.0/20 LH rear PTO control switch Resistance between Pin 1 and 40-990 40-1205
(on fender) Pin 2 with button pressed: 3.9 40-1138 40-1221
Ohms

40-131
 Wiring diagrams
Table 330
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I007 2.7659.177.0/20 Rh rear PTO control switch Resistance between Pin 1 and 40-1138 40-1221
(on fender) Pin 2 with button pressed: 3.9 40-990 40-1205
Ohms
I008 2.7659.271.0 Road lights switch 40-812 40-1238
40-1167 40-1221
40-958 40-1221
40-503 40-1221
40-1138 40-1221

Fig. 2174
I008 2.7659.271.0 Road lights switch 40-981 40-1238
40-951 40-1238
40-910 40-1238
40-489 40-1238
40-202 40-1238
40-1030 40-1238
40-527 40-1238

Fig. 2174
I008 2.7659.271.0 Road lights switch 40-382 40-1238
40-342 40-1238
40-397 40-1221
40-535 40-1221
40-770 40-1238
40-354 40-1205
40-990 40-1205

Fig. 2174
I008 2.7659.271.0 Road lights switch 40-315 40-1221
40-958 40-1205
40-1079 40-1221
40-503 40-1205
40-535 40-1205
40-783 40-1205
40-922 40-1205
40-315 40-1205
40-826 40-1205
Fig. 2174

Table 331
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I008 2.7659.271.0 Road lights switch 40-1043 40-1205
40-1109 40-1221
40-922 40-1221
40-354 40-1221
40-397 40-1205

Fig. 2174

40-132
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I009 2.7659.283.0/10 Upper worklights switch 40-1109 40-1221
40-770 40-1238
40-783 40-1205
40-1079 40-1221
40-826 40-1205
40-812 40-1238
I010 2.7659.152.0/10 Differential lock control 40-958 40-1205
switch 40-958 40-1221
40-951 40-1238

Fig. 2175
I011 2.7659.097.0 Clutch pedal switch 40-229 40-1205
1

Fig. 2175
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I011 2.7659.097.0 Clutch pedal switch 40-229 40-1221
1

Fig. 2175
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I011 2.7659.097.0 Clutch pedal switch 40-202 40-1238
1

Fig. 2175
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I012 2.7659.150.0 Lower front worklights 0 40-503 40-1221
switch 1 40-489 40-1238
40-503 40-1205

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2176

40-133
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I013 2.7659.097.0 Brake pedal switch 40-1043 40-1205
1

Fig. 2176
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
Table 332
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I013 2.7659.097.0 Brake pedal switch 40-1030 40-1238
1

Fig. 2176
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I016 2.7659.158.0 Hazard warning lights 0
1
40-826 40-1205
switch
5 17
18
10
40-783 40-1205
40-1079 40-1221
8 1 2 3
5 1 7 18

Pos
Pin 1 2 3 5 8 10 17 18
40-1109 40-1221
40-812 40-1238
0

1 40-770 40-1238

Fig. 2177
I017 Parking brake switch 40-1030 40-1238
I018 0.015.0485.4 Starter switch 40-868 40-1221
40-202 40-1238
83 40-868 40-1205
50
86s
30
40-229 40-1205
75 15
40-866 40-1238
40-229 40-1221

Pin 30 15 50 75 83
Pos

2
D0010060

Fig. 2178
I020 2.7659.343.0/10 Start enable switch (trans- 40-229 40-1212
mission in neutral) 40-202 40-1233

40-134
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I021 2.7659.096.0/10 Groundpseed PTO en- 40-990 40-1212
gagement switch

CB A
Fig. 2179
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 2 and pin 3: normally
open contact (NO)
I021 2.7659.096.0/10 Groundpseed PTO en- 40-981 40-1233
gagement switch

CB A
Fig. 2179
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 2 and pin 3: normally
open contact (NO)
I021 2.7659.096.0/10 Groundpseed PTO en- 40-1138 40-1212
gagement switch

CB A
Fig. 2179
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 2 and pin 3: normally
open contact (NO)
I023 2.7659.202.0 P.T.O. engagement switch Between pin 2 and pin 3: normally 40-1138 40-1212
ECO closed contact (NC)
Between pin 1 and pin 4: normally
open contact (NO)
With switch free of levers
Table 333
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I023 2.7659.202.0 P.T.O. engagement switch Between pin 2 and pin 3: normally 40-990 40-1212
ECO closed contact (NC)
Between pin 1 and pin 4: normally
open contact (NO)
With switch free of levers
I024 2.7659.078.0 Front worklights switch 0 40-436 40-1242
1

Pin 1 2
Pos

Fig. 2180

40-135
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I024 2.7659.154.0 Front worklights switch 0 40-489 40-1204
1 40-503 40-1204
40-527 40-1204
40-535 40-1204
7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2181
I024 2.7659.078.0 Front worklights switch 0 40-464 40-1242
40-456 40-1242
1
40-428 40-1228
1
40-456 40-1228
2 40-428 40-1242
40-464 40-1228
40-436 40-1228
Pin 1 2
Pos

Fig. 2181
I025 2.7659.126.0 Rotating beacon switch 0 40-304 40-1228
40-315 40-1228
1

Pin 1 2
Pos

Fig. 2181
I025 2.7659.159.0 Rotating beacon switch 0 40-354 40-1204
1
40-342 40-1204
7

8
2 3
7 4 5 6

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2182
I025 2.7659.126.0 Rotating beacon switch 0 40-315 40-1242
40-304 40-1242
1

Pin 1 2
Pos

Fig. 2182

40-136
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I026 2.7659.079.0 Rear worklights switch 0 40-436 40-1242
1

Pin 1 2
Pos

Fig. 2182
I026 2.7659.155.0 Rear worklights switch 0 40-527 40-1204
1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2182
I026 2.7659.079.0 Rear worklights switch 0 40-428 40-1242
1

Pin 1 2
Pos

Fig. 2182

40-137
 Wiring diagrams
Table 334
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I026 2.7659.155.0 Rear worklights switch 0 40-535 40-1204
1 40-503 40-1204

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2182
I026 2.7659.079.0 Rear worklights switch 0 40-464 40-1242
40-456 40-1228
1
40-464 40-1228
1
40-436 40-1228
2 40-428 40-1228

Pin 1 2
Pos

Fig. 2182
I026 2.7659.155.0 Rear worklights switch 0 40-489 40-1204
1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2182
I026 2.7659.079.0 Rear worklights switch 0 40-456 40-1242
1

Pin 1 2
Pos

Fig. 2182
I027 2.7659.091.0 Windscreen washer pump 0 40-890 40-1242
switch 1
3

1
2
4

Pin 1 2
Pos

Fig. 2183

40-138
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I027 2.7659.223.0/10 Windscreen washer pump 40-922 40-1204
switch

Fig. 2183
I027 2.7659.091.0 Windscreen washer pump 0 40-881 40-1242
switch 1
40-881 40-1228
40-890 40-1228

1
2
4
Pin 1 2
Pos

Fig. 2183
I027 2.7659.223.0/10 Windscreen washer pump 40-910 40-1204
switch

Fig. 2183
I028 2.7659.092.0 Windscreen wiper switch 1
0 40-881 40-1228
2
40-890 40-1228
40-881 40-1242
1 2 3 4 40-890 40-1242
5 6 7 8
40-922 40-1204
40-910 40-1204
Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2184
I029 2.7659.224.0/10 Rear screen wiper switch 40-922 40-1204
40-910 40-1204

Fig. 2185
I030 0.015.5549.4/10 A/C activation switch 40-737 40-1204
40-719 40-1204

40-139
 Wiring diagrams
40.2.23 - I - Circuit breakers (R3 EVO 85 -> 16001)
Table 335
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I001 2.7659.203.0/10 Engine speed memory Normally open contact (NO) 40-261 40-1238
button 40-269 40-1221
40-269 40-1205
I002 2.7659.097.0 540 PTO control switch 40-1138 40-1221
1

Fig. 2185
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I002 2.7659.097.0 540 PTO control switch 40-990 40-1205
1

Fig. 2185
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I003 2.7659.097.0 1000 PTO control switch 40-990 40-1205
1

Fig. 2185
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I003 2.7659.097.0 1000 PTO control switch 40-1138 40-1221
1

Fig. 2185
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I004 2.7659.277.0 Front PTO control switch 40-990 40-1205
40-1138 40-1221
40-202 40-1238
40-981 40-1238

Fig. 2185

40-140
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I005 2.7659.274.0 Rear PTO control switch 40-981 40-1238
40-202 40-1238
I005 2.7659.278.0 Rear PTO control switch 40-1138 40-1221
40-990 40-1205

Fig. 2185
I006 2.7659.177.0/20 LH rear PTO control switch Resistance between Pin 1 and 40-990 40-1205
(on fender) Pin 2 with button pressed: 3.9 40-1138 40-1221
Ohms
Table 336
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I007 2.7659.177.0/20 Rh rear PTO control switch Resistance between Pin 1 and 40-1138 40-1221
(on fender) Pin 2 with button pressed: 3.9 40-990 40-1205
Ohms
I008 2.7659.271.0 Road lights switch 40-812 40-1238
40-1167 40-1221
40-958 40-1221
40-503 40-1221
40-1138 40-1221

Fig. 2185
I008 2.7659.271.0 Road lights switch 40-981 40-1238
40-951 40-1238
40-910 40-1238
40-489 40-1238
40-202 40-1238
40-1030 40-1238
40-527 40-1238

Fig. 2185
I008 2.7659.271.0 Road lights switch 40-382 40-1238
40-342 40-1238
40-397 40-1221
40-535 40-1221
40-770 40-1238
40-354 40-1205
40-990 40-1205

Fig. 2185

40-141
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I008 2.7659.271.0 Road lights switch 40-315 40-1221
40-958 40-1205
40-1079 40-1221
40-503 40-1205
40-535 40-1205
40-783 40-1205
40-922 40-1205
40-315 40-1205
40-826 40-1205
Fig. 2185

Table 337
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I008 2.7659.271.0 Road lights switch 40-1043 40-1205
40-1109 40-1221
40-922 40-1221
40-354 40-1221
40-397 40-1205

Fig. 2185
I009 2.7659.283.0/10 Upper worklights switch 40-1109 40-1221
40-770 40-1238
40-783 40-1205
40-1079 40-1221
40-826 40-1205
40-812 40-1238
I010 2.7659.152.0/10 Differential lock control 40-958 40-1205
switch 40-958 40-1221
40-951 40-1238

Fig. 2185
I011 2.7659.097.0 Clutch pedal switch 40-229 40-1205
1

Fig. 2185
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I011 2.7659.097.0 Clutch pedal switch 40-229 40-1221
1

Fig. 2185
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)

40-142
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I011 2.7659.097.0 Clutch pedal switch 40-202 40-1238
1

Fig. 2185
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I012 2.7659.150.0 Lower front worklights 0 40-503 40-1221
switch 1 40-489 40-1238
40-503 40-1205

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2185
I013 2.7659.097.0 Brake pedal switch 40-1043 40-1205
1

Fig. 2185
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)

40-143
 Wiring diagrams
Table 338
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I013 2.7659.097.0 Brake pedal switch 40-1030 40-1238
1

Fig. 2185
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I016 2.7659.158.0 Hazard warning lights 0
1
40-826 40-1205
switch
5 17
18
10
40-783 40-1205
40-1079 40-1221
8 1 2 3
5 1 7 18

Pos
Pin 1 2 3 5 8 10 17 18
40-1109 40-1221
40-812 40-1238
0

1 40-770 40-1238

Fig. 2185
I017 Parking brake switch 40-1030 40-1238
I018 0.015.0485.4 Starter switch 40-868 40-1221
40-202 40-1238
83 40-868 40-1205
50
86s
30
40-229 40-1205
75 15
40-866 40-1238
40-229 40-1221

Pin 30 15 50 75 83
Pos

2
D0010060

Fig. 2185
I020 2.7659.343.0/10 Start enable switch (trans- 40-229 40-1212
mission in neutral) 40-202 40-1233
I021 2.7659.096.0/10 Groundpseed PTO en- 40-990 40-1212
gagement switch
CB A

Fig. 2185
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 2 and pin 3: normally
open contact (NO)
I021 2.7659.096.0/10 Groundpseed PTO en- 40-981 40-1233
gagement switch
CB A

Fig. 2185
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 2 and pin 3: normally
open contact (NO)

40-144
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I021 2.7659.096.0/10 Groundpseed PTO en- 40-1138 40-1212
gagement switch

CB A
Fig. 2185
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 2 and pin 3: normally
open contact (NO)
I023 2.7659.202.0 P.T.O. engagement switch Between pin 2 and pin 3: normally 40-1138 40-1212
ECO closed contact (NC)
Between pin 1 and pin 4: normally
open contact (NO)
With switch free of levers
Table 339
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I023 2.7659.202.0 P.T.O. engagement switch Between pin 2 and pin 3: normally 40-990 40-1212
ECO closed contact (NC)
Between pin 1 and pin 4: normally
open contact (NO)
With switch free of levers
I024 2.7659.078.0 Front worklights switch 0 40-436 40-1242
1

Pin 1 2
Pos

Fig. 2185
I024 2.7659.154.0 Front worklights switch 0 40-489 40-1204
1 40-503 40-1204
40-527 40-1204
40-535 40-1204
7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2185
I024 2.7659.078.0 Front worklights switch 0 40-464 40-1242
40-456 40-1242
1
40-428 40-1228
1
40-456 40-1228
2 40-428 40-1242
40-464 40-1228
40-436 40-1228
Pin 1 2
Pos

Fig. 2185

40-145
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I025 2.7659.126.0 Rotating beacon switch 0 40-304 40-1228
40-315 40-1228
1

Pin 1 2
Pos

Fig. 2185
I025 2.7659.159.0 Rotating beacon switch 0 40-354 40-1204
1
40-342 40-1204
7

8
2 3
7 4 5 6

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2185
I025 2.7659.126.0 Rotating beacon switch 0 40-315 40-1242
40-304 40-1242
1

Pin 1 2
Pos

Fig. 2185
I026 2.7659.079.0 Rear worklights switch 0 40-436 40-1242
1

Pin 1 2
Pos

Fig. 2185
I026 2.7659.155.0 Rear worklights switch 0 40-527 40-1204
1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2185

40-146
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I026 2.7659.079.0 Rear worklights switch 0 40-428 40-1242
1

Pin 1 2
Pos

Fig. 2185

Table 340
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I026 2.7659.155.0 Rear worklights switch 0 40-535 40-1204
1 40-503 40-1204

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2185
I026 2.7659.079.0 Rear worklights switch 0 40-464 40-1242
40-456 40-1228
1
40-464 40-1228
1
40-436 40-1228
2 40-428 40-1228

Pin 1 2
Pos

Fig. 2185
I026 2.7659.155.0 Rear worklights switch 0 40-489 40-1204
1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2185

40-147
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I026 2.7659.079.0 Rear worklights switch 0 40-456 40-1242
1

Pin 1 2
Pos

Fig. 2185
I027 2.7659.091.0 Windscreen washer pump 0 40-890 40-1242
switch 1

1
2
4
Pin 1 2
Pos

Fig. 2185
I027 2.7659.223.0/10 Windscreen washer pump 40-922 40-1204
switch

Fig. 2185
I027 2.7659.091.0 Windscreen washer pump 0 40-881 40-1242
switch 1
40-881 40-1228
40-890 40-1228
3

1
2
4

Pin 1 2
Pos

Fig. 2185
I027 2.7659.223.0/10 Windscreen washer pump 40-910 40-1204
switch

Fig. 2185

40-148
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
I028 2.7659.092.0 Windscreen wiper switch 1
0 40-881 40-1228
2
40-890 40-1228
40-881 40-1242
1 2 3 4 40-890 40-1242
5 6 7 8
40-922 40-1204
40-910 40-1204
Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2185
I029 2.7659.224.0/10 Rear screen wiper switch 40-922 40-1204
40-910 40-1204

Fig. 2185
I030 0.015.5549.4/10 A/C activation switch 40-737 40-1204
40-719 40-1204

40-149
 Wiring diagrams
40.2.24 - J - Relays (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)

MF5
40A FT1-2-3 B029
MF4
40A START B028

PK1 PK2
+15
START FAN SPEED J008 J009
COMPRESSOR
MU1

MU4

RELAY
B030
COMPRESSOR

30A
MK3
FT 5-6-7-8

FAN SPEED
RELAY

B025

B026

B027
MK1

20 A B032
30A
30A

30A

POWER
B031 B033
MU6
MU3

30A +15
MF1

20 A
MK3 MF3

SOCKET
MK1

+15 +15
HI/LO J002 J003 J004
F14-15 F11-12-13

+15 ROOF +15

FAN SPEED J005 J006 J007
MK4

MK6

FT5.6.7.8 MU6
M11

B006 B016

B010 B020
B011 B021
B005 B015

B009 B019

B012 B022
B013 B023
STOLL SOCKET

B007 B017
B008 B018

B014 B024
RELAY

L R
+15 +15 +15 +15 +15 +15 +15 +15
M20

7.5A 7.5A 7.5 A 10A 3A 15 A 15 A 7.5 A 7.5 A 15 A

COMPRESSOR

STOP(EU)
STOP +30
+15 +30 +30 USA +30 +30 +30
10 A 7.5 A 20 A 15 A 15 A 5A 7.5A 15 A 15 A 15 A
M1

M10

D0063290

Fig. 2186 - Fusebox

Table 341
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J001 2.7659.240.0/10 Preheating relay 40-175 40-1234
40-175 40-1236
2.7659.240.0/10 Preheating relay 40-175 40-1194
2.7659.240.0/10 Preheating relay 40-175 40-1194
J002 Relay 40-515 40-1221
40-445 40-1221
40-1153 40-1221
40-934 40-1221
40-410 40-1221
40-473 40-1221
40-515 40-1209
40-934 40-1209
40-445 40-1209
40-410 40-1209
J002 Relay 40-473 40-1209
40-1016 40-1209

40-150
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J003 Relay 40-934 40-1221
40-934 40-1209
J004 Relay 40-515 40-1221
40-290 40-1209
40-700 40-1209
40-410 40-1209
40-567 40-1209
40-327 40-1221
40-369 40-1221
40-1153 40-1221
40-410 40-1221
40-543 40-1221
J004 Relay 40-898 40-1221
40-473 40-1209
40-797 40-1209
Table 342
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J004 Relay 40-445 40-1221
40-1016 40-1209
40-647 40-1209
40-898 40-1209
40-327 40-1209
40-543 40-1209
40-445 40-1209
40-593 40-1209
40-966 40-1209
40-1064 40-1221
J004 Relay 40-870 40-1209
40-567 40-1221
40-755 40-1209
40-934 40-1209
40-369 40-1209
40-515 40-1209
40-1123 40-1221
40-700 40-1221
40-290 40-1221
40-593 40-1221
J004 Relay 40-473 40-1221
40-934 40-1221
40-870 40-1221
40-1094 40-1221
40-647 40-1221
J005 Relay 40-515 40-1209
40-410 40-1221
40-445 40-1221
40-515 40-1221
40-473 40-1221
40-898 40-1221

40-151
 Wiring diagrams
Table 343
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J005 Relay 40-870 40-1221
40-898 40-1209
40-290 40-1221
40-410 40-1209
40-473 40-1209
40-290 40-1209
40-870 40-1209
40-445 40-1209
J006 Relay 40-1153 40-1221
40-934 40-1209
40-934 40-1221
40-1016 40-1209
J007 Relay 40-700 40-1221
40-647 40-1221
40-543 40-1221
40-593 40-1221
40-567 40-1221
40-700 40-1209
40-593 40-1209
40-567 40-1209
40-543 40-1209
40-647 40-1209
J008 Relay 40-175 40-1209
40-700 40-1209
40-175 40-1221
40-700 40-1221
J009 Relay 40-700 40-1221
40-567 40-1221
40-567 40-1209
40-700 40-1209
J010 Max. fan speed relay 40-700 40-1204
40-567 40-1204
Table 344
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J011 Compressor and A/C 1st 40-700 40-1204
speed start relay
J012 3rd fan speed relay 40-700 40-1204
40-567 40-1204
J013 Compressor relay 40-593 40-1183
40-647 40-1183
J014 Control relay for air condi- 40-700 40-1215
tioning cooler fan
J014 Control relay for air condi- 40-647 40-1217
tioning cooler fan
J014 2.7659.101.0 Control relay for air condi- 40-593 40-1180
tioning cooler fan
J015 Control relay for auxiliary 40-647 40-1217
air conditioning cooler fan 40-700 40-1215

40-152
Wiring diagrams
40.2.25 - J - Relays (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

MF5
40A FT1-2-3 B029
MF4
40A START B028

PK1 PK2
+15
START FAN SPEED J008 J009
COMPRESSOR
MU1

MU4

RELAY
B030
COMPRESSOR

30A
MK3
FT 5-6-7-8

FAN SPEED
RELAY

B025

B026

B027
MK1

20 A B032
30A
30A

30A

POWER
B031 B033
MU6
MU3

30A +15
MF1

20 A
MK3 MF3

SOCKET
MK1

+15 +15
HI/LO J002 J003 J004
F14-15 F11-12-13

+15 ROOF +15

FAN SPEED J005 J006 J007
MK4

MK6

FT5.6.7.8 MU6
M11

B006 B016

B010 B020
B011 B021
B005 B015

B009 B019

B012 B022
B013 B023
STOLL SOCKET

B007 B017
B008 B018

B014 B024
RELAY

L R
+15 +15 +15 +15 +15 +15 +15 +15
M20

7.5A 7.5A 7.5 A 10A 3A 15 A 15 A 7.5 A 7.5 A 15 A

COMPRESSOR

STOP(EU)
STOP +30
+15 +30 +30 USA +30 +30 +30
10 A 7.5 A 20 A 15 A 15 A 5A 7.5A 15 A 15 A 15 A
M1

M10

D0063290

Fig. 2186 - Fusebox - version with digital instrument panel

40-153
 Wiring diagrams

MF5
40A FT1-2-3 B029
MF4
40A START B028

PK1 PK2
+15
START FAN SPEED J008 J009
COMPRESSOR
MU1

MU4

30A
RELAY
MK3
COMPRESSOR B030
FT 5-6-7-8

FAN SPEED
RELAY

B025

B026

B027
MK1

20 A B032
30A
30A

30A

POWER
B031 B033
MU6
MU3

30A +15
MF1

20 A
MK3 MF3

SOCKET
MK1

+15 +15
J002 J004
F14-15 F11-12-13

+15 ROOF +15

FAN SPEED J005 J007
MK4

MK6

FT5.6.7.8 MU6
M11

B016

B010 B020
B011 B021
B005 B015

B009 B019

B012 B022
B013 B023
+15 EV STOLL SOCKET

B007 B017
B008 B018

B014 B024
RELAY
EU
L R
+15 +15 +15 +15 +15 +15
M20

7.5A 7.5A 7.5 A 10A 3A 15 A 15 A 7.5 A 7.5 A 15 A

COMPRESSOR

STOP

+30 +30 +30 +30

10 A 20 A 15 A 15 A 15 A 15 A 15 A
M1

M10

D0064740

Fig. 2186 - Fusebox - version with analog instrument panel

Table 345
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J001 2.7659.240.0/10 Preheating relay 40-202 40-1234
40-202 40-1236
40-229 40-1236
40-229 40-1234
2.7659.240.0/10 Preheating relay 40-229 40-1194
40-202 40-1194
2.7659.240.0/10 Preheating relay 40-229 40-1194
40-202 40-1194
J002 Relay 40-1030 40-1238
40-981 40-1238
40-489 40-1238
40-527 40-1238
40-1167 40-1221
40-535 40-1221
40-535 40-1205
40-1043 40-1205
40-503 40-1205

40-154
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J002 Relay 40-503 40-1221
40-951 40-1238
J004 Relay 40-737 40-1221
40-611 40-1238
40-503 40-1221
40-436 40-1221
40-682 40-1221
40-585 40-1221
40-559 40-1221
40-629 40-1221
40-464 40-1221
40-958 40-1221
Table 346
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J004 Relay 40-1030 40-1238
40-719 40-1238
40-1079 40-1221
40-382 40-1238
40-342 40-1238
40-456 40-1238
40-304 40-1238
40-881 40-1238
40-981 40-1238
40-489 40-1238
J004 Relay 40-812 40-1238
40-397 40-1221
40-951 40-1238
40-585 40-1205
40-577 40-1238
40-770 40-1238
40-428 40-1238
40-315 40-1205
40-826 40-1205
40-990 40-1205
J004 Relay 40-503 40-1205
40-890 40-1205
40-783 40-1205
40-559 40-1205
40-629 40-1205
40-922 40-1205
40-354 40-1205
40-535 40-1205
40-1043 40-1205
Table 347
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J004 Relay 40-922 40-1221
40-958 40-1205
40-354 40-1221
40-737 40-1205
40-397 40-1205
40-682 40-1205
40-910 40-1238
40-464 40-1205
40-552 40-1238
40-1138 40-1221

40-155
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J004 Relay 40-535 40-1221
40-1167 40-1221
40-1109 40-1221
40-890 40-1221
40-315 40-1221
40-436 40-1205
40-527 40-1238
40-664 40-1238
J005 Relay 40-535 40-1221
40-489 40-1238
40-527 40-1238
40-456 40-1238
40-910 40-1238
40-881 40-1238
40-304 40-1238
Table 348
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J005 Relay 40-464 40-1221
40-503 40-1221
40-315 40-1221
40-436 40-1205
40-315 40-1205
40-428 40-1238
40-922 40-1205
40-890 40-1221
40-503 40-1205
40-890 40-1205
J005 Relay 40-535 40-1205
40-436 40-1221
40-922 40-1221
40-464 40-1205
J007 Relay 40-629 40-1221
40-664 40-1238
40-611 40-1238
40-719 40-1238
40-552 40-1238
40-577 40-1238
40-559 40-1221
40-737 40-1221
40-585 40-1221
40-585 40-1205
J007 Relay 40-629 40-1205
40-737 40-1205
40-682 40-1205
40-559 40-1205
40-682 40-1221
Table 349
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J008 Relay 40-229 40-1221
40-719 40-1238
40-737 40-1221
40-229 40-1205
40-737 40-1205
40-202 40-1238

40-156
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J009 Relay 40-585 40-1205
40-737 40-1205
40-737 40-1221
40-585 40-1221
40-577 40-1238
40-719 40-1238
J010 Max. fan speed relay 40-577 40-1204
40-585 40-1204
40-737 40-1204
40-719 40-1204
J011 Compressor and A/C 1st 40-737 40-1204
speed start relay 40-719 40-1204
J012 3rd fan speed relay 40-719 40-1204
40-737 40-1204
40-585 40-1204
40-577 40-1204
J013 Compressor relay 40-611 40-1183
40-629 40-1183
40-664 40-1183
40-682 40-1183
J014 2.7659.101.0 Control relay for air condi- 40-611 40-1180
tioning cooler fan 40-682 40-1217
40-664 40-1217

Table 350
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
J014 Control relay for air condi- 40-737 40-1215
tioning cooler fan 40-719 40-1215
J014 2.7659.101.0 Control relay for air condi- 40-629 40-1180
tioning cooler fan
J015 Control relay for auxiliary 40-719 40-1215
air conditioning cooler fan 40-664 40-1217
40-682 40-1217
40-737 40-1215

40.2.26 - K - Sensors and transmitters (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO
85 -> 20001)
Table 351
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K001 2.7099.320.0/10 Air cleaner clogged sensor Normally open contact 40-369 40-1236
Switching pressure: 0.93 to 0.94
bar absolute pressure
K001 2.7099.320.0/10 Air cleaner clogged sensor Normally open contact 40-369 40-1234
Switching pressure: 0.93 to 0.94
bar absolute pressure
K002 0.257.6654.3/10 Brake fluid level sensor 40-1016 40-1234
40-1153 40-1234
40-1153 40-1236
40-1016 40-1236
K003 01182792 Engine oil pressure switch 40-369 40-1234
40-369 40-1236
K004 Engine temperature sen- 40-369 40-1234
sor 40-369 40-1236

40-157
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K005 04429390/10 Hand throttle position sen- Sensor N°1 40-254 40-1209
sor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K005 04429390/10 Hand throttle position sen- Sensor N°1 40-254 40-1221
sor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
Table 352
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K006 04429390/10 Accelerator pedal position Sensor N°1 40-254 40-1221
sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K006 04429390/10 Accelerator pedal position Sensor N°1 40-254 40-1209
sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K007 Operator present sensor 40-934 40-1209
40-934 40-1221
K008 2.7099.670.0/10 Park Brake pressure brake Normally open contact (NO) 40-1016 40-1209
Switching pressure: 15 bar
K008 2.7099.670.0/10 Park Brake pressure brake Normally open contact (NO) 40-1153 40-1221
Switching pressure: 15 bar
K009 2.7099.660.0/10 Transmission oil filter clog- Normally open contact 40-934 40-1214
ging pressure switch Calibration pressure: 0.5 to 0.4
bar absolute pressure
K010 2.7099.996.0 Wheels speed sensor This cannot be checked using an 40-934 40-1214
ordinary tester; use the ART.
K011 2.7099.750.0/10 Services circuit alarm Normally closed (NC) contact 40-369 40-1214
Switching pressure: 11 bar ± 1
K012 0.010.1214.4 Rear PTO speed sensor Pin 1 = earth 40-1123 40-1214
(USA version) Pin 2 = analog signal:
0 Volt with sensor covered by
metal
12 Volt with sensor exposed
Pin 3 = 12 V power input
Table 353
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K013 2.7099.960.0 Hydraulic trailer braking Normally closed (NC) contact 40-1016 40-1214
Switching pressure: 11 bar

40-158
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K013 2.7099.960.0 Hydraulic trailer braking Normally closed (NC) contact 40-1153 40-1214
Switching pressure: 11 bar
K014 2.7059.836.0 Fuel level sensor Resistance between pin 2 and pin 40-369 40-1214
3:
with tank full: 5.25 ± 1.25 Ohm
with tank half full:105.50 ± 6 Ohm
with tank empty: 332.75 ± 17.25
Ohm
K015 Engine speed sensor 40-934 40-1201
K016 2.7099.996.0 Shuttle sensor This cannot be checked using an 40-934 40-1201
ordinary tester; use the ART.
K017 2.7099.800.0 Oil temperature sensor Resistance between pins 1 and 2 40-934 40-1201
at 0±1 °C: 7351 Ohms
at 20±1 °C: 2812 Ohms
at 40±1 °C: 1199 Ohms
at 60±1 °C: 560.2 Ohms
at 80±1 °C: 283.2 Ohms
K018 2.7099.690.0/10 Clutch oil pressure switch Normally closed (NC) contact 40-934 40-1201
Switching pressure: 4 bar
K019 2.7099.700.0 PALL filter clogging sensor Normally open contact (NO) 40-934 40-1201
Differential switching pressure:
2.4 bar
Reset pressure: 1.8 bar
K020 2.7099.740.0/10 Clutch pedal position sen- Pin 1 = power (Nominal 5.0V) 40-934 40-1195
sor Pin 2 = earth
Pin 4 = analog signal
K021 Air conditioning tempera- 40-700 40-1204
ture thermostat
K022 0.009.4744.1 Air conditioning tempera- 40-593 40-1183
ture thermostat 40-647 40-1183
K023 0.010.2262.0 Air conditioning pressure 40-647 40-1217
switch 40-700 40-1215
K023 0.900.0304.1 Air conditioning pressure 40-593 40-1180
switch

40-159
 Wiring diagrams
Table 354
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K024 0.900.0304.1 Air conditioning pressure 40-593 40-1180
switch
K025 0.011.9428.0 Compressed air pressure Power 12V DC 40-1153 40-1191
sensor Resistance at 0 bar 10-13 Ohm
Resistance at 6 bar 119-129 Ohm
K025 0.011.9428.0 Compressed air pressure Power 12V DC 40-1016 40-1191
sensor Resistance at 0 bar 10-13 Ohm
Resistance at 6 bar 119-129 Ohm
K026 04213839 Engine coolant tempera- 40-254 40-1249
ture sensor
K028 04213838 Turbine air temperature/ 40-254 40-1249
pressure sensor
K031 01182834 Camshaft speed sensor 40-254 40-1249
K032 04213839 Fuel temperature sensor 40-254 40-1249

40.2.27 - K - Sensors and senders (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001)
Table 355
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K001 2.7099.320.0/10 Air cleaner clogged sensor Normally open contact 40-382 40-1234
Switching pressure: 0.93 to 0.94 40-397 40-1236
bar absolute pressure
2.7099.320.0/10 Air cleaner clogged sensor Normally open contact 40-382 40-1236
Switching pressure: 0.93 to 0.94 40-397 40-1234
bar absolute pressure
K002 0.257.6654.3/10 Brake fluid level sensor 40-1030 40-1236
40-1043 40-1234
40-1167 40-1234
40-1030 40-1234
40-1167 40-1236
40-1043 40-1236
K003 01182792 Engine oil pressure switch 40-397 40-1236
40-382 40-1236
40-382 40-1234
40-397 40-1234
K004 Engine temperature sen- 40-382 40-1234
sor 40-397 40-1234
40-382 40-1236
40-397 40-1236
Table 356
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K005 04429390/10 Hand throttle position sen- Sensor N°1 40-283 40-1221
sor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K005 04429390/10 Hand throttle position sen- Sensor N°1 40-276 40-1238
sor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal

40-160
Wiring diagrams
Table 357
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K005 04429390/10 Hand throttle position sen- Sensor N°1 40-283 40-1205
sor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K006 04429390/10 Accelerator pedal position Sensor N°1 40-283 40-1205
sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
Table 358
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K006 04429390/10 Accelerator pedal position Sensor N°1 40-283 40-1221
sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K006 04429390/10 Accelerator pedal position Sensor N°1 40-276 40-1238
sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
Table 359
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K009 2.7099.660.0/10 Transmission oil filter clog- Normally open contact 40-958 40-1212
ging pressure switch Calibration pressure: 0.5 to 0.4 40-951 40-1233
bar absolute pressure
K011 2.7099.750.0/10 Services circuit alarm Normally closed (NC) contact 40-397 40-1212
pressure switch Switching pressure: 11 bar ± 1 40-382 40-1233
K012 0.010.1214.4 Rear PTO speed sensor Pin 1 = earth 40-1138 40-1212
(USA version) Pin 2 = analog signal:
0 Volt with sensor covered by
metal
12 Volt with sensor exposed
Pin 3 = 12 V power input
K013 2.7099.960.0 Hydraulic trailer braking Normally closed (NC) contact 40-1030 40-1233
Switching pressure: 11 bar
K013 2.7099.960.0 Hydraulic trailer braking Normally closed (NC) contact 40-1043 40-1212
Switching pressure: 11 bar
K013 2.7099.960.0 Hydraulic trailer braking Normally closed (NC) contact 40-1167 40-1212
Switching pressure: 11 bar

40-161
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K014 2.7059.836.0 Fuel level sensor Resistance between pin 2 and pin 40-397 40-1212
3:
with tank full: 5.25 ± 1.25 Ohm
with tank half full:105.50 ± 6 Ohm
with tank empty: 332.75 ± 17.25
Ohm
K014 2.7059.836.0 Fuel level sensor Resistance between pin 2 and pin 40-382 40-1233
3:
with tank full: 5.25 ± 1.25 Ohm
with tank half full:105.50 ± 6 Ohm
with tank empty: 332.75 ± 17.25
Ohm
K021 Air conditioning tempera- 40-737 40-1204
ture thermostat 40-719 40-1204
K022 0.009.4744.1 Air conditioning tempera- 40-629 40-1183
ture thermostat 40-664 40-1183
40-682 40-1183
40-611 40-1183
Table 360
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K023 0.900.0304.1 Air conditioning pressure 40-629 40-1180
switch 40-611 40-1180
K023 0.010.2262.0 Air conditioning pressure 40-664 40-1217
switch 40-682 40-1217
40-737 40-1215
40-719 40-1215
K024 0.900.0304.1 Air conditioning pressure 40-629 40-1180
switch 40-611 40-1180
K025 0.011.9428.0 Compressed air pressure Power 12V DC 40-1167 40-1191
sensor Resistance at 0 bar 10-13 Ohm 40-1043 40-1191
Resistance at 6 bar 119-129 Ohm 40-1030 40-1191
K026 04213839 Engine coolant tempera- 40-276 40-1248
ture sensor 40-283 40-1248
K028 04213838 Turbine air temperature/ 40-276 40-1248
pressure sensor 40-283 40-1248
K031 01182834 Camshaft speed sensor 40-276 40-1248
40-283 40-1248
K032 04213839 Fuel temperature sensor 40-283 40-1248
40-276 40-1248

40.2.28 - K - Sensors and transmitters (R3 EVO 85 -> 16001)

Table 361
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K001 2.7099.320.0/10 Air cleaner clogged sensor Normally open contact 40-382 40-1234
Switching pressure: 0.93 to 0.94 40-397 40-1236
bar absolute pressure
2.7099.320.0/10 Air cleaner clogged sensor Normally open contact 40-382 40-1236
Switching pressure: 0.93 to 0.94 40-397 40-1234
bar absolute pressure
K002 0.257.6654.3/10 Brake fluid level sensor 40-1030 40-1236
40-1043 40-1234
40-1167 40-1234
40-1030 40-1234
40-1167 40-1236
40-1043 40-1236

40-162
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K003 01182792 Engine oil pressure switch 40-397 40-1236
40-382 40-1236
40-382 40-1234
40-397 40-1234
K004 Engine temperature sen- 40-382 40-1234
sor 40-397 40-1234
40-382 40-1236
40-397 40-1236
Table 362
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K005 04429390/10 Hand throttle position sen- Sensor N°1 40-261 40-1238
sor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K005 04429390/10 Hand throttle position sen- Sensor N°1 40-269 40-1221
sor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
Table 363
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K005 04429390/10 Hand throttle position sen- Sensor N°1 40-269 40-1205
sor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K006 04429390/10 Accelerator pedal position Sensor N°1 40-269 40-1205
sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
Table 364
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K006 04429390/10 Accelerator pedal position Sensor N°1 40-269 40-1221
sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal

40-163
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K006 04429390/10 Accelerator pedal position Sensor N°1 40-261 40-1238
sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
Table 365
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K009 2.7099.660.0/10 Transmission oil filter clog- Normally open contact 40-958 40-1212
ging pressure switch Calibration pressure: 0.5 to 0.4 40-951 40-1233
bar absolute pressure
K011 2.7099.750.0/10 Services circuit alarm Normally closed (NC) contact 40-397 40-1212
pressure switch Switching pressure: 11 bar ± 1 40-382 40-1233
K012 0.010.1214.4 Rear PTO speed sensor Pin 1 = earth 40-1138 40-1212
(USA version) Pin 2 = analog signal:
0 Volt with sensor covered by
metal
12 Volt with sensor exposed
Pin 3 = 12 V power input
K013 2.7099.960.0 Hydraulic trailer braking Normally closed (NC) contact 40-1030 40-1233
Switching pressure: 11 bar
K013 2.7099.960.0 Hydraulic trailer braking Normally closed (NC) contact 40-1043 40-1212
Switching pressure: 11 bar
K013 2.7099.960.0 Hydraulic trailer braking Normally closed (NC) contact 40-1167 40-1212
Switching pressure: 11 bar
K014 2.7059.836.0 Fuel level sensor Resistance between pin 2 and pin 40-397 40-1212
3:
with tank full: 5.25 ± 1.25 Ohm
with tank half full:105.50 ± 6 Ohm
with tank empty: 332.75 ± 17.25
Ohm
K014 2.7059.836.0 Fuel level sensor Resistance between pin 2 and pin 40-382 40-1233
3:
with tank full: 5.25 ± 1.25 Ohm
with tank half full:105.50 ± 6 Ohm
with tank empty: 332.75 ± 17.25
Ohm
K021 Air conditioning tempera- 40-737 40-1204
ture thermostat 40-719 40-1204
K022 0.009.4744.1 Air conditioning tempera- 40-629 40-1183
ture thermostat 40-664 40-1183
40-682 40-1183
40-611 40-1183

Table 366
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K023 0.900.0304.1 Air conditioning pressure 40-629 40-1180
switch 40-611 40-1180
K023 0.010.2262.0 Air conditioning pressure 40-664 40-1217
switch 40-682 40-1217
40-737 40-1215
40-719 40-1215
K024 0.900.0304.1 Air conditioning pressure 40-629 40-1180
switch 40-611 40-1180

40-164
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
K025 0.011.9428.0 Compressed air pressure Power 12V DC 40-1167 40-1191
sensor Resistance at 0 bar 10-13 Ohm 40-1043 40-1191
Resistance at 6 bar 119-129 Ohm 40-1030 40-1191
K026 04213839 Engine coolant tempera- 40-261 40-1246
ture sensor 40-269 40-1246
K028 04213838 Turbine air temperature/ 40-261 40-1246
pressure sensor 40-269 40-1246
K031 01182834 Camshaft speed sensor 40-261 40-1246
40-269 40-1246

40.2.29 - L - Electromagnets and solenoid valves (R3 EVO 100 -> 20001, R3 EVO 110 ->
1001, R3 EVO 85 -> 20001)
Table 367
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
L001 0.900.1130.7 Differential lock control so- 40-934 40-1214
lenoid valve
L002 0.900.1130.7 4WD control solenoid 40-934 40-1214
valve
L003 2.3729.250.0/60 Rear PTO control solenoid Pin 1 = earth 40-1123 40-1214
valve Pin 2 = power
Impedance between Pin1 and
Pin2: ~ 8 Ohm (at 20 °C)
L003 2.3729.250.0/60 Rear PTO control solenoid Pin 1 = earth 40-966 40-1214
valve Pin 2 = power
Impedance between Pin1 and
Pin2: ~ 8 Ohm (at 20 °C)
L004 0.900.1130.7 Hi/Lo drive control sole- 40-934 40-1214
noid valve
L005 2.3729.400.0/20 Front PTO control sole- 40-966 40-1180
noid valve
L005 2.3729.400.0/20 Front PTO control sole- 40-1123 40-1180
noid valve
L006 0.900.0532.1 Forward gear selection so- 40-934 40-1201
lenoid
L007 0.900.0532.1 Reverse gear selection so- 40-934 40-1201
lenoid
L008 0.900.1130.7 Solenoid-operated propor- 40-934 40-1201
tional valve
L009 2.3729.714.0/30 Trailer parking brake con- Pin 1 = power 40-1153 40-1232
trol solenoid valve Pin 2 = earth
Impedance between Pin1 and
Pin2: ~ 8 Ohm (at 20 °C)
L009 2.3729.714.0/30 Trailer parking brake con- Pin 1 = power 40-1016 40-1232
trol solenoid valve Pin 2 = earth
Impedance between Pin1 and
Pin2: ~ 8 Ohm (at 20 °C)

40.2.30 - L - Electromagnets and solenoid valves (R3 EVO 100 -> 16001, R3 EVO 110 ->
5001, R3 EVO 85 -> 16001)
Table 368
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
L001 0.900.1130.7 Differential lock control so- 40-951 40-1233
lenoid valve 40-958 40-1212

40-165
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
L003 2.3729.250.0/60 Rear PTO control solenoid Pin 1 = earth 40-981 40-1233
valve Pin 2 = power 40-990 40-1212
Impedance between Pin1 and 40-1138 40-1212
Pin2: ~ 8 Ohm (at 20 °C)
L005 2.3729.400.0/20 Front PTO control sole- 40-981 40-1180
noid valve 40-990 40-1180
40-1138 40-1180

40.2.31 - M - Electrical/electronic devices, flasher units and timers (R3 EVO 100 -> 20001,
R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
Table 369
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
M001 Engine ECU 40-254 40-1209
40-175 40-1209
40-254 40-1221
40-175 40-1221
M002 Engine ECU 40-175 40-1221
40-254 40-1209
40-290 40-1209
40-175 40-1209
40-1003 40-1209
40-254 40-1221
40-290 40-1221
40-1003 40-1221
40-327 40-1221
40-327 40-1209
M003 2.8519.057.0/10 Rear PTO ECU 40-966 40-1209
40-1123 40-1221
M004 2.8639.007.0/10 Hazard warning lights 40-797 40-1209
ECU 40-755 40-1209
M004 2.8639.012.0 Hazard warning lights 40-1064 40-1221
ECU 40-1094 40-1221
M005 2.8639.008.0 Windscreen wiper intermit- 40-898 40-1204
tent timer 40-870 40-1226
40-870 40-1244

40.2.32 - M - Electrical/electronic devices, flasher units and timers (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001)
Table 370
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
M001 02959599 Engine control unit 40-276 40-1238
40-202 40-1238
40-229 40-1221
40-283 40-1221
40-229 40-1205
40-283 40-1205
M002 02959599 Engine control unit 40-354 40-1221
40-229 40-1205
40-354 40-1205
40-283 40-1205
40-1012 40-1205
40-283 40-1221
40-229 40-1221

40-166
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
M002 02959599 Engine control unit 40-315 40-1205
40-1012 40-1221
40-342 40-1238
40-276 40-1238
40-1008 40-1238
40-202 40-1238
40-304 40-1238
40-315 40-1221
Table 371
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
M003 2.8519.057.0/10 Rear PTO ECU 40-990 40-1205
40-1138 40-1221
M004 2.8639.007.0/10 Hazard warning lights 40-783 40-1205
ECU 40-812 40-1238
40-770 40-1238
40-826 40-1205
M004 2.8639.012.0 Hazard warning lights 40-1109 40-1221
ECU 40-1079 40-1221
M005 2.8639.008.0 Windscreen wiper intermit- 40-910 40-1204
tent timer 40-890 40-1228
40-881 40-1228
40-890 40-1242
40-881 40-1242
40-922 40-1204

40.2.33 - M - Electrical/electronic devices, flasher units and timers (R3 EVO 85 -> 16001)
Table 372
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
M001 02959599 Engine control unit 40-202 40-1238
40-261 40-1238
40-269 40-1221
40-229 40-1221
40-269 40-1205
40-229 40-1205
M002 02959599 Engine control unit 40-354 40-1221
40-269 40-1221
40-229 40-1205
40-354 40-1205
40-1012 40-1205
40-269 40-1205
40-229 40-1221
M002 02959599 Engine control unit 40-315 40-1205
40-1012 40-1221
40-342 40-1238
40-1008 40-1238
40-202 40-1238
40-261 40-1238
40-304 40-1238
40-315 40-1221
Table 373
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
M003 2.8519.057.0/10 Rear PTO ECU 40-990 40-1205
40-1138 40-1221

40-167
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
M004 2.8639.007.0/10 Hazard warning lights 40-783 40-1205
ECU 40-812 40-1238
40-770 40-1238
40-826 40-1205
M004 2.8639.012.0 Hazard warning lights 40-1109 40-1221
ECU 40-1079 40-1221
M005 2.8639.008.0 Windscreen wiper intermit- 40-910 40-1204
tent timer 40-890 40-1228
40-881 40-1228
40-890 40-1242
40-881 40-1242
40-922 40-1204

40.2.34 - N - Electric motors and actuators (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001,
R3 EVO 85 -> 20001)
Table 374
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
N001 01183677 Starter motor “+30” 40-175 40-1198
40-175 40-1199
40-175 40-1200
40-175 40-1241
N002 01183677 Starter motor “+50” 40-175 40-1234
40-175 40-1236
N003 0.010.3085.0 Windscreen washer pump 40-870 40-1221
40-870 40-1209
40-898 40-1209
40-898 40-1221
N004 0.010.3085.0 Rear screen washer pump 40-898 40-1209
40-898 40-1221
40-870 40-1221
40-870 40-1209
N005 02941435 Rear screen wiper motor 40-898 40-1204
40-870 40-1203
N006 2.9019.200.0/10 Windscreen wiper motor 40-870 40-1185
40-898 40-1186
N007 02113597 Actuator 40-254 40-1249

40.2.35 - N - Electric motors and actuators (R3 EVO 85 -> 16001)

Table 375
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
N001 01183677 Starter motor “+30” 40-229 40-1241
40-202 40-1198
40-229 40-1198
40-202 40-1199
40-229 40-1199
40-229 40-1200
40-202 40-1200
40-202 40-1241
N002 01183677 Starter motor “+50” 40-202 40-1234
40-229 40-1234
40-229 40-1236
40-202 40-1236
N003 0.010.3085.0 Windscreen washer pump 40-910 40-1238
40-890 40-1205
40-922 40-1205
40-881 40-1238
40-922 40-1221
40-890 40-1221

40-168
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
N004 0.010.3085.0 Rear screen washer pump 40-922 40-1205
40-922 40-1221
40-910 40-1238
N005 02941435 Rear screen wiper motor 40-922 40-1204
40-910 40-1204
N006 2.9019.200.0/10 Windscreen wiper motor 40-910 40-1186
40-922 40-1186
40-881 40-1185
40-890 40-1185
N007 02113597 Actuator 40-269 40-1246
40-261 40-1246

40.2.36 - N - Electric motors and actuators (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001)
Table 376
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
N001 01183677 Starter motor “+30” 40-229 40-1241
40-202 40-1198
40-229 40-1198
40-202 40-1199
40-229 40-1199
40-229 40-1200
40-202 40-1200
40-202 40-1241
N002 01183677 Starter motor “+50” 40-202 40-1234
40-229 40-1234
40-229 40-1236
40-202 40-1236
N003 0.010.3085.0 Windscreen washer pump 40-910 40-1238
40-890 40-1205
40-922 40-1205
40-881 40-1238
40-922 40-1221
40-890 40-1221
N004 0.010.3085.0 Rear screen washer pump 40-922 40-1205
40-922 40-1221
40-910 40-1238
N005 02941435 Rear screen wiper motor 40-922 40-1204
40-910 40-1204
N006 2.9019.200.0/10 Windscreen wiper motor 40-910 40-1186
40-922 40-1186
40-881 40-1185
40-890 40-1185
N007 02113597 Actuator 40-276 40-1248
40-283 40-1248

40.2.37 - O - Resistors and rheostats (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO
85 -> 20001)
Table 377
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
O001 Lh resistor 40-567 40-1204
40-700 40-1204
O002 Rh resistor 40-700 40-1204
40-567 40-1204
O003 0.009.9526.2 Resistor 40-593 40-1183
40-647 40-1183
40-543 40-1182

40-169
 Wiring diagrams
40.2.38 - O - Resistors and rheostats (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO
85 -> 16001)
Table 378
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
O001 Lh resistor 40-585 40-1204
40-577 40-1204
40-719 40-1204
40-737 40-1204
O002 Rh resistor 40-577 40-1204
40-719 40-1204
40-585 40-1204
40-737 40-1204
O003 0.009.9526.2 Resistor 40-611 40-1183
40-629 40-1183
40-664 40-1183
40-682 40-1183
40-552 40-1182
40-559 40-1182

40.2.39 - P - Various services (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)
Table 379
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
P001 04437338 Air conditioning compres- 40-647 40-1234
sor 40-593 40-1234
40-593 40-1236
40-647 40-1236
40-700 40-1236
40-700 40-1234
P002 2.6039.020.0 Auxiliary power socket 40-327 40-1209
(25A) 40-290 40-1221
40-290 40-1209
40-327 40-1221
2.6039.020.0 Auxiliary power socket 40-290 40-1221
(25A) 40-290 40-1209
40-327 40-1209
40-327 40-1221
2.6039.020.0 Auxiliary power socket 40-327 40-1221
(25A) 40-290 40-1221
40-290 40-1209
40-327 40-1209
P003 CAN BUS diagnostics 40-1003 40-1209
socket 40-1003 40-1221
P004 2.7099.770.0 Cigar lighter 40-327 40-1209
40-290 40-1209
40-290 40-1221
40-327 40-1221
2.7099.770.0 Cigar lighter 40-290 40-1221
40-327 40-1209
40-290 40-1209
40-327 40-1221
P005 0.900.0307.9 Pneumatic seat compres- 40-327 40-1209
sor 40-290 40-1221
40-327 40-1221
40-290 40-1209

40-170
Wiring diagrams
Table 380
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
P006 2.6030.011.0 Trailer socket 40-1064 40-1214
40-1094 40-1214
40-797 40-1214
40-1016 40-1214
40-755 40-1214
P007 CAN BUS auxiliary socket 40-1003 40-1195
P008 Radio (power supply) 40-290 40-1226
40-290 40-1244
40-327 40-1204
P009 0.011.5631.3 Lh loudspeaker 40-327 40-1204
P010 0.011.5631.3 Rh loudspeaker 40-327 40-1204
P011 Radio (loudspeakers) 40-327 40-1204
P012 0.011.2047.4 Rh fan 40-567 40-1204
40-700 40-1204
P013 0.011.2047.4 Lh fan 40-567 40-1204
40-700 40-1204
P014 0.900.1281.6 Electric fan 40-543 40-1182
40-593 40-1183
40-647 40-1183
P015 0.010.0618.4 Air conditioning condenser 40-593 40-1180
fan 40-647 40-1217
40-700 40-1215
P016 0.010.2545.2 Auxiliary air conditioning 40-700 40-1215
condenser fan 40-647 40-1217

40.2.40 - P - Various services (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)
Table 381
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
P001 04437338 Air conditioning compres- 40-664 40-1236
sor 40-664 40-1234
40-682 40-1236
40-719 40-1236
40-611 40-1236
40-629 40-1236
P001 04437338 Air conditioning compres- 40-737 40-1234
sor 40-629 40-1234
40-611 40-1234
40-719 40-1234
40-682 40-1234
40-737 40-1236
P002 2.6039.020.0 Auxiliary power socket 40-315 40-1205
(25A) 40-354 40-1205
40-315 40-1221
40-354 40-1221
40-304 40-1238
40-342 40-1238
2.6039.020.0 Auxiliary power socket 40-315 40-1221
(25A) 40-342 40-1238
40-304 40-1238
40-354 40-1205
40-315 40-1205
40-354 40-1221

40-171
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
2.6039.020.0 Auxiliary power socket 40-354 40-1205
(25A) 40-315 40-1205
40-315 40-1221
40-354 40-1221
40-342 40-1238
40-304 40-1238
Table 382
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
P003 CAN BUS diagnostics 40-1012 40-1221
socket 40-1008 40-1238
40-1012 40-1205
P004 2.7099.770.0 Cigar lighter 40-315 40-1205
40-315 40-1221
40-354 40-1221
40-354 40-1205
2.7099.770.0 Cigar lighter 40-315 40-1205
40-354 40-1205
40-315 40-1221
40-354 40-1221
P005 0.900.0307.9 Pneumatic seat compres- 40-342 40-1238
sor 40-354 40-1205
40-315 40-1205
40-315 40-1221
40-304 40-1238
40-354 40-1221
P006 2.6030.011.0 Trailer socket 40-1079 40-1212
40-1109 40-1212
40-1043 40-1212
40-783 40-1212
40-826 40-1212
40-1030 40-1233
40-770 40-1233
40-812 40-1233
P008 Radio (power supply) 40-315 40-1228
40-354 40-1204
40-342 40-1204
40-315 40-1242
40-304 40-1228
40-304 40-1242
Table 383
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
P009 0.011.5631.3 Lh loudspeaker 40-342 40-1204
40-354 40-1204
P010 0.011.5631.3 Rh loudspeaker 40-342 40-1204
40-354 40-1204
P011 Radio (loudspeakers) 40-342 40-1204
40-354 40-1204
P012 0.011.2047.4 Rh fan 40-719 40-1204
40-585 40-1204
40-577 40-1204
40-737 40-1204
P013 0.011.2047.4 Lh fan 40-585 40-1204
40-577 40-1204
40-719 40-1204
40-737 40-1204

40-172
Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
P014 0.900.1281.6 Electric fan 40-629 40-1183
40-611 40-1183
40-664 40-1183
40-682 40-1183
40-559 40-1182
40-552 40-1182
P015 0.010.0618.4 Air conditioning condenser 40-629 40-1180
fan 40-664 40-1217
40-682 40-1217
40-737 40-1215
40-719 40-1215
40-611 40-1180
P016 0.010.2545.2 Auxiliary air conditioning 40-719 40-1215
condenser fan 40-664 40-1217
40-682 40-1217
40-737 40-1215

40.2.41 - R - Diagnostics (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
Table 384
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
R001 Diagnostics socket 40-290 40-1221
40-327 40-1221
40-327 40-1209
40-290 40-1209

40.2.42 - R - Diagnostics (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
Table 385
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
R001 Diagnostics socket 40-342 40-1238
40-304 40-1238
40-315 40-1221
40-354 40-1221
40-354 40-1205
40-315 40-1205

40.2.43 - T - Power supply points (+15 o +30) (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001,
R3 EVO 85 -> 20001)
Table 386
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
T001 Battery positive terminal 40-175 40-1241
40-839 40-1241
Battery positive terminal 40-175 40-1194
Battery positive terminal 40-175 40-1236
40-175 40-1234

40.2.44 - T - Power supply points (+15 o +30) (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001,
R3 EVO 85 -> 16001)
Table 387
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
T001 Battery positive terminal 40-856 40-1241
40-202 40-1241
40-848 40-1241
40-229 40-1241

40-173
 Wiring diagrams
Sys- P/N Description Characteristics/notes Link to system Link to wiring
tem
Battery positive terminal 40-202 40-1194
40-229 40-1194
Battery positive terminal 40-229 40-1236
40-202 40-1236
40-229 40-1234
40-202 40-1234

40-174
Wiring diagrams
40.3 - Systems
40.3.1 - S001 - Starting and preheating (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3
EVO 85 -> 20001)

M001
E002 E003 M002
I018 J008 I011

PRE HEATING LAMP

(M3)

START CONSENT
1 0

PREHEATING

H.D.COMAND
GENERATOR
2

-31 ELECTR

-31 ELECTR
+12V(+30)

+12V(+30)

+15

+15
-31

-31
W
75 83 15 50 30 87 85 86 30 15 21 14 8 20 24 13 15 3 3 14 6 2 1 1 2 3 4
B028
40A

C008

C008

C004
B010

B021

C003
10A

B022
5A

7.5A
+15

+15
A001
J001b

J001
J001a
D001

D005

D011
8 14 1 6 5 4
A A A B B
A1 A8 D1 D1 A3
2 1

2 1
B004
B001

125A
60A

I020
C002
T001B
T001a
T001

C001
N001
N002

+30 +30

+30 GND1

BATTERY

D0062850
A004
A002
A003

Fig. 2187 - Starting and preheating - System

l A001 - Preheating device
l A002 - Alternator “B+”
l A003 - Alternator “D+”
l A004 - Alternator “W”
l D001 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D001 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)

40-175
 Wiring diagrams
l D001 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D001 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l E002 - Instrument panel
l E003 - Instrument panel
l I011 - Clutch pedal switch
l IO18 - Ignition switch
l I020 - Start enable switch (transmission in neutral)
l J001 - Preheating relay
l J001a - Preheating relay
l J001b - Preheating relay
l J008 - Relay
l M001 - Engine control unit
l M002 - Engine ECU
l N001 - Starter motor “+30”
l N002 - Starter motor “+50”

40-176
Wiring diagrams

B028

J008

B010

B022
B021

E002

E003 C004

D005

I018

D001
A
I011

D0063610

Fig. 2188 - Starting and preheating - Connector positions

Table 388
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1209
B010 Fuse (5A) 40-1221
B021 Fuse (10A) 40-1209
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1209
B022 Fuse (7.5A) 40-1221
B028 Fuse (40A) 40-1209
B028 Fuse (40A) 40-1221

40-177
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1209
40-1221

Fig. 2189
D001 Wiring connector 40-1198
40-1209
40-1221
40-1198

Fig. 2190
D005 Wiring connector 40-1234
40-1236
40-1209
40-1221
40-1209
40-1221
40-1234
40-1236

Fig. 2191
E002 Instrument panel 40-1209
40-1221

Fig. 2192
E003 Instrument panel 40-1209
40-1221

Fig. 2193

40-178
Wiring diagrams
Table 389
Sys- P/N Description Characteristics/notes Position Wiring
tem
I011 Clutch pedal switch 40-1209
1

Fig. 2194
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I011 Clutch pedal switch 40-1221
1

Fig. 2194
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I018 Starter switch 40-1209
40-1221
J008 Relay 40-1209
40-1221

Fig. 2197

40-179
 Wiring diagrams

C003

B
C008

D011

M001
M002

D0063600

Fig. 2198 - Connector positions

Table 390
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1209
40-1221

Fig. 2199

40-180
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C008 Earthing point 8 40-1209
40-1221

Fig. 2200
D011 Wiring connector 40-1209
40-1214
40-1221
40-1214

Fig. 2201
M001 02959599 Engine ECU 40-1209
40-1221

Fig. 2202
M002 02959599 Engine ECU 40-1209
40-1221

Fig. 2203

40-181
 Wiring diagrams

D011

I020

D0063590

Fig. 2204 - Connector positions

Table 391
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1209
40-1214
40-1221
40-1214

Fig. 2204

40-182
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I020 Start enable switch 40-1214
(transmission in
neutral)

Fig. 2205

40-183
 Wiring diagrams

D001

B001

N001

D0063620

Fig. 2206

Table 392
Sys- P/N Description Characteristics/notes Position Wiring
tem
B001 Fuse 40-1198

40-184
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D001 Wiring connector 40-1198
40-1209
40-1221
40-1198

Fig. 2206
N001 01183677 Starter motor “+30” 40-1198
40-1199
40-1200
40-1241

Fig. 2207

40-185
 Wiring diagrams

A001

J001b
J001a

B004

T001a

D0063550

Fig. 2208 - Connector positions - Version with preheating and front battery

40-186
Wiring diagrams
Table 393
Sys- P/N Description Characteristics/notes Position Wiring
tem
A001 04258670 Preheating device Power supply: 12V 40-1194
Total resistance at 20°C: 0.061
Ohms
B004 Fuse 40-1194
Preheating relay Version with front battery 40-1194

Fig. 2210
Version with lateral battery

Fig. 2211
Preheating relay Version with front battery 40-1194

Fig. 2212
Version with lateral battery

Fig. 2213

40-187
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
Battery positive ter- Version with front battery 40-1194
minal

Fig. 2214
Version with lateral battery

Fig. 2215

40-188
Wiring diagrams

A001

T001a

J001a

J001b
B004

D0064600

Fig. 2216

Table 394
Sys- P/N Description Characteristics/notes Position Wiring
tem
A001 04258670 Preheating device Power supply: 12V 40-1194
Total resistance at 20°C: 0.061
Ohms
B004 Fuse 40-1194
Battery positive ter- Version with lateral battery 40-1194
minal

Fig. 2216

40-189
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
Battery positive ter- 40-1236
minal

Fig. 2217
Preheating relay Version with lateral battery 40-1194

Fig. 2217

40-190
Wiring diagrams

C001

N001

T001
T001a
C002 T001b

D0063540

Fig. 2218 - Connector positions - Version with front battery

40-191
 Wiring diagrams
Table 395
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative Version with front battery 40-1241
terminal

Fig. 2219
Version with lateral battery

Fig. 2220
C002 Earthing point 2 40-1241

Fig. 2221
N001 01183677 Starter motor “+30” 40-1241
40-1198
40-1199

Fig. 2222
T001 Battery positive ter- Version with front battery 40-1241
minal

Fig. 2223
Version with lateral battery

Fig. 2224

40-192
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
Battery positive ter- Version with front battery 40-1194
minal

Fig. 2224
Version with lateral battery

Fig. 2224
Battery positive ter- 40-1236
minal 40-1234

Fig. 2224

40-193
 Wiring diagrams

N001

C002

T001
T001a
C001 T001b

D0064590

Fig. 2225 - Connector positions - Version with lateral battery

Table 396
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative Version with lateral battery 40-1241
terminal

Fig. 2225

40-194
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C002 Earthing point 2 40-1241

Fig. 2225
T001 Battery positive ter- Version with lateral battery 40-1241
minal

Fig. 2225
Battery positive ter- Version with lateral battery 40-1194
minal

Fig. 2225
Battery positive ter- 40-1236
minal

Fig. 2225
N001 01183677 Starter motor “+30” 40-1241
40-1198
40-1199
40-1200

Fig. 2225

40-195
 Wiring diagrams

D005

J001

N002
A004

A003

A002

T001b

D0063560

Fig. 2226 - Connector positions - Version with front battery

40-196
Wiring diagrams
Table 397
Sys- P/N Description Characteristics/notes Position Wiring
tem
A002 01183630 Alternator “B+” 40-1234
40-1236

Fig. 2227
A003 01183630 Alternator “D+” 40-1234
40-1236

Fig. 2228
A004 01183630 Alternator “W” 40-1234
40-1236

Fig. 2229
D005 Wiring connector 40-1234
40-1236
40-1209
40-1221
40-1209
40-1221
40-1234
40-1236

Fig. 2229
J001 Preheating relay 40-1234
40-1236

Fig. 2230
N002 01183677 Starter motor “+50” 40-1236

Fig. 2231

40-197
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
Battery positive ter- 40-1234
minal

Fig. 2232

40-198
Wiring diagrams

D005

A
C B

N002
A004

A003

A002

D0063580

Fig. 2233 - Connector positions - Version with lateral battery (1/2)

40-199
 Wiring diagrams
Table 398
Sys- P/N Description Characteristics/notes Position Wiring
tem
A002 01183630 Alternator “B+” 40-1234
40-1236

Fig. 2233
A003 01183630 Alternator “D+” 40-1234
40-1236

Fig. 2233
A004 01183630 Alternator “W” 40-1234
40-1236

Fig. 2233
D005 Wiring connector 40-1234
40-1236
40-1209
40-1221
40-1209
40-1221
40-1234
40-1236

Fig. 2233
N002 01183677 Starter motor “+50” 40-1234
40-1236

Fig. 2233

40-200
Wiring diagrams

B
C

T001b

J001

D0063570

Fig. 2234 - Connector positions - Version with lateral battery (2/2)

Table 399
Sys- P/N Description Characteristics/notes Position Wiring
tem
Battery positive ter- 40-1236
minal

Fig. 2234

40-201
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J001 Preheating relay 40-1234
40-1236

Fig. 2234

40-202
Wiring diagrams
40.3.2 - S001A - Starting and preheating - Version with analog instrument panel (R3 EVO
100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

M001
E008
E009 E010 M002
I004 I005
J008

PRE HEATING LAMP

(M3)

START CONSENT
+PRE-HEATING

PRE-HEATING

H.D.COMAND
GENERATOR

-31 ELECTR

-31 ELECTR
+15

+15

+15
-31

-31

87 85 86 30 A5 A A3 A4 B1 1 3 4 3 3 14 6 2 1 2 3 7 8 4 5 7 2 1 3 4 6 5 8
12
C004

C009

D013
7 9 2 3

C003
B028
40A

B021

B022
7.5A
10A

I011

75 83 15 50 30
+15

4 3 2 1

2
D005

1 0

I018 14 1 8 6 5 4
C003

C004
A001

B024
C004

7.5A
J001b

J001
J001a
D001

2 1
D011

10 9 5 6 2 3 7 8

B A A A
A3 A1 D1 B1
B004
B001

125A
60A

I008
1 2
C002

I020
T001b
T001a
T001

C001

B+ D+ W
N001
N002

+30 +30
+30 GND1

D0065030
A004
A002
A003

BATTERY

Fig. 2235 - Starting and preheating - Version with analog instrument panel - System
l A001 - Preheating device
l A002 - Alternator “B+”
l A003 - Alternator “D+”
l A004 - Alternator “W”
l D001 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D001 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)

40-203
 Wiring diagrams
l D005 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D011 (M) - Wiring connector (Wiring loom 0.016.1999.4/10)
l D011 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l E008 - Instrument panel
l E009 - Instrument panel
l E010 - Instrument panel
l I004 - Front PTO control switch
l I005 - Rear PTO control switch
l I008 - Road lights switch
l I011 - Clutch pedal switch
l I018 - Ignition switch
l I020 - Start enable switch (transmission in neutral)
l J001 - Preheating relay
l J001a - Preheating relay
l J001b - Preheating relay
l J008 - Relay
l M001 - Engine control unit
l M002 - Engine ECU
l N001 - Starter motor “+30”
l N002 - Starter motor “+50”

40-204
Wiring diagrams

B028

J008

B024
B022
B021

C004
E008
E010

E009

D005

I018

D001
A
I011 I008

D0063611

Fig. 2236 - Starting and preheating - Version with analog instrument panel - Connector positions
Table 400
Sys- P/N Description Characteristics/notes Position Wiring
tem
B021 Fuse (10A) 40-1238
B022 Fuse (7.5A) 40-1238
B024 Fuse (7.5A) 40-1238
B028 Fuse (40A) 40-1238

40-205
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1238

Fig. 2237
D001 Wiring connector 40-1238
40-1198

Fig. 2238
D005 Wiring connector 40-1238
40-1238
40-1234
40-1236

Fig. 2239
E008 Instrument panel 40-1238
E009 Instrument panel 40-1238
E010 Instrument panel 40-1238
I008 Road lights switch 40-1238

Fig. 2240 Fig. 2241

I011 Clutch pedal switch 40-1238
1

Fig. 2242
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)

40-206
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I018 Starter switch 40-1238

83
50
30
86s

75 15

Pin 30 15 50 75 83
Pos Fig. 2244
0

2
D0010060

Fig. 2243
J008 Relay 40-1238

Fig. 2245

40-207
 Wiring diagrams

I005
I004

D013

C003

D011

M001
M002

C009
D0063601

Fig. 2246 - Connector positions

Table 401
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1238

Fig. 2247

40-208
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1238

Fig. 2248
D011 Wiring connector 40-1233
40-1238

Fig. 2249
D013 Wiring connector 40-1238
40-1238

Fig. 2250
I004 Front PTO control 40-1238
switch

Fig. 2252
Fig. 2251
I005 Rear PTO control 40-1238
switch

Fig. 2253
M001 02959599 Engine control unit 40-1238

Fig. 2254

40-209
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
M002 02959599 Engine control unit 40-1238

Fig. 2255

D011

I020

D0063590

Fig. 2256 - Connector positions

40-210
Wiring diagrams
Table 402
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1233
40-1238

Fig. 2256
I020 Start enable switch 40-1233
(transmission in
neutral)

Fig. 2257

40-211
 Wiring diagrams

D001

B001

N001

D0063620

Fig. 2258 - Connector positions

Table 403
Sys- P/N Description Characteristics/notes Position Wiring
tem
B001 Fuse 40-1198

40-212
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D001 Wiring connector 40-1238
40-1198

Fig. 2258
N001 01183677 Starter motor “+30” 40-1241

Fig. 2259
N001 01183677 Starter motor “+30” 40-1198
40-1199
40-1200

Fig. 2260

40-213
 Wiring diagrams

D005

A
C B

N002
A004

A003

A002

D0063580

Fig. 2261 - Connector positions - Version with lateral battery (1/2)

40-214
Wiring diagrams
Table 404
Sys- P/N Description Characteristics/notes Position Wiring
tem
A002 01183630 Alternator “B+” 40-1236

Fig. 2262
A003 01183630 Alternator “D+” 40-1236

Fig. 2263
A004 01183630 Alternator “W” 40-1236

Fig. 2264
D005 Wiring connector 40-1238
40-1238
40-1236

Fig. 2264
N002 01183677 Starter motor “+50” 40-1236

Fig. 2265

40-215
 Wiring diagrams

B
C

T001b

J001

D0063570

Fig. 2266 - Connector positions - Version with lateral battery (2/2)

Table 405
Sys- P/N Description Characteristics/notes Position Wiring
tem
J001 Preheating relay 40-1236

Fig. 2267

40-216
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
Battery positive ter- Version with lateral battery 40-1236
minal

Fig. 2268

40-217
 Wiring diagrams

D005

J001

N002
A004

A003

A002

T001b

D0063560

Fig. 2269 - Connector positions - Version with front battery

40-218
Wiring diagrams
Table 406
Sys- P/N Description Characteristics/notes Position Wiring
tem
A002 01183630 Alternator “B+” 40-1234

Fig. 2269
A003 01183630 Alternator “D+” 40-1234

Fig. 2269
A004 01183630 Alternator “W” 40-1234

Fig. 2269
J001 Preheating relay 40-1234

Fig. 2269
D005 Wiring connector 40-1238
40-1238
40-1234

Fig. 2269
N002 01183677 Starter motor “+50” 40-1234

Fig. 2269

40-219
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
Battery positive ter- Version with front battery 40-1234
minal

Fig. 2270

40-220
Wiring diagrams

A001

J001b
J001a

B004

T001a

D0063550

Fig. 2271 - Connector positions - Preheating version with front battery

40-221
 Wiring diagrams
Table 407
Sys- P/N Description Characteristics/notes Position Wiring
tem
A001 04258670 Preheating device Power supply: 12V 40-1194
Total resistance at 20°C: 0.061
Ohms
B004 Fuse 40-1194
Preheating relay Version with front battery 40-1194

Fig. 2273
Preheating relay Version with front battery 40-1194

Fig. 2274
Battery positive ter- Version with front battery 40-1194
minal

Fig. 2275

40-222
Wiring diagrams

A001

T001a

J001a

J001b
B004

D0064600

Fig. 2276 - Connector positions - Preheating version with lateral battery

Table 408
Sys- P/N Description Characteristics/notes Position Wiring
tem
A001 04258670 Preheating device Power supply: 12V 40-1194
Total resistance at 20°C: 0.061
Ohms
B004 Fuse 40-1194
Preheating relay Version with lateral battery 40-1194

Fig. 2277

40-223
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
Preheating relay Version with lateral battery 40-1194

Fig. 2278
Battery positive ter- Version with lateral battery 40-1194
minal

Fig. 2279

40-224
Wiring diagrams

C001

N001

T001
T001a
C002 T001b

D0063540

Fig. 2280 - Connector positions - Version with front battery

Table 409
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative Version with front battery 40-1241
terminal

Fig. 2281

40-225
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C002 Earthing point 2 40-1241

Fig. 2282
T001 Battery positive ter- Version with front battery 40-1241
minal

Fig. 2283
Battery positive ter- Version with front battery 40-1194
minal

Fig. 2283
Battery positive ter- Version with front battery 40-1234
minal

Fig. 2283
N001 01183677 Starter motor “+30” 40-1241

Fig. 2283

40-226
Wiring diagrams

N001

C002

T001
T001a
C001 T001b

D0064590

Fig. 2284 - Connector positions - Version with lateral battery

Table 410
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative Version with lateral battery 40-1241
terminal

Fig. 2285

40-227
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C002 Earthing point 2 40-1241

Fig. 2285
T001 Battery positive ter- Version with lateral battery 40-1241
minal

Fig. 2286
Battery positive ter- Version with lateral battery 40-1194
minal

Fig. 2286
Battery positive ter- Version with lateral battery 40-1236
minal

Fig. 2286
N001 01183677 Starter motor “+30” 40-1241

Fig. 2286

40-228
Wiring diagrams
40.3.3 - S001D - Starting and preheating - Version with digital instrument panel (R3 EVO
100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

M001
E002 E003 M002
I018 J008 I011

PRE HEATING LAMP

(M3)

START CONSENT
1 0

PREHEATING

H.D.COMAND
GENERATOR
2

-31 ELECTR

-31 ELECTR
+12V(+30)

+12V(+30)

+15

+15
-31

-31
W
75 83 15 50 30 87 85 86 30 15 21 14 8 20 24 13 15 3 3 14 6 2 1 1 2 3 4
B028
40A

C008

C008

C004
B010

B021

C003
10A

B022
5A

7.5A
+15

+15
A001
J001b

J001
J001a
D001

D005

D011
8 14 1 6 5 4
A A A B B
A1 A8 D1 D1 A3
2 1

2 1
B004
B001

125A
60A

I020
C002
T001b
T001a
T001

C001
N001
N002

+30 +30

+30 GND1

BATTERY

D0062850
A004
A002
A003

Fig. 2287 - Starting and preheating - Version with digital instrument panel - System
l A001 - Preheating device
l A002 - Alternator “B+”
l A003 - Alternator “D+”
l A004 - Alternator “W”
l D001 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D001 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)

40-229
 Wiring diagrams
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l E002 - Instrument panel
l E003 - Instrument panel
l I011 - Clutch pedal switch
l I018 - Ignition switch
l I020 - Start enable switch (transmission in neutral)
l J001 - Preheating relay
l J001a - Preheating relay
l J001b - Preheating relay
l J008 - Relay
l M001 - Engine control unit
l M002 - Engine ECU
l N001 - Starter motor “+30”
l N002 - Starter motor “+50”

40-230
Wiring diagrams

B028

J008

B010

B022
B021

E002

E003 C004

D005

I018

D001
A
I011

D0063610

Fig. 2288 - Starting and preheating - Version with digital instrument panel - Connector positions
Table 411
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1205
B010 Fuse (5A) 40-1221
B021 Fuse (10A) 40-1205
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1205
B022 Fuse (7.5A) 40-1221
B028 Fuse (40A) 40-1205
B028 Fuse (40A) 40-1221

40-231
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1205
40-1221

Fig. 2289
D001 Wiring connector 40-1198
40-1205
40-1221

Fig. 2290
D005 Wiring connector 40-1234
40-1236
40-1205
40-1205
40-1221

Fig. 2291
E002 Instrument panel 40-1205
40-1221

Fig. 2292
E003 Instrument panel 40-1205
40-1221

Fig. 2293
I011 Clutch pedal switch 40-1205
1

Fig. 2294
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)

40-232
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I011 Clutch pedal switch 40-1221
1

Fig. 2294
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I018 Starter switch 40-1205

83
50
30
86s

75 15

Pin 30 15 50 75 83
Pos Fig. 2296
0

2
D0010060

Fig. 2295
I018 Starter switch 40-1221

83
50
30
86s

75 15

Pin 30 15 50 75 83
Pos

2
D0010060

Fig. 2296
J008 Relay 40-1205
40-1221

Fig. 2297

40-233
 Wiring diagrams

C003

B
C008

D011

M001
M002

D0063600

Fig. 2298 - Starting and preheating - Version with digital instrument panel - Connector positions
Table 412
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1205
40-1221

Fig. 2299

40-234
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C008 Earthing point 8 40-1205
40-1221

Fig. 2300
D011 Wiring connector 40-1205
40-1212
40-1221

Fig. 2301
M001 02959599 Engine control unit 40-1205
40-1221

Fig. 2302
M002 02959599 Engine control unit 40-1205
40-1221

Fig. 2303

40-235
 Wiring diagrams

D011

I020

D0063590

Fig. 2304 - Starting and preheating - Version with digital instrument panel - Connector positions
Table 413
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1205
40-1212
40-1221

Fig. 2304

40-236
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I020 Start enable switch 40-1212
(transmission in
neutral)

Fig. 2305

40-237
 Wiring diagrams

D001

B001

N001

D0063620

Fig. 2306 - Starting and preheating - Version with digital instrument panel - Connector positions
Table 414
Sys- P/N Description Characteristics/notes Position Wiring
tem
B001 Fuse 40-1198

40-238
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D001 Wiring connector 40-1198
40-1205
40-1221

Fig. 2306
N001 01183677 Starter motor “+30” 40-1241
40-1198
40-1199
40-1200

Fig. 2307

40-239
 Wiring diagrams

A001

J001b
J001a

B004

T001a

D0063550

Fig. 2308 - Starting and preheating - Version with digital instrument panel - Connector positions - Version with
preheating and front battery

40-240
Wiring diagrams
Table 415
Sys- P/N Description Characteristics/notes Position Wiring
tem
A001 04258670 Preheating device Power supply: 12V 40-1194
Total resistance at 20°C: 0.061
Ohms
B004 Fuse 40-1194
Battery positive ter- 40-1194
minal

Fig. 2310
Preheating relay 40-1194

Fig. 2311
Preheating relay 40-1194

Fig. 2312

40-241
 Wiring diagrams

A001

T001a

J001a

J001b
B004

D0064600

Fig. 2313 - Starting and preheating - Version with digital instrument panel - Connector positions
Table 416
Sys- P/N Description Characteristics/notes Position Wiring
tem
A001 04258670 Preheating device Power supply: 12V 40-1194
Total resistance at 20°C: 0.061
Ohms
B004 Fuse 40-1194
Battery positive ter- 40-1194
minal

Fig. 2314

40-242
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
Preheating relay 40-1194

Fig. 2315
Preheating relay 40-1194

Fig. 2316

40-243
 Wiring diagrams

C001

N001

T001
T001a
C002 T001b

D0063540

Fig. 2317 - Starting and preheating - Version with digital instrument panel - Connector positions - Version with
front battery

40-244
Wiring diagrams
Table 417
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative 40-1241
terminal

Fig. 2318
C002 Earthing point 2 40-1241
T001 Battery positive ter- 40-1241
minal

Fig. 2319
Battery positive ter- 40-1194
minal

Fig. 2319
Battery positive ter- 40-1234
minal

Fig. 2320
N001 01183677 Starter motor “+30” 40-1241
40-1198
40-1199
40-1200

Fig. 2320

40-245
 Wiring diagrams

N001

C002

T001
T001a
C001 T001b

D0064590

Fig. 2321 - Starting and preheating - Version with digital instrument panel - Connector positions - Version with
lateral battery
Table 418
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative 40-1241
terminal

Fig. 2322

40-246
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C002 Earthing point 2 40-1241

Fig. 2323
T001 Battery positive ter- 40-1241
minal

Fig. 2324
Battery positive ter- 40-1194
minal

Fig. 2324
Battery positive ter- 40-1236
minal

Fig. 2325
N001 01183677 Starter motor “+30” 40-1241
40-1198
40-1199
40-1200

Fig. 2325

40-247
 Wiring diagrams

D005

J001

N002
A004

A003

A002

T001b

D0063560

Fig. 2326 - Starting and preheating - Version with digital instrument panel - Connector positions - Version with
front battery

40-248
Wiring diagrams
Table 419
Sys- P/N Description Characteristics/notes Position Wiring
tem
A002 01183630 Alternator “B+” 40-1234

Fig. 2327
A003 01183630 Alternator “D+” 40-1234

Fig. 2328
A004 01183630 Alternator “W” 40-1234

Fig. 2329
D005 Wiring connector 40-1234
40-1205
40-1221

Fig. 2329
J001 Preheating relay 40-1234

Fig. 2329
N002 01183677 Starter motor “+50” 40-1234

Fig. 2330

40-249
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
Battery positive ter- 40-1234
minal

Fig. 2330

40-250
Wiring diagrams

D005

A
C B

N002
A004

A003

A002

D0063580

Fig. 2331 - Starting and preheating - Version with digital instrument panel - Connector positions - Version with
lateral battery (1/2)

40-251
 Wiring diagrams
Table 420
Sys- P/N Description Characteristics/notes Position Wiring
tem
A002 01183630 Alternator “B+” 40-1236

Fig. 2331
A003 01183630 Alternator “D+” 40-1236

Fig. 2331
A004 01183630 Alternator “W” 40-1236

Fig. 2331
D005 Wiring connector 40-1236
40-1205
40-1221

Fig. 2331
N002 01183677 Starter motor “+50” 40-1236

Fig. 2331

40-252
Wiring diagrams

B
C

T001b

J001

D0063570

Fig. 2332 - Starting and preheating - Version with digital instrument panel - Connector positions - Version with
lateral battery (2/2)
Table 421
Sys- P/N Description Characteristics/notes Position Wiring
tem
J001 Preheating relay 40-1236

Fig. 2333

40-253
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
Battery positive ter- 40-1236
minal

Fig. 2333

40.3.4 - S002 - Electronic engine governor (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001,
R3 EVO 85 -> 20001)

M002 M001

CHARGE AIR PRESSURE SIGNAL (M24)

CHARGE AIR PRESSURE GND (M23)

CHARGE AIR PRESSURE +5V (M25)

WATER TEMPERATURE (M8) GND

CHARGE AIR PRESS.TEMPER.

WATER TEMPERATURE (M9)
E003 E002
SIGNAL PEDAL GAS
HAND GAS SIGNAL

ATTUATOR (M18)

ATTUATOR (M19)
ATTUATOR (M17)
ATTUATOR (M15)
ATTUATOR (M14)
FUEL TEMP (M5)

PICK-UP+ (M13)
PICK-UP- (M12)
GND COM 24/20

GND SCREEN
-31 ELECTR.

-31 ELECTR.

HOLD LAMP
HOLD LAMP

GND COM
+12/30

+12/30

+5V 24
HOLD
GND

+15

+15
-31

17 13 8 15 21 14 2 1 14 15 17 18 20 23 24 25 5 8 9 16 12 13 14 15 17 18 19 23 24 25 4
C004

C008

D011
D013
B022
B021
B010

7.5A
10A
5A

A A B A A A A A A A A A A B A
10 11 A5 B1 C4 B4 B5 B6 B7 C1 C2 C3 C4 C7 C8 C5 A4
+30

+15

D015

5 8 9 12 13 14 15 17 18 19 23 24 25 4

2 4 1 2 1 2 4 1

pos pos

I001
K005 K006

1 2 2 1 2 1 1 2 3 5 4 1 4 3 2
freq
t
t

D0062860
K032 K026 K031 N007 K028

Fig. 2334 - Electronic engine governor - System

l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)

40-254
Wiring diagrams
M002 M001

CHARGE AIR PRESSURE SIGNAL (M24)

CHARGE AIR PRESSURE GND (M23)

CHARGE AIR PRESSURE +5V (M25)

WATER TEMPERATURE (M8) GND

CHARGE AIR PRESS.TEMPER.

WATER TEMPERATURE (M9)
E003 E002

SIGNAL PEDAL GAS

HAND GAS SIGNAL

ATTUATOR (M18)

ATTUATOR (M19)
ATTUATOR (M17)
ATTUATOR (M15)
ATTUATOR (M14)
FUEL TEMP (M5)

PICK-UP+ (M13)
PICK-UP- (M12)
GND COM 24/20

GND SCREEN
-31 ELECTR.

-31 ELECTR.

HOLD LAMP
HOLD LAMP

GND COM
+12/30

+12/30

+5V 24
HOLD
GND

+15

+15
-31

17 13 8 15 21 14 2 1 14 15 17 18 20 23 24 25 5 8 9 16 12 13 14 15 17 18 19 23 24 25 4
C004

C008

D011
D013
B022
B021
B010

7.5A
10A
5A

A A B A A A A A A A A A A B A
10 11 A5 B1 C4 B4 B5 B6 B7 C1 C2 C3 C4 C7 C8 C5 A4
+30

+15

D015

5 8 9 12 13 14 15 17 18 19 23 24 25 4

2 4 1 2 1 2 4 1

pos pos

I001
K005 K006

1 2 2 1 2 1 1 2 3 5 4 1 4 3 2
freq
t
t

D0062860
K032 K026 K031 N007 K028

Fig. 2334 - Electronic engine governor - System

l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D013 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D013 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D013 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D013 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D015 (M) - Wiring connector (Wiring loom 04215655)
l D015 (F) - Wiring connector (Wiring loom 0.015.7023.4/50)
l E002 - Instrument panel
l E003 - Instrument panel
l I001 - Engine speed memory button.
l K005 - Hand throttle position sensor
l K006 - Accelerator pedal position sensor
l K026 - Engine coolant temperature sensor
l K028 - Turbo air temperature/pressure sensor
l K031 - Camshaft rotation speed sensor
l K032 - Fuel temperature sensor
l M001 - Engine control unit
l M002 - Engine ECU
l N007 - Actuator

40-255
 Wiring diagrams

B010

B022
B021

C004
E002

E003

A K006

D0063650

Fig. 2335 - Electronic engine governor - Connector positions

Table 422
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1209
B010 Fuse (5A) 40-1221
B021 Fuse (10A) 40-1209
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1209
B022 Fuse (7.5A) 40-1221

40-256
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1209
40-1221

Fig. 2336
E002 Instrument panel 40-1209
40-1221

Fig. 2337
E003 Instrument panel 40-1209
40-1221

Fig. 2338
K006 Accelerator pedal Sensor N°1 40-1209
position sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K006 Accelerator pedal Sensor N°1 40-1221
position sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth

40-257
 Wiring diagrams

I001

K005

D013

C008 B

D011

M001

M002

D0063660

Fig. 2340 - Connector positions

Table 423
Sys- P/N Description Characteristics/notes Position Wiring
tem
C008 Earthing point 8 40-1209
40-1221

Fig. 2341

40-258
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1209
40-1214
40-1221
40-1214

Fig. 2342
D013 Wiring connector 40-1209
40-1221

Fig. 2343
I001 Engine speed Normally open contact (NO) 40-1209
memory button 40-1221

Fig. 2344
K005 Hand throttle posi- Sensor N°1 40-1209
tion sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K005 Hand throttle posi- Sensor N°1 40-1221
tion sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
M001 02959599 Engine control unit 40-1209
40-1221
M002 02959599 Engine control unit 40-1209
40-1221

40-259
 Wiring diagrams

D011

D015

D0063640

Fig. 2346 - Connector positions

Table 424
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1209
D011 Wiring connector 40-1214
D011 Wiring connector 40-1221
D011 Wiring connector 40-1214
D015 Wiring connector 40-1214
40-1249

40-260
Wiring diagrams
K026
K028

D015

K032

N007

K031 D0063630

Fig. 2347 - Connector positions

Table 425
Sys- P/N Description Characteristics/notes Position Wiring
tem
D015 Wiring connector 40-1214
40-1249
K026 04213839 Engine coolant 40-1249
temperature sensor
K028 04213838 Turbine air tem- 40-1249
perature/pressure
sensor
K031 01182834 Camshaft speed 40-1249
sensor
K032 04213839 Fuel temperature 40-1249
sensor
N007 02113597 Actuator 40-1249

40-261
 Wiring diagrams
40.3.5 - S002A - Electronic engine governor - Version with analog instrument panel (R3
EVO 85 -> 16001)

M002 M001

CHARGE AIR PRESSURE SIGNAL (M24)

CHARGE AIR PRESSURE GND (M23)

CHARGE AIR PRESSURE +5V (M25)

WATER TEMPERATURE (M8) GND

CHARGE AIR PRESS.TEMPER.

WATER TEMPERATURE (M9)
E008

SIGNAL PEDAL GAS

HAND GAS SIGNAL

ATTUATOR (M18)

ATTUATOR (M19)
ATTUATOR (M17)
ATTUATOR (M15)
ATTUATOR (M14)
FUEL TEMP (M5)

PICK-UP+ (M13)
PICK-UP- (M12)
GND COM 24/20

GND SCREEN
ALLARM LAMP
ENGINE MEM.

-31 ELECTR.

-31 ELECTR.

HOLD LAMP

GND COM

+5V 24
HOLD
+15

+15
-31

B
12 B7 B1 4 2 1 15 14 17 18 20 23 24 25 5 8 9 16 12 13 14 15 17 18 19 23 24 25 4
C004

C009

D013a

D011
D013
B021

B022
7.5A
10A

A A B A A A A A A A A A A B A
1 2 10 11 A5 A8 C4 B4 B5 B6 B7 C1 C2 C3 C4 C7 C8 C5 A4
+15

D015

5 8 9 12 13 14 15 17 18 19 23 24 25 4

2 4 1 2 4 2 1 2 4 1

pos pos

I001
K005 K006

1 2 2 1 1 2 1 2 3 5 4 1 4 3 2
t
t

D0065150 freq

K032 K026 K031 N007 K028

Fig. 2348 - Electronic engine governor - Version with analog instrument panel - System
l D011 (M) - Wiring connector (Wiring loom 0.016.1999.4/10)
l D011 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013a (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013a (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D015 (M) - Wiring connector (Wiring loom 04214707)
l D015 (F) - Wiring connector (Wiring loom 0.016.1999.4/10)
l E008 - Instrument panel
l I001 - Engine speed memory button.
l K005 - Hand throttle position sensor
l K006 - Accelerator pedal position sensor
l K026 - Engine coolant temperature sensor
l K028 - Turbo air temperature/pressure sensor
l K031 - Camshaft rotation speed sensor
l K032 - Fuel temperature sensor

40-262
Wiring diagrams
l M001 - Engine control unit
l M002 - Engine ECU
l N007 - Actuator

B022
B021

E008
C004

A
A K006

D0063651

Fig. 2349 - Electronic engine governor - Version with analog instrument panel - Connector positions
Table 426
Sys- P/N Description Characteristics/notes Position Wiring
tem
B021 Fuse (10A) 40-1238
B022 Fuse (7.5A) 40-1238

40-263
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1238

Fig. 2350
E008 Instrument panel 40-1238
K006 Accelerator pedal Sensor N°1 40-1238
position sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal

40-264
Wiring diagrams

I001

K005

D013a
D013

D011

M001

M002

C009

D0063661

Fig. 2352 - Connector positioning

Table 427
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1238

Fig. 2353

40-265
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1233
40-1238

Fig. 2354
D013 Wiring connector 40-1238
40-1238

Fig. 2355
Wiring connector 40-1238
40-1238
I001 Engine speed Normally open contact (NO) 40-1238
memory button

Fig. 2356
K005 Hand throttle posi- Sensor N°1 40-1238
tion sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
M001 02959599 Engine control unit 40-1238

Fig. 2358
M002 02959599 Engine control unit 40-1238

Fig. 2359

40-266
Wiring diagrams

D011

D015

D0063640

Fig. 2360 - Connector positioning

40-267
 Wiring diagrams
Table 428
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1233
40-1238

Fig. 2360
D015 Wiring connector 40-1246
D015 Wiring connector 40-1233

K026
K028

D015

K032

N007

K031 D0063630

Fig. 2361 - Connector positioning

Table 429
Sys- P/N Description Characteristics/notes Position Wiring
tem
D015 Wiring connector 40-1246
D015 Wiring connector 40-1233
K026 04213839 Engine coolant 40-1246
temperature sensor
K028 04213838 Turbine air tem- 40-1246
perature/pressure
sensor

40-268
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
K031 01182834 Camshaft speed 40-1246
sensor
K032 04213839 Fuel temperature 40-1246
sensor
N007 02113597 Actuator 40-1246

40.3.6 - S002D - Electronic engine governor - Version with digital instrument panel (R3
EVO 85 -> 16001)

M002 M001

CHARGE AIR PRESSURE SIGNAL (M24)

CHARGE AIR PRESSURE GND (M23)

CHARGE AIR PRESSURE +5V (M25)

WATER TEMPERATURE (M8) GND

CHARGE AIR PRESS.TEMPER.

WATER TEMPERATURE (M9)
E003 E002

SIGNAL PEDAL GAS

HAND GAS SIGNAL

ATTUATOR (M18)

ATTUATOR (M19)
ATTUATOR (M17)
ATTUATOR (M15)
ATTUATOR (M14)
FUEL TEMP (M5)

PICK-UP+ (M13)
PICK-UP- (M12)
GND COM 24/20

GND SCREEN
-31 ELECTR.

-31 ELECTR.

HOLD LAMP
HOLD LAMP

GND COM
+12/30

+12/30

+5V 24
HOLD
GND

+15

+15
-31

17 13 8 15 21 14 2 1 14 15 17 18 20 23 24 25 5 8 9 16 12 13 14 15 17 18 19 23 24 25 4
C004

C008

D011
D013
B022
B010

B021

7.5A
10A
5A

A A B A A A A A A A A A A B A
10 11 A5 B1 C4 B4 B5 B6 B7 C1 C2 C3 C4 C7 C8 C5 A4
+30

+15

D015

5 8 9 12 13 14 15 17 18 19 23 24 25 4

2 4 1 2 1 2 4 1

pos pos

K005 I001 K006

1 2 2 1 1 2 1 2 3 5 4 1 4 3 2
t
t

D0065140 freq

K032 K026 K031 N007 K028

Fig. 2362 - Electronic engine governor - Version with digital instrument panel - System
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D013 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D013 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D013 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)

40-269
 Wiring diagrams
l D013 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D015 (M) - Wiring connector (Wiring loom 04214707)
l D015 (F) - Wiring connector (Wiring loom 0.015.7023.4/50)
l E002 - Instrument panel
l E003 - Instrument panel
l I001 - Engine speed memory button.
l K005 - Hand throttle position sensor
l K006 - Accelerator pedal position sensor
l K026 - Engine coolant temperature sensor
l K028 - Turbo air temperature/pressure sensor
l K031 - Camshaft rotation speed sensor
l K032 - Fuel temperature sensor
l M001 - Engine control unit
l M002 - Engine ECU
l N007 - Actuator

B010

B022
B021

C004
E002

E003

A K006

D0063650

Fig. 2363 - Electronic engine governor - Version with digital instrument panel - Connector positions

40-270
Wiring diagrams
Table 430
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1205
B010 Fuse (5A) 40-1221
B021 Fuse (10A) 40-1205
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1205
B022 Fuse (7.5A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 2364
E002 Instrument panel 40-1205
40-1221

Fig. 2365
E003 Instrument panel 40-1205
40-1221

Fig. 2366
K006 Accelerator pedal Sensor N°1 40-1205
position sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K006 Accelerator pedal Sensor N°1 40-1221
position sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal

40-271
 Wiring diagrams

I001

K005

D013

C008 B

D011

M001

M002

D0063660

Fig. 2368 - Connector positioning

Table 431
Sys- P/N Description Characteristics/notes Position Wiring
tem
C008 Earthing point 8 40-1205
40-1221

Fig. 2369

40-272
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1205
40-1212
40-1221

Fig. 2370
D013 Wiring connector 40-1205
40-1221

Fig. 2370
I001 Engine speed Normally open contact (NO) 40-1205
memory button 40-1221

Fig. 2371
K005 Hand throttle posi- Sensor N°1 40-1205
tion sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K005 Hand throttle posi- Sensor N°1 40-1221
tion sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
M001 02959599 Engine control unit 40-1205
40-1221

Fig. 2373

40-273
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
M002 02959599 Engine control unit 40-1205
40-1221

Fig. 2374

D011

D015

D0063640

Fig. 2375 - Connector positioning

40-274
Wiring diagrams
Table 432
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1205
40-1212
40-1221

Fig. 2375
D015 Wiring connector 40-1246
40-1212

K026
K028

D015

K032

N007

K031 D0063630

Fig. 2376 - Connector positioning

Table 433
Sys- P/N Description Characteristics/notes Position Wiring
tem
D015 Wiring connector 40-1246
40-1212
K026 04213839 Engine coolant 40-1246
temperature sensor
K028 04213838 Turbine air tem- 40-1246
perature/pressure
sensor

40-275
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
K031 01182834 Camshaft speed 40-1246
sensor
K032 04213839 Fuel temperature 40-1246
sensor
N007 02113597 Actuator 40-1246

40.3.7 - S002A - Electronic engine governor - Version with analog instrument panel (R3
EVO 100 -> 16001, R3 EVO 110 -> 5001)

M002 M001

CHARGE AIR PRESSURE SIGNAL (M24)

CHARGE AIR PRESSURE GND (M23)

CHARGE AIR PRESSURE +5V (M25)

WATER TEMPERATURE (M8) GND

CHARGE AIR PRESS.TEMPER.

WATER TEMPERATURE (M9)
E008

SIGNAL PEDAL GAS

HAND GAS SIGNAL

ATTUATOR (M18)

ATTUATOR (M19)
ATTUATOR (M17)
ATTUATOR (M15)
ATTUATOR (M14)
FUEL TEMP (M5)

PICK-UP+ (M13)
PICK-UP- (M12)
GND COM 24/20

GND SCREEN
ALLARM LAMP
ENGINE MEM.

-31 ELECTR.

-31 ELECTR.

HOLD LAMP

GND COM

+5V 24
HOLD
+15

-31

+15

B
12 B7 B1 4 2 1 15 14 17 18 20 23 24 25 5 8 9 16 12 13 14 15 17 18 19 23 24 25 4
C004

C009

D013a

D011
D013
B022
B021

7.5A
10A

A A B A A A A A A A A A A B A
1 2 10 11 A5 A8 C4 B4 B5 B6 B7 C1 C2 C3 C4 C7 C8 C5 A4
+15

D015

5 8 9 12 13 14 15 17 18 19 23 24 25 4

2 4 1 2 4 2 1 2 4 1

pos pos

I001
K005 K006

1 2 2 1 2 1 1 2 3 5 4 1 4 3 2
t
t

D0065180 freq

K032 K026 K031 N007 K028

Fig. 2377 - Electronic engine governor - Version with analog instrument panel - System
l D011 (M) - Wiring connector (Wiring loom 0.016.1999.4/10)
l D011 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013a (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013a (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D015 (F) - Wiring connector (Wiring loom 0.016.1999.4/10)
l D015 (M) - Wiring connector (Wiring loom 04215655)

40-276
Wiring diagrams
l E008 - Instrument panel
l I001 - Engine speed memory button.
l K005 - Hand throttle position sensor
l K006 - Accelerator pedal position sensor
l K026 - Engine coolant temperature sensor
l K028 - Turbo air temperature/pressure sensor
l K031 - Camshaft rotation speed sensor
l K032 - Fuel temperature sensor
l M001 - Engine control unit
l M002 - Engine ECU
l N007 - Actuator

B022
B021

E008
C004

A
A K006

D0063651

Fig. 2378 - Electronic engine governor - Version with analog instrument panel - Connector positions
Table 434
Sys- P/N Description Characteristics/notes Position Wiring
tem
B021 Fuse (10A) 40-1238

40-277
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B022 Fuse (7.5A) 40-1238
C004 Earthing point 4 40-1238

Fig. 2379
E008 Instrument panel 40-1238
K006 Accelerator pedal Sensor N°1 40-1238
position sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal

40-278
Wiring diagrams

I001

K005

D013a
D013

D011

M001

M002

C009

D0063661

Fig. 2381 - Connector positions

Table 435
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1238

Fig. 2382

40-279
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1233
40-1238

Fig. 2383
D013 Wiring connector 40-1238
40-1238

Fig. 2384
Wiring connector 40-1238
Wiring connector 40-1238
I001 Engine speed Normally open contact (NO) 40-1238
memory button

Fig. 2385
K005 Hand throttle posi- Sensor N°1 40-1238
tion sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
M001 02959599 Engine control unit 40-1238

Fig. 2387
M002 02959599 Engine control unit 40-1238

Fig. 2388

40-280
Wiring diagrams

D011

D015

D0063640

Fig. 2389 - Connector positions

40-281
 Wiring diagrams
Table 436
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1233
40-1238

Fig. 2389
D015 Wiring connector 40-1233
D015 Wiring connector 40-1248

K026
K028

D015

K032

N007

K031 D0063630

Fig. 2390 - Connector positions

Table 437
Sys- P/N Description Characteristics/notes Position Wiring
tem
D015 Wiring connector 40-1233
D015 Wiring connector 40-1248
K026 04213839 Engine coolant 40-1248
temperature sensor
K028 04213838 Turbine air tem- 40-1248
perature/pressure
sensor

40-282
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
K031 01182834 Camshaft speed 40-1248
sensor
K032 04213839 Fuel temperature 40-1248
sensor
N007 02113597 Actuator 40-1248

40.3.8 - S002D - Electronic engine governor - Version with digital instrument panel (R3
EVO 100 -> 16001, R3 EVO 110 -> 5001)

M002 M001

CHARGE AIR PRESSURE SIGNAL (M24)

CHARGE AIR PRESSURE GND (M23)

CHARGE AIR PRESSURE +5V (M25)

WATER TEMPERATURE (M8) GND

CHARGE AIR PRESS.TEMPER.

WATER TEMPERATURE (M9)
E003 E002

SIGNAL PEDAL GAS

HAND GAS SIGNAL

ATTUATOR (M18)

ATTUATOR (M19)
ATTUATOR (M17)
ATTUATOR (M15)
ATTUATOR (M14)
FUEL TEMP (M5)

PICK-UP+ (M13)
PICK-UP- (M12)
GND COM 24/20

GND SCREEN
-31 ELECTR.

-31 ELECTR.

HOLD LAMP
HOLD LAMP

GND COM
+12/30

+12/30

+5V 24
HOLD
GND

+15

+15
-31

17 13 8 15 21 14 2 1 14 15 17 18 20 23 24 25 5 8 9 16 12 13 14 15 17 18 19 23 24 25 4
C004

C008

D011
D013
B022
B021
B010

7.5A
10A
5A

A A B A A A A A A A A A A B A
10 11 A5 B1 C4 B4 B5 B6 B7 C1 C2 C3 C4 C7 C8 C5 A4
+30

+15

D015

5 8 9 12 13 14 15 17 18 19 23 24 25 4

2 4 1 2 1 2 4 1

pos pos

I001
K005 K006

1 2 2 1 2 1 1 2 3 5 4 1 4 3 2
freq
t
t

D0062860
K032 K026 K031 N007 K028

Fig. 2391 - Electronic engine governor - Version with digital instrument panel - System
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D013 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D013 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D013 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D013 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)

40-283
 Wiring diagrams
l D015 (M) - Wiring connector (Wiring loom 04215655)
l D015 (M) - Wiring connector (Wiring loom 04214707)
l D015 (F) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D015 (F) - Wiring connector (Wiring loom 0.015.7023.4/50)
l E002 - Instrument panel
l E003 - Instrument panel
l I001 - Engine speed memory button.
l K005 - Hand throttle position sensor
l K006 - Accelerator pedal position sensor
l K026 - Engine coolant temperature sensor
l K028 - Turbo air temperature/pressure sensor
l K031 - Camshaft rotation speed sensor
l K032 - Fuel temperature sensor
l M001 - Engine control unit
l M002 - Engine ECU
l N007 - Actuator

B010

B022
B021

C004
E002

E003

A K006

D0063650

Fig. 2392 - Electronic engine governor - Version with digital instrument panel - Connector positions

40-284
Wiring diagrams
Table 438
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1205
B010 Fuse (5A) 40-1221
B021 Fuse (10A) 40-1205
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1205
B022 Fuse (7.5A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 2393
E002 Instrument panel 40-1205
40-1221

Fig. 2394
E003 Instrument panel 40-1205
40-1221

Fig. 2395
K006 Accelerator pedal Sensor N°1 40-1205
position sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K006 Accelerator pedal Sensor N°1 40-1221
position sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal

40-285
 Wiring diagrams

I001

K005

D013

C008 B

D011

M001

M002

D0063660

Fig. 2397 - Connector positions

Table 439
Sys- P/N Description Characteristics/notes Position Wiring
tem
C008 Earthing point 8 40-1205
40-1221

Fig. 2398

40-286
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
K005 Hand throttle posi- Sensor N°1 40-1205
tion sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
K005 Hand throttle posi- Sensor N°1 40-1221
tion sensor Pin 1 = 5.0Vdc power
Pin 2 = earth
Pin 4 = 0.5V - 4.5V analog signal
Sensor N°2
Pin 6 = 5.0Vdc power
Pin 5 = earth
Pin 3 = 0.5V - 4.5V analog signal
I001 Engine speed Normally open contact (NO) 40-1205
memory button 40-1221

Fig. 2400
D011 Wiring connector 40-1205
40-1212
40-1221

Fig. 2401
D013 Wiring connector 40-1205
40-1205
40-1221
40-1221

Fig. 2402
M001 02959599 Engine control unit 40-1205
40-1221

Fig. 2403

40-287
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
M002 02959599 Engine control unit 40-1205
40-1221

Fig. 2404

D011

D015

D0063640

Fig. 2405 - Connector positions

40-288
Wiring diagrams
Table 440
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1205
40-1212
40-1221

Fig. 2405
D015 Wiring connector 40-1212
40-1248

K026
K028

D015

K032

N007

K031 D0063630

Fig. 2406 - Connector positions

Table 441
Sys- P/N Description Characteristics/notes Position Wiring
tem
D015 Wiring connector 40-1212
40-1248
K026 04213839 Engine coolant 40-1248
temperature sensor
K028 04213838 Turbine air tem- 40-1248
perature/pressure
sensor

40-289
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
K031 01182834 Camshaft speed 40-1248
sensor
K032 04213839 Fuel temperature 40-1248
sensor
N007 02113597 Actuator 40-1248

40.3.9 - S003 - Diagnostics and accessories - Version with standard cab (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)

P004a
P002a

P002b
P002

P004
J005 J004 E003 E002 R001
P005

+12/30

+12/30
GND
ISO

+15
-31
NC NO 85 86 30 NC NO 85 86 30 1 2 3 1 2 3 1 2 1 13 8 14 15 21 1 2 10 13 3 4
B026

C008
C004

C003

C004

C004
30A
+30

F018 F019
+30
B029

2 1 2 1
40A
D031

D008
D032

B022

B031
B021

B010
B011
B020

B024
B030

B016

B008
B015
7.5A

7.5A

7.5A

2 1 2 1
30A

15A
30A
10A

15A
7.5

5A
3A

4 2
+30

+30
D023
D029

+30
+15

C004

4 8 4 2
D007
C007

C004
B035

B034

B038
7.5A
10A

C008
5A

1 3 2 6

10 9 5 6 2 3 7 8 1 2 9 8 15 17 14 10 11 2 1
ISO 9141
+15
+30

+30

-31

-31

. -31 ELECTR

.-31 ELECTR
ISO K

ISO L

+15

2 4 3 1 2 1 1 2 2 1 3 4

P008 G001 E005 I008 H003 M002

I025

D0062890

Fig. 2407 - Diagnostics and accessories - Version with standard cab - System
l D007 (M) - Wiring connector (Wiring loom 0.015.1418.4/30)
l D007 (M) - Wiring connector (Wiring loom 0.015.1418.4/30)
l D007 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D007 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D007 (M) - Wiring connector (Wiring loom 0.015.1418.4/30)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)

40-290
Wiring diagrams

P004a
P002a

P002b
P002

P004
J005 J004 E003 E002 R001
P005

+12/30

+12/30
GND
ISO

+15
-31
NC NO 85 86 30 NC NO 85 86 30 1 2 3 1 2 3 1 2 1 13 8 14 15 21 1 2 10 13 3 4

B026

C008
C004

C003

C004

C004
30A
+30

F018 F019
+30
B029

2 1 2 1
40A
D031

D008
D032

B022

B031
B021

B010
B011
B020

B024
B030

B016

B008
B015
7.5A

7.5A

7.5A
2 1 2 1
30A

15A
30A
10A

15A
7.5

5A
3A

4 2
+30

+30
D023
D029

+30
+15

C004
4 8 4 2

D007
C007

C004
B035

B034

B038
7.5A
10A

C008
5A

1 3 2 6

10 9 5 6 2 3 7 8 1 2 9 8 15 17 14 10 11 2 1
ISO 9141
+15
+30

+30

-31

-31

. -31 ELECTR

.-31 ELECTR
ISO K

ISO L

+15
2 4 3 1 2 1 1 2 2 1 3 4

P008 G001 E005 I008 H003 M002

I025

D0062890

Fig. 2407 - Diagnostics and accessories - Version with standard cab - System
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D031 (F) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D031 (M) - Wiring connector (Wiring loom 0.013.6327.4)
l D032 (F) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D032 (M) - Wiring connector (Wiring loom 0.013.6327.4)
l E002 - Instrument panel
l E003 - Instrument panel
l E005 - Clock
l F018 - Rotating beacon

40-291
 Wiring diagrams

P004a
P002a

P002b
P002

P004
J005 J004 E003 E002 R001
P005

+12/30

+12/30
GND
ISO

+15
-31
NC NO 85 86 30 NC NO 85 86 30 1 2 3 1 2 3 1 2 1 13 8 14 15 21 1 2 10 13 3 4

B026

C008
C004

C003

C004

C004
30A
+30

F018 F019
+30
B029

2 1 2 1
40A
D031

D008
D032

B022

B031
B021

B010
B011
B020

B024
B030

B016

B008
B015
7.5A

7.5A

7.5A
2 1 2 1
30A

15A
30A
10A

15A
7.5

5A
3A

4 2
+30

+30
D023
D029

+30
+15

C004
4 8 4 2

D007
C007

C004
B035

B034

B038
7.5A
10A

C008
5A

1 3 2 6

10 9 5 6 2 3 7 8 1 2 9 8 15 17 14 10 11 2 1
ISO 9141
+15
+30

+30

-31

-31

. -31 ELECTR

.-31 ELECTR
ISO K

ISO L

+15
2 4 3 1 2 1 1 2 2 1 3 4

P008 G001 E005 I008 H003 M002

I025

D0062890

Fig. 2407 - Diagnostics and accessories - Version with standard cab - System
l F019 - Rotating beacon
l G001 - Cab courtesy light
l H003 - Shuttle lever
l I008 - Road lights switch
l I025 - Rotating beacon on/off switch
l J004 - Relay
l J005 - Relay
l M002 - Engine ECU
l P002 - Auxiliary power socket (25A)
l P002a - Auxiliary power socket (25A)
l P002b - Auxiliary power socket (25A)
l P004 - Cigar lighter
l P004a - Cigar lighter
l P005 - Pneumatic seat compressor
l P008 - Radio (power supply)
l R001 - Diagnostics port

40-292
Wiring diagrams
B029

B030
B031
B026
J005
J004
B015
A
B016
B020

B021
B008 B022 B024
B010 B011

D008 E002
D007

E003 C004

R001

I008

D0063670

Fig. 2408 - Accessory diagnostics - Version with standard cab - Connector positions
Table 442
Sys- P/N Description Characteristics/notes Position Wiring
tem
B008 Fuse (15A) 40-1209
B008 Fuse (15A) 40-1221
B010 Fuse (5A) 40-1209
B010 Fuse (5A) 40-1221
B011 Fuse (7.5A) 40-1209
B011 Fuse (7.5A) 40-1221
B015 Fuse (15A) 40-1209

40-293
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1221
B016 Fuse (7.5A) 40-1209
B016 Fuse (7.5A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1209
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1209
B022 Fuse (7.5A) 40-1221
B024 Fuse (7.5A) 40-1209
B024 Fuse (7.5A) 40-1221
B026 Fuse (30A) 40-1209
B026 Fuse (30A) 40-1221
B029 Fuse (40A) 40-1209
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221
B031 Fuse (30A) 40-1209
B031 Fuse (30A) 40-1221
C004 Earthing point 4 40-1209
40-1221

Fig. 2409

Table 443
Sys- P/N Description Characteristics/notes Position Wiring
tem
D007 Wiring connector 40-1209
40-1195
40-1221
40-1195

Fig. 2410
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2411

40-294
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
E002 Instrument panel 40-1209
40-1221

Fig. 2412
E003 Instrument panel 40-1209
40-1221

Fig. 2413
I008 Road lights switch 40-1209

Fig. 2414 Fig. 2415

J004 Relay 40-1209
40-1221

Fig. 2416
R001 Diagnostics socket 40-1209
40-1221

Fig. 2417
J005 Relay 40-1209
40-1221

Fig. 2418

40-295
 Wiring diagrams

C003

P002

P005
C008 B

P004a
P004
P002b
P002a
M002

D0063690

Fig. 2419 - Connector positions

Table 444
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1209
40-1221

Fig. 2420

40-296
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C008 Earthing point 8 40-1209
40-1221

Fig. 2421
P002 Auxiliary power 40-1209
socket (25A) 40-1221

Fig. 2422
Auxiliary power 40-1209
socket (25A) 40-1221

Fig. 2422
Auxiliary power 40-1209
socket (25A) 40-1221

Fig. 2422
P004 Cigar lighter 40-1209
40-1221

Fig. 2423
Cigar lighter 40-1209
40-1221

Fig. 2423

40-297
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
P005 Pneumatic seat 40-1209
compressor 40-1221

Fig. 2424
M002 02959599 Engine control unit 40-1209
40-1221

Fig. 2425

D007

G8

X53

H003

G19
X54

X55

D0063710

Fig. 2426 - Connector positions

40-298
Wiring diagrams
Table 445
Sys- P/N Description Characteristics/notes Position Wiring
tem
D007 Wiring connector 40-1209
40-1195
40-1221
40-1195

Fig. 2426
H003 Shuttle lever 40-1195

Fig. 2427

40-299
 Wiring diagrams

D023

D008

D0063720

Fig. 2428 - Connector positions

Table 446
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2428

40-300
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1220
40-1226
40-1244
40-1220

Fig. 2429

B034-B035-B038
C007

E005

P008
D029
G001
D023
I025

D0063740

Fig. 2430 - Connector positions

Table 447
Sys- P/N Description Characteristics/notes Position Wiring
tem
B034 Fuse (10A) 40-1226
B034 Fuse (10A) 40-1244
B035 Fuse (5A) 40-1226
B035 Fuse (5A) 40-1244
B038 Fuse (7.5A) 40-1226
B038 Fuse (7.5A) 40-1244

40-301
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1226
40-1244

Fig. 2431
D023 Wiring connector 40-1220
40-1226
40-1244
40-1220

Fig. 2431
D029 Wiring connector 40-1226
40-1244
40-1230
40-1230
E005 Clock 40-1226
40-1244
G001 Interior roof light 40-1226
40-1244

Fig. 2432
I025 Rotating beacon 0 40-1226
switch 1

Pin 1 2
Pos

0
Fig. 2434
1

Fig. 2433
I025 Rotating beacon 0 40-1244
switch 1

Pin 1 2
Pos

0
Fig. 2434
1

Fig. 2434

40-302
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
P008 Radio (power sup- 40-1226
ply) 40-1244

Fig. 2435

F018

D032

D031 F019

D0063750

Fig. 2436 - Connector positions

40-303
 Wiring diagrams
Table 448
Sys- P/N Description Characteristics/notes Position Wiring
tem
D031 Wiring connector 40-1230
40-1189

Fig. 2437
D032 Wiring connector 40-1230
40-1190

Fig. 2438
F018 Rotating beacon 40-1190
F019 Rotating beacon 40-1189

40-304
Wiring diagrams
40.3.10 - S003A - Accessories and diagnostics - Version with analog instrument panel
(R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

P002a

P002b
P002
J005 J004 R001
P005

NC NO 85 86 30 NC NO 85 86 30 1 2 3 1 2 1 2 10 13 3 4

B026

C009
C004

C003

C004
30A
+30

F018 F019
+30
B029

2 1 2 1
40A
D031

D008
D032

B022
B021

B031

B008
B020

B030

B016
7.5A

2 1 2 1
30A

15A
30A
10A

7.5

3A

4 2
+30
D023
D029

+30
+15

4 8 4 2
C007

B035

B034

B038
7.5A
10A

C009
5A

14 10 11 2 1
. -31 ELECTR

.-31 ELECTR
ISO K

ISO L

+15

2 4 3 1 2 1 1 2 2 1 3 4

D0065190
P008 G001 E005 M002
I025

Fig. 2439 - Accessories and diagnostics - Version with analog instrument panel - System
l D008 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D031 (F) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D031 (M) - Wiring connector (Wiring loom 0.013.6327.4)
l D032 (F) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D032 (M) - Wiring connector (Wiring loom 0.013.6327.4)
l E005 - Clock

40-305
 Wiring diagrams
l F018 - Rotating beacon
l F019 - Rotating beacon
l G001 - Cab courtesy light
l I025 - Rotating beacon on/off switch
l J004 - Relay
l J005 - Relay
l M002 - Engine ECU
l P002 - Auxiliary power socket (25A)
l P002a - Auxiliary power socket (25A)
l P002b - Auxiliary power socket (25A)
l P005 - Pneumatic seat compressor
l P008 - Radio (power supply)
l R001 - Diagnostics port

40-306
Wiring diagrams
B029

B030
B031
B026
J005
J004
B016 A
B020

B008 B021
B022

D008

C004

R001

D0063672

Fig. 2440 - Accessories and diagnostics - Version with analog instrument panel - Connector positions
Table 449
Sys- P/N Description Characteristics/notes Position Wiring
tem
B008 Fuse (15A) 40-1238
B016 Fuse (7.5A) 40-1238
B020 Fuse (3A) 40-1238
B021 Fuse (10A) 40-1238
B022 Fuse (7.5A) 40-1238
B026 Fuse (30A) 40-1238
B029 Fuse (40A) 40-1238

40-307
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B030 Fuse (30A) 40-1238
B031 Fuse (30A) 40-1238
D008 Wiring connector 40-1238
40-1220

Fig. 2441
C004 Earthing point 4 40-1238

Fig. 2442
J004 Relay 40-1238

Fig. 2443
J005 Relay 40-1238

Fig. 2444
R001 Diagnostics socket 40-1238

Fig. 2445

40-308
Wiring diagrams

C003

P002

P005
B

P002b
P002a
M002

C009

D0063691

Fig. 2446 - Connector positions

Table 450
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1238

Fig. 2447

40-309
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1238

Fig. 2448
M002 02959599 Engine control unit 40-1238

Fig. 2449
P002 Auxiliary power 40-1238
socket (25A)

Fig. 2450
Auxiliary power 40-1238
socket (25A)

Fig. 2450
Auxiliary power 40-1238
socket (25A)

Fig. 2450
P005 Pneumatic seat 40-1238
compressor

Fig. 2451

40-310
Wiring diagrams

D023

D008

D0063720

Fig. 2452 - Connector positions

Table 451
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1238
40-1220

Fig. 2452

40-311
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2453

B034-B035-B038
C007

E005

P008
D029
G001
D023
I025

D0063740

Fig. 2454 - Connector positions

Table 452
Sys- P/N Description Characteristics/notes Position Wiring
tem
B034 Fuse (10A) 40-1228
B034 Fuse (10A) 40-1242
B035 Fuse (5A) 40-1228
B035 Fuse (5A) 40-1242
B038 Fuse (7.5A) 40-1228
B038 Fuse (7.5A) 40-1242

40-312
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1228
40-1242

Fig. 2455
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2455
D029 Wiring connector 40-1228
40-1242
40-1230
40-1230
E005 Clock 40-1228
E005 Clock 40-1242
G001 Interior roof light 40-1228
40-1242

Fig. 2456
I025 Rotating beacon 40-1228
40-1242
P008 Radio (power sup- 40-1228
ply) 40-1242

Fig. 2459

40-313
 Wiring diagrams
F018

D032

D031 F019

D0063750

Fig. 2460 - Connector positions

Table 453
Sys- P/N Description Characteristics/notes Position Wiring
tem
D031 Wiring connector 40-1230
40-1189

Fig. 2461

40-314
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D032 Wiring connector 40-1230
40-1190

Fig. 2462
F018 Rotating beacon 40-1190
F019 Rotating beacon 40-1189

40.3.11 - S003D - Accessories and diagnostics - Version with standard cab - Version with
digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

P004a
P002a

P002b
P002

P004
J004 E003 E002 R001
J005 P005

+12/30

+12/30
GND
ISO

+15
-31
NC NO 85 86 30 NC NO 85 86 30 1 2 3 1 2 3 1 2 1 13 8 14 15 21 1 2 10 3 4
B026

C008
C004

C003

C004

C004
+3030A

F018 F019
+30
B029

2 1 2 1
40A
D031

D008
D032

B021

B022

B031

B010
B020

B015

B024
B030

B016

B008
7.5A

7.5A
30A

15A
30A
10A

15A
7.5

2 1 2 1
5A
3A

4 2
+30

+30
D023
D029

+30
+15

4 8 4 2
C007

C004
B038
B035

B034

7.5A
10A

C008
5A

10 9 5 6 2 3 7 8 14 10 11 2 1
-31 ELECTR

-31 ELECTR
ISO K

ISO L

+15

2 4 3 1 2 1 1 2 2 1 3 4

P008 G001 E005 I008 M002

I025

D0064790

Fig. 2463 - Accessories and diagnostics - Version with standard cab - Version with digital instrument panel -
System

40-315
 Wiring diagrams
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D031 (F) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D031 (M) - Wiring connector (Wiring loom 0.013.6327.4)
l D032 (F) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D032 (M) - Wiring connector (Wiring loom 0.013.6327.4)
l E002 - Instrument panel
l E003 - Instrument panel
l E005 - Clock
l F018 - Rotating beacon
l F019 - Rotating beacon
l G001 - Cab courtesy light
l I008 - Road lights switch
l I025 - Rotating beacon on/off switch
l J004 - Relay
l J005 - Relay
l M002 - Engine ECU
l P002 - Auxiliary power socket (25A)
l P002a - Auxiliary power socket (25A)
l P002b - Auxiliary power socket (25A)
l P004 - Cigar lighter
l P004a - Cigar lighter
l P005 - Pneumatic seat compressor
l P008 - Radio (power supply)
l R001 - Diagnostics port

40-316
Wiring diagrams
B029

B030
B031
B026
J005
J004
B015
A
B016
B020

B021
B008 B022 B024
B010

D008 E002

E003 C004

R001

I008

D0063671

Fig. 2464 - Accessories and diagnostics - Version with standard cab - Version with digital instrument panel - Con-
nector positions
Table 454
Sys- P/N Description Characteristics/notes Position Wiring
tem
B008 Fuse (15A) 40-1205
B008 Fuse (15A) 40-1221
B010 Fuse (5A) 40-1205
B010 Fuse (5A) 40-1221
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221

40-317
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B016 Fuse (7.5A) 40-1205
B016 Fuse (7.5A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1205
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1205
B022 Fuse (7.5A) 40-1221
B024 Fuse (7.5A) 40-1205
B024 Fuse (7.5A) 40-1221
B026 Fuse (30A) 40-1205
B026 Fuse (30A) 40-1221
B029 Fuse (40A) 40-1205
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
B031 Fuse (30A) 40-1205
B031 Fuse (30A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 2465
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 2466
E002 Instrument panel 40-1205
40-1221

Fig. 2467
E003 Instrument panel 40-1205
40-1221

Fig. 2468
I008 Road lights switch 40-1205
40-1221

40-318
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J004 Relay 40-1205
40-1221

Fig. 2471
J005 Relay 40-1205
40-1221

Fig. 2472
R001 Diagnostics socket 40-1205
40-1221

Fig. 2473

40-319
 Wiring diagrams

C003

P002

P005
C008 B

P004a
P004
P002b
P002a
M002

D0063690

Fig. 2474 - Connector positions

Table 455
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1205
40-1221

Fig. 2475

40-320
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C008 Earthing point 8 40-1205
40-1221

Fig. 2476
M002 02959599 Engine control unit 40-1205
40-1221

Fig. 2477
P002 Auxiliary power 40-1205
socket (25A) 40-1221

Fig. 2478
Auxiliary power 40-1205
socket (25A) 40-1221

Fig. 2478
Auxiliary power 40-1205
socket (25A) 40-1221

Fig. 2478
P004 Cigar lighter 40-1205
40-1221

Fig. 2479

40-321
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
Cigar lighter 40-1205
40-1221

Fig. 2479
P005 Pneumatic seat 40-1205
compressor 40-1221

Fig. 2480

40-322
Wiring diagrams

D023

D008

D0063720

Fig. 2481 - Connector positions

Table 456
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 2481

40-323
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2482

B034-B035-B038
C007

E005

P008
D029
G001
D023
I025

D0063740

Fig. 2483 - Connector positions

Table 457
Sys- P/N Description Characteristics/notes Position Wiring
tem
B034 Fuse (10A) 40-1228
B034 Fuse (10A) 40-1242
B035 Fuse (5A) 40-1228
B035 Fuse (5A) 40-1242
B038 Fuse (7.5A) 40-1228
B038 Fuse (7.5A) 40-1242

40-324
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1228
40-1242

Fig. 2484
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2484
D029 Wiring connector 40-1228
40-1242
40-1230
40-1230
E005 Clock 40-1228
40-1242
G001 Interior roof light 40-1228
40-1242

Fig. 2485
I025 Rotating beacon 40-1228
40-1242
P008 Radio (power sup- 40-1228
ply) 40-1242

Fig. 2488

40-325
 Wiring diagrams
F018

D032

D031 F019

D0063750

Fig. 2489 - Connector positions

Table 458
Sys- P/N Description Characteristics/notes Position Wiring
tem
D031 Wiring connector 40-1230
40-1189

Fig. 2490

40-326
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D032 Wiring connector 40-1230
40-1190

Fig. 2491
F018 Rotating beacon 40-1190
F019 Rotating beacon 40-1189

40.3.12 - S004 - Diagnostics and accessories - Version with high-visibility cab (R3 EVO
100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001) P002a

P002b

P004a
P002

P004
J004 E003 E002 R001
P005

+12/30

+12/30
GND
ISO

+15
-31
NC NO 85 86 30 1 2 3 1 2 1 2 3 1 13 8 15 21 14 1 10 2 13 3 4
C004

C003
C008
C003

C004
C004

F018 F019 G001 G002

2 1 2 1 1 2 2 1
D008
D032

D031

B010
B029

6 4
B011
B031

B008
B021

B020

B024
B015
B030

B016
B022

7.5A
7.5A

7.5A

7.5A
40A
30A

15A

5A
30A
10A

15A
3A

2 1 2 1
C007

D023

+15

+30
+30
+30

6 4

P010
C007

C004

-
+

1 2

P009
D007
C007

C004

-
B035
B034

+
10A

5A

2 1
C007

C008

1 3 2 6

7 4 6 5 1 3 2 8 1 2 1 3 2 4 10 9 5 6 2 3 7 8 1 2 9 8 15 17 14 10 11 2 1
ISO 9141
+15
+30

+30

-31

-31

. -31 ELECTR
+15

.-31 ELECTR
ISO K

ISO L

I025 I008 H003 M002

P008 P011
D0063050

Fig. 2492 - Diagnostics and accessories - Version with high-visibility cab - System

40-327
 Wiring diagrams
l D007 (M) - Wiring connector (Wiring loom 0.015.1418.4/30)
l D007 (M) - Wiring connector (Wiring loom 0.015.1418.4/30)
l D007 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D007 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D007 (M) - Wiring connector (Wiring loom 0.015.1418.4/30)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D031 (M) - Wiring connector (Wiring loom 0.013.6327.4)
l D031 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D032 (M) - Wiring connector (Wiring loom 0.013.6327.4)
l D032 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l E002 - Instrument panel
l E003 - Instrument panel
l F018 - Rotating beacon
l F019 - Rotating beacon
l G001 - Cab courtesy light
l G002 - Spot light
l H003 - Shuttle lever
l I008 - Road lights switch
l I025 - Rotating beacon on/off switch
l J004 - Relay
l M002 - Engine ECU
l P002 - Auxiliary power socket (25A)
l P002a - Auxiliary power socket (25A)
l P002b - Auxiliary power socket (25A)
l P004 - Cigar lighter
l P004a - Cigar lighter
l P005 - Pneumatic seat compressor
l P008 - Radio (power supply)
l P009 - LH loudspeaker
l P010 - RH loudspeaker
l P011 - Radio (speakers)
l R001 - Diagnostics port

40-328
Wiring diagrams
B029

B030
B031

J004
B015
A
B016
B020

B021
B008 B022 B024
B010 B011

D008 E002
D007

E003 C004

R001

I008
B

D0063760

Fig. 2493 - Diagnostics and accessories - Version with high-visibility cab - Connector positions
Table 459
Sys- P/N Description Characteristics/notes Position Wiring
tem
B008 Fuse (15A) 40-1209
B008 Fuse (15A) 40-1221
B010 Fuse (5A) 40-1209
B010 Fuse (5A) 40-1221
B011 Fuse (7.5A) 40-1209
B011 Fuse (7.5A) 40-1221
B015 Fuse (15A) 40-1209

40-329
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1221
B016 Fuse (7.5A) 40-1209
B016 Fuse (7.5A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1209
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1209
B022 Fuse (7.5A) 40-1221
B024 Fuse (7.5A) 40-1209
B024 Fuse (7.5A) 40-1221
B029 Fuse (40A) 40-1209
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221
B031 Fuse (30A) 40-1209
B031 Fuse (30A) 40-1221
C004 Earthing point 4 40-1209
40-1221

Fig. 2494
D007 Wiring connector 40-1209
40-1195
40-1221
40-1195

Fig. 2495

40-330
Wiring diagrams
Table 460
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2496
E002 Instrument panel 40-1209
40-1221

Fig. 2497
E003 Instrument panel 40-1209
40-1221

Fig. 2498
I008 Road lights switch 40-1209
40-1221
R001 Diagnostics socket 40-1209
40-1221

Fig. 2501
J004 Relay 40-1209
40-1221

Fig. 2502

40-331
 Wiring diagrams

C003

P002

P005
C008 B

P004a
P004
P002b
P002a
M002

D0063690

Fig. 2503 - Connector positions

Table 461
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1209
40-1221

Fig. 2504

40-332
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C008 Earthing point 8 40-1209
40-1221

Fig. 2505
M002 02959599 Engine control unit 40-1209
40-1221

Fig. 2506
P002 Auxiliary power 40-1209
socket (25A) 40-1221

Fig. 2507
Auxiliary power 40-1209
socket (25A) 40-1221

Fig. 2507
Auxiliary power 40-1209
socket (25A) 40-1221

Fig. 2507
P004 Cigar lighter 40-1209
40-1221

Fig. 2508

40-333
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
Cigar lighter 40-1209
40-1221

Fig. 2508
P005 Pneumatic seat 40-1209
compressor 40-1221

Fig. 2509

D007

G8

X53

H003

G19
X54

X55

D0063710

Fig. 2510 - Connector positions

40-334
Wiring diagrams
Table 462
Sys- P/N Description Characteristics/notes Position Wiring
tem
D007 Wiring connector 40-1209
40-1195
40-1221
40-1195

Fig. 2510
H003 Shuttle lever 40-1195

Fig. 2511

40-335
 Wiring diagrams

D023

D008

D0063720

Fig. 2512 - Connector positions

Table 463
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2512

40-336
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1204
40-1220

Fig. 2513

40-337
 Wiring diagrams
P010

I025

D032

B034-B035
G002
C007
D023
P009

P008
P011
G001

D031

D0063770

Fig. 2514 - Connector positions

Table 464
Sys- P/N Description Characteristics/notes Position Wiring
tem
B034 Fuse (15A) 40-1204
B035 Fuse (5A) 40-1204

40-338
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 2515
D023 Wiring connector 40-1204
40-1220

Fig. 2515
D031 Wiring connector 40-1204
40-1189

Fig. 2516
D032 Wiring connector 40-1204
40-1190

Fig. 2517
G001 Interior roof light 40-1204

Fig. 2518
G002 Spot light 40-1204

Fig. 2519

40-339
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I025 Rotating beacon 0 40-1204
1
switch
7

8
2 3
7 4 5 6

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2520
P008 Radio (power sup- 40-1204
ply)

Fig. 2521
P009 Lh loudspeaker 40-1204

Fig. 2522
P010 Rh loudspeaker 40-1204
P011 Radio (loudspeak- 40-1204
ers)

Fig. 2523

40-340
Wiring diagrams
F018

D032

D031 F019

D0063750

Fig. 2524 - Connector positions

Table 465
Sys- P/N Description Characteristics/notes Position Wiring
tem
D031 Wiring connector 40-1204
40-1189

Fig. 2524

40-341
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D032 Wiring connector 40-1204
40-1190

Fig. 2524
F018 Rotating beacon 40-1190
F019 Rotating beacon 40-1189

40.3.13 - S004A - Accessories and diagnostics - Version with high-visibility cab - Version
with analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)

40-342
Wiring diagrams

P002a

P002b
P002
J004 R001
P005

NC NO 85 86 30 1 2 3 1 2 1 10 2 13 3 4

C004

C004
C009
C003
F018 F019 G001 G002

2 1 2 1 1 2 2 1
D008

6 4
D032

D031

B031

B008
B021

B020

B024
B015
B030
B029

B016
B022

7.5A
7.5A

7.5A
40A

30A

15A
30A
10A

15A
3A

2 1 2 1
C007

D023

+15
+30

+30
+30

6 4
P010
C007

-
+

1 2

P009
-
B035
B034

+
10A

5A

2 1
C004
C007

C007

C009
7 4 6 5 1 3 2 8 1 2 1 3 2 4 10 9 5 6 2 3 7 8 14 10 11 2 1

. -31 ELECTR
+15

.-31 ELECTR
ISO K

ISO L

I025 P008 P011 I008 M002

D0065390

Fig. 2525 - Accessories and diagnostics - Version with high-visibility cab - Version with analog instrument panel
- System
l D008 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D031 (M) - Wiring connector (Wiring loom 0.013.6327.4)
l D031 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D032 (M) - Wiring connector (Wiring loom 0.013.6327.4)
l D032 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l F018 - Rotating beacon
l F019 - Rotating beacon
l G001 - Cab courtesy light
l G002 - Spot light
l I008 - Road lights switch
l I025 - Rotating beacon on/off switch
l J004 - Relay
l M002 - Engine ECU
l P002 - Auxiliary power socket (25A)

40-343
 Wiring diagrams
l P002a - Auxiliary power socket (25A)
l P002b - Auxiliary power socket (25A)
l P005 - Pneumatic seat compressor
l P008 - Radio (power supply)
l P009 - LH loudspeaker
l P010 - RH loudspeaker
l P011 - Radio (speakers)
l R001 - Diagnostics port

B029

B030 J004 A
B031

B015
B016
B024
B008
B020 B021 B022

D008

C004

R001

A
I008

D0065460

Fig. 2526 - Accessories and diagnostics - Version with high-visibility cab - Version with analog instrument panel
- System

40-344
Wiring diagrams
Table 466
Sys- P/N Description Characteristics/notes Position Wiring
tem
B008 Fuse (15A) 40-1238
B015 Fuse (15A) 40-1238
B016 Fuse (7.5A) 40-1238
B020 Fuse (3A) 40-1238
B021 Fuse (10A) 40-1238
B022 Fuse (7.5A) 40-1238
B024 Fuse (7.5A) 40-1238
B029 Fuse (40A) 40-1238
B030 Fuse (30A) 40-1238
B031 Fuse (30A) 40-1238
C004 Earthing point 4 40-1238

Fig. 2527
D008 Wiring connector 40-1238
40-1220

Fig. 2528
I008 Road lights switch 40-1238

Fig. 2529 Fig. 2530

J004 Relay 40-1238

Fig. 2531
R001 Diagnostics socket 40-1238

Fig. 2532

40-345
 Wiring diagrams

C003

P002

P005
B

P002b

P002a
M002

C009

D0065470

Fig. 2533 - Connector positions

Table 467
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1238

Fig. 2534

40-346
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1238

Fig. 2535
M002 02959599 Engine control unit 40-1238

Fig. 2536
P002 Auxiliary power 40-1238
socket (25A)

Fig. 2537
Auxiliary power 40-1238
socket (25A)

Fig. 2537
Auxiliary power 40-1238
socket (25A)

Fig. 2537
P005 Pneumatic seat 40-1238
compressor

Fig. 2538

40-347
 Wiring diagrams

D023

D008

D0063720

Fig. 2539 - Connector positions

Table 468
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1238
40-1220

Fig. 2539

40-348
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1204
40-1220

Fig. 2540

40-349
 Wiring diagrams
P010

I025

D032

B034-B035
G002
C007
D023
P009

P008
P011
G001

D031

D0063770

Fig. 2541 - Connector positions

Table 469
Sys- P/N Description Characteristics/notes Position Wiring
tem
B034 Fuse (15A) 40-1204
B035 Fuse (5A) 40-1204

40-350
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 2542
D023 Wiring connector 40-1204
40-1220

Fig. 2542
D031 Wiring connector 40-1204
40-1189

Fig. 2543
D032 Wiring connector 40-1204
40-1190

Fig. 2544
G001 Interior roof light 40-1204

Fig. 2545
G002 Spot light 40-1204

Fig. 2546

40-351
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I025 Rotating beacon 0 40-1204
1
switch
7

8
2 3
7 4 5 6

Pin 1 2 3 4 5 6 7 8
Pos

Fig. 2548
Fig. 2547
P008 Radio (power sup- 40-1204
ply)

Fig. 2549
P009 Lh loudspeaker 40-1204

Fig. 2550
P010 Rh loudspeaker 40-1204
P011 Radio (loudspeak- 40-1204
ers)

Fig. 2551

40-352
Wiring diagrams
F018

D032

D031 F019

D0063750

Fig. 2552 - Connector positions

Table 470
Sys- P/N Description Characteristics/notes Position Wiring
tem
D031 Wiring connector 40-1204
40-1189

Fig. 2552

40-353
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D032 Wiring connector 40-1204
40-1190

Fig. 2552
F018 Rotating beacon 40-1190
F019 Rotating beacon 40-1189

40.3.14 - S004D - Accessories and diagnostics - Version with high-visibility cab - Version
with digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)

40-354
Wiring diagrams

P002a

P002b

P004a
P002

P004
J004 E003 E002 R001
P005

+12/30

+12/30
GND
ISO

+15
-31
NC NO 85 86 30 1 2 3 1 2 1 2 3 1 13 8 15 21 14 1 10 2 3 4

C003
C008
C004

C003

C004
C004
F018 F019 G001 G002

2 1 2 1 1 2 2 1
D008
D032

D031

B010
B029
6 4
B031

B008
B021

B020

B024
B015
B030

B016
B022

7.5A
7.5A

7.5A

40A
30A

15A
30A
10A

15A
3A

5A
2 1 2 1
C007

D023

+30
+30
+15

+30

6 4
P010
C007

-
+

1 2

P009
C007

C004

-
B035
B034

+
10A

5A

2 1
C007

C008
7 4 6 5 1 3 2 8 1 2 1 3 2 4 10 9 5 6 2 3 7 8 14 10 11 2 1

-31 ELECTR
+15

-31 ELECTR
ISO K

ISO L

I025 P008 P011 I008 M002

D0064810

Fig. 2553 - Accessories and diagnostics - Version with high-visibility cab - Version with digital instrument panel
- System
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D031 (M) - Wiring connector (Wiring loom 0.013.6327.4)
l D031 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D032 (M) - Wiring connector (Wiring loom 0.013.6327.4)
l D032 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l E002 - Instrument panel
l E003 - Instrument panel
l F018 - Rotating beacon
l F019 - Rotating beacon
l G001 - Cab courtesy light
l G002 - Spot light
l I008 - Road lights switch
l I025 - Rotating beacon on/off switch
l J004 - Relay

40-355
 Wiring diagrams
l M002 - Engine ECU
l P002 - Auxiliary power socket (25A)
l P002a - Auxiliary power socket (25A)
l P002b - Auxiliary power socket (25A)
l P004 - Cigar lighter
l P004a - Cigar lighter
l P005 - Pneumatic seat compressor
l P008 - Radio (power supply)
l P009 - LH loudspeaker
l P010 - RH loudspeaker
l P011 - Radio (speakers)
l R001 - Diagnostics port

40-356
Wiring diagrams
B029

B030
B031

J004
B015
A
B016
B020

B021
B008 B022 B024
B010

D008 E002

E003 C004

R001

I008
B

D0063761

Fig. 2554 - Accessories and diagnostics - Version with high-visibility cab - Version with digital instrument panel
- Connector positions
Table 471
Sys- P/N Description Characteristics/notes Position Wiring
tem
B008 Fuse (15A) 40-1205
B008 Fuse (15A) 40-1221
B010 Fuse (5A) 40-1205
B010 Fuse (5A) 40-1221
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221

40-357
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B016 Fuse (7.5A) 40-1205
B016 Fuse (7.5A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1205
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1205
B022 Fuse (7.5A) 40-1221
B024 Fuse (7.5A) 40-1205
B024 Fuse (7.5A) 40-1221
B029 Fuse (40A) 40-1205
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
B031 Fuse (30A) 40-1205
B031 Fuse (30A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 2555
D008 Wiring connector 40-1220
40-1220

Fig. 2556
E002 Instrument panel 40-1205
40-1221

Fig. 2557
E003 Instrument panel 40-1205
40-1221

Fig. 2558
I008 Road lights switch 40-1205
40-1221

40-358
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
R001 Diagnostics socket 40-1205
40-1221

Fig. 2561
J004 Relay 40-1205
40-1221

Fig. 2562

40-359
 Wiring diagrams

C003

P002

P005
C008 B

P004a
P004
P002b
P002a
M002

D0063690

Fig. 2563 - Connector positions

Table 472
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1205
40-1221

Fig. 2564

40-360
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C008 Earthing point 8 40-1205
40-1221

Fig. 2565
M002 02959599 Engine control unit 40-1205
40-1221

Fig. 2566
P002 Auxiliary power 40-1205
socket (25A) 40-1221

Fig. 2567
Auxiliary power 40-1205
socket (25A) 40-1221

Fig. 2567
Auxiliary power 40-1205
socket (25A) 40-1221

Fig. 2567
P004 Cigar lighter 40-1205
40-1221

Fig. 2568

40-361
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
Cigar lighter 40-1205
40-1221

Fig. 2568
P005 Pneumatic seat 40-1205
compressor 40-1221

Fig. 2569

40-362
Wiring diagrams

D023

D008

D0063720

Fig. 2570 - Connector positions

Table 473
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1220
40-1220

Fig. 2570

40-363
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1204
40-1220

Fig. 2571

40-364
Wiring diagrams
P010

I025

D032

B034-B035
G002
C007
D023
P009

P008
P011
G001

D031

D0063770

Fig. 2572 - Connector positions

Table 474
Sys- P/N Description Characteristics/notes Position Wiring
tem
B034 Fuse (15A) 40-1204
B035 Fuse (5A) 40-1204

40-365
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 2573
D023 Wiring connector 40-1204
40-1220

Fig. 2573
D031 Wiring connector 40-1204
40-1189

Fig. 2574
D032 Wiring connector 40-1204
40-1190

Fig. 2575
G001 Interior roof light 40-1204
G002 Spot light 40-1204

Fig. 2576
I025 Rotating beacon Drawing D0015280.eps 40-1204
switch

Fig. 2577

40-366
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
P008 Radio (power sup- 40-1204
ply)

Fig. 2578
P009 Lh loudspeaker 40-1204

Fig. 2579
P010 Rh loudspeaker 40-1204
P011 Radio (loudspeak- 40-1204
ers)

Fig. 2580

40-367
 Wiring diagrams
F018

D032

D031 F019

D0063750

Fig. 2581 - Connector positions

Table 475
Sys- P/N Description Characteristics/notes Position Wiring
tem
F018 Rotating beacon 40-1190
F019 Rotating beacon 40-1189
D031 Wiring connector 40-1204
40-1189

Fig. 2581

40-368
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D032 Wiring connector 40-1204
40-1190

Fig. 2581

40.3.15 - S005 - Instrument panel (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85
-> 20001)
E003 E002

I008
ENGINE OIL PRESSURE

J004
RESERVE LIGHT
FUEL LEVEL

AIR FILTER

SERVICE
+12/30

+12/30
+58

+15
-31

NC NO 85 86 30 13 8 21 14 6 5 4 15 21 19 -31
8 10 9 5 6 2 3 7 8
C004

C004

C004
B015

B021

B010
B020

B024
B030

7.5A
15A

30A

10A
3A

5A
+30

+30
+15

C003
C004
D005

D011

12 7 9 11
A A A A A B A
C6 D7 A1 A8 D1 D1 A2

1 2 1 2 1 2 4 1 3 2

t P

P P

D0062900
K001 K003 K004 K014 K011

Fig. 2582 - Instrument panel - System

40-369
 Wiring diagrams
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l E002 - Instrument panel
l E003 - Instrument panel
l I008 - Road lights switch
l J004 - Relay
l K001 - Air filter clogging sensor
l K003 - Engine oil pressure switch
l K005 - Engine temperature sensor
l K011 - Services circuit alarm pressure switch
l K014 - Fuel level sensor

40-370
Wiring diagrams

B030
J004 A

B015

B020 B024
B021
B010

E002

E003 C004

D005

I008
B

D0063780

Fig. 2583 - Instrument panel - Positions

Table 476
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1209
B010 Fuse (5A) 40-1221
B015 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1209
B021 Fuse (10A) 40-1221
B024 Fuse (7.5A) 40-1209
B024 Fuse (7.5A) 40-1221
B030 Fuse (30A) 40-1209

40-371
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1209
40-1221

Fig. 2584
D005 Wiring connector 40-1234
40-1236
40-1209
40-1209
40-1221

Fig. 2585
E002 Instrument panel 40-1209
40-1221

Fig. 2586
E003 Instrument panel 40-1209
40-1221

Fig. 2587
I008 Road lights switch 40-1209
40-1221
J004 Relay 40-1209
40-1221

Fig. 2590

40-372
Wiring diagrams

C003

D011

D0063790

Fig. 2591 - Connector positions

Table 477
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1209
40-1221

Fig. 2592

40-373
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1209
40-1214
40-1221
40-1214

Fig. 2593

D011

K011

D0063800

Fig. 2594 - Connector positions

40-374
Wiring diagrams
Table 478
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1209
40-1214
40-1221
40-1214

Fig. 2594
K011 Services circuit Normally closed (NC) contact 40-1214
Switching pressure: 11 bar ± 1

40-375
 Wiring diagrams

G22

ECO

S
G23

G20
X65

X67

X66

K014

D0063810

Fig. 2596 - Connector positions

Table 479
Sys- P/N Description Characteristics/notes Position Wiring
tem
K014 Fuel level sensor Resistance between pin 2 and pin 40-1214
3:
with tank full: 5.25 ± 1.25 Ohm
with tank half full:105.50 ± 6 Ohm
with tank empty: 332.75 ± 17.25
Ohm

40-376
Wiring diagrams

D005

A
C B

K001

D0063820

Fig. 2598 - Connector positions - Version with lateral battery (1/2)

40-377
 Wiring diagrams

D005

K001

D0063840

Fig. 2599 - Connector positions - Version with front battery (1/2)

40-378
Wiring diagrams
Table 480
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1236
40-1209
40-1209
40-1221

Fig. 2599
K001 Air cleaner clogged Normally open contact 40-1234
sensor Switching pressure: 0.93 to 0.94
bar absolute pressure
Normally open contact 40-1236
Switching pressure: 0.93 to 0.94
bar absolute pressure

40-379
 Wiring diagrams

A K004

B
C

K003

D0063830

Fig. 2601 - Connector positions - Version with lateral battery (2/2)

40-380
Wiring diagrams

K004

K003

D0063850

Fig. 2602 - Connector positions - Version with front battery (2/2)

40-381
 Wiring diagrams
Table 481
Sys- P/N Description Characteristics/notes Position Wiring
tem
K003 01182792 Engine oil pressure 40-1234
switch 40-1236

Fig. 2603
K004 Engine tempera- 40-1234
ture sensor 40-1236

Fig. 2604

40-382
Wiring diagrams
40.3.16 - S005A - Instrument panel - Version with analog instrument panel (R3 EVO 100
-> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

E008
E009 E012

E011 E010
I008

ENGINE OIL PRESSURE

J004

TANK INDICATOR

RESERVE LIGHT
TEMPERATURE

AIR FILTER

SERVICE
+15

+15
+15

+15

-31

-31
-31

-31
-58

-58

-58
A
NC NO 85 86 30 3 4 1 2 4 1 2 12 A8 A2 A7 B1 5 4 3 1 6 10 9 5 6 2 3 7 8
C004

C004
C004
B015

B021
B020

B024
B030

7.5A
15A

30A

10A
3A

+30
+15

C003
C004
D005

D011

12 7 9 11
A A A A A A
C6 D7 A1 D1 B1 A2

1 2 1 2 1 2 4 1 3 2

t P

P P

D0065110
K001 K003 K004 K014 K011

Fig. 2605 - Instrument panel - Version with analog instrument panel - System

40-383
 Wiring diagrams

B030

J004
A

B015

B024

B020 B021

E010 E011

E012

C004

E008
E009

I008

D0065480

Fig. 2606 - Instrument panel - Version with analog instrument panel - Connector positions
Table 482
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1238
B020 Fuse (3A) 40-1238
B021 Fuse (10A) 40-1238
B024 Fuse (7.5A) 40-1238
B030 Fuse (30A) 40-1238

40-384
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1238

Fig. 2607
E008 Instrument panel 40-1238
E009 Instrument panel 40-1238
E010 Instrument panel 40-1238
E011 Instrument panel 40-1238
E012 Instrument panel 40-1238
I008 Road lights switch 40-1238

Fig. 2608 Fig. 2609

J004 Relay 40-1238

Fig. 2610

40-385
 Wiring diagrams

C003

D011

D0065490

Fig. 2611 - Connector positions

Table 483
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1238

Fig. 2612

40-386
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1233
40-1238

Fig. 2613

D011

K011

D0065500

Fig. 2614 - Connector positions

40-387
 Wiring diagrams
Table 484
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1233
40-1238

Fig. 2614
K011 Services circuit Normally closed (NC) contact 40-1233
Switching pressure: 11 bar ± 1

40-388
Wiring diagrams

G22

ECO

G23

G20
X65

X67

X66

K014

D0065510

Fig. 2616 - Connector positions

Table 485
Sys- P/N Description Characteristics/notes Position Wiring
tem
K014 Fuel level sensor Resistance between pin 2 and pin 40-1233
3:
with tank full: 5.25 ± 1.25 Ohm
with tank half full:105.50 ± 6 Ohm
with tank empty: 332.75 ± 17.25
Ohm

40-389
 Wiring diagrams

D005

K001

D0063840

Fig. 2618 - Connector positions - Version with front battery (1/2)

40-390
Wiring diagrams
Table 486
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1238
40-1238
40-1234
40-1236

Fig. 2619
K001 Air cleaner clogged Normally open contact 40-1234
sensor Switching pressure: 0.93 to 0.94
bar absolute pressure

40-391
 Wiring diagrams

K004

K003

D0063850

Fig. 2621 - Connector positions - Version with front battery (2/2)

40-392
Wiring diagrams
Table 487
Sys- P/N Description Characteristics/notes Position Wiring
tem
K003 01182792 Engine oil pressure 40-1234
switch

Fig. 2622
K004 Engine tempera- 40-1234
ture sensor

Fig. 2623

40-393
 Wiring diagrams

D005

A
C B

K001

D0063820

Fig. 2624 - Connector positions - Version with lateral battery (1/2)

40-394
Wiring diagrams
Table 488
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1238
40-1238
40-1234
40-1236

Fig. 2624
K001 Air cleaner clogged Normally open contact 40-1236
sensor Switching pressure: 0.93 to 0.94
bar absolute pressure

40-395
 Wiring diagrams

A K004

B
C

K003

D0063830

Fig. 2625 - Connector positions - Version with lateral battery (2/2)

Table 489
Sys- P/N Description Characteristics/notes Position Wiring
tem
K003 01182792 Engine oil pressure 40-1236
switch

Fig. 2625

40-396
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
K004 Engine tempera- 40-1236
ture sensor

Fig. 2625

40.3.17 - S005D - Instrument panel - Version with digital instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
E003 E002

I008
ENGINE OIL PRESSURE

J004
RESERVE LIGHT
FUEL LEVEL

AIR FILTER

SERVICE
+12/30

+12/30
+58

+15
-31

NC NO 85 86 30 13 8 21 14 6 5 4 15 21 19 -31
8 10 9 5 6 2 3 7 8
C004

C004

C004
B015

B021

B010
B020

B024
B030

7.5A
15A

30A

10A
3A

5A
+30

+30
+15

C003
C004
D005

D011

12 7 9 11
A A A A A B A
C6 D7 A1 A8 D1 D1 A2

1 2 1 2 1 2 4 1 3 2

t P

P P

D0062900
K001 K003 K004 K014 K011

Fig. 2626 - Instrument panel - Version with digital instrument panel - System

40-397
 Wiring diagrams
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l E002 - Instrument panel
l E003 - Instrument panel
l I008 - Road lights switch
l J004 - Relay
l K001 - Air filter clogging sensor
l K003 - Engine oil pressure switch
l K005 - Engine temperature sensor
l K011 - Services circuit alarm pressure switch
l K014 - Fuel level sensor

40-398
Wiring diagrams

B030
J004 A

B015

B020 B024
B021
B010

E002

E003 C004

D005

I008
B

D0063780

Fig. 2627 - Instrument panel - Version with digital instrument panel - Connector positions
Table 490
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1205
B010 Fuse (5A) 40-1221
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1205
B021 Fuse (10A) 40-1221
B024 Fuse (7.5A) 40-1205
B024 Fuse (7.5A) 40-1221
B030 Fuse (30A) 40-1205

40-399
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 2628
D005 Wiring connector 40-1234
40-1236
40-1205
40-1221
40-1205
40-1221
40-1234
40-1236

Fig. 2629
E002 Instrument panel 40-1205
40-1221

Fig. 2630
E003 Instrument panel 40-1205
40-1221

Fig. 2631
I008 Road lights switch 40-1205
40-1221
J004 Relay 40-1205
40-1221

Fig. 2634

40-400
Wiring diagrams

C003

D011

D0063790

Fig. 2635 - Connector positions

Table 491
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1205
40-1221

Fig. 2636

40-401
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1205
40-1212
40-1221
40-1212

Fig. 2637

D011

K011

D0063800

Fig. 2638 - Connector positions

40-402
Wiring diagrams
Table 492
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1205
40-1212
40-1221
40-1212

Fig. 2638
K011 Services circuit Normally closed (NC) contact 40-1212
Switching pressure: 11 bar ± 1

40-403
 Wiring diagrams

G22

ECO

S
G23

G20
X65

X67

X66

K014

D0063810

Fig. 2640 - Connector positions

Table 493
Sys- P/N Description Characteristics/notes Position Wiring
tem
K014 Fuel level sensor Resistance between pin 2 and pin 40-1212
3:
with tank full: 5.25 ± 1.25 Ohm
with tank half full:105.50 ± 6 Ohm
with tank empty: 332.75 ± 17.25
Ohm

40-404
Wiring diagrams

D005

A
C B

K001

D0063820

Fig. 2642 - Connector positions - Version with lateral battery (1/2)

40-405
 Wiring diagrams
Table 494
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1236
40-1205
40-1221
40-1205
40-1221
40-1234
40-1236

Fig. 2642
K001 Air cleaner clogged Normally open contact 40-1236
sensor Switching pressure: 0.93 to 0.94
bar absolute pressure

40-406
Wiring diagrams

A K004

B
C

K003

D0063830

Fig. 2644 - Connector positions - Version with lateral battery (2/2)

Table 495
Sys- P/N Description Characteristics/notes Position Wiring
tem
K003 01182792 Engine oil pressure 40-1236
switch

Fig. 2645

40-407
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
K004 Engine tempera- 40-1236
ture sensor

Fig. 2646

40-408
Wiring diagrams

K004

K003

D0063850

Fig. 2647 - Connector positions - Version with front battery

40-409
 Wiring diagrams
Table 496
Sys- P/N Description Characteristics/notes Position Wiring
tem
K003 01182792 Engine oil pressure 40-1234
switch

Fig. 2647
K004 Engine tempera- 40-1234
ture sensor

Fig. 2647

40-410
Wiring diagrams
40.3.18 - S006 - Work lights - Version with standard cab without front lift (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
I012 I019
J002 J004 J005

2 3 7 8 2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004
B024

B019

B025
B015

B030

B020

B026
B018
7.5A

15A

15A

15A

30A

30A

30A
3A
+30

+30
+15
F010 F013 F011 F012

1 2 1 2 1 2 1 2
C004
C004

D008

D029
D023
D014

D004

2 6 1 5

2
7 6 11 12
4 7 8 1
C007
D040

D039

D037

D038

1 1
C004

C007
D041

D042

B039
B040
10A

10A

3 1 1 3

2 1 1 2 1 2 1 2 10 9 5 6 2 3 7 8 2 4 3 1 1 3 4 2

F016 F017 F006 F001

I008 I024 I026 D0062910

Fig. 2648 - Work lights - Version with standard cab without front lift - System
l D004 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D004 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D004 (F) - Wiring connector (Wiring loom 0.014.8107.4/30)
l D004 (F) - Wiring connector (Wiring loom 0.014.8107.4/30)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D014 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D014 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)

40-411
 Wiring diagrams
I012 I019
J002 J004 J005

2 3 7 8 2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004
B024

B019

B025
B015

B030

B020

B026
B018
7.5A

15A

15A

15A

30A

30A

30A
3A
+30

+30
+15
F010 F013 F011 F012

1 2 1 2 1 2 1 2
C004
C004

D008
2

D029
D023
D014

D004

2 6 1 5

2
7 6 11 12
4 7 8 1

C007
D040

D039

D037

D038

1 1
C004

C007
D041

D042

B039
B040
10A

10A

3 1 1 3

2 1 1 2 1 2 1 2 10 9 5 6 2 3 7 8 2 4 3 1 1 3 4 2

F016 F017 F006 F001

I008 I024 I026 D0062910

Fig. 2648 - Work lights - Version with standard cab without front lift - System
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)

40-412
Wiring diagrams
I012 I019
J002 J004 J005

2 3 7 8 2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004
B024

B019

B025
B015

B030

B020

B026
B018
7.5A

15A

15A

15A

30A

30A

30A
3A
+30

+30
+15
F010 F013 F011 F012

1 2 1 2 1 2 1 2
C004
C004

D008
2

D029
D023
D014

D004

2 6 1 5

2
7 6 11 12
4 7 8 1

C007
D040

D039

D037

D038

1 1
C004

C007
D041

D042

B039
B040
10A

10A

3 1 1 3

2 1 1 2 1 2 1 2 10 9 5 6 2 3 7 8 2 4 3 1 1 3 4 2

F016 F017 F006 F001

I008 I024 I026 D0062910

Fig. 2648 - Work lights - Version with standard cab without front lift - System
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D039 (F) - Wiring connector (Wiring loom 04411923.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D040 (F) - Wiring connector (Wiring loom 04411923.4)
l D041 (M) - Wiring connector (Wiring loom 0.015.1435.4/20)
l D041 (F) - Wiring connector (Wiring loom 04411923.4)
l D042 (M) - Wiring connector (Wiring loom 0.015.1435.4/20)
l D042 (F) - Wiring connector (Wiring loom 04411923.4)
l F001 - RH front work light (on hood)
l F006 - LH front work light (on hood)
l F010 - RH front work light (on cab roof)

40-413
 Wiring diagrams
I012 I019
J002 J004 J005

2 3 7 8 2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004
B024

B019

B025
B015

B030

B020

B026
B018
7.5A

15A

15A

15A

30A

30A

30A
3A
+30

+30
+15
F010 F013 F011 F012

1 2 1 2 1 2 1 2
C004
C004

D008
2

D029
D023
D014

D004

2 6 1 5

2
7 6 11 12
4 7 8 1

C007
D040

D039

D037

D038

1 1
C004

C007
D041

D042

B039
B040
10A

10A

3 1 1 3

2 1 1 2 1 2 1 2 10 9 5 6 2 3 7 8 2 4 3 1 1 3 4 2

F016 F017 F006 F001

I008 I024 I026 D0062910

Fig. 2648 - Work lights - Version with standard cab without front lift - System
l F011 - LH rear work light (on cab roof)
l F012 - RH rear work light (on cab roof)
l F013 - LH front work light (on cab roof)
l F016 - RH supplementary work light
l F017 - LH supplementary work light
l I008 - Road lights switch
l I012 - Low front work lights switch
l I019 - Corner work lights switch
l I024 - Front work lights switch
l I026 - Rear work lights switch
l J002 - Relay
l J004 - Relay

40-414
Wiring diagrams
I012 I019
J002 J004 J005

2 3 7 8 2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004
B024

B019

B025
B015

B030

B020

B026
B018
7.5A

15A

15A

15A

30A

30A

30A
3A
+30

+30
+15
F010 F013 F011 F012

1 2 1 2 1 2 1 2
C004
C004

D008
2

D029
D023
D014

D004

2 6 1 5

2
7 6 11 12
4 7 8 1

C007
D040

D039

D037

D038

1 1
C004

C007
D041

D042

B039
B040
10A

10A

3 1 1 3

2 1 1 2 1 2 1 2 10 9 5 6 2 3 7 8 2 4 3 1 1 3 4 2

F016 F017 F006 F001

I008 I024 I026 D0062910

Fig. 2648 - Work lights - Version with standard cab without front lift - System
l J005 - Relay

40-415
 Wiring diagrams
B030
B025
J002
B026

J005 J004
A
B015

B018

B019 B024
B020

D008
D004

D014
C004

I019
I012
I008

D0063860

Fig. 2649 - Work lights - Version with standard cab without front lift - Connector positions
Table 497
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1221
B018 Fuse (15A) 40-1209
B018 Fuse (15A) 40-1221
B019 Fuse (15A) 40-1209
B019 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B024 Fuse (7.5A) 40-1209
B024 Fuse (7.5A) 40-1221
B025 Fuse (30A) 40-1209

40-416
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B025 Fuse (30A) 40-1221
B026 Fuse (30A) 40-1209
B026 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1209
40-1221

Fig. 2650
D004 Wiring connector 40-1193
40-1209
40-1221
40-1193

Fig. 2651
D008 Wiring connector 40-1209
40-1220

Fig. 2652
D014 Wiring connector 40-1209
40-1224
40-1221
40-1224

Fig. 2653

40-417
 Wiring diagrams
Table 498
Sys- P/N Description Characteristics/notes Position Wiring
tem
I008 Road lights switch 40-1209
40-1221
I012 Lower front work- 40-1209
40-1221
I019 Corner lights switch 40-1209
40-1221
J002 Relay 40-1209
40-1221

Fig. 2660
J004 Relay 40-1209
40-1221

Fig. 2661
J005 Relay 40-1209
40-1221

Fig. 2662

40-418
Wiring diagrams

D004

F001

F006

D0063880

Fig. 2663 - Connector positions

Table 499
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1193
40-1209
40-1221
40-1193

Fig. 2663

40-419
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F001 Rh front worklight 40-1193
(on hood)

Fig. 2664
F006 Lh front worklight 40-1193
(on hood)

Fig. 2665

40-420
Wiring diagrams

D039

D014
D040

D037

D038

D0063870

Fig. 2666 - Connector positions

Table 500
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1209
40-1224
40-1221
40-1224

Fig. 2666
D037 Wiring connector 40-1224
D037 Wiring connector 40-1251
D038 Wiring connector 40-1224
D038 Wiring connector 40-1251
D039 Wiring connector 40-1224
D039 Wiring connector 40-1250
D040 Wiring connector 40-1224

40-421
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D040 Wiring connector 40-1250

D039
D040

D041 D037
D038

D042

D0063890

Fig. 2667 - Connector positions

Table 501
Sys- P/N Description Characteristics/notes Position Wiring
tem
D037 Wiring connector 40-1224
D037 Wiring connector 40-1251
D038 Wiring connector 40-1224
D038 Wiring connector 40-1251
D039 Wiring connector 40-1224
D039 Wiring connector 40-1250
D040 Wiring connector 40-1224
D040 Wiring connector 40-1250
D041 Wiring connector 40-1196
D041 Wiring connector 40-1250
D042 Wiring connector 40-1251
D042 Wiring connector 40-1197

40-422
Wiring diagrams

F016

D041

F017

D042

D0063910

Fig. 2668 - Connector positions

Table 502
Sys- P/N Description Characteristics/notes Position Wiring
tem
D041 Wiring connector 40-1196
D041 Wiring connector 40-1250
D042 Wiring connector 40-1251
D042 Wiring connector 40-1197
F016 Rh auxiliary work- 40-1196
light
F017 Lh auxiliary work- 40-1197
light

40-423
 Wiring diagrams

D023

D008

D0063720

Fig. 2669 - Connector positions

Table 503
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1209
40-1220

Fig. 2669

40-424
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1220
40-1226
40-1244
40-1220

Fig. 2670

B039-B040
C007

D029

I024
D023

I026

D0063920

Fig. 2671 - Connector positions

Table 504
Sys- P/N Description Characteristics/notes Position Wiring
tem
B039 Fuse (10A) 40-1226
B039 Fuse (10A) 40-1244
B040 Fuse (10A) 40-1226
B040 Fuse (10A) 40-1244

40-425
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1226
40-1244

Fig. 2672
D023 Wiring connector 40-1220
40-1226
40-1244
40-1220

Fig. 2672
D029 Wiring connector 40-1226
D029 Wiring connector 40-1244
D029 Wiring connector 40-1230
D029 Wiring connector 40-1230
I024 Front worklights 40-1226
40-1244
I026 Rear worklights 40-1226
40-1244

40-426
Wiring diagrams

F012

F011

F010

D029

F013

D0063930

Fig. 2676 - Connector positions

Table 505
Sys- P/N Description Characteristics/notes Position Wiring
tem
D029 Wiring connector 40-1226
D029 Wiring connector 40-1244
D029 Wiring connector 40-1230
D029 Wiring connector 40-1230
F010 Rh front worklight 40-1230
(on cab roof)

Fig. 2677
F011 Lh rear worklight 40-1230
(on cab roof)

Fig. 2678

40-427
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F012 Rh rear worklight 40-1230
(on cab roof)

Fig. 2679
F013 Lh front worklight 40-1230
(on cab roof)

40-428
Wiring diagrams
40.3.19 - S006A - Work lights - Version with standard cab without front lift - Version with
analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

J004 J005

NC NO 85 86 30 NC NO 85 86 30

C004
B015

B030
B020

B026
15A

30A

30A
3A

+30

+30
+15

F010 F013 F011 F012

1 2 1 2 1 2 1 2
D008

2
D029
D023

2 6 1 5

2
C007
C007

B039
B040
10A

10A

2 4 3 1 1 3 4 2

I024 I026 D0065420

Fig. 2680 - Work lights - Version with standard cab without front lift - Version with analog instrument panel -
System
l D008 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)

40-429
 Wiring diagrams
l D029 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l F010 - RH front work light (on cab roof)
l F011 - LH rear work light (on cab roof)
l F012 - RH rear work light (on cab roof)
l F013 - LH front work light (on cab roof)
l I024 - Front work lights switch
l I026 - Rear work lights switch
l J004 - Relay
l J005 - Relay

B030

B026

J005 J004
A
B015

B020

D008

C004

D0065520

Fig. 2681 - Work lights - Version with standard cab without front lift - Version with analog instrument panel - Con-
nector positions

40-430
Wiring diagrams
Table 506
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1238
B020 Fuse (3A) 40-1238
B026 Fuse (30A) 40-1238
B030 Fuse (30A) 40-1238
C004 Earthing point 4 40-1238

Fig. 2682
D008 Wiring connector 40-1238
40-1220

Fig. 2683
J004 Relay 40-1238

Fig. 2684
J005 Relay 40-1238

Fig. 2685

40-431
 Wiring diagrams

D023

D008

D0063720

Fig. 2686 - Connector positions

Table 507
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1238
40-1220

Fig. 2686

40-432
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2687

B039-B040
C007

D029

I024
D023

I026

D0063920

Fig. 2688 - Connector positions

Table 508
Sys- P/N Description Characteristics/notes Position Wiring
tem
B039 Fuse (10A) 40-1228
B039 Fuse (10A) 40-1242
B040 Fuse (10A) 40-1228
B040 Fuse (10A) 40-1242

40-433
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1228
40-1242

Fig. 2689
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2689
D029 Wiring connector 40-1228
D029 Wiring connector 40-1242
D029 Wiring connector 40-1230
D029 Wiring connector 40-1230
I024 Front work lights 40-1228
40-1242
I026 Rear work lights 40-1228
40-1242

40-434
Wiring diagrams

F012

F011

F010

D029

F013

D0063930

Fig. 2693 - Connector positions

Table 509
Sys- P/N Description Characteristics/notes Position Wiring
tem
D029 Wiring connector 40-1228
D029 Wiring connector 40-1242
D029 Wiring connector 40-1230
D029 Wiring connector 40-1230
F010 RH front work light 40-1230
(on cab roof)

Fig. 2694
F011 LH rear work light 40-1230
(on cab roof)

Fig. 2695

40-435
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F012 RH rear work light 40-1230
(on cab roof)

Fig. 2696
F013 LH front work light 40-1230
(on cab roof)

40-436
Wiring diagrams
40.3.20 - S006D - Work lights - Version with standard cab without front lift - Version with
digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

J004 J005

NC NO 85 86 30 NC NO 85 86 30

C004
B015

B026
B030

B020
15A

30A

30A
+15 3A
+30

+30
F010 F013 F011 F012

1 2 1 2 1 2 1 2
D008

2
D029
D023

2 6 1 5

2
C007
C007

B039
B040
10A

10A

2 4 3 1 1 3 4 2

I024 I026
D0064870

Fig. 2697 - Work lights - Version with standard cab without front lift - Version with digital instrument panel - Sys-
tem
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)

40-437
 Wiring diagrams
l D029 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l F010 - RH front work light (on cab roof)
l F011 - LH rear work light (on cab roof)
l F012 - RH rear work light (on cab roof)
l F013 - LH front work light (on cab roof)
l I024 - Front work lights switch
l I026 - Rear work lights switch
l J004 - Relay
l J005 - Relay

B030

B026

J005 J004
A
B015

B024
B020

D008

C004

D0063861

Fig. 2698 - Work lights - Version with standard cab without front lift - Version with digital instrument panel - Con-
nector positions

40-438
Wiring diagrams
Table 510
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B026 Fuse (30A) 40-1205
B026 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 2699
D008 Wiring connector 40-1205
40-1220
40-1221

Fig. 2700
J004 Relay 40-1205
40-1221

Fig. 2701
J005 Relay 40-1205
40-1221

Fig. 2702

40-439
 Wiring diagrams

D023

D008

D0063720

Fig. 2703 - Connector positions

Table 511
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221

Fig. 2703

40-440
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2704

B039-B040
C007

D029

I024
D023

I026

D0063920

Fig. 2705 - Connector positions

Table 512
Sys- P/N Description Characteristics/notes Position Wiring
tem
B039 Fuse (10A) 40-1228
B039 Fuse (10A) 40-1242
B040 Fuse (10A) 40-1228
B040 Fuse (10A) 40-1242

40-441
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1228
40-1242

Fig. 2706
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2706
D029 Wiring connector 40-1228
40-1242
40-1230
40-1230
I024 Front work lights 0 40-1228
switch 1

Pin 1 2
Pos

0
Fig. 2708
1

Fig. 2707
I024 Front work lights 0 40-1242
switch 1

Pin 1 2
Pos

0
Fig. 2708
1

Fig. 2708
I026 Rear work lights 0 40-1228
switch 1

Pin 1 2
Pos

0
Fig. 2709
1

Fig. 2708

40-442
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I026 Rear work lights 0 40-1242
switch 1

Pin 1 2
Pos

0
Fig. 2709
1

Fig. 2709

F012

F011

F010

D029

F013

D0063930

Fig. 2710 - Connector positions

Table 513
Sys- P/N Description Characteristics/notes Position Wiring
tem
D029 Wiring connector 40-1228
40-1242
40-1230
40-1230

40-443
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F010 RH front work light 40-1230
(on cab roof)

Fig. 2711
F011 LH rear work light 40-1230
(on cab roof)

Fig. 2712
F012 RH rear work light 40-1230
(on cab roof)

Fig. 2713
F013 LH front work light 40-1230
(on cab roof)

40-444
Wiring diagrams
40.3.21 - S007 - Work lights - Version with standard cab with front lift (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
I019
J002 J004 J005

2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004
B024

B025
B015

B030

B020

B026
B018
7.5A

15A

15A

30A

30A

30A
3A
+30

+30
+15
F010 F013 F011 F012

1 2 1 2 1 2 1 2
C004

D008

2 D029
D023
D004

2 6 1 5

2
7 6 11 12
C007
C004

C007

B039
B040
10A

10A

1 2 1 2 10 9 5 6 2 3 7 8 2 4 3 1 1 3 4 2

F006 F001

I008 I024 I026 D0062920

Fig. 2714 - Work lights - Version with standard cab with front lift - System
l D004 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D004 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D004 (F) - Wiring connector (Wiring loom 0.014.8107.4/30)
l D004 (F) - Wiring connector (Wiring loom 0.014.8107.4/30)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)

40-445
 Wiring diagrams
I019
J002 J004 J005

2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004
B024

B025
B015

B030

B020

B026
B018
7.5A

15A

15A

30A

30A

30A
3A
+30

+30
+15
F010 F013 F011 F012

1 2 1 2 1 2 1 2
C004

D008

D029
D023
D004

2 6 1 5

2
7 6 11 12

C007
C004

C007

B039
B040
10A

10A

1 2 1 2 10 9 5 6 2 3 7 8 2 4 3 1 1 3 4 2

F006 F001

I008 I024 I026 D0062920

Fig. 2714 - Work lights - Version with standard cab with front lift - System
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l F001 - RH front work light (on hood)
l F006 - LH front work light (on hood)
l F010 - RH front work light (on cab roof)
l F011 - LH rear work light (on cab roof)
l F012 - RH rear work light (on cab roof)

40-446
Wiring diagrams
I019
J002 J004 J005

2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004
B024

B025
B015

B030

B020

B026
B018
7.5A

15A

15A

30A

30A

30A
3A
+30

+30
+15
F010 F013 F011 F012

1 2 1 2 1 2 1 2
C004

D008

D029
D023
D004

2 6 1 5

2
7 6 11 12

C007
C004

C007

B039
B040
10A

10A

1 2 1 2 10 9 5 6 2 3 7 8 2 4 3 1 1 3 4 2

F006 F001

I008 I024 I026 D0062920

Fig. 2714 - Work lights - Version with standard cab with front lift - System
l F013 - LH front work light (on cab roof)
l I008 - Road lights switch
l I019 - Corner work lights switch
l I024 - Front work lights switch
l I026 - Rear work lights switch
l J002 - Relay
l J004 - Relay
l J005 - Relay

40-447
 Wiring diagrams
B030
B025
J002
B026

J005 J004
A
B015

B018

B024
B020

D008
D004

C004

I019

I008

D0063940

Fig. 2715 - Work lights - Version with standard cab with front lift - Connector positions
Table 514
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1221
B018 Fuse (15A) 40-1209
B018 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B024 Fuse (7.5A) 40-1209
B024 Fuse (7.5A) 40-1221
B025 Fuse (30A) 40-1209
B025 Fuse (30A) 40-1221
B026 Fuse (30A) 40-1209

40-448
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B026 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1209
40-1221

Fig. 2716
D004 Wiring connector 40-1193
40-1209
40-1221
40-1193

Fig. 2717
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2718
I008 Road lights switch 40-1209
40-1221
I019 Corner lights switch 40-1209
40-1221
J002 Relay 40-1209
40-1221

Fig. 2723
J004 Relay 40-1209
40-1221

Fig. 2724

40-449
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J005 Relay 40-1209
40-1221

Fig. 2725

D004

F001

F006

D0063880

Fig. 2726 - Connector positions

40-450
Wiring diagrams
Table 515
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1193
40-1209
40-1221
40-1193

Fig. 2726
F001 Rh front worklight 40-1193
(on hood)

Fig. 2727
F006 Lh front worklight 40-1193
(on hood)

Fig. 2728

40-451
 Wiring diagrams

D023

D008

D0063720

Fig. 2729 - Connector positions

Table 516
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2729

40-452
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1220
40-1226
40-1244
40-1220

Fig. 2730

B039-B040
C007

D029

I024
D023

I026

D0063920

Fig. 2731 - Connector positions

Table 517
Sys- P/N Description Characteristics/notes Position Wiring
tem
B039 Fuse (10A) 40-1226
B039 Fuse (10A) 40-1244
B040 Fuse (10A) 40-1226
B040 Fuse (10A) 40-1244

40-453
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1226
40-1244

Fig. 2732
D023 Wiring connector 40-1220
40-1226
40-1244
40-1220

Fig. 2732
D029 Wiring connector 40-1226
40-1244
40-1230
40-1230
I024 Front worklights 40-1226
40-1244
I026 Rear worklights 40-1226
40-1244

40-454
Wiring diagrams

F012

F011

F010

D029

F013

D0063930

Fig. 2736 - Connector positions

Table 518
Sys- P/N Description Characteristics/notes Position Wiring
tem
D029 Wiring connector 40-1226
40-1244
40-1230
40-1230
F010 Rh front worklight 40-1230
(on cab roof)

Fig. 2737
F011 Lh rear worklight 40-1230
(on cab roof)

Fig. 2738

40-455
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F012 Rh rear worklight 40-1230
(on cab roof)

Fig. 2739
F013 Lh front worklight 40-1230
(on cab roof)

40-456
Wiring diagrams
40.3.22 - S007A - Work lights - Version with standard cab with front lift - Version with
analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

J004 J005

NC NO 85 86 30 NC NO 85 86 30

C004
B015

B030
B020

B026
15A

30A

30A
3A

+30

+30
+15

F010 F013 F011 F012

1 2 1 2 1 2 1 2
D008

2
D029
D023

2 6 1 5

2
C007
C007

B039
B040
10A

10A

2 4 3 1 1 3 4 2

I024 I026 D0065430

Fig. 2740 - Work lights - Version with standard cab with front lift - Version with analog instrument panel - System
l D008 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.018.5825.4)

40-457
 Wiring diagrams
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l F010 - RH front work light (on cab roof)
l F011 - LH rear work light (on cab roof)
l F012 - RH rear work light (on cab roof)
l F013 - LH front work light (on cab roof)
l I024 - Front work lights switch
l I026 - Rear work lights switch
l J004 - Relay
l J005 - Relay

B030

B026

J005 J004
A
B015

B020

D008

C004

D0065520

Fig. 2741 - Work lights - Version with standard cab with front lift - Version with analog instrument panel - Con-
nector positions

40-458
Wiring diagrams
Table 519
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1238
B020 Fuse (3A) 40-1238
B026 Fuse (30A) 40-1238
B030 Fuse (30A) 40-1238
C004 Earthing point 4 40-1238

Fig. 2742
D008 Wiring connector 40-1238
40-1220

Fig. 2743
J004 Relay 40-1238

Fig. 2744
J005 Relay 40-1238

Fig. 2745

40-459
 Wiring diagrams

D023

D008

D0063720

Fig. 2746 - Connector positions

Table 520
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1238
40-1220

Fig. 2746

40-460
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2747

B039-B040
C007

D029

I024
D023

I026

D0063920

Fig. 2748 - Connector positions

Table 521
Sys- P/N Description Characteristics/notes Position Wiring
tem
B039 Fuse (10A) 40-1228
B039 Fuse (10A) 40-1242
B040 Fuse (10A) 40-1228
B040 Fuse (10A) 40-1242

40-461
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1228
40-1242

Fig. 2749
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2749
D029 Wiring connector 40-1228
40-1242
40-1230
40-1230
I024 Front work lights 40-1228
40-1242
I026 Rear work lights 40-1228
40-1242

40-462
Wiring diagrams

F012

F011

F010

D029

F013

D0063930

Fig. 2753 - Connector positions

Table 522
Sys- P/N Description Characteristics/notes Position Wiring
tem
D029 Wiring connector 40-1228
40-1242
40-1230
40-1230
F010 RH front work light 40-1230
(on cab roof)

Fig. 2754
F011 LH rear work light 40-1230
(on cab roof)

Fig. 2755

40-463
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F012 RH rear work light 40-1230
(on cab roof)

Fig. 2756
F013 LH front work light 40-1230
(on cab roof)

40-464
Wiring diagrams
40.3.23 - S007D - Work lights - Version with standard cab with front lift - Version with
digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

J004 J005

NC NO 85 86 30 NC NO 85 86 30

C004
B015

B030

B020

B026
15A

30A

30A
3A

+30
+15
+30

F010 F013 F011 F012

1 2 1 2 1 2 1 2
D008

2
D029
D023

2 6 1 5

2
C007
C007

B039
B040
10A

10A

2 4 3 1 1 3 4 2

I024 I026 D0064880

Fig. 2757 - Work lights - Version with standard cab with front lift - Version with digital instrument panel - System
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)

40-465
 Wiring diagrams
l D029 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l F010 - RH front work light (on cab roof)
l F011 - LH rear work light (on cab roof)
l F012 - RH rear work light (on cab roof)
l F013 - LH front work light (on cab roof)
l I024 - Front work lights switch
l I026 - Rear work lights switch
l J004 - Relay
l J005 - Relay

B030

B026

J005 J004
A
B015

B020

D008

C004

D0063941

Fig. 2758 - Work lights - Version with standard cab with front lift - Version with digital instrument panel - Con-
nector positions

40-466
Wiring diagrams
Table 523
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B026 Fuse (30A) 40-1205
B026 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 2759
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 2760
J004 Relay 40-1205
40-1221

Fig. 2761
J005 Relay 40-1205
40-1221

Fig. 2762

40-467
 Wiring diagrams

D023

D008

D0063720

Fig. 2763 - Connector positions

Table 524
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 2763

40-468
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2764

B039-B040
C007

D029

I024
D023

I026

D0063920

Fig. 2765 - Connector positions

Table 525
Sys- P/N Description Characteristics/notes Position Wiring
tem
B039 Fuse (10A) 40-1228
40-1242
B040 Fuse (10A) 40-1228
40-1242

40-469
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1228
40-1242

Fig. 2766
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2766
D029 Wiring connector 40-1228
40-1242
40-1230
40-1230
I024 Front work lights 0 40-1228
switch 1

Pin 1 2
Pos

0
Fig. 2768
1

Fig. 2767
I024 Front work lights 0 40-1242
switch 1

Pin 1 2
Pos

0
Fig. 2768
1

Fig. 2768
I026 Rear work lights 0 40-1228
switch 1

Pin 1 2
Pos

0
Fig. 2769
1

Fig. 2768

40-470
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I026 Rear work lights 0 40-1242
switch 1

Pin 1 2
Pos

0
Fig. 2769
1

Fig. 2769

F012

F011

F010

D029

F013

D0063930

Fig. 2770 - Connector positions

Table 526
Sys- P/N Description Characteristics/notes Position Wiring
tem
D029 Wiring connector 40-1228
40-1242
40-1230
40-1230

40-471
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F010 RH front work light 40-1230
(on cab roof)

Fig. 2771
F011 LH rear work light 40-1230
(on cab roof)

Fig. 2772
F012 RH rear work light 40-1230
(on cab roof)

Fig. 2773
F013 LH front work light 40-1230
(on cab roof)

40-472
Wiring diagrams
40.3.24 - Work lights - Version with high-visibility cab without front lift (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)

I012 I019
J002 J004 J005

2 3 7 8 2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004

B026
B018

B019

B025

B030

B015

B020
30A

30A
30A

15A
15A

15A

3A

+30
+30

+15
C004
C004

D008

F013 F010 F011 F012

B024
7.5A

6 2

2 1 2 1 2 1 2 1
D023
D004
D014

7 12 6 11 6 2
4 7 8 1
C007
D040

D039

D037

D038

1 1
C004

C007

B039
B040
10A

10A
D041

D042

3 1 1 3

10 9 5 6 2 3 7 8
7 4 6 5 1 3 2 8 7 4 6 5 1 3 2 8
2 1 1 2 2 1 2 1

F016 F017 F001 F006 I008 I024 I026

D0062930

Fig. 2774 - Work lights - Version with high-visibility cab without front lift - System
l D004 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D004 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D004 (F) - Wiring connector (Wiring loom 0.014.8107.4/30)
l D004 (F) - Wiring connector (Wiring loom 0.014.8107.4/30)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D014 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D014 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)

40-473
 Wiring diagrams
I012 I019
J002 J004 J005

2 3 7 8 2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004

B026
B018

B019

B025

B030

B015

B020
30A

30A
30A

15A
15A

15A

3A

+30
+30

+15
C004
C004

D008
F013 F010 F011 F012
B024
7.5A

6 2

2 1 2 1 2 1 2 1
D023
D004
D014

7 12 6 11 6 2
4 7 8 1

C007
D040

D039

D037

D038

1 1
C004

C007

B039
B040
10A

10A
D041

D042

3 1 1 3

10 9 5 6 2 3 7 8
7 4 6 5 1 3 2 8 7 4 6 5 1 3 2 8
2 1 1 2 2 1 2 1

F016 F017 F001 F006 I008 I024 I026

D0062930

Fig. 2774 - Work lights - Version with high-visibility cab without front lift - System
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D039 (F) - Wiring connector (Wiring loom 04411923.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D040 (F) - Wiring connector (Wiring loom 04411923.4)
l D041 (M) - Wiring connector (Wiring loom 0.014.3927.4/40)
l D041 (F) - Wiring connector (Wiring loom 04411923.4)
l D042 (M) - Wiring connector (Wiring loom 0.014.3927.4/40)

40-474
Wiring diagrams
I012 I019
J002 J004 J005

2 3 7 8 2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004

B026
B018

B019

B025

B030

B015

B020
30A

30A
30A

15A
15A

15A

3A

+30
+30

+15
C004
C004

D008
F013 F010 F011 F012
B024
7.5A

6 2

2 1 2 1 2 1 2 1
D023
D004
D014

7 12 6 11 6 2
4 7 8 1

C007
D040

D039

D037

D038

1 1
C004

C007

B039
B040
10A

10A
D041

D042

3 1 1 3

10 9 5 6 2 3 7 8
7 4 6 5 1 3 2 8 7 4 6 5 1 3 2 8
2 1 1 2 2 1 2 1

F016 F017 F001 F006 I008 I024 I026

D0062930

Fig. 2774 - Work lights - Version with high-visibility cab without front lift - System
l D042 (F) - Wiring connector (Wiring loom 04411923.4)
l F001 - RH front work light (on hood)
l F006 - LH front work light (on hood)
l F010 - RH front work light (on cab roof)
l F011 - LH rear work light (on cab roof)
l F012 - RH rear work light (on cab roof)
l F013 - LH front work light (on cab roof)
l F016 - RH supplementary work light
l F017 - LH supplementary work light
l I008 - Road lights switch
l I012 - Low front work lights switch
l I019 - Corner work lights switch
l I024 - Front work lights switch
l I026 - Rear work lights switch

40-475
 Wiring diagrams
I012 I019
J002 J004 J005

2 3 7 8 2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004

B026
B018

B019

B025

B030

B015

B020
30A

30A
30A

15A
15A

15A

3A

+30
+30

+15
C004
C004

D008
F013 F010 F011 F012
B024
7.5A

6 2

2 1 2 1 2 1 2 1
D023
D004
D014

7 12 6 11 6 2
4 7 8 1

C007
D040

D039

D037

D038

1 1
C004

C007

B039
B040
10A

10A
D041

D042

3 1 1 3

10 9 5 6 2 3 7 8
7 4 6 5 1 3 2 8 7 4 6 5 1 3 2 8
2 1 1 2 2 1 2 1

F016 F017 F001 F006 I008 I024 I026

D0062930

Fig. 2774 - Work lights - Version with high-visibility cab without front lift - System
l J002 - Relay
l J004 - Relay
l J005 - Relay

40-476
Wiring diagrams
B030
B025
J002
B026

J005 J004
A
B015

B018

B019 B024
B020

D008
D004

D014
C004

I019
I012
I008

D0063860

Fig. 2775 - Work lights - Version with high-visibility cab without front lift - Connector positions
Table 527
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1221
B018 Fuse (15A) 40-1209
B018 Fuse (15A) 40-1221
B019 Fuse (15A) 40-1209
B019 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B024 Fuse (7.5A) 40-1209
B024 Fuse (7.5A) 40-1221
B025 Fuse (30A) 40-1209

40-477
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B025 Fuse (30A) 40-1221
B026 Fuse (30A) 40-1209
B026 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1209
40-1221

Fig. 2776
D004 Wiring connector 40-1193
40-1209
40-1221
40-1193

Fig. 2777
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2778
D014 Wiring connector 40-1209
40-1224
40-1221
40-1224

Fig. 2779

40-478
Wiring diagrams
Table 528
Sys- P/N Description Characteristics/notes Position Wiring
tem
I008 Road lights switch 40-1209
40-1221
I012 Lower front work- 40-1209
40-1221
I019 Corner lights switch 40-1209
40-1221
J002 Relay 40-1209
40-1221

Fig. 2786
J004 Relay 40-1209
40-1221

Fig. 2787
J005 Relay 40-1209
40-1221

Fig. 2788

40-479
 Wiring diagrams

D004

F001

F006

D0063880

Fig. 2789 - Connector positions

Table 529
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1193
40-1209
40-1221
40-1193

Fig. 2789

40-480
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F001 Rh front worklight 40-1193
(on hood)

Fig. 2790
F006 Lh front worklight 40-1193
(on hood)

Fig. 2791

40-481
 Wiring diagrams

D039

D014
D040

D037

D038

D0063870

Fig. 2792 - Connector positions

Table 530
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1209
40-1224
40-1221
40-1224

Fig. 2792
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250

40-482
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D040 Wiring connector 40-1224
40-1250

D039
D040

D041 D037
D038

D042

D0063890

Fig. 2793 - Connector positions

Table 531
Sys- P/N Description Characteristics/notes Position Wiring
tem
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250
D040 Wiring connector 40-1224
40-1250
D041 Wiring connector 40-1250
40-1192
D042 Wiring connector 40-1192
40-1251

40-483
 Wiring diagrams

F016

D041 F017

D042

D0063900

Fig. 2794 - Connector positions

Table 532
Sys- P/N Description Characteristics/notes Position Wiring
tem
D041 Wiring connector 40-1250
40-1192
D042 Wiring connector 40-1192
40-1251
F016 Rh auxiliary work- 40-1192
light
F017 Lh auxiliary work- 40-1192
light

40-484
Wiring diagrams

D023

D008

D0063720

Fig. 2795 - Connector positions

Table 533
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2795

40-485
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1204
40-1220

Fig. 2796

40-486
Wiring diagrams

F012

F011
F010

B039-B040

I026
I024
D023 C007

F013

D0063980

Fig. 2797 - Connector positions

Table 534
Sys- P/N Description Characteristics/notes Position Wiring
tem
B039 Fuse (10A) 40-1204
B040 Fuse (10A) 40-1204

40-487
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 2798
D023 Wiring connector 40-1204
40-1220

Fig. 2798
F010 Rh front worklight 40-1204
(on cab roof)

Fig. 2799
F011 Lh rear worklight 40-1204
(on cab roof)

Fig. 2800
F012 Rh rear worklight 40-1204
(on cab roof)

Fig. 2801
F013 Lh front worklight 40-1204
(on cab roof)

40-488
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I024 Front worklights 0 40-1204
switch 1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2803
Fig. 2802
I026 Rear worklights 0 40-1204
switch 1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2804
Fig. 2803

40-489
 Wiring diagrams
40.3.25 - S008A - Work lights - Version with high-visibility cab without front lift - Version
with front instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)

I012
J002 J004 J005

2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004

B026
B024

B019

B025

B030

B015

B020
30A
7.5A

30A
30A

15A
15A

3A

+30
+15
+30
C004

D008

F013 F010 F011 F012

6 2

2 1 2 1 2 1 2 1
D023
D014

6 2
4 7 8 1
C007
D040

D039

D037

D038

1 1
C007
C004

B039
B040
10A

10A
D041

D042

3 1 1 3

10 9 5 6 2 3 7 8 7 4 6 5 1 3 2 8 7 4 6 5 1 3 2 8
2 1 1 2

F016 F017 I024 I026

I008 D0065440

Fig. 2805 - Work lights - Version with high-visibility cab without front lift - Version with front instrument panel -
System
l D008 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D014 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)

40-490
Wiring diagrams
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D039 (F) - Wiring connector (Wiring loom 04411923.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D040 (F) - Wiring connector (Wiring loom 04411923.4)
l D041 (M) - Wiring connector (Wiring loom 0.014.3927.4/40)
l D041 (F) - Wiring connector (Wiring loom 04411923.4)
l D041 (F) - RH front light on arm (Wiring loom 04411923.4)
l D042 (M) - Wiring connector (Wiring loom 0.014.3927.4/40)
l D042 (F) - Wiring connector (Wiring loom 04411923.4)
l D042 (F) - LH front light on arm (Wiring loom 04411923.4)
l F010 - RH front work light (on cab roof)
l F011 - LH rear work light (on cab roof)
l F012 - RH rear work light (on cab roof)
l F013 - LH front work light (on cab roof)
l F016 - RH supplementary work light
l F017 - LH supplementary work light
l I008 - Road lights switch
l I012 - Low front work lights switch
l I024 - Front work lights switch
l I026 - Rear work lights switch
l J002 - Relay
l J004 - Relay
l J005 - Relay

40-491
 Wiring diagrams
B030
B025
J002
B026

J005 J004

A
B015

B019 B024
B020

D008

D014
C004

I012
I008

D0065530

Fig. 2806 - Work lights - Version with high-visibility cab without front lift - Version with front instrument panel -
Connector positions
Table 535
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1238
B019 Fuse (15A) 40-1238
B020 Fuse (3A) 40-1238
B024 Fuse (7.5A) 40-1238
B025 Fuse (30A) 40-1238
B026 Fuse (30A) 40-1238
B030 Fuse (30A) 40-1238

40-492
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1238

Fig. 2807
D008 Wiring connector 40-1238
40-1220

Fig. 2808
D014 Wiring connector 40-1238
40-1224

Fig. 2809
I008 Road lights switch 40-1238

Fig. 2810 Fig. 2811

I012 Lower front work 0 40-1238
lights switch 1

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2813
Fig. 2812
J002 Relay 40-1238

Fig. 2814

40-493
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J004 Relay 40-1238

Fig. 2815
J005 Relay 40-1238

Fig. 2816

40-494
Wiring diagrams

D023

D008

D0063720

Fig. 2817 - Connector positions

Table 536
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1238
40-1220

Fig. 2817

40-495
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1204
40-1220

Fig. 2818

40-496
Wiring diagrams

F012

F011
F010

B039-B040

I026
I024
D023 C007

F013

D0063980

Fig. 2819 - Connector positions

Table 537
Sys- P/N Description Characteristics/notes Position Wiring
tem
B039 Fuse (10A) 40-1204
B040 Fuse (10A) 40-1204

40-497
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 2820
D023 Wiring connector 40-1204
40-1220

Fig. 2820
F010 RH front work light 40-1204
(on cab roof)

Fig. 2821
F011 LH rear work light 40-1204
(on cab roof)

Fig. 2822
F012 RH rear work light 40-1204
(on cab roof)

Fig. 2823
F013 LH front work light 40-1204
(on cab roof)

40-498
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I024 Front work lights 0 40-1204
switch 1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2825
Fig. 2824
I026 Rear work lights 0 40-1204
switch 1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2826
Fig. 2825

40-499
 Wiring diagrams

D039

D014
D040

D037

D038

D0063870

Fig. 2827 - Connector positions

Table 538
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1238
40-1224

Fig. 2827
D037 Wiring connector 40-1224
D037 Wiring connector 40-1251
D038 Wiring connector 40-1224
D038 Wiring connector 40-1251
D039 Wiring connector 40-1224
D039 Wiring connector 40-1250
D040 Wiring connector 40-1224

40-500
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D040 Wiring connector 40-1250

D039
D040

D041 D037
D038

D042

D0063890

Fig. 2828 - Connector positions

Table 539
Sys- P/N Description Characteristics/notes Position Wiring
tem
D037 Wiring connector 40-1224
D037 Wiring connector 40-1251
D038 Wiring connector 40-1224
D038 Wiring connector 40-1251
D039 Wiring connector 40-1224
D039 Wiring connector 40-1250
D040 Wiring connector 40-1224
D040 Wiring connector 40-1250
D041 Wiring connector 40-1250
D041 Wiring connector 40-1192
D041 Rh front light on 40-1250
arms
D042 Wiring connector 40-1192
D042 Wiring connector 40-1251

40-501
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D042 LH front light on 40-1251
arms

F016

D041 F017

D042

D0063900

Fig. 2829 - Connector positions

Table 540
Sys- P/N Description Characteristics/notes Position Wiring
tem
F016 RH auxiliary work 40-1192
light
F017 LH auxiliary work 40-1192
light
D041 Wiring connector 40-1250
D041 Wiring connector 40-1192
D041 Rh front light on 40-1250
arms
D042 Wiring connector 40-1192
D042 Wiring connector 40-1251
D042 LH front light on 40-1251
arms

40-502
Wiring diagrams
40.3.26 - S008D - Work lights - Version with high-visibility cab without front lift - Version
with digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)

I012
J002 J004 J005

2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004

B026
B024

B019

B025

B030

B015

B020
30A
7.5A

30A
30A

15A
15A

3A
+30

+30
+15
C004

D008

F013 F010 F011 F012

6 2

2 1 2 1 2 1 2 1
D023
D014

6 2
4 7 8 1
C007
D040

D039

D037

D038

1 1
C004

C007

B039
B040
10A

10A
D041

D042

3 1 1 3

10 9 5 6 2 3 7 8
7 4 6 5 1 3 2 8 7 4 6 5 1 3 2 8
2 1 1 2

F016 F017 I008 I024 I026

D0064890

Fig. 2830 - Work lights - Version with high-visibility cab without front lift - Version with digital instrument panel
- System
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D014 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D014 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)

40-503
 Wiring diagrams
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D039 (F) - Wiring connector (Wiring loom 04411923.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D040 (F) - Wiring connector (Wiring loom 04411923.4)
l D041 (M) - Wiring connector (Wiring loom 0.014.3927.4/40)
l D041 (F) - Wiring connector (Wiring loom 04411923.4)
l D041 (F) - RH front light on arm (Wiring loom 04411923.4)
l D042 (M) - Wiring connector (Wiring loom 0.014.3927.4/40)
l D042 (F) - Wiring connector (Wiring loom 04411923.4)
l D042 (F) - LH front light on arm (Wiring loom 04411923.4)
l F010 - RH front work light (on cab roof)
l F011 - LH rear work light (on cab roof)
l F012 - RH rear work light (on cab roof)
l F013 - LH front work light (on cab roof)
l F016 - RH supplementary work light
l F017 - LH supplementary work light
l I008 - Road lights switch
l I012 - Low front work lights switch
l I024 - Front work lights switch
l I026 - Rear work lights switch
l J002 - Relay
l J004 - Relay
l J005 - Relay

40-504
Wiring diagrams
B030
B025
J002
B026

J005 J004
A
B015

B019 B024
B020

D008

D014
C004

I012
I008

D0063862

Fig. 2831 - Work lights - Version with high-visibility cab without front lift - Version with digital instrument panel
- Connector positions
Table 541
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B019 Fuse (15A) 40-1205
B019 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B024 Fuse (7.5A) 40-1205
B024 Fuse (7.5A) 40-1221
B025 Fuse (30A) 40-1205
B025 Fuse (30A) 40-1221

40-505
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B026 Fuse (30A) 40-1205
B026 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 2832
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 2833
D014 Wiring connector 40-1205
40-1224
40-1221
40-1224

Fig. 2834
I008 Road lights switch 40-1205

Fig. 2835 Fig. 2836

I008 Road lights switch 40-1221

Fig. 2836 Fig. 2836

40-506
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I012 Lower front work 0 40-1205
lights switch 1

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2838
Fig. 2837
I012 Lower front work 0 40-1221
lights switch 1

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2838
Fig. 2838
J002 Relay 40-1205
40-1221

Fig. 2839
J004 Relay 40-1205
40-1221

Fig. 2840
J005 Relay 40-1205
40-1221

Fig. 2841

40-507
 Wiring diagrams

D039

D014
D040

D037

D038

D0063870

Fig. 2842 - Connector positions

Table 542
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1205
40-1224
40-1221
40-1224

Fig. 2842
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250

40-508
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D040 Wiring connector 40-1224
40-1250

D039
D040

D041 D037
D038

D042

D0063890

Fig. 2843 - Connector positions

Table 543
Sys- P/N Description Characteristics/notes Position Wiring
tem
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250
D040 Wiring connector 40-1224
40-1250
D041 Wiring connector 40-1250
D041 Wiring connector 40-1192
D041 Rh front light on 40-1250
arms
D042 Wiring connector 40-1192

40-509
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D042 Wiring connector 40-1251
D042 LH front light on 40-1251
arms

F016

D041 F017

D042

D0063900

Fig. 2844 - Connector positions

Table 544
Sys- P/N Description Characteristics/notes Position Wiring
tem
D041 Wiring connector 40-1250
D041 Wiring connector 40-1192
D041 Rh front light on 40-1250
arms
D042 Wiring connector 40-1192
D042 Wiring connector 40-1251
D042 LH front light on 40-1251
arms
F016 RH auxiliary work 40-1192
light

40-510
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F017 LH auxiliary work 40-1192
light

D023

D008

D0063720

Fig. 2845 - Connector positions

Table 545
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 2845

40-511
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1204
40-1220

Fig. 2846

40-512
Wiring diagrams

F012

F011
F010

B039-B040

I026
I024
D023 C007

F013

D0063980

Fig. 2847 - Connector positions

Table 546
Sys- P/N Description Characteristics/notes Position Wiring
tem
B039 Fuse (10A) 40-1204
B040 Fuse (10A) 40-1204

40-513
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 2848
D023 Wiring connector 40-1204
40-1220

Fig. 2848
F010 RH front work light 40-1204
(on cab roof)

Fig. 2849
F011 LH rear work light 40-1204
(on cab roof)

Fig. 2850
F012 RH rear work light 40-1204
(on cab roof)

Fig. 2851
F013 LH front work light 40-1204
(on cab roof)

40-514
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I024 Front work lights 0 40-1204
switch 1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2853
Fig. 2852
I026 Rear work lights 0 40-1204
switch 1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2854
Fig. 2853

40-515
 Wiring diagrams
40.3.27 - S009 - Work lights - Version with high-visibility cab with front lift (R3 EVO 100
-> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)

I019
J002 J004 J005

2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004

B026
B018

B025

B030

B015

B020
30A

30A
30A

15A
15A

3A

+30
+30

+15
C004

D008

F013 F010 F011 F012

B024
7.5A

6 2

2 1 2 1 2 1 2 1
D023
D004

7 12 6 11 6 2
C007
C004

C007

B039
B040
10A

10A

10 9 5 6 2 3 7 8
7 4 6 5 1 3 2 8 7 4 6 5 1 3 2 8
2 1 2 1

F001 F006 I008 I024 I026

D0062940

Fig. 2855 - Work lights - Version with high-visibility cab with front lift - System
l D004 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D004 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D004 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D004 (F) - Wiring connector (Wiring loom 0.014.8107.4/30)
l D004 (F) - Wiring connector (Wiring loom 0.014.8107.4/30)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)

40-516
Wiring diagrams
I019
J002 J004 J005

2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004

B026
B018

B025

B030

B015

B020
30A

30A
30A

15A
15A

3A

+30
+30

+15
C004

D008
F013 F010 F011 F012
B024
7.5A

6 2

2 1 2 1 2 1 2 1
D023
D004

7 12 6 11 6 2

C007
C004

C007

B039
B040
10A

10A

10 9 5 6 2 3 7 8
7 4 6 5 1 3 2 8 7 4 6 5 1 3 2 8
2 1 2 1

F001 F006 I008 I024 I026

D0062940

Fig. 2855 - Work lights - Version with high-visibility cab with front lift - System
l F001 - RH front work light (on hood)
l F006 - LH front work light (on hood)
l F010 - RH front work light (on cab roof)
l F011 - LH rear work light (on cab roof)
l F012 - RH rear work light (on cab roof)
l F013 - LH front work light (on cab roof)
l I008 - Road lights switch
l I019 - Corner work lights switch
l I024 - Front work lights switch
l I026 - Rear work lights switch
l J002 - Relay
l J004 - Relay
l J005 - Relay

40-517
 Wiring diagrams
B030
B025
J002
B026

J005 J004
A
B015

B018

B024
B020

D008
D004

C004

I019

I008

D0063940

Fig. 2856 - Work lights - Version with high-visibility cab with front lift - Connector positions
Table 547
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1221
B018 Fuse (15A) 40-1209
B018 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B024 Fuse (7.5A) 40-1209
B024 Fuse (7.5A) 40-1221
B025 Fuse (30A) 40-1209
B025 Fuse (30A) 40-1221
B026 Fuse (30A) 40-1209

40-518
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B026 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1209
40-1221

Fig. 2857
D004 Wiring connector 40-1193
40-1209
40-1221
40-1193

Fig. 2858
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2859
I008 Road lights switch 40-1209
40-1221
I019 Corner lights switch 40-1209
40-1221

40-519
 Wiring diagrams
Table 548
Sys- P/N Description Characteristics/notes Position Wiring
tem
J002 Relay 40-1209
40-1221

Fig. 2864
J004 Relay 40-1209
40-1221

Fig. 2865
J005 Relay 40-1209
40-1221

Fig. 2866

40-520
Wiring diagrams

D004

F001

F006

D0063880

Fig. 2867 - Connector positions

Table 549
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1193
40-1209
40-1221
40-1193

Fig. 2867

40-521
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F001 Rh front worklight 40-1193
(on hood)

Fig. 2868
F006 Lh front worklight 40-1193
(on hood)

Fig. 2869

40-522
Wiring diagrams

D023

D008

D0063720

Fig. 2870 - Connector positions

Table 550
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2870

40-523
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1204
40-1220

Fig. 2871

40-524
Wiring diagrams

F012

F011
F010

B039-B040

I026
I024
D023 C007

F013

D0063980

Fig. 2872 - Connector positions

Table 551
Sys- P/N Description Characteristics/notes Position Wiring
tem
B039 Fuse (10A) 40-1204
B040 Fuse (10A) 40-1204

40-525
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 2873
D023 Wiring connector 40-1204
40-1220

Fig. 2873
F010 Rh front worklight 40-1204
(on cab roof)

Fig. 2874
F011 Lh rear worklight 40-1204
(on cab roof)

Fig. 2875
F012 Rh rear worklight 40-1204
(on cab roof)

Fig. 2876
F013 Lh front worklight 40-1204
(on cab roof)

40-526
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I024 Front worklights 0 40-1204
switch 1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2878
Fig. 2877
I026 Rear worklights 0 40-1204
switch 1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2879
Fig. 2878

40-527
 Wiring diagrams
40.3.28 - S009A - Work lights - Version with high-visibility cab with front lift - Version with
analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

J002 J004 J005

NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004

B026
B025

B030

B015

B020
30A

30A
30A

15A

3A

+30
+15
+30

D008

F013 F010 F011 F012

B024
7.5A

6 2

2 1 2 1 2 1 2 1
D023

6 2
C007
C004

C007

B039
B040
10A

10A

10 9 5 6 2 3 7 8
7 4 6 5 1 3 2 8 7 4 6 5 1 3 2 8

I008 I024 I026

D0065450

Fig. 2880 - Work lights - Version with high-visibility cab with front lift - Version with analog instrument panel -
System
l D008 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l F010 - RH front work light (on cab roof)
l F011 - LH rear work light (on cab roof)
l F012 - RH rear work light (on cab roof)
l F013 - LH front work light (on cab roof)
l I008 - Road lights switch
l I024 - Front work lights switch

40-528
Wiring diagrams
l I026 - Rear work lights switch
l J002 - Relay
l J004 - Relay
l J005 - Relay

B030
B025
J002
B026

J005 J004
A
B015

B024
B020

D008

C004

I008

D0065540

Fig. 2881 - Work lights - Version with high-visibility cab with front lift - Version with analog instrument panel -
Connector positions
Table 552
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1238
B020 Fuse (3A) 40-1238
B024 Fuse (7.5A) 40-1238
B025 Fuse (30A) 40-1238
B026 Fuse (30A) 40-1238

40-529
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B030 Fuse (30A) 40-1238
D008 Wiring connector 40-1238
40-1220

Fig. 2882
C004 Earthing point 4 40-1238

Fig. 2883
I008 Road lights switch 40-1238

Fig. 2884 Fig. 2885

J002 Relay 40-1238

Fig. 2886
J004 Relay 40-1238

Fig. 2887
J005 Relay 40-1238

Fig. 2888

40-530
Wiring diagrams

D023

D008

D0063720

Fig. 2889 - Connector positions

Table 553
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1238
40-1220

Fig. 2889

40-531
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1204
40-1220

Fig. 2890

40-532
Wiring diagrams

F012

F011
F010

B039-B040

I026
I024
D023 C007

F013

D0063980

Fig. 2891 - Connector positions

Table 554
Sys- P/N Description Characteristics/notes Position Wiring
tem
B039 Fuse (10A) 40-1204
B040 Fuse (10A) 40-1204

40-533
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 2892
D023 Wiring connector 40-1204
40-1220

Fig. 2892
F010 RH front work light 40-1204
(on cab roof)

Fig. 2893
F011 LH rear work light 40-1204
(on cab roof)

Fig. 2894
F012 RH rear work light 40-1204
(on cab roof)

Fig. 2895
F013 LH front work light 40-1204
(on cab roof)

40-534
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I024 Front work lights 0 40-1204
switch 1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2897
Fig. 2896
I026 Rear work lights 0 40-1204
switch 1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2898
Fig. 2897

40-535
 Wiring diagrams
40.3.29 - S009D - Work lights - Version with high-visibility cab with front lift - Version with
digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

J002 J004 J005

NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30

C004

B026
B025

B030

B015

B020
30A

30A
30A

15A

3A
+30

+30
+15

D008

F013 F010 F011 F012

B024
7.5A

6 2

2 1 2 1 2 1 2 1
D023

6 2
C007
C004

C007

B039
B040
10A

10A

10 9 5 6 2 3 7 8
7 4 6 5 1 3 2 8 7 4 6 5 1 3 2 8

I008 I024 I026

D0064900

Fig. 2899 - Work lights - Version with high-visibility cab with front lift - Version with digital instrument panel -
System
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l F010 - RH front work light (on cab roof)
l F011 - LH rear work light (on cab roof)
l F012 - RH rear work light (on cab roof)
l F013 - LH front work light (on cab roof)
l I008 - Road lights switch
l I024 - Front work lights switch

40-536
Wiring diagrams
l I026 - Rear work lights switch
l J002 - Relay
l J004 - Relay
l J005 - Relay

B030
B025
J002
B026

J005 J004
A
B015

B024
B020

D008

C004

I008

D0063942

Fig. 2900 - Work lights - Version with high-visibility cab with front lift - Version with digital instrument panel -
Connector positions
Table 555
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B024 Fuse (7.5A) 40-1205

40-537
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B024 Fuse (7.5A) 40-1221
B025 Fuse (30A) 40-1205
B025 Fuse (30A) 40-1221
B026 Fuse (30A) 40-1205
B026 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 2901
D008 Wiring connector 40-1205
40-1220
40-1221

Fig. 2902
I008 Road lights switch 40-1205
40-1221
J002 Relay 40-1205
40-1221

Fig. 2905
J004 Relay 40-1205
40-1221

Fig. 2906
J005 Relay 40-1205
40-1221

Fig. 2907

40-538
Wiring diagrams

D023

D008

D0063720

Fig. 2908 - Connector positions

Table 556
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221

Fig. 2908

40-539
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1204
40-1220

Fig. 2909

40-540
Wiring diagrams

F012

F011
F010

B039-B040

I026
I024
D023 C007

F013

D0063980

Fig. 2910 - Connector positions

Table 557
Sys- P/N Description Characteristics/notes Position Wiring
tem
B039 Fuse (10A) 40-1204
B040 Fuse (10A) 40-1204

40-541
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 2911
F010 RH front work light 40-1204
(on cab roof)

Fig. 2912
F011 LH rear work light 40-1204
(on cab roof)

Fig. 2913
F012 RH rear work light 40-1204
(on cab roof)

Fig. 2914
F013 LH front work light 40-1204
(on cab roof)
I024 Front work lights 0 40-1204
switch 1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2916
Fig. 2915

40-542
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I026 Rear work lights 0 40-1204
switch 1

7 4 5 6 3 2 1 8

Pin 1 2 3 4 5 6 7 8
Pos

1
Fig. 2917
Fig. 2916
D023 Wiring connector 40-1204
40-1220

Fig. 2917

40.3.30 - S010 - Heating - Version with standard cab (R3 EVO 100 -> 20001, R3 EVO 110
-> 1001, R3 EVO 85 -> 20001)

40-543
 Wiring diagrams

J004 J007

NC NO 85 86 30 NC NO 85 86 30

D009

D003
1
C004

D024
B030

B015

B003
B020

30A

15A

60A
+15 3A

+30

+30
C007
D027

2 1

1 2 3 4 5 1 2 3 4 1 2
I II III IV C

O003 P014 D0062950

H005

Fig. 2918 - Heating - Version with standard cab - System

l D003 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D003 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D003 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D003 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D009 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D024 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D027 (M) - Wiring connector (Wiring loom 0.010.2147.2)
l D027 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D027 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D027 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D027 (M) - Wiring connector (Wiring loom 0.010.2147.2)
l D027 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D027 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D027 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l H005 - Fan speed selector switch
l J004 - Relay
l J007 - Relay
l O003 - Resistor
l P014 - Fan

40-544
Wiring diagrams
B030

J004

A
B015

J007

B020

D009

C004

A
D003

D0063990

Fig. 2919 - Heating - Version with standard cab - Positions

Table 558
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221

40-545
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1209
40-1221

Fig. 2920
D003 Wiring connector 40-1200
40-1209
40-1221
40-1200

Fig. 2921
D009 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2922
J004 Relay 40-1209
40-1221

Fig. 2923
J007 Relay 40-1209
40-1221

Fig. 2924

40-546
Wiring diagrams

D003

B003

D0064000

Fig. 2925 - Connector positions

Table 559
Sys- P/N Description Characteristics/notes Position Wiring
tem
B003 Fuse 40-1200

40-547
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D003 Wiring connector 40-1200
40-1209
40-1221
40-1200

Fig. 2925

D024

D009

D0064010

Fig. 2926 - Connector positions

40-548
Wiring diagrams
Table 560
Sys- P/N Description Characteristics/notes Position Wiring
tem
D009 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2926
D024 Wiring connector 40-1220
40-1226
40-1244
40-1220

Fig. 2927

C007
D027

D024

D0064020

Fig. 2928 - Connector positions

40-549
 Wiring diagrams
Table 561
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1226
40-1244

Fig. 2929
D027 Wiring connector 40-1226
40-1244
40-1182
40-1183
40-1182
40-1183
40-1226
40-1244
D024 Wiring connector 40-1220
40-1226
40-1244
40-1220

Fig. 2929

P014

O003
D027

H005
D0064030

Fig. 2930 - Connector positions

40-550
Wiring diagrams
Table 562
Sys- P/N Description Characteristics/notes Position Wiring
tem
D027 Wiring connector 40-1226
40-1244
40-1182
40-1183
40-1182
40-1183
40-1226
40-1244
H005 Blower speed se- 40-1182
lector switch

Fig. 2931
O003 Resistor 40-1182

Fig. 2932
P014 Electric fan 40-1182

Fig. 2933

40-551
 Wiring diagrams
40.3.31 - S010A - Heating - Version with standard cab - Version with digital instrument
panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

J004 J007

NC NO 85 86 30 NC NO 85 86 30

D009

D003
1
C004

D024
B030

B015

B003
B020

30A

15A

60A
+15 3A

+30

+30
C007
D027

2 1

1 2 3 4 5 1 2 3 4 1 2
I II III IV C

O003 P014 D0062950

H005

Fig. 2934 - Heating - Version with standard cab - Version with digital instrument panel - System
l D003 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D003 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D003 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D003 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D009 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D024 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D027 (M) - Wiring connector (Wiring loom 0.010.2147.2)
l D027 (M) - Wiring connector (Wiring loom 0.010.2147.2)
l D027 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D027 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l H005 - Fan speed selector switch
l J004 - Relay
l J007 - Relay
l O003 - Resistor
l P014 - Fan

40-552
Wiring diagrams
B030

J004

A
B015

J007

B020

D009

C004

A
D003

D0063990

Fig. 2935 - Heating - Version with standard cab - Version with digital instrument panel - Connector positions
Table 563
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221

40-553
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1205
40-1221

Fig. 2936
D003 Wiring connector 40-1200
40-1205
40-1221
40-1200

Fig. 2937
D009 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 2938
J004 Relay 40-1205
40-1221

Fig. 2939
J007 Relay 40-1205
40-1221

Fig. 2940

40-554
Wiring diagrams

D003

B003

D0064000

Fig. 2941 - Connector positions

Table 564
Sys- P/N Description Characteristics/notes Position Wiring
tem
B003 Fuse 40-1200

40-555
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D003 Wiring connector 40-1200
40-1205
40-1221
40-1200

Fig. 2941

D024

D009

D0064010

Fig. 2942 - Connector positions

40-556
Wiring diagrams
Table 565
Sys- P/N Description Characteristics/notes Position Wiring
tem
D024 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2943
D009 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 2943

C007
D027

D024

D0064020

Fig. 2944 - Connector positions

40-557
 Wiring diagrams
Table 566
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1228
40-1242

Fig. 2945
D024 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2945
D027 Wiring connector 40-1182
40-1182
40-1228
40-1242

Fig. 2945

P014

O003
D027

H005
D0064030

Fig. 2946 - Connector positions

40-558
Wiring diagrams
Table 567
Sys- P/N Description Characteristics/notes Position Wiring
tem
D027 Wiring connector 40-1182
40-1182
40-1228
40-1242

Fig. 2946
H005 Blower speed se- 40-1182
lector switch

Fig. 2947
O003 Resistor 40-1182

Fig. 2948
P014 Electric fan 40-1182

Fig. 2949

40-559
 Wiring diagrams
40.3.32 - S010D - Heating - Version with standard cab - Version with digital instrument
panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

J004 J007

NC NO 85 86 30 NC NO 85 86 30

D009

D003
1
C004

D024
B030

B015

B003
B020

30A

15A

60A
+15 3A

+30

+30
C007
D027

2 1

1 2 3 4 5 1 2 3 4 1 2
I II III IV C

O003 P014 D0062950

H005

Fig. 2949 - Heating - Version with standard cab - Version with digital instrument panel - System
l D003 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D003 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D003 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D003 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D009 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D024 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D027 (M) - Wiring connector (Wiring loom 0.010.2147.2)
l D027 (M) - Wiring connector (Wiring loom 0.010.2147.2)
l D027 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D027 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l H005 - Fan speed selector switch
l J004 - Relay
l J007 - Relay
l O003 - Resistor
l P014 - Fan

40-560
Wiring diagrams
B030

J004

A
B015

J007

B020

D009

C004

A
D003

D0063990

Fig. 2949 - Heating - Version with standard cab - Version with digital instrument panel - Connector positions
Table 568
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221

40-561
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1205
40-1221

Fig. 2949
D003 Wiring connector 40-1200
40-1205
40-1221
40-1200

Fig. 2949
D009 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 2949
J004 Relay 40-1205
40-1221

Fig. 2949
J007 Relay 40-1205
40-1221

Fig. 2949

40-562
Wiring diagrams

D003

B003

D0064000

Fig. 2949 - Connector positions

Table 569
Sys- P/N Description Characteristics/notes Position Wiring
tem
B003 Fuse 40-1200

40-563
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D003 Wiring connector 40-1200
40-1205
40-1221
40-1200

Fig. 2949

D024

D009

D0064010

Fig. 2949 - Connector positions

40-564
Wiring diagrams
Table 570
Sys- P/N Description Characteristics/notes Position Wiring
tem
D024 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2949
D009 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 2949

C007
D027

D024

D0064020

Fig. 2949 - Connector positions

40-565
 Wiring diagrams
Table 571
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1228
40-1242

Fig. 2949
D024 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 2949
D027 Wiring connector 40-1182
40-1182
40-1228
40-1242

Fig. 2949

P014

O003
D027

H005
D0064030

Fig. 2949 - Connector positions

40-566
Wiring diagrams
Table 572
Sys- P/N Description Characteristics/notes Position Wiring
tem
D027 Wiring connector 40-1182
40-1182
40-1228
40-1242

Fig. 2949
H005 Blower speed se- 40-1182
lector switch

Fig. 2949
O003 Resistor 40-1182

Fig. 2949
P014 Electric fan 40-1182

Fig. 2949

40-567
 Wiring diagrams
40.3.33 - S011 - Heating - Version with high-visibility cab (R3 EVO 100 -> 20001, R3 EVO
110 -> 1001, R3 EVO 85 -> 20001)

J004 J007 J009

NC NO 85 86 30 NC NO 85 86 30 87 85 86 30

B030

B015
B020

B033

B027
30A
30A

15A
20A
3A
C004
+15

+30

+30
D009

1 2 H004
O002
D025
D024

IV

III

II

I
4 3 2 1 5 4 3 2 1
C007

C007
D034

D035

A B A B

87b 87 86 85 30 30 85 86 87 87b 4 3 2 1

M M

D0062960
P012 P013 O001
J010 J012

Fig. 2950 - Heating - Version with high-visibility cab - System

l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D009 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D025 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D025 (F) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D034 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D034 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D035 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D035 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l H004 - Fan speed selector switch
l J004 - Relay

40-568
Wiring diagrams

J004 J007 J009

NC NO 85 86 30 NC NO 85 86 30 87 85 86 30

B030

B015
B020

B033

B027
30A
30A

15A
20A
3A
C004
+15

+30

+30
D009 1 2 H004
O002
D025
D024

IV

III

II

I
4 3 2 1 5 4 3 2 1
C007

C007
D034

D035

A B A B

87b 87 86 85 30 30 85 86 87 87b 4 3 2 1

M M

D0062960
P012 P013 O001
J010 J012

Fig. 2950 - Heating - Version with high-visibility cab - System

l J007 - Relay
l J009 - Relay
l J010 - Max. fan speed relay
l J012 - 3rd fan speed relay
l O001 - LH resistor
l O002 - RH resistor
l P012 - RH fan
l P013 - LH fan

40-569
 Wiring diagrams
B030

J009

B027
B033 J004
A
B015

J007

B020

D009

C004

D0064040

Fig. 2951 - Heating - Version with high-visibility cab - Positions

Table 573
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B027 Fuse (30A) 40-1209
B027 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221
B033 Fuse (20A) 40-1209
B033 Fuse (20A) 40-1221

40-570
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1209
40-1221

Fig. 2952
D009 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2953
J004 Relay 40-1209
40-1221

Fig. 2954
J007 Relay 40-1209
40-1221

Fig. 2955
J009 Relay 40-1209
40-1221

Fig. 2956

40-571
 Wiring diagrams

D025

D024

D009

D0064050

Fig. 2957 - Connector positions

Table 574
Sys- P/N Description Characteristics/notes Position Wiring
tem
D009 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2957

40-572
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D024 Wiring connector 40-1204
40-1220

Fig. 2958
D025 Wiring connector 40-1220
40-1204

Fig. 2959

40-573
 Wiring diagrams
P013
J010 J012
D035
O002

H004

C007
D025 D034

D024 P012

O001

D0064060

Fig. 2960 - Connector positions

40-574
Wiring diagrams
Table 575
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 2961
D024 Wiring connector 40-1204
40-1220

Fig. 2961
D025 Wiring connector 40-1220
40-1204

Fig. 2961
D034 Wiring connector 40-1204
40-1204

Fig. 2962
D035 Wiring connector 40-1204
40-1204

Fig. 2963
H004 Blower speed se- 40-1204
lector switch
H004 Blower speed se- 40-1204
lector switch

Fig. 2964

40-575
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J010 Max. fan speed re- 40-1204
lay

Fig. 2965
J012 3rd fan speed relay 40-1204

Fig. 2966
O001 LH resistor 40-1204
O002 RH resistor 40-1204

Fig. 2967
P012 RH fan 40-1204

Fig. 2968
P013 LH fan 40-1204

Fig. 2969

40-576
Wiring diagrams
40.3.34 - S011A - Heating - Version with high-visibility cab - Version with digital instru-
ment panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

J004 J007 J009

NC NO 85 86 30 NC NO 85 86 30 87 85 86 30

B030

B015
B020

B033

B027
30A
30A

15A
20A
3A
C004
+15

+30

+30
D009

1 2 H004
O002
D025
D024

IV

III

II

I
4 3 2 1 5 4 3 2 1
C007

C007
D034

D035

A B A B

87b 87 86 85 30 30 85 86 87 87b 4 3 2 1

M M

D0062960
P012 P013 O001
J010 J012

Fig. 2970 - Heating - Version with high-visibility cab - Version with digital instrument panel - System
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D024 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D025 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D025 (F) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D034 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D034 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D035 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D035 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l H004 - Fan speed selector switch
l J004 - Relay
l J007 - Relay
l J009 - Relay

40-577
 Wiring diagrams
l J010 - Max. fan speed relay
l J012 - 3rd fan speed relay
l O001 - LH resistor
l O002 - RH resistor
l P012 - RH fan
l P013 - LH fan

B030

J009

B027
B033 J004
A
B015

J007

B020

D009

C004

D0064040

Fig. 2971 - Heating - Version with high-visibility cab - Version with digital instrument panel - Connector positions
Table 576
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221

40-578
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B027 Fuse (30A) 40-1205
B027 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
B033 Fuse (20A) 40-1205
B033 Fuse (20A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 2972
D009 Wiring connector 40-1205
40-1220
40-1221

Fig. 2973
J004 Relay 40-1205
40-1221

Fig. 2974
J007 Relay 40-1205
40-1221

Fig. 2975
J009 Relay 40-1205
40-1221

Fig. 2976

40-579
 Wiring diagrams

D025

D024

D009

D0064050

Fig. 2977 - Connector positions

Table 577
Sys- P/N Description Characteristics/notes Position Wiring
tem
D009 Wiring connector 40-1205
40-1220
40-1221

Fig. 2977

40-580
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D024 Wiring connector 40-1204
40-1220

Fig. 2978
D025 Wiring connector 40-1220
40-1204

Fig. 2979

40-581
 Wiring diagrams
P013
J010 J012
D035
O002

H004

C007
D025 D034

D024 P012

O001

D0064060

Fig. 2980 - Connector positions

40-582
Wiring diagrams
Table 578
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 2981
D024 Wiring connector 40-1204
40-1220

Fig. 2981
D025 Wiring connector 40-1220
40-1204

Fig. 2981
D034 Wiring connector 40-1204
40-1204

Fig. 2982
D035 Wiring connector 40-1204
40-1204

Fig. 2983
H004 Blower speed se- 40-1204
lector switch 40-1204

Fig. 2984

40-583
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J010 Max. fan speed re- 40-1204
lay

Fig. 2984
J012 3rd fan speed relay 40-1204

Fig. 2985
O001 Lh resistor 40-1204
O002 Rh resistor 40-1204

Fig. 2986
P012 Rh fan 40-1204

Fig. 2987
P013 Lh fan 40-1204

Fig. 2988

40-584
Wiring diagrams
40.3.35 - S011DA - Heating - Version with high-visibility cab - Version with digital instru-
ment panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

J004 J007 J009

NC NO 85 86 30 NC NO 85 86 30 87 85 86 30

B030

B015
B020

B033

B027
30A
30A

15A
20A
3A
C004
+15

+30

+30
D009

1 2 H004
O002
D025
D024

IV

III

II

I
4 3 2 1 5 4 3 2 1
C007

C007
D034

D035

A B A B

87b 87 86 85 30 30 85 86 87 87b 4 3 2 1

M M

D0062960
P012 P013 O001
J010 J012

Fig. 2988 - Heating - Version with high-visibility cab - Version with digital instrument panel - System
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D024 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D025 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D025 (F) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D034 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D034 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D035 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D035 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l H004 - Fan speed selector switch
l J004 - Relay
l J007 - Relay
l J009 - Relay

40-585
 Wiring diagrams
l J010 - Max. fan speed relay
l J012 - 3rd fan speed relay
l O001 - LH resistor
l O002 - RH resistor
l P012 - RH fan
l P013 - LH fan

B030

J009

B027
B033 J004
A
B015

J007

B020

D009

C004

D0064040

Fig. 2988 - Heating - Version with high-visibility cab - Version with digital instrument panel - Connector positions
Table 579
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221

40-586
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B027 Fuse (30A) 40-1205
B027 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
B033 Fuse (20A) 40-1205
B033 Fuse (20A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 2988
D009 Wiring connector 40-1205
40-1220
40-1221

Fig. 2988
J004 Relay 40-1205
40-1221

Fig. 2988
J007 Relay 40-1205
40-1221

Fig. 2988
J009 Relay 40-1205
40-1221

Fig. 2988

40-587
 Wiring diagrams

D025

D024

D009

D0064050

Fig. 2988 - Connector positions

Table 580
Sys- P/N Description Characteristics/notes Position Wiring
tem
D009 Wiring connector 40-1205
40-1220
40-1221

Fig. 2988

40-588
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D024 Wiring connector 40-1204
40-1220

Fig. 2988
D025 Wiring connector 40-1220
40-1204

Fig. 2988

40-589
 Wiring diagrams
P013
J010 J012
D035
O002

H004

C007
D025 D034

D024 P012

O001

D0064060

Fig. 2988 - Connector positions

40-590
Wiring diagrams
Table 581
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 2988
D024 Wiring connector 40-1204
40-1220

Fig. 2988
D025 Wiring connector 40-1220
40-1204

Fig. 2988
D034 Wiring connector 40-1204
40-1204

Fig. 2988
D035 Wiring connector 40-1204
40-1204

Fig. 2988
H004 Blower speed se- 40-1204
lector switch 40-1204

Fig. 2988

40-591
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J010 Max. fan speed re- 40-1204
lay

Fig. 2988
J012 3rd fan speed relay 40-1204

Fig. 2988
O001 Lh resistor 40-1204
O002 Rh resistor 40-1204

Fig. 2988
P012 Rh fan 40-1204

Fig. 2988
P013 Lh fan 40-1204

Fig. 2988

40-592
Wiring diagrams
40.3.36 - S012 - Manual climate control - Version with standard cab (R3 EVO 100 -> 20001,
R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
Up to Serial No.
l Explorer
m 85: 20154 <-
m 100: 20486 <-
m 110: 1275 <-

l R3 EVO
m 85: 20043<-
m 100: 20182 <-
m 110: 1106 <-

l XB MAX
m 85: 20020<-
m 100: 20031<-
m 110: 1022 <-

l AGROFARM
m 410: 20552 <-
m 420: 21292 <-
m 430: 1419 <-

40-593
 Wiring diagrams

J004 J007
P001

NC NO 85 86 30 NC NO 85 86 30 1

D005
13

B030

B015
B020

B033

B029

B005
30A

15A
20A

40A

10A
3A
C004
+15

+30

+30
D009

D008
1 4 1

D024

D023
4 1

B036
30A
C007

D028
D027

D026

2 1 1 2 3 4 1 2 3 4

1 2 3 4 5 1 2 3 4 1 2 30 86 85 87 1 2 2 1 30 86 85 87 87a 1 2 3 1
I II III IV C
t
M M

O003 P014 K022 P015

H005 J013 J014 K023 K024
D0062970

Fig. 2989 - Manual climate control - Version with standard cab - System
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)

40-594
Wiring diagrams

J004 J007
P001

NC NO 85 86 30 NC NO 85 86 30 1

D005
13

B030

B015
B020

B033

B029

B005
30A

15A
20A

40A

10A
3A
C004
+15

+30

+30
D009

D008
1 4 1

D024

D023
4 1

B036
30A
C007

D028
D027

D026

2 1 1 2 3 4 1 2 3 4

1 2 3 4 5 1 2 3 4 1 2 30 86 85 87 1 2 2 1 30 86 85 87 87a 1 2 3 1
I II III IV C
t
M M

O003 P014 K022 P015

H005 J013 J014 K023 K024
D0062970

Fig. 2989 - Manual climate control - Version with standard cab - System
l D009 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D026 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D026 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D027 (M) - Wiring connector (Wiring loom 0.010.2147.2)
l D027 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D027 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D027 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D028 (M) - Wiring connector (Wiring loom 0.009.7853.3/20)
l D028 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)

40-595
 Wiring diagrams

J004 J007
P001

NC NO 85 86 30 NC NO 85 86 30 1

D005
13

B030

B015
B020

B033

B029

B005
30A

15A
20A

40A

10A
3A
C004
+15

+30

+30
D009

D008
1 4 1

D024

D023
4 1

B036
30A
C007

D028
D027

D026

2 1 1 2 3 4 1 2 3 4

1 2 3 4 5 1 2 3 4 1 2 30 86 85 87 1 2 2 1 30 86 85 87 87a 1 2 3 1
I II III IV C
t
M M

O003 P014 K022 P015

H005 J013 J014 K023 K024
D0062970

Fig. 2989 - Manual climate control - Version with standard cab - System
l H005 - Fan speed selector switch
l J004 - Relay
l J007 - Relay
l J013 - Compressor relay
l J014 - Control relay for air conditioning condenser fan
l K022 - Air conditioning temperature thermostat
l K023 - Air conditioning pressure switch
l K024 - Air conditioning pressure switch
l O003 - Resistor
l P001 - Air conditioning system compressor
l P014 - Fan
l P015 - Air conditioning condenser fan

40-596
Wiring diagrams
B029

B030

B033

A
B015

B005 J004
B020
J007

D009
D008

C004

D005

D0064070

Fig. 2990 - Manual climate control - Version with standard cab - Connector positions
Table 582
Sys- P/N Description Characteristics/notes Position Wiring
tem
B005 Fuse (10A) 40-1209
B005 Fuse (10A) 40-1221
B015 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B029 Fuse (40A) 40-1209

40-597
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221
B033 Fuse (20A) 40-1209
B033 Fuse (20A) 40-1221
C004 Earthing point 4 40-1209
40-1221

Fig. 2991
D005 Wiring connector 40-1234
40-1236
40-1209
40-1221
40-1209
40-1221
40-1234
40-1236

Fig. 2992
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2993
D009 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2994

40-598
Wiring diagrams
Table 583
Sys- P/N Description Characteristics/notes Position Wiring
tem
J004 Relay 40-1209
40-1221

Fig. 2995
J007 Relay 40-1209
40-1221

Fig. 2996

40-599
 Wiring diagrams

D023

D024

D009
D008

D0064080

Fig. 2997 - Connector positions

Table 584
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2997

40-600
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D009 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 2997
D023 Wiring connector 40-1220
40-1226

Fig. 2998
D024 Wiring connector 40-1220
40-1226

Fig. 2999

40-601
 Wiring diagrams

B036 C007 D026

D027
D028

D023

D024

D0064090

Fig. 3000 - Connector positions

Table 585
Sys- P/N Description Characteristics/notes Position Wiring
tem
B036 Fuse (30A) 40-1226
C007 Earthing point 7 40-1226
40-1244

Fig. 3001
D023 Wiring connector 40-1220
40-1226

Fig. 3001

40-602
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D024 Wiring connector 40-1220
40-1226

Fig. 3001
D026 Wiring connector 40-1226
40-1183
D027 Wiring connector 40-1226
40-1182
40-1183
40-1226
D028 Wiring connector 40-1226
40-1180

Fig. 3002

P014
D026

O003

D027

K022

H005 J013

D0064100

Fig. 3003 - Connector positions

Table 586
Sys- P/N Description Characteristics/notes Position Wiring
tem
D026 Wiring connector 40-1226
40-1183

40-603
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D027 Wiring connector 40-1226
40-1182
40-1183
40-1226
H005 Blower speed se- 40-1183
lector switch

Fig. 3004
J013 Compressor relay 40-1183
K022 Air conditioning 40-1183
temperature ther-
mostat

Fig. 3005
O003 Resistor 40-1183

Fig. 3006
P014 Electric fan 40-1183

Fig. 3007

40-604
Wiring diagrams
P015
K023

K024

D028
J014

D0064110

Fig. 3008 - Connector positions

Table 587
Sys- P/N Description Characteristics/notes Position Wiring
tem
J014 Control relay for air 40-1180
conditioning cooler
fan

Fig. 3009
D028 Wiring connector 40-1226
40-1180

Fig. 3009

40-605
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
K023 Air conditioning 40-1180
pressure switch

Fig. 3010
K024 Air conditioning 40-1180
pressure switch
P015 Air conditioning 40-1180
condenser fan

Fig. 3011

40-606
Wiring diagrams

D005

D0064120

Fig. 3012 - Connector positions - Version with front battery (1/2)

40-607
 Wiring diagrams

D005

A
C B

D0064140

Fig. 3013 - Connector positions - Version with lateral battery (1/2)

40-608
Wiring diagrams
Table 588
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1236
40-1209
40-1221
40-1209
40-1221
40-1234
40-1236

Fig. 3013

40-609
 Wiring diagrams

P001

D0064130

Fig. 3014 - Connector positions - Version with front battery (2/2)

40-610
Wiring diagrams

B
C

P001

D0064150

Fig. 3015 - Connector positions - Version with lateral battery (2/2)

Table 589
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1234
compressor 40-1236

Fig. 3016

40.3.37 - S012A - Heating - Version with standard cab - Version with digital instrument
panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
Up to Serial No.
l Explorer
m 85 with air conditioning: 16657 <-
m 100 with air conditioning: 16481 <-
m 110 with air conditioning: 5167<-

40-611
 Wiring diagrams
l R3 EVO
m 85 with air conditioning: 16285 <-
m 100 with air conditioning: 16305 <-
m 110 with air conditioning: 5138 <-

l XB MAX
m 85 with air conditioning: 16015 <-
m 100 with air conditioning: 16015<-
m 110 with air conditioning: 5002 <-

l AGROFARM
m 410 with air conditioning: 16904 <-
m 420 with air conditioning: 16867 <-
m 430 with air conditioning: 5252 <-

J004 J007
P001

NC NO 85 86 30 NC NO 85 86 30 1

D005
13
B030

B015
B020

B033

B029

B005
30A

15A
20A

40A

10A
3A
C004
+15

+30

+30
D009

D008

1 4 1
D024

D023

4 1
B036
30A
C007

D028
D027

D026

2 1 1 2 3 4 1 2 3 4

1 2 3 4 5 1 2 3 4 1 2 30 86 85 87 1 2 2 1 30 86 85 87 87a 1 2 3 1
I II III IV C
t
M M

O003 P014 K022 P015

H005 J013 J014 K023 K024
D0062970

Fig. 3017 - Manual climate control - Version with standard cab - Version with digital instrument panel - System

40-612
Wiring diagrams
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D009 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D026 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D026 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D027 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D027 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D028 (M) - Wiring connector (Wiring loom 0.009.7853.3/20)
l D028 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l H005 - Fan speed selector switch
l J004 - Relay
l J007 - Relay
l J013 - Compressor relay
l J014 - Control relay for air conditioning condenser fan
l K022 - Air conditioning temperature thermostat
l K023 - Air conditioning pressure switch
l K024 - Air conditioning pressure switch
l O003 - Resistor
l P001 - Air conditioning system compressor
l P014 - Fan
l P015 - Air conditioning condenser fan

40-613
 Wiring diagrams
B029

B030

B033

A
B015

B005 J004
B020
J007

D009
D008

C004

D005

D0064070

Fig. 3018 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions
Table 590
Sys- P/N Description Characteristics/notes Position Wiring
tem
B005 Fuse (10A) 40-1205
B005 Fuse (10A) 40-1221
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221

40-614
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B029 Fuse (40A) 40-1205
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
B033 Fuse (20A) 40-1205
B033 Fuse (20A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 3019
D005 Wiring connector 40-1234
40-1236
40-1205
40-1221
40-1205
40-1221
40-1234
40-1236

Fig. 3020
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3021
D009 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3022
J004 Relay 40-1205
40-1221

Fig. 3023

40-615
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J007 Relay 40-1205
40-1221

Fig. 3024

D023

D024

D009
D008

D0064080

Fig. 3025 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions

40-616
Wiring diagrams
Table 591
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3025
D009 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3025
D023 Wiring connector 40-1220
40-1228

Fig. 3026
D024 Wiring connector 40-1220
40-1228

Fig. 3027

40-617
 Wiring diagrams

B036 C007 D026

D027
D028

D023

D024

D0064090

Fig. 3028 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions
Table 592
Sys- P/N Description Characteristics/notes Position Wiring
tem
B036 Fuse (30A) 40-1228
C007 Earthing point 7 40-1228

Fig. 3029
D023 Wiring connector 40-1220
40-1228

Fig. 3029

40-618
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D024 Wiring connector 40-1220
40-1228

Fig. 3029
D026 Wiring connector 40-1228
40-1183
D027 Wiring connector 40-1228
40-1183
D028 Wiring connector 40-1228
40-1180

Fig. 3030

P014
D026

O003

D027

K022

H005 J013

D0064100

Fig. 3031 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions
Table 593
Sys- P/N Description Characteristics/notes Position Wiring
tem
D026 Wiring connector 40-1228
40-1183
D027 Wiring connector 40-1228
40-1183

40-619
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
H005 Blower speed se- 40-1183
lector switch

Fig. 3032
J013 Compressor relay 40-1183
K022 Air conditioning 40-1183
temperature ther-
mostat

Fig. 3033
O003 Resistor 40-1183

Fig. 3034
P014 Electric fan 40-1183

Fig. 3035

40-620
Wiring diagrams
P015
K023

K024

D028
J014

D0064110

Fig. 3036 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions
Table 594
Sys- P/N Description Characteristics/notes Position Wiring
tem
D028 Wiring connector 40-1228
40-1180

Fig. 3036
K023 Air conditioning 40-1180
pressure switch

Fig. 3037
K024 Air conditioning 40-1180
pressure switch

40-621
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
P015 Air conditioning 40-1180
condenser fan

Fig. 3038
J014 Control relay for air 40-1180
conditioning cooler
fan

Fig. 3039

40-622
Wiring diagrams

D005

D0064120

Fig. 3040 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions - Version with front battery (1/2)

40-623
 Wiring diagrams
Table 595
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1205
40-1221
40-1205
40-1221
40-1234

Fig. 3040

40-624
Wiring diagrams

D005

A
C B

D0064140

Fig. 3041 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions - Version with lateral battery (1/2)

40-625
 Wiring diagrams
Table 596
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1236
40-1236
40-1205
40-1221
40-1205
40-1221
40-1236

Fig. 3041

40-626
Wiring diagrams

P001

D0064130

Fig. 3042 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions - Version with front battery (2/2)

40-627
 Wiring diagrams
Table 597
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1234
compressor

Fig. 3043

B
C

P001

D0064150

Fig. 3044 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions - Version with lateral battery (2/2)

40-628
Wiring diagrams
Table 598
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1236
compressor

Fig. 3044

40.3.38 - S012D - Manual climate control - Version with standard cab - Version with digi-
tal instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
Up to Serial No.
l Explorer
m 85 with air conditioning: 16657 <-
m 100 with air conditioning: 16481 <-
m 110 with air conditioning: 5167<-

l R3 EVO
m 85 with air conditioning: 16285 <-
m 100 with air conditioning: 16305 <-
m 110 with air conditioning: 5138 <-

l XB MAX
m 85 with air conditioning: 16015 <-
m 100 with air conditioning: 16015<-
m 110 with air conditioning: 5002 <-

l AGROFARM
m 410 with air conditioning: 16904 <-
m 420 with air conditioning: 16867 <-
m 430 with air conditioning: 5252 <-

40-629
 Wiring diagrams

J004 J007
P001

NC NO 85 86 30 NC NO 85 86 30 1

D005
13

B030

B015
B020

B033

B029

B005
30A

15A
20A

40A

10A
3A
C004
+15

+30

+30
D009

D008
1 4 1

D024

D023
4 1

B036
30A
C007

D028
D027

D026

2 1 1 2 3 4 1 2 3 4

1 2 3 4 5 1 2 3 4 1 2 30 86 85 87 1 2 2 1 30 86 85 87 87a 1 2 3 1
I II III IV C
t
M M

O003 P014 K022 P015

H005 J013 J014 K023 K024
D0062970

Fig. 3044 - Manual climate control - Version with standard cab - Version with digital instrument panel - System
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)

40-630
Wiring diagrams
l D009 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D026 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D026 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D027 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D027 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D028 (M) - Wiring connector (Wiring loom 0.009.7853.3/20)
l D028 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l H005 - Fan speed selector switch
l J004 - Relay
l J007 - Relay
l J013 - Compressor relay
l J014 - Control relay for air conditioning condenser fan
l K022 - Air conditioning temperature thermostat
l K023 - Air conditioning pressure switch
l K024 - Air conditioning pressure switch
l O003 - Resistor
l P001 - Air conditioning system compressor
l P014 - Fan
l P015 - Air conditioning condenser fan

40-631
 Wiring diagrams
B029

B030

B033

A
B015

B005 J004
B020
J007

D009
D008

C004

D005

D0064070

Fig. 3044 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions
Table 599
Sys- P/N Description Characteristics/notes Position Wiring
tem
B005 Fuse (10A) 40-1205
B005 Fuse (10A) 40-1221
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221

40-632
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B029 Fuse (40A) 40-1205
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
B033 Fuse (20A) 40-1205
B033 Fuse (20A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 3044
D005 Wiring connector 40-1234
40-1236
40-1205
40-1221
40-1205
40-1221
40-1234
40-1236

Fig. 3044
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3044
D009 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3044
J004 Relay 40-1205
40-1221

Fig. 3044

40-633
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J007 Relay 40-1205
40-1221

Fig. 3044

D023

D024

D009
D008

D0064080

Fig. 3044 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions

40-634
Wiring diagrams
Table 600
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3044
D009 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3044
D023 Wiring connector 40-1220
40-1228

Fig. 3044
D024 Wiring connector 40-1220
40-1228

Fig. 3044

40-635
 Wiring diagrams

B036 C007 D026

D027
D028

D023

D024

D0064090

Fig. 3044 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions
Table 601
Sys- P/N Description Characteristics/notes Position Wiring
tem
B036 Fuse (30A) 40-1228
C007 Earthing point 7 40-1228

Fig. 3044
D023 Wiring connector 40-1220
40-1228

Fig. 3044

40-636
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D024 Wiring connector 40-1220
40-1228

Fig. 3044
D026 Wiring connector 40-1228
40-1183
D027 Wiring connector 40-1228
40-1183
D028 Wiring connector 40-1228
40-1180

Fig. 3044

P014
D026

O003

D027

K022

H005 J013

D0064100

Fig. 3044 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions
Table 602
Sys- P/N Description Characteristics/notes Position Wiring
tem
D026 Wiring connector 40-1228
40-1183
D027 Wiring connector 40-1228
40-1183

40-637
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
H005 Blower speed se- 40-1183
lector switch

Fig. 3044
J013 Compressor relay 40-1183
K022 Air conditioning 40-1183
temperature ther-
mostat

Fig. 3044
O003 Resistor 40-1183

Fig. 3044
P014 Electric fan 40-1183

Fig. 3044

40-638
Wiring diagrams
P015
K023

K024

D028
J014

D0064110

Fig. 3044 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions
Table 603
Sys- P/N Description Characteristics/notes Position Wiring
tem
D028 Wiring connector 40-1228
40-1180

Fig. 3044
K023 Air conditioning 40-1180
pressure switch

Fig. 3044
K024 Air conditioning 40-1180
pressure switch

40-639
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
P015 Air conditioning 40-1180
condenser fan

Fig. 3044
J014 Control relay for air 40-1180
conditioning cooler
fan

Fig. 3044

40-640
Wiring diagrams

D005

D0064120

Fig. 3044 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions - Version with front battery (1/2)

40-641
 Wiring diagrams
Table 604
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1205
40-1221
40-1205
40-1221
40-1234

Fig. 3044

40-642
Wiring diagrams

D005

A
C B

D0064140

Fig. 3044 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions - Version with lateral battery (1/2)

40-643
 Wiring diagrams
Table 605
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1236
40-1236
40-1205
40-1221
40-1205
40-1221
40-1236

Fig. 3044

40-644
Wiring diagrams

P001

D0064130

Fig. 3044 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions - Version with front battery (2/2)

40-645
 Wiring diagrams
Table 606
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1234
compressor

Fig. 3044

B
C

P001

D0064150

Fig. 3044 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions - Version with lateral battery (2/2)

40-646
Wiring diagrams
Table 607
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1236
compressor

Fig. 3044

40.3.39 - S013 - Manual climate control - Version with standard cab (R3 EVO 100 -> 20001,
R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
From Serial No.
l Explorer
m 85: -> 20155
m 100: -> 20487
m 110: -> 1276

l R3 EVO
m 85: -> 20044
m 100: -> 20183
m 110: -> 1107

l XB MAX
m 85: -> 20021
m 100: -> 20032
m 110: -> 1023

l AGROFARM
m 410: -> 20553
m 420: -> 21293
m 430: -> 1420

40-647
 Wiring diagrams

J004 J007
P001

NC NO 85 86 30 NC NO 85 86 30 1

D005
13

B030

B015
B020

B033

B029

B005
30A

15A
20A

40A

10A
3A
C004
+15

+30

+30
D009

D008
1 4 1
D024

D023
4 1

B036
30A
C007

D028
D027

D026

2 1 1 2 3 4 8 7 1 2 3 4 5 6

1 2 3 4 5 1 2 3 4 1 2 30 86 85 87 2 1 4 2 6 8 B A 4 2 6 8 1 2 3 5 6 A B
I II III IV C
t
M M M

O003 P014 K022 P015 P016

H005 J013 J014 J015
K023
D0063110

Fig. 3045 - Manual climate control - Version with standard cab - System
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)

40-648
Wiring diagrams

J004 J007
P001

NC NO 85 86 30 NC NO 85 86 30 1

D005
13

B030

B015
B020

B033

B029

B005
30A

15A
20A

40A

10A
3A
C004
+15

+30

+30
D009

D008
1 4 1
D024

D023
4 1

B036
30A
C007

D028
D027

D026

2 1 1 2 3 4 8 7 1 2 3 4 5 6

1 2 3 4 5 1 2 3 4 1 2 30 86 85 87 2 1 4 2 6 8 B A 4 2 6 8 1 2 3 5 6 A B
I II III IV C
t
M M M

O003 P014 K022 P015 P016

H005 J013 J014 J015
K023
D0063110

Fig. 3045 - Manual climate control - Version with standard cab - System
l D009 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D026 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D026 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D027 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D027 (M) - Wiring connector (Wiring loom 0.010.2147.2)
l D027 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D027 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D028 (M) - Wiring connector (Wiring loom 0.015.7266.4/40)
l D028 (F) - Wiring connector (Wiring loom 0.018.5825.4)

40-649
 Wiring diagrams

J004 J007
P001

NC NO 85 86 30 NC NO 85 86 30 1

D005
13

B030

B015
B020

B033

B029

B005
30A

15A
20A

40A

10A
3A
C004
+15

+30

+30
D009

D008
1 4 1
D024

D023
4 1

B036
30A
C007

D028
D027

D026

2 1 1 2 3 4 8 7 1 2 3 4 5 6

1 2 3 4 5 1 2 3 4 1 2 30 86 85 87 2 1 4 2 6 8 B A 4 2 6 8 1 2 3 5 6 A B
I II III IV C
t
M M M

O003 P014 K022 P015 P016

H005 J013 J014 J015
K023
D0063110

Fig. 3045 - Manual climate control - Version with standard cab - System
l H005 - Fan speed selector switch
l J004 - Relay
l J007 - Relay
l J013 - Compressor relay
l J014 - Control relay for air conditioning condenser fan
l J015 - Control relay for supplementary air conditioning cooler fan
l K022 - Air conditioning temperature thermostat
l K023 - Air conditioning pressure switch
l O003 - Resistor
l P001 - Air conditioning system compressor
l P014 - Fan
l P015 - Air conditioning condenser fan
l P016 - Supplementary air conditioning cooler fan

40-650
Wiring diagrams
B029

B030

B033

A
B015

B005 J004
B020
J007

D009
D008

C004

D005

D0064070

Fig. 3046 - Manual climate control - Version with standard cab - Connector positions
Table 608
Sys- P/N Description Characteristics/notes Position Wiring
tem
B005 Fuse (10A) 40-1209
B005 Fuse (10A) 40-1221
B015 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B029 Fuse (40A) 40-1209

40-651
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221
B033 Fuse (20A) 40-1209
B033 Fuse (20A) 40-1221
J004 Relay 40-1209

Fig. 3047
J007 Relay 40-1209

Fig. 3048
C004 Earthing point 4 40-1209
40-1221

Fig. 3049
D005 Wiring connector 40-1234
40-1236
40-1209
40-1221
40-1209
40-1221
40-1234
40-1236

Fig. 3050
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 3051

40-652
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D009 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 3052

D023

D024

D009
D008

D0064080

Fig. 3053 - Connector positions

40-653
 Wiring diagrams
Table 609
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 3053
D009 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 3053
D023 Wiring connector 40-1244
40-1220

Fig. 3054
D024 Wiring connector 40-1244
40-1220

Fig. 3055

40-654
Wiring diagrams

B036 C007 D026

D027
D028

D023

D024

D0064090

Fig. 3056 - Connector positions

Table 610
Sys- P/N Description Characteristics/notes Position Wiring
tem
B036 Fuse (30A) 40-1244
C007 Earthing point 7 40-1226
40-1244

Fig. 3057
D026 Wiring connector 40-1244
40-1183
D027 Wiring connector 40-1244
40-1182
40-1183
40-1244

40-655
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D028 Wiring connector 40-1244
40-1217

Fig. 3058
D023 Wiring connector 40-1244
40-1220

Fig. 3058
D024 Wiring connector 40-1244
40-1220

Fig. 3058

P014
D026

O003

D027

K022

H005 J013

D0064100

Fig. 3059 - Connector positions

40-656
Wiring diagrams
Table 611
Sys- P/N Description Characteristics/notes Position Wiring
tem
H005 Blower speed se- 40-1183
lector switch

Fig. 3060
J013 Compressor relay 40-1183
K022 Air conditioning 40-1183
temperature ther-
mostat

Fig. 3061
O003 Resistor 40-1183

Fig. 3062
P014 Electric fan 40-1183

Fig. 3063
D026 Wiring connector 40-1244
40-1183
D027 Wiring connector 40-1244
40-1182
40-1183
40-1244

40-657
 Wiring diagrams
J015 D028
J014
P015
K023
P016

D0064160

Fig. 3064 - Connector positions

Table 612
Sys- P/N Description Characteristics/notes Position Wiring
tem
D028 Wiring connector 40-1244
40-1217

Fig. 3064
J014 Control relay for air 40-1217
conditioning cooler
fan

Fig. 3065
J015 Control relay for 40-1217
auxiliary air condi-
tioning cooler fan

Fig. 3066

40-658
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
P015 Air conditioning 40-1217
condenser fan

Fig. 3067
P016 Auxiliary air condi- 40-1217
tioning condenser
fan

Fig. 3068
K023 Air conditioning 40-1217
pressure switch

Fig. 3069

40-659
 Wiring diagrams

D005

D0064120

Fig. 3070 - Connector positions - Version with front battery (1/2)

40-660
Wiring diagrams

D005

A
C B

D0064140

Fig. 3071 - Connector positions - Version with lateral battery (1/2)

40-661
 Wiring diagrams
Table 613
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1236
40-1209
40-1221
40-1209
40-1221
40-1234
40-1236

Fig. 3071

40-662
Wiring diagrams

P001

D0064130

Fig. 3072 - Connector positions - Version with front battery (2/2)

40-663
 Wiring diagrams

B
C

P001

D0064150

Fig. 3073 - Connector positions - Version with lateral battery (2/2)

Table 614
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1234
compressor 40-1236

Fig. 3074

40.3.40 - S013A - Manual climate control - Version with standard cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
From Serial No.
l Explorer
m 85 with air conditioning: -> 16658
m 100 with air conditioning: -> 16482
m 110 with air conditioning: -> 5168

40-664
Wiring diagrams
l R3 EVO
m 85 with air conditioning: -> 16286
m 100 with air conditioning: -> 16306
m 110 with air conditioning: -> 5139

l XB MAX
m 85 with air conditioning: -> 16016
m 100 with air conditioning: -> 16016
m 110 with air conditioning: -> 5003

l AGROFARM
m 410 with air conditioning: -> 16905
m 420 with air conditioning: -> 16868
m 430 with air conditioning: -> 5253

J004 J007
P001

NC NO 85 86 30 NC NO 85 86 30 1

D005
13
B030

B015
B020

B033

B029

B005
30A

15A
20A

40A

10A
3A
C004
+15

+30

+30
D009

D008

1 4 1
D024

D023

4 1
B036
30A
C007

D028
D027

D026

2 1 1 2 3 4 8 7 1 2 3 4 5 6

1 2 3 4 5 1 2 3 4 1 2 30 86 85 87 2 1 4 2 6 8 B A 4 2 6 8 1 2 3 5 6 A B
I II III IV C
t
M M M

O003 P014 K022 P015 P016

H005 J013 J014 J015
K023
D0063110

Fig. 3075 - Manual climate control - Version with standard cab - Version with digital instrument panel - System

40-665
 Wiring diagrams
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D009 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D026 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D026 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D027 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D027 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D028 (M) - Wiring connector (Wiring loom 0.015.7266.4/40)
l D028 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l H005 - Fan speed selector switch
l J004 - Relay
l J007 - Relay
l J013 - Compressor relay
l J014 - Control relay for air conditioning condenser fan
l J015 - Control relay for supplementary air conditioning cooler fan
l K022 - Air conditioning temperature thermostat
l K023 - Air conditioning pressure switch
l O003 - Resistor
l P001 - Air conditioning system compressor
l P014 - Fan
l P015 - Air conditioning condenser fan
l P016 - Supplementary air conditioning cooler fan

40-666
Wiring diagrams
B029

B030

B033

A
B015

B005 J004
B020
J007

D009
D008

C004

D005

D0064070

Fig. 3076 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions
Table 615
Sys- P/N Description Characteristics/notes Position Wiring
tem
B005 Fuse (10A) 40-1205
B005 Fuse (10A) 40-1221
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221

40-667
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B029 Fuse (40A) 40-1205
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
B033 Fuse (20A) 40-1205
B033 Fuse (20A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 3077
D005 Wiring connector 40-1234
40-1236
40-1205
40-1221
40-1205
40-1221
40-1234
40-1236

Fig. 3078
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3079
D009 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3080
J004 Relay 40-1205
40-1221

Fig. 3081

40-668
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J007 Relay 40-1205
40-1221

Fig. 3082

D023

D024

D009
D008

D0064080

Fig. 3083 - Connector positions

40-669
 Wiring diagrams
Table 616
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3083
D009 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3083
D023 Wiring connector 40-1242
40-1220

Fig. 3084
D024 Wiring connector 40-1242
40-1220

Fig. 3085

40-670
Wiring diagrams

B036 C007 D026

D027
D028

D023

D024

D0064090

Fig. 3086 - Connector positions

Table 617
Sys- P/N Description Characteristics/notes Position Wiring
tem
B036 Fuse (30A) 40-1242
D023 Wiring connector 40-1242
40-1220

Fig. 3086
D024 Wiring connector 40-1242
40-1220

Fig. 3086
D026 Wiring connector 40-1242
D026 Wiring connector 40-1183
D027 Wiring connector 40-1242
D027 Wiring connector 40-1183

40-671
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D028 Wiring connector 40-1242
40-1217

Fig. 3087
C007 Earthing point 7 40-1242

Fig. 3088

P014
D026

O003

D027

K022

H005 J013

D0064100

Fig. 3089 - Connector positions

Table 618
Sys- P/N Description Characteristics/notes Position Wiring
tem
D026 Wiring connector 40-1242
D026 Wiring connector 40-1183
D027 Wiring connector 40-1242
D027 Wiring connector 40-1183

40-672
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
H005 Blower speed se- 40-1183
lector switch

Fig. 3090
J013 Compressor relay 40-1183
K022 Air conditioning 40-1183
temperature ther-
mostat

Fig. 3091
P014 Electric fan 40-1183

Fig. 3092
O003 Resistor 40-1183

Fig. 3093

40-673
 Wiring diagrams
J015 D028
J014
P015
K023
P016

D0064160

Fig. 3094 - Connector positions

Table 619
Sys- P/N Description Characteristics/notes Position Wiring
tem
J014 Control relay for air 40-1217
conditioning cooler
fan

Fig. 3095
J015 Control relay for 40-1217
auxiliary air condi-
tioning cooler fan

Fig. 3096
K023 Air conditioning 40-1217
pressure switch

Fig. 3097

40-674
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D028 Wiring connector 40-1242
40-1217

Fig. 3097
P015 Air conditioning 40-1217
condenser fan

Fig. 3098
P016 Auxiliary air condi- 40-1217
tioning condenser
fan

Fig. 3099

40-675
 Wiring diagrams

D005

D0064120

Fig. 3100 - Connector positions - Version with front battery (1/2)

40-676
Wiring diagrams
Table 620
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1205
40-1221
40-1205
40-1221
40-1234

Fig. 3100

40-677
 Wiring diagrams

D005

A
C B

D0064140

Fig. 3101 - Connector positions - Version with lateral battery (1/2)

40-678
Wiring diagrams
Table 621
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1236
40-1205
40-1221
40-1205
40-1221
40-1236

Fig. 3101

40-679
 Wiring diagrams

P001

D0064130

Fig. 3102 - Connector positions - Version with front battery (2/2)

40-680
Wiring diagrams
Table 622
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1234
compressor

Fig. 3103

B
C

P001

D0064150

Fig. 3104 - Connector positions - Version with lateral battery (2/2)

40-681
 Wiring diagrams
Table 623
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1236
compressor

Fig. 3104

40.3.41 - S013D - Manual climate control - Version with standard cab - Version with digi-
tal instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
From Serial No.
l Explorer
m 85 with air conditioning: -> 16658
m 100 with air conditioning: -> 16482
m 110 with air conditioning: -> 5168

l R3 EVO
m 85 with air conditioning: -> 16286
m 100 with air conditioning: -> 16306
m 110 with air conditioning: -> 5139

l XB MAX
m 85 with air conditioning: -> 16016
m 100 with air conditioning: -> 16016
m 110 with air conditioning: -> 5003

l AGROFARM
m 410 with air conditioning: -> 16905
m 420 with air conditioning: -> 16868
m 430 with air conditioning: -> 5253

40-682
Wiring diagrams

J004 J007
P001

NC NO 85 86 30 NC NO 85 86 30 1

D005
13

B030

B015
B020

B033

B029

B005
30A

15A
20A

40A

10A
3A
C004
+15

+30

+30
D009

D008
1 4 1
D024

D023
4 1

B036
30A
C007

D028
D027

D026

2 1 1 2 3 4 8 7 1 2 3 4 5 6

1 2 3 4 5 1 2 3 4 1 2 30 86 85 87 2 1 4 2 6 8 B A 4 2 6 8 1 2 3 5 6 A B
I II III IV C
t
M M M

O003 P014 K022 P015 P016

H005 J013 J014 J015
K023
D0063110

Fig. 3104 - Manual climate control - Version with standard cab - Version with digital instrument panel - System
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)

40-683
 Wiring diagrams
l D009 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D026 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D026 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D027 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D027 (M) - Wiring connector (Wiring loom 0.010.2153.2)
l D028 (M) - Wiring connector (Wiring loom 0.015.7266.4/40)
l D028 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l H005 - Fan speed selector switch
l J004 - Relay
l J007 - Relay
l J013 - Compressor relay
l J014 - Control relay for air conditioning condenser fan
l J015 - Control relay for supplementary air conditioning cooler fan
l K022 - Air conditioning temperature thermostat
l K023 - Air conditioning pressure switch
l O003 - Resistor
l P001 - Air conditioning system compressor
l P014 - Fan
l P015 - Air conditioning condenser fan
l P016 - Supplementary air conditioning cooler fan

40-684
Wiring diagrams
B029

B030

B033

A
B015

B005 J004
B020
J007

D009
D008

C004

D005

D0064070

Fig. 3104 - Manual climate control - Version with standard cab - Version with digital instrument panel - Connector
positions
Table 624
Sys- P/N Description Characteristics/notes Position Wiring
tem
B005 Fuse (10A) 40-1205
B005 Fuse (10A) 40-1221
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221

40-685
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B029 Fuse (40A) 40-1205
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
B033 Fuse (20A) 40-1205
B033 Fuse (20A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 3104
D005 Wiring connector 40-1234
40-1236
40-1205
40-1221
40-1205
40-1221
40-1234
40-1236

Fig. 3104
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3104
D009 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3104
J004 Relay 40-1205
40-1221

Fig. 3104

40-686
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J007 Relay 40-1205
40-1221

Fig. 3104

D023

D024

D009
D008

D0064080

Fig. 3104 - Connector positions

40-687
 Wiring diagrams
Table 625
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3104
D009 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3104
D023 Wiring connector 40-1242
40-1220

Fig. 3104
D024 Wiring connector 40-1242
40-1220

Fig. 3104

40-688
Wiring diagrams

B036 C007 D026

D027
D028

D023

D024

D0064090

Fig. 3104 - Connector positions

Table 626
Sys- P/N Description Characteristics/notes Position Wiring
tem
B036 Fuse (30A) 40-1242
D023 Wiring connector 40-1242
40-1220

Fig. 3104
D024 Wiring connector 40-1242
40-1220

Fig. 3104
D026 Wiring connector 40-1242
D026 Wiring connector 40-1183
D027 Wiring connector 40-1242
D027 Wiring connector 40-1183

40-689
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D028 Wiring connector 40-1242
40-1217

Fig. 3104
C007 Earthing point 7 40-1242

Fig. 3104

P014
D026

O003

D027

K022

H005 J013

D0064100

Fig. 3104 - Connector positions

Table 627
Sys- P/N Description Characteristics/notes Position Wiring
tem
D026 Wiring connector 40-1242
D026 Wiring connector 40-1183
D027 Wiring connector 40-1242
D027 Wiring connector 40-1183

40-690
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
H005 Blower speed se- 40-1183
lector switch

Fig. 3104
J013 Compressor relay 40-1183
K022 Air conditioning 40-1183
temperature ther-
mostat

Fig. 3104
P014 Electric fan 40-1183

Fig. 3104
O003 Resistor 40-1183

Fig. 3104

40-691
 Wiring diagrams
J015 D028
J014
P015
K023
P016

D0064160

Fig. 3104 - Connector positions

Table 628
Sys- P/N Description Characteristics/notes Position Wiring
tem
J014 Control relay for air 40-1217
conditioning cooler
fan

Fig. 3104
J015 Control relay for 40-1217
auxiliary air condi-
tioning cooler fan

Fig. 3104
K023 Air conditioning 40-1217
pressure switch

Fig. 3104

40-692
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D028 Wiring connector 40-1242
40-1217

Fig. 3104
P015 Air conditioning 40-1217
condenser fan

Fig. 3104
P016 Auxiliary air condi- 40-1217
tioning condenser
fan

Fig. 3104

40-693
 Wiring diagrams

D005

D0064120

Fig. 3104 - Connector positions - Version with front battery (1/2)

40-694
Wiring diagrams
Table 629
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1205
40-1221
40-1205
40-1221
40-1234

Fig. 3104

40-695
 Wiring diagrams

D005

A
C B

D0064140

Fig. 3104 - Connector positions - Version with lateral battery (1/2)

40-696
Wiring diagrams
Table 630
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1236
40-1205
40-1221
40-1205
40-1221
40-1236

Fig. 3104

40-697
 Wiring diagrams

P001

D0064130

Fig. 3104 - Connector positions - Version with front battery (2/2)

40-698
Wiring diagrams
Table 631
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1234
compressor

Fig. 3104

B
C

P001

D0064150

Fig. 3104 - Connector positions - Version with lateral battery (2/2)

40-699
 Wiring diagrams
Table 632
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1236
compressor

Fig. 3104

40-700
Wiring diagrams
40.3.42 - S014 - Manual climate control - Version with high-visibility cab (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
J008
J009 J004 J007
P001

87 85 86 30 NC NO 85 86 30 NC NO 85 86 30 10 9 5 6 2 3 7 8 1

D005
13

B030

B015
B027

B020

B033

B029

B024

B005
7.5A
30A

15A
30A

20A

40A

10A
3A
C004

+15

+30
+30

D008
+30
J010 J011 6 4 1

P012 P013
M M
E007

D023
30 85 86 87 87b 30 85 86 87 87b

6 4 1

2 1
D034

D035

D009

B036
A B A B

30A
2 1
C007

C007

C007
D024

D025
C007

C007

J012
E006 K021 I030
t

30 85 86 87 87b 2 1 1 2 3 4
C007
C007

C007

D028

8 7 1 2 3 4 5 6

1 2 3 4 1 2 3 4 5 4 3 2 1 4 2 6 8 B A 4 2 6 8 1 2 3 5 6 A B
IV
III

C
II
I

M M

O002 O001 P015 P016

H004 J014 J015
D0062980 K023

Fig. 3105 - Manual climate control - Version with high-visibility cab - System
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)

40-701
 Wiring diagrams
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D009 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D025 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D025 (F) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D028 (M) - Wiring connector (Wiring loom 0.015.7266.4/40)
l D028 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D034 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D034 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D035 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D035 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l E006 - A/C ‘ON’ LED
l E007 - A/C controls lighting
l H004 - Fan speed selector switch
l I030 - A/C switch
l J004 - Relay
l J007 - Relay
l J008 - Relay
l J009 - Relay
l J010 - Max. fan speed relay
l J011 - Compressor and A/C 1st speed start relay
l J012 - 3rd fan speed relay
l J014 - Control relay for air conditioning condenser fan
l J015 - Control relay for supplementary air conditioning cooler fan
l K021 - Air conditioning temperature thermostat
l K023 - Air conditioning pressure switch
l O001 - LH resistor
l O002 - RH resistor
l P001 - Air conditioning system compressor
l P012 - RH fan
l P013 - LH fan
l P015 - Air conditioning condenser fan
l P016 - Supplementary air conditioning cooler fan

40-702
Wiring diagrams
B029

J008 J009

B030 B027

B033
J004 A

B015

B005
B020 B024
J007

D009
D008

C004

D005

D0064170

Fig. 3106 - Manual climate control - Version with high-visibility cab - Connector positions
Table 633
Sys- P/N Description Characteristics/notes Position Wiring
tem
B005 Fuse (10A) 40-1209
B005 Fuse (10A) 40-1221
B015 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B024 Fuse (7.5A) 40-1209

40-703
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B024 Fuse (7.5A) 40-1221
B027 Fuse (30A) 40-1209
B027 Fuse (30A) 40-1221
B029 Fuse (40A) 40-1209
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221
B033 Fuse (20A) 40-1209
B033 Fuse (20A) 40-1221
C004 Earthing point 4 40-1209
40-1221

Fig. 3107
D005 Wiring connector 40-1234
40-1236
40-1209
40-1221
40-1209
40-1221
40-1234
40-1236

Fig. 3108
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 3109

40-704
Wiring diagrams
Table 634
Sys- P/N Description Characteristics/notes Position Wiring
tem
D009 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 3110
J004 Relay 40-1209
40-1221

Fig. 3111
J007 Relay 40-1209
40-1221

Fig. 3112
J008 Relay 40-1209
40-1221

Fig. 3113
J009 Relay 40-1209
40-1221

Fig. 3114

40-705
 Wiring diagrams

D023

D025

D024

D009
D008

D0064180

Fig. 3115 - Connector positions

Table 635
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 3115

40-706
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D009 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 3115
D023 Wiring connector 40-1204
40-1220

Fig. 3116
D024 Wiring connector 40-1204
40-1220

Fig. 3117
D025 Wiring connector 40-1220
40-1204

Fig. 3118

40-707
 Wiring diagrams
J011 J010 J012 P013 D035
O002 D028

I030
K021
H004

E007

E006

D023 B036
C007
D025 D034

D024
P012
O001

D0064190

Fig. 3119 - Connector positions

Table 636
Sys- P/N Description Characteristics/notes Position Wiring
tem
B036 Fuse (20A) 40-1204

40-708
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 3120
D023 Wiring connector 40-1204
40-1220

Fig. 3120
D024 Wiring connector 40-1204
40-1220

Fig. 3120
D025 Wiring connector 40-1220
40-1204

Fig. 3120
D028 Wiring connector 40-1204
40-1215

Fig. 3121
D034 Wiring connector 40-1204
40-1204

Fig. 3122

40-709
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D035 Wiring connector 40-1204
40-1204

Fig. 3123
E006 Climate control 40-1204
LED

Fig. 3124
E007 Climate control 40-1204
panel lighting

Fig. 3125
H004 Blower speed se- 40-1204
lector switch

Fig. 3126
H004 Blower speed se- 40-1204
lector switch

Fig. 3126
I030 A/C activation 40-1204
switch

Fig. 3127

40-710
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J010 Max. fan speed re- 40-1204
lay

Fig. 3128
J011 Compressor and 40-1204
A/C 1st speed start
relay

Fig. 3129
J012 3rd fan speed relay 40-1204

Fig. 3130
K021 Air conditioning 40-1204
temperature ther-
mostat

Fig. 3131
O001 LH resistor 40-1204
O002 RH resistor 40-1204

Fig. 3132
P012 RH fan 40-1204

Fig. 3133

40-711
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
P013 LH fan 40-1204

Fig. 3134

J015 D028
J014
P015
K023
P016

D0064160

Fig. 3135 - Connector positions

Table 637
Sys- P/N Description Characteristics/notes Position Wiring
tem
D028 Wiring connector 40-1204
40-1215

Fig. 3135

40-712
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J014 Control relay for air 40-1215
conditioning cooler
fan

Fig. 3136
J015 Control relay for 40-1215
auxiliary air condi-
tioning cooler fan

Fig. 3137
K023 Air conditioning 40-1215
pressure switch

Fig. 3138
P015 Air conditioning 40-1215
condenser fan

Fig. 3139
P016 Auxiliary air condi- 40-1215
tioning condenser
fan

Fig. 3140

40-713
 Wiring diagrams

D005

D0064120

Fig. 3141 - Connector positions - Version with front battery (1/2)

40-714
Wiring diagrams

D005

A
C B

D0064140

Fig. 3142 - Connector positions - Version with lateral battery (1/2)

40-715
 Wiring diagrams
Table 638
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1236
40-1209
40-1221
40-1209
40-1221
40-1234
40-1236

Fig. 3142

40-716
Wiring diagrams

P001

D0064130

Fig. 3143 - Connector positions - Version with front battery (2/2)

40-717
 Wiring diagrams

B
C

P001

D0064150

Fig. 3144 - Connector positions - Version with lateral battery (2/2)

Table 639
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1234
compressor

Fig. 3145

40-718
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1236
compressor

Fig. 3146

40-719
 Wiring diagrams
40.3.43 - S014A - Manual climate control - Version with high-visibility cab - Version with
digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
J008
J009 J004 J007
P001

87 85 86 30 NC NO 85 86 30 NC NO 85 86 30 10 9 5 6 2 3 7 8 1

D005
13

B030

B015
B027

B020

B033

B029

B024

B005
7.5A
30A

15A
30A

20A

40A

10A
3A
C004

+15

+30
+30

D008
+30
J010 J011 6 4 1

P012 P013
M M
E007

D023
30 85 86 87 87b 30 85 86 87 87b

6 4 1

2 1
D034

D035

D009

B036
A B A B

30A
2 1
C007

C007

C007
D024

D025
C007

C007

J012
E006 K021 I030
t

30 85 86 87 87b 2 1 1 2 3 4
C007
C007

C007

D028

8 7 1 2 3 4 5 6

1 2 3 4 1 2 3 4 5 4 3 2 1 4 2 6 8 B A 4 2 6 8 1 2 3 5 6 A B
IV
II

III

C
I

M M

O002 O001 P015 P016

H004 J014 J015
D0062980 K023

Fig. 3147 - Manual climate control - Version with high-visibility cab - Version with digital instrument panel - Sys-
tem
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)

40-720
Wiring diagrams
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D025 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D025 (F) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D028 (M) - Wiring connector (Wiring loom 0.015.7266.4/40)
l D028 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D034 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D034 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D035 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D035 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l E006 - A/C ‘ON’ LED
l E007 - A/C controls lighting
l H004 - Fan speed selector switch
l I030 - A/C switch
l J004 - Relay
l J007 - Relay
l J008 - Relay
l J009 - Relay
l J010 - Max. fan speed relay
l J011 - Compressor and A/C 1st speed start relay
l J012 - 3rd fan speed relay
l J014 - Control relay for air conditioning condenser fan
l J015 - Control relay for supplementary air conditioning cooler fan
l K021 - Air conditioning temperature thermostat
l K023 - Air conditioning pressure switch
l O001 - LH resistor
l O002 - RH resistor
l P001 - Air conditioning system compressor
l P012 - RH fan
l P013 - LH fan
l P015 - Air conditioning condenser fan
l P016 - Supplementary air conditioning cooler fan

40-721
 Wiring diagrams
B029

J008 J009

B030 B027

B033
J004 A

B015

B005
B020 B024
J007

D009
D008

C004

D005

D0064170

Fig. 3148 - Manual climate control - Version with high-visibility cab - Version with digital instrument panel - Con-
nector positions
Table 640
Sys- P/N Description Characteristics/notes Position Wiring
tem
B005 Fuse (10A) 40-1205
B005 Fuse (10A) 40-1221
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221

40-722
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B024 Fuse (7.5A) 40-1205
B024 Fuse (7.5A) 40-1221
B027 Fuse (30A) 40-1205
B027 Fuse (30A) 40-1221
B029 Fuse (40A) 40-1205
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
B033 Fuse (20A) 40-1205
B033 Fuse (20A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 3149
D005 Wiring connector 40-1234
40-1236
40-1205
40-1205
40-1205
40-1221

Fig. 3150
D008 Wiring connector 40-1205
40-1220
40-1221

Fig. 3151
D009 Wiring connector 40-1205
40-1220
40-1221

Fig. 3152
J004 Relay 40-1205
40-1221

Fig. 3153

40-723
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J007 Relay 40-1205
40-1221

Fig. 3154
J008 Relay 40-1205
40-1221

Fig. 3155
J009 Relay 40-1205
40-1221

Fig. 3156

40-724
Wiring diagrams

D023

D025

D024

D009
D008

D0064180

Fig. 3157 - Connector positions

Table 641
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221

Fig. 3157

40-725
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D009 Wiring connector 40-1205
40-1220
40-1221

Fig. 3157
D023 Wiring connector 40-1204
40-1220

Fig. 3158
D024 Wiring connector 40-1204
40-1220

Fig. 3159
D025 Wiring connector 40-1220
40-1204

Fig. 3160

40-726
Wiring diagrams
J011 J010 J012 P013 D035
O002 D028

I030
K021
H004

E007

E006

D023 B036
C007
D025 D034

D024
P012
O001

D0064190

Fig. 3161 - Connector positions

Table 642
Sys- P/N Description Characteristics/notes Position Wiring
tem
B036 Fuse (20A) 40-1204

40-727
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 3162
D023 Wiring connector 40-1204
40-1220

Fig. 3162
D024 Wiring connector 40-1204
40-1220

Fig. 3162
D025 Wiring connector 40-1220
40-1204

Fig. 3162
D028 Wiring connector 40-1204
40-1215

Fig. 3163
D034 Wiring connector 40-1204
40-1204

Fig. 3164

40-728
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D035 Wiring connector 40-1204
40-1204

Fig. 3165
E006 Climate control 40-1204
LED

Fig. 3166
E007 Climate control 40-1204
panel lighting

Fig. 3167
H004 Blower speed se- 40-1204
lector switch
H004 Blower speed se- 40-1204
lector switch

Fig. 3168
I030 A/C activation 40-1204
switch

Fig. 3169
J010 Max. fan speed re- 40-1204
lay

Fig. 3170

40-729
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J011 Compressor and 40-1204
A/C 1st speed start
relay

Fig. 3171
J012 3rd fan speed relay 40-1204

Fig. 3172
K021 Air conditioning 40-1204
temperature ther-
mostat

Fig. 3173
O001 Lh resistor 40-1204
O002 Rh resistor 40-1204

Fig. 3174
P012 Rh fan 40-1204

Fig. 3175
P013 Lh fan 40-1204

Fig. 3176

40-730
Wiring diagrams
J015 D028
J014
P015
K023
P016

D0064160

Fig. 3177 - Connector positions

Table 643
Sys- P/N Description Characteristics/notes Position Wiring
tem
J014 Control relay for air 40-1215
conditioning cooler
fan

Fig. 3178
J015 Control relay for 40-1215
auxiliary air condi-
tioning cooler fan

Fig. 3179
K023 Air conditioning 40-1215
pressure switch

Fig. 3180

40-731
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
P015 Air conditioning 40-1215
condenser fan

Fig. 3181
P016 Auxiliary air condi- 40-1215
tioning condenser
fan

Fig. 3182
D028 Wiring connector 40-1204
40-1215

Fig. 3182

40-732
Wiring diagrams

D005

D0064120

Fig. 3183 - Connector positions - Version with front battery

40-733
 Wiring diagrams
Table 644
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1236
40-1205
40-1205
40-1205
40-1221

Fig. 3183

40-734
Wiring diagrams

D005

A
C B

D0064140

Fig. 3184 - Connector positions - Version with lateral battery (1/2)

40-735
 Wiring diagrams
Table 645
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1236
40-1205
40-1205
40-1205
40-1221

Fig. 3184

B
C

P001

D0064150

Fig. 3185 - Connector positions - Version with lateral battery (2/2)

40-736
Wiring diagrams
Table 646
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1234
compressor 40-1236

Fig. 3186

40-737
 Wiring diagrams
40.3.44 - S014D - Manual climate control - Version with high-visibility cab - Version with
digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
J008
J009 J004 J007
P001

87 85 86 30 NC NO 85 86 30 NC NO 85 86 30 10 9 5 6 2 3 7 8 1

D005
13

B030

B015
B027

B020

B033

B029

B024

B005
7.5A
30A

15A
30A

20A

40A

10A
3A
C004

+15

+30
+30

D008
+30
J010 J011 6 4 1

P012 P013
M M
E007

D023
30 85 86 87 87b 30 85 86 87 87b

6 4 1

2 1
D034

D035

D009

B036
A B A B

30A
2 1
C007

C007

C007
D024

D025
C007

C007

J012
E006 K021 I030
t

30 85 86 87 87b 2 1 1 2 3 4
C007
C007

C007

D028

8 7 1 2 3 4 5 6

1 2 3 4 1 2 3 4 5 4 3 2 1 4 2 6 8 B A 4 2 6 8 1 2 3 5 6 A B
IV
II

III

C
I

M M

O002 O001 P015 P016

H004 J014 J015
D0062980 K023

Fig. 3186 - Manual climate control - Version with high-visibility cab - Version with digital instrument panel - Sys-
tem
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)

40-738
Wiring diagrams
l D009 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D009 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D024 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D024 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D025 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D025 (F) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D028 (M) - Wiring connector (Wiring loom 0.015.7266.4/40)
l D028 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D034 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D034 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D035 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D035 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l E006 - A/C ‘ON’ LED
l E007 - A/C controls lighting
l H004 - Fan speed selector switch
l I030 - A/C switch
l J004 - Relay
l J007 - Relay
l J008 - Relay
l J009 - Relay
l J010 - Max. fan speed relay
l J011 - Compressor and A/C 1st speed start relay
l J012 - 3rd fan speed relay
l J014 - Control relay for air conditioning condenser fan
l J015 - Control relay for supplementary air conditioning cooler fan
l K021 - Air conditioning temperature thermostat
l K023 - Air conditioning pressure switch
l O001 - LH resistor
l O002 - RH resistor
l P001 - Air conditioning system compressor
l P012 - RH fan
l P013 - LH fan
l P015 - Air conditioning condenser fan
l P016 - Supplementary air conditioning cooler fan

40-739
 Wiring diagrams
B029

J008 J009

B030 B027

B033
J004 A

B015

B005
B020 B024
J007

D009
D008

C004

D005

D0064170

Fig. 3186 - Manual climate control - Version with high-visibility cab - Version with digital instrument panel - Con-
nector positions
Table 647
Sys- P/N Description Characteristics/notes Position Wiring
tem
B005 Fuse (10A) 40-1205
B005 Fuse (10A) 40-1221
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221

40-740
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B024 Fuse (7.5A) 40-1205
B024 Fuse (7.5A) 40-1221
B027 Fuse (30A) 40-1205
B027 Fuse (30A) 40-1221
B029 Fuse (40A) 40-1205
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
B033 Fuse (20A) 40-1205
B033 Fuse (20A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 3186
D005 Wiring connector 40-1234
40-1236
40-1205
40-1205
40-1205
40-1221

Fig. 3186
D008 Wiring connector 40-1205
40-1220
40-1221

Fig. 3186
D009 Wiring connector 40-1205
40-1220
40-1221

Fig. 3186
J004 Relay 40-1205
40-1221

Fig. 3186

40-741
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J007 Relay 40-1205
40-1221

Fig. 3186
J008 Relay 40-1205
40-1221

Fig. 3186
J009 Relay 40-1205
40-1221

Fig. 3186

40-742
Wiring diagrams

D023

D025

D024

D009
D008

D0064180

Fig. 3186 - Connector positions

Table 648
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221

Fig. 3186

40-743
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D009 Wiring connector 40-1205
40-1220
40-1221

Fig. 3186
D023 Wiring connector 40-1204
40-1220

Fig. 3186
D024 Wiring connector 40-1204
40-1220

Fig. 3186
D025 Wiring connector 40-1220
40-1204

Fig. 3186

40-744
Wiring diagrams
J011 J010 J012 P013 D035
O002 D028

I030
K021
H004

E007

E006

D023 B036
C007
D025 D034

D024
P012
O001

D0064190

Fig. 3186 - Connector positions

Table 649
Sys- P/N Description Characteristics/notes Position Wiring
tem
B036 Fuse (20A) 40-1204

40-745
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 3186
D023 Wiring connector 40-1204
40-1220

Fig. 3186
D024 Wiring connector 40-1204
40-1220

Fig. 3186
D025 Wiring connector 40-1220
40-1204

Fig. 3186
D028 Wiring connector 40-1204
40-1215

Fig. 3186
D034 Wiring connector 40-1204
40-1204

Fig. 3186

40-746
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D035 Wiring connector 40-1204
40-1204

Fig. 3186
E006 Climate control 40-1204
LED

Fig. 3186
E007 Climate control 40-1204
panel lighting

Fig. 3186
H004 Blower speed se- 40-1204
lector switch
H004 Blower speed se- 40-1204
lector switch

Fig. 3186
I030 A/C activation 40-1204
switch

Fig. 3186
J010 Max. fan speed re- 40-1204
lay

Fig. 3186

40-747
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J011 Compressor and 40-1204
A/C 1st speed start
relay

Fig. 3186
J012 3rd fan speed relay 40-1204

Fig. 3186
K021 Air conditioning 40-1204
temperature ther-
mostat

Fig. 3186
O001 Lh resistor 40-1204
O002 Rh resistor 40-1204

Fig. 3186
P012 Rh fan 40-1204

Fig. 3186
P013 Lh fan 40-1204

Fig. 3186

40-748
Wiring diagrams
J015 D028
J014
P015
K023
P016

D0064160

Fig. 3186 - Connector positions

Table 650
Sys- P/N Description Characteristics/notes Position Wiring
tem
J014 Control relay for air 40-1215
conditioning cooler
fan

Fig. 3186
J015 Control relay for 40-1215
auxiliary air condi-
tioning cooler fan

Fig. 3186
K023 Air conditioning 40-1215
pressure switch

Fig. 3186

40-749
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
P015 Air conditioning 40-1215
condenser fan

Fig. 3186
P016 Auxiliary air condi- 40-1215
tioning condenser
fan

Fig. 3186
D028 Wiring connector 40-1204
40-1215

Fig. 3186

40-750
Wiring diagrams

D005

D0064120

Fig. 3186 - Connector positions - Version with front battery

40-751
 Wiring diagrams
Table 651
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1236
40-1205
40-1205
40-1205
40-1221

Fig. 3186

40-752
Wiring diagrams

D005

A
C B

D0064140

Fig. 3186 - Connector positions - Version with lateral battery (1/2)

40-753
 Wiring diagrams
Table 652
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1236
40-1205
40-1205
40-1205
40-1221

Fig. 3186

B
C

P001

D0064150

Fig. 3186 - Connector positions - Version with lateral battery (2/2)

40-754
Wiring diagrams
Table 653
Sys- P/N Description Characteristics/notes Position Wiring
tem
P001 04437338 Air conditioning 40-1234
compressor 40-1236

Fig. 3186

40-755
 Wiring diagrams
40.3.45 - S015 - Steering column lights switch - Version with cab without front lift (R3
EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
E003 E002
I016

DIRECTION INDICATOR

DIRECTION INDICATOR

DIRECTION INDICATOR
POSITION BEAM

FULL BEAM

2°TRAILER
1°TRAILER

+12/30

+12/30
+12V
GND

GND
13 8 9 10 11 12 8 14 15 21 1 3 2 17 18 10 8 5

C004
C004

J004 H001 F008 F009

M004
RIGHT

LEFT

58
54

58

31

54

31
F

F
49a 4 3 2 1 4 3 2 1

C2

C3

31

49
C
NC NO 85 86 30 31 31b 56d 56b 56a 56 L R 49a 5 2 3 4 1 6

C003
C009
C004
C004

C004

B007
B030

B010
B020

B021

B032
B015

B024
B012

B023
B013

7.5A

7.5A
30A

20A
15A

15A

15A

20A
10A
3A

5A
+15

+30
C004

C004
C004

C009

7 4 1 5 2 10 9 5 6 2 3 7 8 1 2 1 2

I009
F007a F007
I008
C004
C004

C003
D004

D011
D014

10 5 3 4 14 9 8 13 1 2
B B A A A
D0062990 1 4 6 5 2 3 B5 D8 D2 D5 D3

TO SISTEM 2/2 TO SISTEM 2/2 TO SISTEM 2/2

Fig. 3187 - Steering column lights switch - Version with cab without front lift - System (1/2)

40-756
Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004
C004

C003
D004

D011
D014
10 5 3 4 14 9 8 13 1 2
B B A A A
1 4 6 5 2 3 B5 D8 D2 D5 D3

D038
D040

D037
D039
1 2 1 2 1 2 1 2 1 2
1 3 4 7 5
3 4 3 4

+58 RX

+58 SX
RIGHT DIRECTIONS
LEFT DIRECTIONS

-31
E001 F005 F002 F003 F004

P006

3 2 1 1 2 3
-31

-31
F.D.

FS.
58

58

D0063430
F014 F015

Fig. 3188 - Steering column lights switch - Version with cab without front lift - System (2/2)
l D004 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D004 (F) - Wiring connector (Wiring loom 0.014.8107.4/30)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D014 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D039 (F) - Wiring connector (Wiring loom 04411923.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l E001 - Horn
l E002 - Instrument panel
l E003 - Instrument panel
l F002 - RH high beam headlight
l F003 - RH low beam headlight
l F004 - LH low beam headlight
l F005 - LH high beam headlight
l F007 - Number plate light
l F007a - Number plate light
l F008 - LH rear light
l F009 - RH rear light
l F014 - RH front sidelight and direction indicator
l F015 - LH front sidelight and direction indicator
l H001 - Lights selector switch
l I008 - Road lights switch
l I009 - Top work lights switch
l I016 - Hazard warning lights switch
l J004 - Relay
l M004 - Hazard warning lights flasher unit

40-757
 Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004
C004

C003
D004

D011
D014
10 5 3 4 14 9 8 13 1 2
B B A A A
1 4 6 5 2 3 B5 D8 D2 D5 D3

D038
D040

D037
D039
1 2 1 2 1 2 1 2 1 2
1 3 4 7 5
3 4 3 4

+58 RX

+58 SX
RIGHT DIRECTIONS
LEFT DIRECTIONS

-31
E001 F005 F002 F003 F004

P006

3 2 1 1 2 3
-31

-31
F.D.

FS.
58

58

D0063430
F014 F015

Fig. 3188 - Steering column lights switch - Version with cab without front lift - System (2/2)
l P006 - Trailer socket

40-758
Wiring diagrams
J004

B030 B021

B032 B023

B015 A

B007
B020 B024
B010 B012 B013

E002 D004
E003
D014 C004

H001

I016
M004

I009
I008
B

D0064610

Fig. 3189 - Steering column lights switch - Version with cab without front lift - Connector positions
Table 654
Sys- P/N Description Characteristics/notes Position Wiring
tem
B007 Fuse (20A) 40-1209
B010 Fuse (5A) 40-1209
B012 Fuse (15A) 40-1209
B013 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1209
B020 Fuse (3A) 40-1209
B021 Fuse (10A) 40-1209
B023 Fuse (7.5A) 40-1209
B024 Fuse (7.5A) 40-1209
B030 Fuse (30A) 40-1209
B032 Fuse (20A) 40-1209

40-759
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1209

Fig. 3190
D004 Wiring connector 40-1193
40-1209

Fig. 3191
D014 Wiring connector 40-1209
40-1224

Fig. 3192
E002 Instrument panel 40-1209

Fig. 3193
E003 Instrument panel 40-1209

Fig. 3194
H001 Lights selector 40-1209
switch

40-760
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I008 Road lights switch 40-1209

Fig. 3195 Fig. 3196

I009 Upper worklights 40-1209
switch

Fig. 3197
I016 Hazard warning 0
1
40-1209
lights switch
5 17
18
10
8 1 2 3
5 1 7 18

Pin 1 2 3 5 8 10 17 18
Pos

Fig. 3198
Fig. 3199
J004 Relay 40-1209

Fig. 3200
M004 Hazard warning 40-1209
lights ECU

Fig. 3201

40-761
 Wiring diagrams

C003 F009

D0064620

D011

C009
F007a
F008
F007

Fig. 3202 - Connector positions

Table 655
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1209

Fig. 3203

40-762
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1209

Fig. 3204
F007 Number plate light 40-1209

Fig. 3205
Number plate light 40-1209

Fig. 3206
F008 LH rear light 40-1209

Fig. 3207
F009 RH rear light 40-1209

Fig. 3208

40-763
 Wiring diagrams

D011

D0064640

Fig. 3209 - Connector positions

Table 656
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1209
40-1214

Fig. 3210

40-764
Wiring diagrams

P006

G22

ECO

A
S
G23

G20
X65

X67

D0064630

Fig. 3211 - Connector positions

Table 657
Sys- P/N Description Characteristics/notes Position Wiring
tem
P006 Trailer socket 40-1214

Fig. 3212

40-765
 Wiring diagrams

D039

D014
D040
D037

D038

D0064650

Fig. 3213 - Connector positions

Table 658
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1209
40-1224

Fig. 3213
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250
D040 Wiring connector 40-1224

40-766
Wiring diagrams

D039
F014 D040

D037
D038

F015

D0064660

Fig. 3214 - Connector positions

Table 659
Sys- P/N Description Characteristics/notes Position Wiring
tem
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250
D040 Wiring connector 40-1224
F014 04411921.4 Front RH sidelight 40-1250
and direction indi-
cator
F015 04411920.4 Front LH sidelight 40-1251
and direction indi-
cator

40-767
 Wiring diagrams

D004

F003

F004
F002

F005

E001

D0064670

Fig. 3215 - Connector positions

Table 660
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1193
40-1209

Fig. 3215

40-768
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F002 Rh high beam 40-1193
headlight

Fig. 3216
F003 Rh low beam head- 40-1193
light
F003 Rh low beam head- 40-1193
light

Fig. 3217
F004 Lh low beam head- 40-1193
light
F004 Lh low beam head- 40-1193
light

Fig. 3218
F005 Lh high beam 40-1193
headlight

Fig. 3219
E001 Horn 40-1193

Fig. 3220

40-769
 Wiring diagrams
40.3.46 - S015A - Steering column lights switch - Version with cab without front lift - Ver-
sion with analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO
85 -> 16001)
E008
I016

DIRECTION INDICATOR

DIRECTION INDICATOR
FULL BEAM

1°TRAILER

+15
-31
B1 B2 B4 B3
B
12
1 3 2 17 18 10 8 5

C004
C004

J004 H001 F008 F009

M004
RIGHT

LEFT

58
54

58

31

54

31
F

F
4 3 2 1 4 3 2 1
49a

C2

C3

31

49
C
NC NO 85 86 30 31 31b 56d 56b 56a 56 L R 49a 5 2 3 4 1 6

C003
C009
C004
C004

C004

B007
B030
B020

B021

B032
B015

B024
B012

B023
B013

7.5A

7.5A
30A

20A
15A

15A

15A

20A
10A
+15 3A

+30
C004

C004
C004

C009

7 4 1 5 2 10 9 5 6 2 3 7 8 1 2 1 2

I009
F007a F007
I008
C004
C004

C003
D004

D011
D014

10 5 3 4 14 9 8 13 1 2
A A A A A A A
1 4 6 5 2 3 A1 D1 B1 B1 D2 D5 D3

D0065070
TO SISTEM 2/2 TO SISTEM 2/2 TO SISTEM 2/2

Fig. 3221 - Steering column lights switch - Version with cab without front lift - Version with analog instrument
panel - System (1/2)

40-770
Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004
C004

C003
D004

D014

D011
10 5 3 4 14 9 8 13 1 2
A A A A A A A
1 4 6 5 2 3 A1 D1 B1 B1 D2 D5 D3

D038
D040

D037
D039
1 2 1 2 1 2 1 2 1 2
1 3 4 7 5
3 4 3 4

+58 SX
+58 DX
RIGHT DIRECTIONS
LEFT DIRECTIONS

-31
E001 F005 F002 F003 F004

P006

3 2 1 1 2 3
-31

-31
F.D.

FS.
58

58

D0065080
F014 F015

Fig. 3222 - System (2/2)

l D004 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D004 (F) - Wiring connector (Wiring loom 0.015.7310.4)
l D011 (M) - Wiring connector (Wiring loom 0.016.1999.4/10)
l D011 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D014 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D039 (F) - Wiring connector (Wiring loom 04411923.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D040 (F) - Wiring connector (Wiring loom 04411923.4)
l E001 - Horn
l E008 - Instrument panel
l F002 - RH high beam headlight
l F003 - RH low beam headlight
l F004 - LH low beam headlight
l F005 - LH high beam headlight
l F007 - Number plate light
l F007a - Number plate light
l F008 - LH rear light
l F009 - RH rear light
l F014 - RH front sidelight and direction indicator
l F015 - LH front sidelight and direction indicator
l H001 - Lights selector switch
l I008 - Road lights switch
l I009 - Top work lights switch
l I016 - Hazard warning lights switch
l J004 - Relay
l M004 - Hazard warning lights flasher unit

40-771
 Wiring diagrams
l P006 - Trailer socket

J004

B030 B021

B032 B023

B015 A

B007

B024
B020 B012 B013

C004
D004
M004

D014

H001

I016

E008

I009
I008
B

D0065550

Fig. 3223 - Steering column lights switch - Version with cab without front lift - Version with analog instrument
panel - Connector positions
Table 661
Sys- P/N Description Characteristics/notes Position Wiring
tem
B007 Fuse (20A) 40-1238
B012 Fuse (15A) 40-1238
B013 Fuse (15A) 40-1238
B015 Fuse (15A) 40-1238
B020 Fuse (3A) 40-1238
B021 Fuse (10A) 40-1238
B023 Fuse (7.5A) 40-1238
B024 Fuse (7.5A) 40-1238

40-772
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B030 Fuse (30A) 40-1238
B032 Fuse (20A) 40-1238
C004 Earthing point 4 40-1238

Fig. 3224
D004 Wiring connector 40-1238
40-1218

Fig. 3225
D014 Wiring connector 40-1238
40-1224

Fig. 3226
E008 Instrument panel 40-1238
H001 Lights selector 40-1238
switch
I008 Road lights switch 40-1238

Fig. 3227 Fig. 3228

I009 Top work lights 40-1238
switch

Fig. 3229

40-773
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I016 Hazard warning 0
1
40-1238
lights switch
5 17
18
10
8 1 2 3
5 1 7 18

Pin 1 2 3 5 8 10 17 18
Pos

Fig. 3230
Fig. 3231
J004 Relay 40-1238

Fig. 3232
M004 Hazard warning 40-1238
lights ECU

Fig. 3233

40-774
Wiring diagrams

C003 F009

D0065560

D011

C009
F007a
F008
F007

Fig. 3234 - Connector positions

Table 662
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1238

Fig. 3235

40-775
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1238

Fig. 3236
D011 Wiring connector 40-1233
40-1238

Fig. 3237
F007 Number plate light 40-1238

Fig. 3238
Number plate light 40-1238

Fig. 3239
F008 LH rear light 40-1238

Fig. 3240
F009 RH rear light 40-1238

Fig. 3241

40-776
Wiring diagrams

D011

D0065570

Fig. 3242 - Connector positions

Table 663
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1233
40-1238

Fig. 3242

40-777
 Wiring diagrams

P006

G22

G23

G20
X65

X67

X66

D0065580

Fig. 3243 - Connector positions

Table 664
Sys- P/N Description Characteristics/notes Position Wiring
tem
P006 Trailer socket 40-1233

Fig. 3244

40-778
Wiring diagrams

D039
F014 D040

D037
D038

F015

D0064660

Fig. 3245 - Connector positions

Table 665
Sys- P/N Description Characteristics/notes Position Wiring
tem
D037 Wiring connector 40-1224
D037 Wiring connector 40-1251
D038 Wiring connector 40-1224
D038 Wiring connector 40-1251
D039 Wiring connector 40-1224
D039 Wiring connector 40-1250
D040 Wiring connector 40-1224
D040 Wiring connector 40-1250
F014 04411921.4 RH front sidelight 40-1250
and direction indi-
cator
F015 04411920.4 LH front sidelight 40-1251
and direction indi-
cator

40-779
 Wiring diagrams

D039

D014
D040
D037

D038

D0064650

Fig. 3246 - Connector positions

Table 666
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1238
40-1224

Fig. 3246
D037 Wiring connector 40-1224
D037 Wiring connector 40-1251
D038 Wiring connector 40-1224
D038 Wiring connector 40-1251
D039 Wiring connector 40-1224
D039 Wiring connector 40-1250
D040 Wiring connector 40-1224

40-780
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D040 Wiring connector 40-1250

D004

F003

F004
F002

F005

E001

D0064670

Fig. 3247 - Connector positions

40-781
 Wiring diagrams
Table 667
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1238
40-1218

Fig. 3247
E001 Horn 40-1218
F002 Rh high beam 40-1218
headlight

Fig. 3248
F003 Rh low beam head- 40-1218
light

Fig. 3249
F003 Rh low beam head- 40-1218
light

Fig. 3249
F004 Lh low beam head- 40-1218
light

Fig. 3250

40-782
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F004 Lh low beam head- 40-1218
light

Fig. 3250
F005 Lh high beam 40-1218
headlight

Fig. 3251

40-783
 Wiring diagrams
40.3.47 - S015D - Steering column lights switch - Version with cab without front lift - Ver-
sion with digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85
-> 16001)
E003 E002
I016

DIRECTION INDICATOR

DIRECTION INDICATOR

DIRECTION INDICATOR
POSITION BEAM

FULL BEAM

2°TRAILER
1°TRAILER

+12/30

+12/30
+12V
GND

GND
13 8 9 10 11 12 8 14 15 21 1 3 2 17 18 10 8 5

C004
C004

J004 H001 F008 F009

M004
RIGHT

LEFT

58
54

58

31

54

31
F

F
49a

C2
4 3 2 1 4 3 2 1

C3

31

49
C
NC NO 85 86 30 31 31b 56d 56b 56a 56 L R 49a 5 2 3 4 1 6

C003
C009
C004
C004

C004

B007
B030

B010
B020

B021

B032
B015

B024
B012

B023
B013

7.5A

7.5A
30A

20A
15A

15A

15A

20A
10A
3A

5A
+15

+30
C004

C004
C004

C009

7 4 1 5 2 10 9 5 6 2 3 7 8 1 2 1 2

I009 F007a F007

I008
C004
C004

C003
D004

D011
D014

10 5 3 4 14 9 8 13 1 2
B B A A A
1 4 6 5 2 3
D0062990 B5 D8 D2 D5 D3

TO SISTEM 2/2 TO SISTEM 2/2 TO SISTEM 2/2

Fig. 3252 - Steering column lights switch - Version with cab without front lift - Version with digital instrument
panel - System (1/2)

40-784
Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004
C004

C003
D004

D011
D014
10 5 3 4 14 9 8 13 1 2
B B A A A
1 4 6 5 2 3 B5 D8 D2 D5 D3

D038
D040

D037
D039
1 2 1 2 1 2 1 2 1 2
1 3 4 7 5
3 4 3 4

+58 RX

+58 SX
RIGHT DIRECTIONS
LEFT DIRECTIONS

-31
E001 F005 F002 F003 F004

P006

3 2 1 1 2 3
-31

-31
F.D.

FS.
58

58

D0063430
F014 F015

Fig. 3253 - System (2/2)

l D004 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D004 (F) - Wiring connector (Wiring loom 0.015.7310.4)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D014 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D039 (F) - Wiring connector (Wiring loom 04411923.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D040 (F) - Wiring connector (Wiring loom 04411923.4)
l E001 - Horn
l E002 - Instrument panel
l E003 - Instrument panel
l F002 - RH high beam headlight
l F003 - RH low beam headlight
l F004 - LH low beam headlight
l F005 - LH high beam headlight
l F007 - Number plate light
l F007a - Number plate light
l F008 - LH rear light
l F009 - RH rear light
l F014 - RH front sidelight and direction indicator
l F015 - LH front sidelight and direction indicator
l H001 - Lights selector switch
l I008 - Road lights switch
l I009 - Top work lights switch
l I016 - Hazard warning lights switch
l J004 - Relay

40-785
 Wiring diagrams
l M004 - Hazard warning lights flasher unit
l P006 - Trailer socket

J004

B030 B021

B032 B023

B015 A

B007
B020 B024
B010 B012 B013

E002 D004
E003
D014 C004

H001

I016
M004

I009
I008
B

D0064610

Fig. 3254 - Steering column lights switch - Version with cab without front lift - Version with digital instrument
panel - Connector positions
Table 668
Sys- P/N Description Characteristics/notes Position Wiring
tem
B007 Fuse (20A) 40-1205
B010 Fuse (5A) 40-1205
B012 Fuse (15A) 40-1205
B013 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1205
B020 Fuse (3A) 40-1205
B021 Fuse (10A) 40-1205

40-786
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B023 Fuse (7.5A) 40-1205
B024 Fuse (7.5A) 40-1205
B030 Fuse (30A) 40-1205
B032 Fuse (20A) 40-1205
C004 Earthing point 4 40-1205

Fig. 3255
D004 Wiring connector 40-1205
40-1218

Fig. 3256
D014 Wiring connector 40-1205
40-1224

Fig. 3257
E002 Instrument panel 40-1205

Fig. 3258
E003 Instrument panel 40-1205

Fig. 3259
H001 Lights selector 40-1205
switch

40-787
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I008 Road lights switch 40-1205

Fig. 3260 Fig. 3261

I009 Top work lights 40-1205
switch

Fig. 3262
I016 Hazard warning 0
1
40-1205
lights switch
5 17
18
10
8 1 2 3
5 1 7 18

Pin 1 2 3 5 8 10 17 18
Pos

Fig. 3263
Fig. 3264
M004 Hazard warning 40-1205
lights ECU

Fig. 3265
J004 Relay 40-1205

Fig. 3266

40-788
Wiring diagrams

C003 F009

D0064620

D011

C009
F007a
F008
F007

Fig. 3267 - Connector positions

Table 669
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1205

Fig. 3268

40-789
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1205

Fig. 3269
D011 Wiring connector 40-1205
40-1212

Fig. 3270
F007 Number plate light 40-1205

Fig. 3271
Number plate light 40-1205

Fig. 3272
F008 LH rear light 40-1205

Fig. 3273
F009 RH rear light 40-1205

Fig. 3274

40-790
Wiring diagrams

D011

D0064640

Fig. 3275 - Connector positions

Table 670
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1205
40-1212

Fig. 3275

40-791
 Wiring diagrams

P006

G22

ECO

A
S
G23

G20
X65

X67

D0064630

Fig. 3276 - Connector positions

Table 671
Sys- P/N Description Characteristics/notes Position Wiring
tem
P006 Trailer socket 40-1212

Fig. 3277

40-792
Wiring diagrams

D039

D014
D040
D037

D038

D0064650

Fig. 3278 - Connector positions

Table 672
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1205
40-1224

Fig. 3278
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250

40-793
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D040 Wiring connector 40-1224
40-1250

D039
F014 D040

D037
D038

F015

D0064660

Fig. 3279 - Connector positions

Table 673
Sys- P/N Description Characteristics/notes Position Wiring
tem
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250
D040 Wiring connector 40-1224
40-1250
F014 04411921.4 RH front sidelight 40-1250
and direction indi-
cator

40-794
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F015 04411920.4 LH front sidelight 40-1251
and direction indi-
cator

D004

F003

F004
F002

F005

E001

D0064670

Fig. 3280 - Connector positions

40-795
 Wiring diagrams
Table 674
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1205
40-1218

Fig. 3280
E001 Horn 40-1218

Fig. 3281
F002 Rh high beam 40-1218
headlight

Fig. 3282
F003 Rh low beam head- 40-1218
light

Fig. 3283
F003 Rh low beam head- 40-1218
light

Fig. 3283
F004 Lh low beam head- 40-1218
light

Fig. 3284

40-796
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F004 Lh low beam head- 40-1218
light

Fig. 3284
F005 Lh high beam 40-1218
headlight

Fig. 3285

40-797
 Wiring diagrams
40.3.48 - S016 - Steering column lights switch – Version with cab with front lift (R3 EVO
100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
E003 E002
I016

DIRECTION INDICATOR

DIRECTION INDICATOR

DIRECTION INDICATOR
POSITION BEAM

FULL BEAM

2°TRAILER
1°TRAILER

+12/30

+12/30
+12V
GND

GND
13 8 9 10 11 12 8 14 15 21 1 3 2 17 18 10 8 5

C004
C004

J004 H001 F008 F009

M004
RIGHT

LEFT

58
54

58

31

54

31
F

F
4 3 2 1 4 3 2 1
49a

C2

C3

31

49
C
NC NO 85 86 30 31 31b 56d 56b 56a 56 L R 49a 5 2 3 4 1 6

C003
C009
C004
C004

C004

B007
B030

B010
B020

B021

B032
B015

B012

B013
30A

20A
15A

15A

15A

20A
10A
3A

5A

B024
B023
7.5A

7.5A
+15

+30

C004
C004
C004

10 9 5 6 2 3 7 8
C009

I008
1 2 1 2

7 4 1 5 2 8 6 3

F007a F007
I009
C004

C003
C004
D004

D011
D014

10 5 3 4 14 9 8 13 1 2
B B A A A
1 4 8 10 6 5 2 3 7 9 B5 D8 D2 D5 D3

D0063000

TO SISTEM 2/2 TO SISTEM 2/2 TO SISTEM 2/2

Fig. 3286 - Steering column lights switch - Version with cab with front lift - System (1/2)

40-798
Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004
C004

C003
D004

D011
D014
10 5 3 4 14 9 8 13 1 2
B B A A A
1 4 8 10 6 5 2 3 7 9 B5 D8 D2 D5 D3

D038
D037
D039
D040
1 2 1 2 1 2 1 2 1 2
1 3 4 7 5
1 2 3 4 3 4 1 2

+58 RX

+58 SX
RIGHT DIRECTIONS
LEFT DIRECTIONS

-31
E001 F005 F002 F003 F004

P006

1 2 3 4 3 2 1 1 2 3 4 3 2 1
-31

-31
F.D.

FS.
58

58

D0063440
F014 F015
D041 D042

Fig. 3287 - Steering column lights switch - Version with cab with front lift - System (2/2)
l D004 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D004 (F) - Wiring connector (Wiring loom 0.014.8107.4/30)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D014 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D039 (F) - Wiring connector (Wiring loom 04411923.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D040 (F) - Wiring connector (Wiring loom 04411923.4)
l D041 (F) - RH front light on arm (Wiring loom 04411923.4)
l D042 (F) - LH front light on arm (Wiring loom 04411923.4)
l E001 - Horn
l E002 - Instrument panel
l E003 - Instrument panel
l F002 - RH high beam headlight
l F003 - RH low beam headlight
l F004 - LH low beam headlight
l F005 - LH high beam headlight
l F007 - Number plate light
l F007a - Number plate light
l F008 - LH rear light
l F009 - RH rear light
l F014 - RH front sidelight and direction indicator
l F015 - LH front sidelight and direction indicator
l H001 - Lights selector switch
l I008 - Road lights switch
l I009 - Top work lights switch

40-799
 Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004
C004

C003
D004

D011
D014
10 5 3 4 14 9 8 13 1 2
B B A A A
1 4 8 10 6 5 2 3 7 9 B5 D8 D2 D5 D3

D038
D037
D039
D040
1 2 1 2 1 2 1 2 1 2
1 3 4 7 5
1 2 3 4 3 4 1 2

+58 RX

+58 SX
RIGHT DIRECTIONS
LEFT DIRECTIONS

-31
E001 F005 F002 F003 F004

P006

1 2 3 4 3 2 1 1 2 3 4 3 2 1
-31

-31
F.D.

FS.
58

58

D0063440
F014 F015
D041 D042

Fig. 3287 - Steering column lights switch - Version with cab with front lift - System (2/2)
l I016 - Hazard warning lights switch
l J004 - Relay
l M004 - Hazard warning lights flasher unit
l P006 - Trailer socket

40-800
Wiring diagrams
J004

B030 B021

B032 B023

B015 A

B007
B020 B024
B010 B012 B013

E002 D004
E003
D014 C004

H001

I016
M004

I009
I008
B

D0064610

Fig. 3288 - Steering column lights switch - Version with cab with front lift - Connector positions
Table 675
Sys- P/N Description Characteristics/notes Position Wiring
tem
B007 Fuse (20A) 40-1209
B010 Fuse (5A) 40-1209
B012 Fuse (15A) 40-1209
B013 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1209
B020 Fuse (3A) 40-1209
B021 Fuse (10A) 40-1209
B023 Fuse (7.5A) 40-1209
B024 Fuse (7.5A) 40-1209
B030 Fuse (30A) 40-1209
B032 Fuse (20A) 40-1209

40-801
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1209

Fig. 3289
D004 Wiring connector 40-1193
40-1209

Fig. 3290
D014 Wiring connector 40-1209
40-1224

Fig. 3291
E002 Instrument panel 40-1209

Fig. 3292
E003 Instrument panel 40-1209

Fig. 3293
H001 Lights selector 40-1209
switch

40-802
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I008 Road lights switch 40-1209

Fig. 3294 Fig. 3295

I009 Upper worklights 40-1209
switch

Fig. 3296
I016 Hazard warning 0
1
40-1209
lights switch
5 17
18
10
8 1 2 3
5 1 7 18

Pin 1 2 3 5 8 10 17 18
Pos

Fig. 3297
Fig. 3298
M004 Hazard warning 40-1209
lights ECU

Fig. 3299
J004 Relay 40-1209

Fig. 3300

40-803
 Wiring diagrams

C003 F009

D0064620

D011

C009
F007a
F008
F007

Fig. 3301 - Connector positions

Table 676
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1209

Fig. 3302

40-804
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1209

Fig. 3303
D011 Wiring connector 40-1209
40-1214

Fig. 3304
F007 Number plate light 40-1209

Fig. 3305
Number plate light 40-1209

Fig. 3306
F008 LH rear light 40-1209

Fig. 3307
F009 RH rear light 40-1209

Fig. 3308

40-805
 Wiring diagrams

D011

D0064640

Fig. 3309 - Connector positions

Table 677
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1209
40-1214

Fig. 3309

40-806
Wiring diagrams

P006

G22

ECO

A
S
G23

G20
X65

X67

D0064630

Fig. 3310 - Connector positions

Table 678
Sys- P/N Description Characteristics/notes Position Wiring
tem
P006 Trailer socket 40-1214

Fig. 3311

40-807
 Wiring diagrams

D039

D014
D040
D037

D038

D0064650

Fig. 3312 - Connector positions

Table 679
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1209
40-1224

Fig. 3312
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250

40-808
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D040 Wiring connector 40-1224
40-1250

D039
D040
F014

D037
D038
D041

F015

D042

D0064680

Fig. 3313 - Connector positions

Table 680
Sys- P/N Description Characteristics/notes Position Wiring
tem
F014 04411921.4 Front RH sidelight 40-1250
and direction indi-
cator
F015 04411920.4 Front LH sidelight 40-1251
and direction indi-
cator
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250

40-809
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D040 Wiring connector 40-1224
40-1250
D041 Rh front light on 40-1250
arms
D042 LH front light on 40-1251
arms

D004

F003

F004
F002

F005

E001

D0064670

Fig. 3314 - Connector positions

40-810
Wiring diagrams
Table 681
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1193
40-1209

Fig. 3314
F002 Rh high beam 40-1193
headlight

Fig. 3315
F003 Rh low beam head- 40-1193
light
F003 Rh low beam head- 40-1193
light

Fig. 3316
F004 Lh low beam head- 40-1193
light
F004 Lh low beam head- 40-1193
light

Fig. 3317
F005 Lh high beam 40-1193
headlight

Fig. 3318
E001 Horn 40-1193

Fig. 3319

40-811
 Wiring diagrams
40.3.49 - S016A - Steering column lights switch - Version with cab without front lift - Ver-
sion with analog instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO
85 -> 16001)
E008
I016

DIRECTION INDICATOR

DIRECTION INDICATOR
FULL BEAM

1°TRAILER

+15
-31
B 1 3 2 17 18 8 5
B1 B2 B4 B3 12 10

C004
C004

J004 H001 F008 F009

M004
RIGHT

LEFT

58
54

58

31

54

31
F

F
4 3 2 1 4 3 2 1
49a
C2

C3

31

49
C
NC NO 85 86 30 31 31b 56d 56b 56a 56 L R 49a 2 5 3 4 1 6

C003
C009
C004
C004

C004

B007
B030
B020

B021

B032
B015

B012

B013
30A

20A
15A

15A

15A

20A
10A
3A

B024
B023
7.5A

7.5A
+15

+30

C004
C004

10 9 5 6 2 3 7 8
C004

C009

I008
1 2 1 2

7 4 1 5 2 8 6 3

F007a F007
I009
C004

C003
C004
D004

D014

D011

10 5 3 4 14 9 8 13 1 2
A A A A A A A
1 4 8 10 6 5 2 3 7 9 A1 D1 B1 B1 D2 D5 D3

D0065060
TO SISTEM 2/2 TO SISTEM 2/2 TO SISTEM 2/2

Fig. 3320 - Steering column lights switch - Version with cab with front lift - Version with analog instrument panel
- System (1/2)

40-812
Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004

C004

C003
D004

D014

D011
10 5 3 4 14 9 8 13 1 2
A A A A A A A
1 4 8 10 6 5 2 3 7 9 A1 D1 B1 B1 D2 D5 D3

D038
D040

D037
D039
1 2 1 2 1 2 1 2 1 2
1 3 4 7 5
1 2 3 4 3 4 1 2

+58 SX
+58 DX
RIGHT DIRECTIONS
LEFT DIRECTIONS

-31
E001 F005 F002 F003 F004

P006

1 2 3 4 3 2 1 1 2 3 4 3 2 1
-31

-31
F.D.

FS.
58

58

D0065050
F014 F015
D041 D042

Fig. 3321 - System (2/2)

l D004 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D004 (F) - Wiring connector (Wiring loom 0.015.7310.4)
l D011 (M) - Wiring connector (Wiring loom 0.016.1999.4/10)
l D011 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D014 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D039 (F) - Wiring connector (Wiring loom 04411923.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D040 (F) - Wiring connector (Wiring loom 04411923.4)
l D041 (M) - Wiring connector (Wiring loom 0.014.3927.4/40)
l D041 (F) - Wiring connector (Wiring loom 04411923.4)
l D041 (F) - RH front light on arm (Wiring loom 04411923.4)
l D042 (M) - Wiring connector (Wiring loom 0.014.3927.4/40)
l D042 (F) - Wiring connector (Wiring loom 04411923.4)
l D042 (F) - LH front light on arm (Wiring loom 04411923.4)
l E001 - Horn
l E008 - Instrument panel
l F002 - RH high beam headlight
l F003 - RH low beam headlight
l F004 - LH low beam headlight
l F005 - LH high beam headlight
l F007 - Number plate light
l F007a - Number plate light
l F008 - LH rear light
l F009 - RH rear light
l F014 - RH front sidelight and direction indicator
l F015 - LH front sidelight and direction indicator

40-813
 Wiring diagrams
l H001 - Lights selector switch
l I008 - Road lights switch
l I009 - Top work lights switch
l I016 - Hazard warning lights switch
l J004 - Relay
l M004 - Hazard warning lights flasher unit
l P006 - Trailer socket

J004

B030 B021

B032 B023

B015 A

B007

B024
B020 B012 B013

C004
D004
M004

D014

H001

I016

E008

I009
I008
B

D0065550

Fig. 3322 - Steering column lights switch - Version with cab with front lift - Version with analog instrument panel
- Connector positions
Table 682
Sys- P/N Description Characteristics/notes Position Wiring
tem
B007 Fuse (20A) 40-1238
B012 Fuse (15A) 40-1238

40-814
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B013 Fuse (15A) 40-1238
B015 Fuse (15A) 40-1238
B020 Fuse (3A) 40-1238
B021 Fuse (10A) 40-1238
B023 Fuse (7.5A) 40-1238
B024 Fuse (7.5A) 40-1238
B030 Fuse (30A) 40-1238
B032 Fuse (20A) 40-1238
C004 Earthing point 4 40-1238

Fig. 3323
D004 Wiring connector 40-1238
40-1218

Fig. 3324
D014 Wiring connector 40-1238
40-1224

Fig. 3325
E008 Instrument panel 40-1238
H001 Lights selector 40-1238
switch
I008 Road lights switch 40-1238

Fig. 3326 Fig. 3327

I009 Top work lights 40-1238
switch

Fig. 3328

40-815
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I016 Hazard warning 0
1
40-1238
lights switch
5 17
18
10
8 1 2 3
5 1 7 18

Pin 1 2 3 5 8 10 17 18
Pos

Fig. 3329
Fig. 3330
J004 Relay 40-1238

Fig. 3331
M004 Hazard warning 40-1238
lights ECU

Fig. 3332

40-816
Wiring diagrams

C003 F009

D0065560

D011

C009
F007a
F008
F007

Fig. 3333 - Connector positions

Table 683
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1238

Fig. 3334

40-817
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1238

Fig. 3335
D011 Wiring connector 40-1233
40-1238

Fig. 3336
F007 Number plate light 40-1238

Fig. 3337
Number plate light 40-1238

Fig. 3338
F008 LH rear light 40-1238

Fig. 3339
F009 RH rear light 40-1238

Fig. 3340

40-818
Wiring diagrams

D011

D0065570

Fig. 3341 - Connector positions

Table 684
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1233
40-1238

Fig. 3341

40-819
 Wiring diagrams

P006

G22

G23

G20
X65

X67

X66

D0065580

Fig. 3342 - Connector positions

Table 685
Sys- P/N Description Characteristics/notes Position Wiring
tem
P006 Trailer socket 40-1233

Fig. 3343

40-820
Wiring diagrams

D004

F003

F004
F002

F005

E001

D0064670

Fig. 3344 - Connector positions

Table 686
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1238
40-1218

Fig. 3344

40-821
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F002 Rh high beam 40-1218
headlight

Fig. 3345
F003 Rh low beam head- 40-1218
light

Fig. 3346
F003 Rh low beam head- 40-1218
light

Fig. 3346
F004 Lh low beam head- 40-1218
light

Fig. 3347
F004 Lh low beam head- 40-1218
light

Fig. 3347
F005 Lh high beam 40-1218
headlight

Fig. 3348

40-822
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
E001 Horn 40-1218

Fig. 3349

D039

D014
D040
D037

D038

D0064650

Fig. 3350 - Connector positions

40-823
 Wiring diagrams
Table 687
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1238
40-1224

Fig. 3350
D037 Wiring connector 40-1224
D037 Wiring connector 40-1251
D038 Wiring connector 40-1224
D038 Wiring connector 40-1251
D039 Wiring connector 40-1224
D039 Wiring connector 40-1250
D040 Wiring connector 40-1224
D040 Wiring connector 40-1250

40-824
Wiring diagrams

D039
D040
F014

D037
D038
D041

F015

D042

D0065590

Fig. 3351 - Connector positions

Table 688
Sys- P/N Description Characteristics/notes Position Wiring
tem
D037 Wiring connector 40-1224
D037 Wiring connector 40-1251
D038 Wiring connector 40-1224
D038 Wiring connector 40-1251
D039 Wiring connector 40-1224
D039 Wiring connector 40-1250
D040 Wiring connector 40-1224
D040 Wiring connector 40-1250
D041 Wiring connector 40-1250
D041 Wiring connector 40-1192
D041 Rh front light on 40-1250
arms
D042 Wiring connector 40-1192
D042 Wiring connector 40-1251
D042 LH front light on 40-1251
arms

40-825
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F014 04411921.4 RH front sidelight 40-1250
and direction indi-
cator
F015 04411920.4 LH front sidelight 40-1251
and direction indi-
cator

40-826
Wiring diagrams
40.3.50 - S016D - Steering column lights switch - Version with cab with front lift - Version
with digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 ->
16001)
E003 E002
I016

DIRECTION INDICATOR

DIRECTION INDICATOR

DIRECTION INDICATOR
POSITION BEAM

FULL BEAM

2°TRAILER
1°TRAILER

+12/30

+12/30
+12V
GND

GND
13 8 9 10 11 12 8 14 15 21 1 3 2 17 18 10 8 5

C004
C004

J004 H001 F008 F009

M004
RIGHT

LEFT

58
54

58

31

54

31
F

F
4 3 2 1 4 3 2 1
49a

C2

C3

31

49
C
NC NO 85 86 30 31 31b 56d 56b 56a 56 L R 49a 5 2 3 4 1 6

C003
C009
C004
C004

C004

B007
B030

B010
B020

B021

B032
B015

B012

B013
30A

20A
15A

15A

15A

20A
10A
3A

5A

B024
B023
7.5A

7.5A
+15

+30

C004
C004
C004

10 9 5 6 2 3 7 8
C009

I008
1 2 1 2

7 4 1 5 2 8 6 3

F007a F007
I009
C004

C003
C004
D004

D011
D014

10 5 3 4 14 9 8 13 1 2
B B A A A
1 4 8 10 6 5 2 3 7 9 B5 D8 D2 D5 D3

D0063000

TO SISTEM 2/2 TO SISTEM 2/2 TO SISTEM 2/2

Fig. 3352 - Steering column lights switch - Version with cab with front lift - Version with digital instrument panel
- System (1/2)

40-827
 Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004
C004

C003
D004

D011
D014
10 5 3 4 14 9 8 13 1 2
B B A A A
1 4 8 10 6 5 2 3 7 9 B5 D8 D2 D5 D3

D038
D037
D039
D040
1 2 1 2 1 2 1 2 1 2
1 3 4 7 5
1 2 3 4 3 4 1 2

+58 RX

+58 SX
RIGHT DIRECTIONS
LEFT DIRECTIONS

-31
E001 F005 F002 F003 F004

P006

1 2 3 4 3 2 1 1 2 3 4 3 2 1
-31

-31
F.D.

FS.
58

58

D0063440
F014 F015
D041 D042

Fig. 3353 - Steering column lights switch - Version with cab with front lift - Version with digital instrument panel
- System (2/2)
l D004 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D004 (F) - Wiring connector (Wiring loom 0.015.7310.4)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D014 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D039 (F) - Wiring connector (Wiring loom 04411923.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D040 (F) - Wiring connector (Wiring loom 04411923.4)
l D041 (M) - Wiring connector (Wiring loom 0.014.3927.4/40)
l D041 (F) - Wiring connector (Wiring loom 04411923.4)
l D041 (F) - RH front light on arm (Wiring loom 04411923.4)
l D042 (M) - Wiring connector (Wiring loom 0.014.3927.4/40)
l D042 (F) - Wiring connector (Wiring loom 04411923.4)
l D042 (F) - LH front light on arm (Wiring loom 04411923.4)
l E001 - Horn
l E002 - Instrument panel
l E003 - Instrument panel
l F002 - RH high beam headlight
l F003 - RH low beam headlight
l F004 - LH low beam headlight
l F005 - LH high beam headlight
l F007 - Number plate light
l F007a - Number plate light
l F008 - LH rear light
l F009 - RH rear light

40-828
Wiring diagrams
l F014 - RH front sidelight and direction indicator
l F015 - LH front sidelight and direction indicator
l H001 - Lights selector switch
l I008 - Road lights switch
l I009 - Top work lights switch
l I016 - Hazard warning lights switch
l J004 - Relay
l M004 - Hazard warning lights flasher unit
l P006 - Trailer socket

J004

B030 B021

B032 B023

B015 A

B007
B020 B024
B010 B012 B013

E002 D004
E003
D014 C004

H001

I016
M004

I009
I008
B

D0064610

Fig. 3354 - Steering column lights switch - Version with cab with front lift - Version with digital instrument panel
- Connector positions

40-829
 Wiring diagrams
Table 689
Sys- P/N Description Characteristics/notes Position Wiring
tem
B007 Fuse (20A) 40-1205
B010 Fuse (5A) 40-1205
B012 Fuse (15A) 40-1205
B013 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1205
B020 Fuse (3A) 40-1205
B021 Fuse (10A) 40-1205
B023 Fuse (7.5A) 40-1205
B024 Fuse (7.5A) 40-1205
B030 Fuse (30A) 40-1205
B032 Fuse (20A) 40-1205
C004 Earthing point 4 40-1205

Fig. 3355
D004 Wiring connector 40-1205
40-1218

Fig. 3356
D014 Wiring connector 40-1205
40-1224

Fig. 3356
E002 Instrument panel 40-1205
E003 Instrument panel 40-1205
H001 Lights selector 40-1205
switch
J004 Relay 40-1205

Fig. 3357

40-830
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I008 Road lights switch Drawing D0037210.eps 40-1205

Fig. 3358
I009 Top work lights 40-1205
switch

Fig. 3359
I016 Hazard warning Drawing D0015410.eps 40-1205
lights switch

Fig. 3360
M004 Hazard warning 40-1205
lights ECU

Fig. 3361

40-831
 Wiring diagrams

C003 F009

D0064620

D011

C009
F007a
F008
F007

Fig. 3362 - Connector positions

Table 690
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1205

Fig. 3363

40-832
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1205

Fig. 3364
D011 Wiring connector 40-1205
40-1212

Fig. 3364
F007 Number plate light 40-1205

Fig. 3365
Number plate light 40-1205

Fig. 3366
F008 LH rear light 40-1205

Fig. 3367
F009 RH rear light 40-1205

Fig. 3368

40-833
 Wiring diagrams

D011

D0064640

Fig. 3369 - Connector positions

Table 691
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1205
40-1212

Fig. 3369

40-834
Wiring diagrams

P006

G22

ECO

A
S
G23

G20
X65

X67

D0064630

Fig. 3370 - Connector positions

Table 692
Sys- P/N Description Characteristics/notes Position Wiring
tem
P006 Trailer socket 40-1212

Fig. 3371

40-835
 Wiring diagrams

D039

D014
D040
D037

D038

D0064650

Fig. 3372 - Connector positions

Table 693
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1205
40-1224

Fig. 3372
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250

40-836
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D040 Wiring connector 40-1224
40-1250

D039
D040
F014

D037
D038
D041

F015

D042

D0064680

Fig. 3373 - Connector positions

Table 694
Sys- P/N Description Characteristics/notes Position Wiring
tem
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250
D040 Wiring connector 40-1224
40-1250
D041 Wiring connector 40-1250
40-1192
D041 Rh front light on 40-1250
arms

40-837
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D042 Wiring connector 40-1192
40-1251
D042 LH front light on 40-1251
arms
F014 04411921.4 RH front sidelight 40-1250
and direction indi-
cator
F015 04411920.4 LH front sidelight 40-1251
and direction indi-
cator

D004

F003

F004
F002

F005

E001

D0064670

Fig. 3374 - Connector positions

40-838
Wiring diagrams
Table 695
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1205
40-1218

Fig. 3374
E001 Horn 40-1218
F002 Rh high beam 40-1218
headlight

Fig. 3375
F003 Rh low beam head- 40-1218
light 40-1218

Fig. 3376
F004 Lh low beam head- 40-1218
light 40-1218

Fig. 3377
F005 Lh high beam 40-1218
headlight

Fig. 3378

40-839
 Wiring diagrams
40.3.51 - S017 - +30 Positives (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)

B026
B027
B029

B007
B010

B030

B025

B032

B031

B009
B008
B011
7.5A

15A
30A

30A

30A
30A

20A

15A
20A

30A
40A

5A
D003

D001

D002
B001
B003

B002
60A

60A

60A
C002

T001 +30 GND1 C001

BATTERY
D0063260

Fig. 3379 - +30 Positives - System

l D001 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D001 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D001 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D001 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D001 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D002 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D002 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D002 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D002 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D003 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D003 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D003 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D003 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)

40-840
Wiring diagrams
B029 B032
B025

B026
B030

A
B031

B007
B027
B008

B009 B010 B011

D001
A
D002
D003

D0064560

Fig. 3380 - +30 Positives - Connector positions

Table 696
Sys- P/N Description Characteristics/notes Position Wiring
tem
B007 Fuse (20A) 40-1209
B007 Fuse (20A) 40-1221
B008 Fuse (15A) 40-1209
B008 Fuse (15A) 40-1221
B009 Fuse (15A) 40-1209
B009 Fuse (15A) 40-1221
B010 Fuse (5A) 40-1209
B010 Fuse (5A) 40-1221
B011 Fuse (7.5A) 40-1209

40-841
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B011 Fuse (7.5A) 40-1221
B025 Fuse (30A) 40-1209
B025 Fuse (30A) 40-1221
B026 Fuse (30A) 40-1209
B026 Fuse (30A) 40-1221
B027 Fuse (30A) 40-1209
B027 Fuse (30A) 40-1221
B029 Fuse (40A) 40-1209
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221
B031 Fuse (30A) 40-1209
B031 Fuse (30A) 40-1221
B032 Fuse (20A) 40-1209
B032 Fuse (20A) 40-1221
D001 Wiring connector 40-1198
40-1209
40-1221

Fig. 3381
D002 Wiring connector 40-1199
40-1209
40-1221

Fig. 3382
D003 Wiring connector 40-1200
40-1209
40-1221

Fig. 3383

40-842
Wiring diagrams

D003
D002
D001

B003

B002

B001

D0064550

Fig. 3384 - Connector positions

Table 697
Sys- P/N Description Characteristics/notes Position Wiring
tem
B001 Fuse 40-1198
B002 Fuse 40-1199
B003 Fuse 40-1200

40-843
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D001 Wiring connector 40-1198
40-1209
40-1221

Fig. 3384
D002 Wiring connector 40-1199
40-1209
40-1221

Fig. 3384
D003 Wiring connector 40-1200
40-1209
40-1221

Fig. 3384

40-844
Wiring diagrams

C001

T001
C002

D0064540

Fig. 3385 - Connector positions - Version with front battery

40-845
 Wiring diagrams
Table 698
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative Version for front battery 40-1241
terminal

Fig. 3386
C002 Earthing point 2 40-1241
T001 Battery positive ter- Version for front battery 40-1241
minal

Fig. 3387

40-846
Wiring diagrams

C002

T001

C001

D0064570

Fig. 3388 - Connector positions - Version with lateral battery

Table 699
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative Version for lateral battery 40-1241
terminal

Fig. 3389

40-847
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C002 Earthing point 2 Version for lateral battery 40-1241

Fig. 3390
T001 Battery positive ter- Version for lateral battery 40-1241
minal

Fig. 3391

40.3.52 - S017A - +30 Positives - Version with analog instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
B026
B027
B029

B007
B030

B025

B032

B031

B009
B008

15A
30A

30A

30A
30A

20A

15A
20A

30A
40A

D003

D002
B003

B002
60A

60A
C002

T001 +30 GND1 C001

BATTERY
D0065400

Fig. 3392 - +30 Positives - Version with analog instrument panel - System
l D002 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D002 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D003 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)

40-848
Wiring diagrams
l D003 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)

B029 B032
B025

B030 B026

B031
A

B007
B027
B008

B009

A
D002
D003

D0065610

Fig. 3393 - +30 Positives - Version with analog instrument panel - Connector positions
Table 700
Sys- P/N Description Characteristics/notes Position Wiring
tem
B007 Fuse (20A) 40-1238
B008 Fuse (15A) 40-1238
B009 Fuse (15A) 40-1238
B025 Fuse (30A) 40-1238
B026 Fuse (30A) 40-1238
B027 Fuse (30A) 40-1238
B029 Fuse (40A) 40-1238

40-849
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B030 Fuse (30A) 40-1238
B031 Fuse (30A) 40-1238
B032 Fuse (20A) 40-1238
D002 Wiring connector 40-1238
40-1199

Fig. 3394
D003 Wiring connector 40-1238
40-1200

Fig. 3395

40-850
Wiring diagrams

D003
D002

B003

B002

D0064551

Fig. 3396 - Connector positions

Table 701
Sys- P/N Description Characteristics/notes Position Wiring
tem
B002 Fuse 40-1199
B003 Fuse 40-1200

40-851
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D002 Wiring connector 40-1238
40-1199

Fig. 3396
D003 Wiring connector 40-1238
40-1200

Fig. 3396

40-852
Wiring diagrams

C001

T001
C002

D0064540

Fig. 3397 - Connector positions - Version with front battery

40-853
 Wiring diagrams
Table 702
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative 40-1241
terminal

Fig. 3398
C002 Earthing point 2 40-1241

Fig. 3399
T001 Battery positive ter- 40-1241
minal

Fig. 3400

40-854
Wiring diagrams

C002

T001

C001

D0064570

Fig. 3401 - Connector positions - Version with lateral battery

Table 703
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative 40-1241
terminal

Fig. 3402

40-855
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C002 Earthing point 2 40-1241

Fig. 3402
T001 Battery positive ter- 40-1241
minal

Fig. 3403

40.3.53 - S017A - +30 Positives - Version with digital instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
B026
B027
B029

B007
B010

B030

B025

B032

B031

B009
B008

15A
30A

30A

30A
30A

20A

15A
20A

30A
40A

5A
D003

D001

D002
B001
B003

B002
60A

60A

60A
C002

T001 +30 GND1 C001

BATTERY
D0065240

Fig. 3404 - +30 Positives - Version with digital instrument panel - System
l D001 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D001 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D002 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)

40-856
Wiring diagrams
l D002 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)
l D003 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D003 (F) - Wiring connector (Wiring loom 0.015.1983.4/10)

B029 B032
B025

B026
B030

A
B031

B007
B027
B008

B009
B010

D001
A
D002
D003

D0064561

Fig. 3405 - +30 Positives - Version with digital instrument panel - Connector positions
Table 704
Sys- P/N Description Characteristics/notes Position Wiring
tem
B007 Fuse (20A) 40-1205
B007 Fuse (20A) 40-1221
B008 Fuse (15A) 40-1205
B008 Fuse (15A) 40-1221
B009 Fuse (15A) 40-1205

40-857
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B009 Fuse (15A) 40-1221
B010 Fuse (5A) 40-1205
B010 Fuse (5A) 40-1221
B025 Fuse (30A) 40-1205
B025 Fuse (30A) 40-1221
B026 Fuse (30A) 40-1205
B026 Fuse (30A) 40-1221
B027 Fuse (30A) 40-1205
B027 Fuse (30A) 40-1221
B029 Fuse (40A) 40-1205
B029 Fuse (40A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
B031 Fuse (30A) 40-1205
B031 Fuse (30A) 40-1221
B032 Fuse (20A) 40-1205
B032 Fuse (20A) 40-1221
D001 Wiring connector 40-1198
40-1205
40-1221

Fig. 3406
D002 Wiring connector 40-1199
40-1205
40-1221

Fig. 3407
D003 Wiring connector 40-1200
40-1205
40-1221

Fig. 3408

40-858
Wiring diagrams

D003
D002
D001

B003

B002

B001

D0064550

Fig. 3409 - Connector positions

Table 705
Sys- P/N Description Characteristics/notes Position Wiring
tem
B001 Fuse 40-1198
B002 Fuse 40-1199
B003 Fuse 40-1200

40-859
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D001 Wiring connector 40-1198
40-1205
40-1221

Fig. 3409
D002 Wiring connector 40-1199
40-1205
40-1221

Fig. 3409
D003 Wiring connector 40-1200
40-1205
40-1221

Fig. 3409

40-860
Wiring diagrams

C001

T001
C002

D0064540

Fig. 3410 - Connector positions - Version with front battery

40-861
 Wiring diagrams
Table 706
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative 40-1241
terminal

Fig. 3411
C002 Earthing point 2 40-1241
T001 Battery positive ter- 40-1241
minal

Fig. 3412

40-862
Wiring diagrams

C002

T001

C001

D0064570

Fig. 3413 - Connector positions - Version with lateral battery

Table 707
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative 40-1241
terminal

Fig. 3414

40-863
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C002 Earthing point 2 40-1241

Fig. 3415
T001 Battery positive ter- 40-1241
minal

Fig. 3416

40.3.54 - S018 - +15 Positives (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)

B022
7.5A
B021
10A

B020
3A
+30

75 83 15 50 30

2
1 0

D0063270
I018

Fig. 3417 - +15 Positives - System

l IO18 - Ignition switch

40-864
Wiring diagrams

B020

B021
B022

I018

D0064580

Fig. 3418

Table 708
Sys- P/N Description Characteristics/notes Position Wiring
tem
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1209
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1209
B022 Fuse (7.5A) 40-1221
I018 Starter switch 40-1209
40-1221

40-865
 Wiring diagrams
40.3.55 - S018A - +15 Positives - Version with digital instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

B022
7.5A
B021
10A

B020
3A

+30
75 83 15 50 30

2
1 0

D0063270
I018

Fig. 3421 - +15 Positives - Version with digital instrument panel - System
l IO18 - Ignition switch

40-866
Wiring diagrams

B020

B021
B022

I018

D0064580

Fig. 3422 - +15 Positives - Version with digital instrument panel - Positions
Table 709
Sys- P/N Description Characteristics/notes Position Wiring
tem
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1205
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1205
B022 Fuse (7.5A) 40-1221
I018 Starter switch 40-1205
40-1221

40-867
 Wiring diagrams
40.3.56 - S018D - +15 Positives - Version with digital instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

B022
7.5A
B021
10A

B020
3A

+30
75 83 15 50 30

2
1 0

D0063270
I018

Fig. 3424 - +15 Positives - Version with digital instrument panel - System
l I018 - Ignition switch

40-868
Wiring diagrams

B020

B021
B022

I018

D0064580

Fig. 3424 - +15 Positives - Version with digital instrument panel - Positions
Table 710
Sys- P/N Description Characteristics/notes Position Wiring
tem
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1205
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1205
B022 Fuse (7.5A) 40-1221
I018 Starter switch 40-1205
40-1221

40-869
 Wiring diagrams
40.3.57 - S019 - Windscreen wipers - Version with standard cab (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001)
J005 J004
N003 N004
M M

NC NO 85 86 30 NC NO 85 86 30 2 1 2 1

B026

B015

B020

B030
C004

C009
30A

15A

30A
3A
+30

+15

+30
D008
2 5 3

D023

2 5 3
B037

B038
7.5A

7.5A

C007
D029
C007

3 7
D036
C007

2 1
D030

2 6 1 3

31 T I 53M 53S 15 2 7 5 8 6 3 3 2 4 1 2 1 3 7 8 6 4 2 1
53

31

31b

53a

M
D0063010
I027 N005
M005 I028 N006 I029

Fig. 3425 - Windscreen wipers - Version with standard cab - System

l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D029 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D029 (M) - Wiring connector (Wiring loom 0.016.0866.4/10)
l D030 (M) - Wiring connector (Wiring loom 0.010.4516.3)
l D0320 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)

40-870
Wiring diagrams
J005 J004
N003 N004
M M

NC NO 85 86 30 NC NO 85 86 30 2 1 2 1

B026

B015

B020

B030
C004

C009
30A

15A

30A
3A
+30

+15

+30
D008
2 5 3

D023
2 5 3
B037

B038
7.5A

7.5A

C007
D029
C007

3 7
D036
C007

2 1
D030

2 6 1 3

31 T I 53M 53S 15 2 7 5 8 6 3 3 2 4 1 2 1 3 7 8 6 4 2 1
53

31

31b

53a

M
D0063010
I027 N005
M005 I028 N006 I029

Fig. 3425 - Windscreen wipers - Version with standard cab - System

l D0320 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D030 (M) - Wiring connector (Wiring loom 0.010.4516.3)
l D036 (M) - Wiring connector (Wiring loom 0.015.6123.4)
l D036 (F) - Wiring connector (Wiring loom 0.016.0866.4/10)
l I027 - Windscreen washer pump switch
l I028 - Windscreen wiper switch
l I029 - Rear window wiper switch
l J004 - Relay
l J005 - Relay
l M005 - Windscreen wiper intermittent timer
l N003 - Windscreen washer pump
l N004 - Rear window washer pump
l N005 - Rear window wiper motor
l N006 - Windscreen wiper motor

40-871
 Wiring diagrams

B026
B030
A
J005

B015

B020
J004

D008

C004

D0064200

Fig. 3426 - Windscreen wipers - Version with standard cab - Connector positions
Table 711
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B026 Fuse (30A) 40-1209
B026 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221

40-872
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1209
40-1221

Fig. 3427
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 3428
J004 Relay 40-1209
40-1221

Fig. 3429
J005 Relay 40-1209
40-1221

Fig. 3430

40-873
 Wiring diagrams

N004

N003

C009

D0064210

Fig. 3431 - Connector positions

Table 712
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1209
40-1221

Fig. 3432

40-874
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
N003 Windscreen wash- 40-1209
er pump 40-1221

Fig. 3433
N004 Rear screen wash- 40-1209
er pump 40-1221

Fig. 3434

40-875
 Wiring diagrams

D023

D008

D0064220

Fig. 3435 - Connector positions

Table 713
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 3435

40-876
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1220
40-1226
40-1244
40-1220

Fig. 3436

I029
B037-B038 M005
I028 C007

D030 D029

D023
I027

D0064230

Fig. 3437 - Connector positions

Table 714
Sys- P/N Description Characteristics/notes Position Wiring
tem
B037 Fuse (7.5A) 40-1226
B037 Fuse (7.5A) 40-1244
B038 Fuse (7.5A) 40-1226
B038 Fuse (7.5A) 40-1244
C007 Earthing point 7 40-1226
40-1244

Fig. 3438

40-877
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1220
40-1226
40-1244
40-1220

Fig. 3438
D029 Wiring connector 40-1226
40-1244
40-1230
40-1230
D030 Wiring connector 40-1226
40-1244
40-1185
40-1185
M005 Windscreen wiper 40-1226
intermittent timer 40-1244

Fig. 3439
I027 Windscreen wash- 40-1226
40-1244
I028 Windscreen wiper 40-1226
40-1244
I029 Rear screen wiper 40-1226
40-1244

40-878
Wiring diagrams

D030

N006
D0064250

Fig. 3446 - Connector positions

Table 715
Sys- P/N Description Characteristics/notes Position Wiring
tem
D030 Wiring connector 40-1226
40-1244
40-1185
40-1185
N006 Windscreen wiper 40-1185
motor

Fig. 3447

40-879
 Wiring diagrams

D036

D029

D0064260

Fig. 3448 - Connector positions

Table 716
Sys- P/N Description Characteristics/notes Position Wiring
tem
D029 Wiring connector 40-1226
40-1244
40-1230
40-1230
D036 Wiring connector 40-1230
40-1203

40-880
Wiring diagrams
D036

N005

D0064270

Fig. 3449 - Connector positions

Table 717
Sys- P/N Description Characteristics/notes Position Wiring
tem
D036 Wiring connector 40-1230
40-1203
N005 02941435 Rear screen wiper 40-1203
motor

40-881
 Wiring diagrams
40.3.58 - S019AD - Windscreen wipers - Version with standard cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
J005 J004
N003
M

NC NO 85 86 30 NC NO 85 86 30 2 1

B026

B015

B020

B030
C004

C009
30A

15A

30A
3A
+30

+15

+30
D008
2 5

D023

2 5
B037
7.5A
C007
C007

D030

2 6 1 3

31 T I 53M 53S 15 7 8 2 3 5 6 3 2 4 1 2 1
53

31

31b

53a

D0064860
I027
M005 I028 N006

Fig. 3450 - Windscreen wipers - Version with standard cab - Version with digital instrument panel - System
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D030 (M) - Wiring connector (Wiring loom 0.010.4516.3)
l D0320 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D0320 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D030 (M) - Wiring connector (Wiring loom 0.010.4516.3)
l I027 - Windscreen washer pump switch
l I028 - Windscreen wiper switch
l J004 - Relay
l J005 - Relay

40-882
Wiring diagrams
l M005 - Windscreen wiper intermittent timer
l N003 - Windscreen washer pump
l N006 - Windscreen wiper motor

B026
B030
A
J005

B015

B020
J004

D008

C004

D0064200

Fig. 3451 - Windscreen wipers - Version with standard cab - Version with digital instrument panel - Connector
positions
Table 718
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B026 Fuse (30A) 40-1205
B026 Fuse (30A) 40-1221

40-883
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 3452
D008 Wiring connector 40-1205
40-1220
40-1221

Fig. 3453
J004 Relay 40-1205
40-1221

Fig. 3454
J005 Relay 40-1205
40-1221

Fig. 3455

40-884
Wiring diagrams

N003

C009

D0064211

Fig. 3456 - Connector positions

Table 719
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1205
40-1221

Fig. 3457

40-885
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
N003 Windscreen wash- 40-1205
er pump 40-1221

Fig. 3458

D023

D008

D0064220

Fig. 3459 - Connector positions

40-886
Wiring diagrams
Table 720
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221

Fig. 3459
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 3460

B037 M005
I028 C007

D030

D023
I027

D0064231

Fig. 3461 - Connector positions

Table 721
Sys- P/N Description Characteristics/notes Position Wiring
tem
B037 Fuse (7.5A) 40-1228
B037 Fuse (7.5A) 40-1242

40-887
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1228
40-1242

Fig. 3462
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 3462
D030 Wiring connector 40-1228
40-1242
40-1185
40-1185

Fig. 3463
I027 Windscreen wash- Drawing D0029620.eps 40-1228
er pump switch 40-1242

Fig. 3464
I028 Windscreen wiper Drawing D0029630.eps 40-1228
switch 40-1242

Fig. 3465
M005 Windscreen wiper 40-1228
intermittent timer 40-1242

Fig. 3466

40-888
Wiring diagrams

D030

N006
D0064250

Fig. 3467 - Connector positions

Table 722
Sys- P/N Description Characteristics/notes Position Wiring
tem
D030 Wiring connector 40-1228
40-1242
40-1185
40-1185

Fig. 3467
N006 Windscreen wiper 40-1185
motor

Fig. 3468

40-889
 Wiring diagrams
40.3.59 - S019D - Windscreen wipers - Version with standard cab - Version with digital
instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
J005 J004
N003
M

NC NO 85 86 30 NC NO 85 86 30 2 1

B026

B015

B020

B030
C004

C009
30A

15A

30A
3A
+30

+15

+30
D008
2 5

D023

2 5
B037
7.5A
C007
C007

D030

2 6 1 3

31 T I 53M 53S 15 7 8 2 3 5 6 3 2 4 1 2 1
53

31

31b

53a

D0064860
I027
M005 I028 N006

Fig. 3468 - Windscreen wipers - Version with standard cab - Version with digital instrument panel - System
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D023 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D030 (M) - Wiring connector (Wiring loom 0.010.4516.3)
l D0320 (F) - Wiring connector (Wiring loom 0.016.0865.4/10)
l D0320 (F) - Wiring connector (Wiring loom 0.018.5825.4)
l D030 (M) - Wiring connector (Wiring loom 0.010.4516.3)
l I027 - Windscreen washer pump switch
l I028 - Windscreen wiper switch
l J004 - Relay
l J005 - Relay

40-890
Wiring diagrams
l M005 - Windscreen wiper intermittent timer
l N003 - Windscreen washer pump
l N006 - Windscreen wiper motor

B026
B030
A
J005

B015

B020
J004

D008

C004

D0064200

Fig. 3468 - Windscreen wipers - Version with standard cab - Version with digital instrument panel - Connector
positions
Table 723
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B026 Fuse (30A) 40-1205
B026 Fuse (30A) 40-1221

40-891
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 3468
D008 Wiring connector 40-1205
40-1220
40-1221

Fig. 3468
J004 Relay 40-1205
40-1221

Fig. 3468
J005 Relay 40-1205
40-1221

Fig. 3468

40-892
Wiring diagrams

N003

C009

D0064211

Fig. 3468 - Connector positions

Table 724
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1205
40-1221

Fig. 3468

40-893
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
N003 Windscreen wash- 40-1205
er pump 40-1221

Fig. 3468

D023

D008

D0064220

Fig. 3468 - Connector positions

40-894
Wiring diagrams
Table 725
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221

Fig. 3468
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 3468

B037 M005
I028 C007

D030

D023
I027

D0064231

Fig. 3468 - Connector positions

Table 726
Sys- P/N Description Characteristics/notes Position Wiring
tem
B037 Fuse (7.5A) 40-1228
B037 Fuse (7.5A) 40-1242

40-895
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1228
40-1242

Fig. 3468
D023 Wiring connector 40-1220
40-1228
40-1242
40-1220

Fig. 3468
D030 Wiring connector 40-1228
40-1242
40-1185
40-1185

Fig. 3468
I027 Windscreen wash- Drawing D0029620.eps 40-1228
er pump switch 40-1242

Fig. 3468
I028 Windscreen wiper Drawing D0029630.eps 40-1228
switch 40-1242

Fig. 3468
M005 Windscreen wiper 40-1228
intermittent timer 40-1242

Fig. 3468

40-896
Wiring diagrams

D030

N006
D0064250

Fig. 3468 - Connector positions

Table 727
Sys- P/N Description Characteristics/notes Position Wiring
tem
D030 Wiring connector 40-1228
40-1242
40-1185
40-1185

Fig. 3468
N006 Windscreen wiper 40-1185
motor

Fig. 3468

40-897
 Wiring diagrams
40.3.60 - S020 - Windscreen wipers - Version with high-visibility cab (R3 EVO 100 ->
20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)

I008
J005 J004
N004 N003
M M

10 9 5 6 2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 2 1 2 1

B026

B015

B020

B030
B024
C004

C004

C009
30A
75A

15A

30A
3A
+30

+15

+30
D008

6 2 5 3
D023

6 2 5 3
B037

B038
7.5A
7.5A

C007
C007

C007

C007
C007

D030

2 4 1 3

31 T I 53M 53S 15 6 5 1 3 2 8 7 3 2 4 1 2 3 8 7 6 5 1 3 2 8 7 2 1
53

31

31b

53a

M
D0063020
N005
M005 N006
I028 I027 I029

Fig. 3469 - Windscreen wipers - Version with high-visibility cab - System

l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D030 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D0320 (F) - Wiring connector (Wiring loom 0.011.3597.3)
l I008 - Road lights switch
l I027 - Windscreen washer pump switch
l I028 - Windscreen wiper switch

40-898
Wiring diagrams

I008
J005 J004
N004 N003
M M

10 9 5 6 2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 2 1 2 1

B026

B015

B020

B030
B024
C004

C004

C009
30A
75A

15A

30A
3A
+30

+15

+30
D008
6 2 5 3

D023

6 2 5 3
B037

B038
7.5A
7.5A

C007
C007

C007

C007
C007

D030

2 4 1 3

31 T I 53M 53S 15 6 5 1 3 2 8 7 3 2 4 1 2 3 8 7 6 5 1 3 2 8 7 2 1
53

31

31b

53a

M
D0063020
N005
M005 N006
I028 I027 I029

Fig. 3469 - Windscreen wipers - Version with high-visibility cab - System

l I029 - Rear window wiper switch
l J004 - Relay
l J005 - Relay
l M005 - Windscreen wiper intermittent timer
l N003 - Windscreen washer pump
l N004 - Rear window washer pump
l N005 - Rear window wiper motor
l N006 - Windscreen wiper motor

40-899
 Wiring diagrams

B026
B030
A
J005

B015
J004

B020 B024

D008

C004

I008
B

D0064280

Fig. 3470 - Windscreen wipers - Version with high-visibility cab - Connector positions
Table 728
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B024 Fuse (7.5A) 40-1209
B024 Fuse (7.5A) 40-1221
B026 Fuse (30A) 40-1209
B026 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221

40-900
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1209
40-1221

Fig. 3471
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 3472
I008 Road lights switch 40-1209
40-1221
J004 Relay 40-1209
40-1221

Fig. 3475
J005 Relay 40-1209
40-1221

Fig. 3476

40-901
 Wiring diagrams

N004

N003

C009

D0064210

Fig. 3477 - Connector positions

Table 729
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1209
40-1221

Fig. 3478

40-902
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
N003 Windscreen wash- 40-1209
er pump 40-1221

Fig. 3479
N004 Rear screen wash- 40-1209
er pump 40-1221

Fig. 3480

40-903
 Wiring diagrams

D023

D008

D0064220

Fig. 3481 - Connector positions

Table 730
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1209
40-1220
40-1221
40-1220

Fig. 3481

40-904
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1204
40-1220

Fig. 3482

40-905
 Wiring diagrams

M005
I029
N005

I028

D023 B037-B038

I027

C007
D030

D0064240

Fig. 3483 - Connector positions

Table 731
Sys- P/N Description Characteristics/notes Position Wiring
tem
B037 Fuse (7.5A) 40-1204
B038 Fuse (7.5A) 40-1204

40-906
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 3484
D023 Wiring connector 40-1204
40-1220

Fig. 3484
D030 Wiring connector 40-1204
40-1186

Fig. 3485
I027 Windscreen wash- 40-1204
er pump switch

Fig. 3487
Fig. 3486
I028 Windscreen wiper 40-1204
switch

Fig. 3489

Fig. 3488

40-907
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I029 Rear screen wiper 40-1204
switch

Fig. 3491

Fig. 3490
M005 Windscreen wiper 40-1204
intermittent timer

Fig. 3492
N005 02941435 Rear screen wiper 40-1204
motor

40-908
Wiring diagrams

D030

N006

D0064290

Fig. 3493 - Connector positions

Table 732
Sys- P/N Description Characteristics/notes Position Wiring
tem
D030 Wiring connector 40-1204
40-1186

Fig. 3493

40-909
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
N006 Windscreen wiper 40-1186
motor

Fig. 3494

40.3.61 - S020A - Windscreen wipers - Version with high-visibility cab - Version with
digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

40-910
Wiring diagrams

I008
J005 J004
N004 N003
M M

10 9 5 6 2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 2 1 2 1

B026

B015

B020

B030
B024
C004

C004

C009
30A
75A

15A

30A
3A
+30

+15

+30
D008
6 2 5 3

D023

6 2 5 3
B037

B038
7.5A
7.5A

C007
C007

C007

C007
C007

D030

2 4 1 3

31 T I 53M 53S 15 6 5 1 3 2 8 7 3 2 4 1 2 3 8 7 6 5 1 3 2 8 7 2 1
53

31

31b

53a

M
D0063020
N005
M005 N006
I028 I027 I029

Fig. 3495 - Windscreen wipers - Version with high-visibility cab - Version with digital instrument panel - System
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D030 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D0320 (F) - Wiring connector (Wiring loom 0.011.3597.3)
l I008 - Road lights switch
l I027 - Windscreen washer pump switch
l I028 - Windscreen wiper switch
l I029 - Rear window wiper switch
l J004 - Relay
l J005 - Relay

40-911
 Wiring diagrams
l M005 - Windscreen wiper intermittent timer
l N003 - Windscreen washer pump
l N004 - Rear window washer pump
l N005 - Rear window wiper motor
l N006 - Windscreen wiper motor

B026
B030
A
J005

B015
J004

B020 B024

D008

C004

I008
B

D0064280

Fig. 3496 - Windscreen wipers - Version with high-visibility cab - Version with digital instrument panel - Connec-
tor positions
Table 733
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221

40-912
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B024 Fuse (7.5A) 40-1205
B024 Fuse (7.5A) 40-1221
B026 Fuse (30A) 40-1205
B026 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 3497
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3498
I008 Road lights switch 40-1205
40-1221
J004 Relay 40-1205
40-1221

Fig. 3501
J005 Relay 40-1205
40-1221

Fig. 3502

40-913
 Wiring diagrams

N004

N003

C009

D0064210

Fig. 3503 - Connector positions

Table 734
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1205
40-1221

Fig. 3504

40-914
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
N003 Windscreen wash- 40-1205
er pump 40-1221

Fig. 3505
N004 Rear screen wash- 40-1205
er pump 40-1221

Fig. 3506

40-915
 Wiring diagrams

D023

D008

D0064220

Fig. 3507 - Connector positions

Table 735
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3507

40-916
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1204
40-1220

Fig. 3508

40-917
 Wiring diagrams

M005
I029
N005

I028

D023 B037-B038

I027

C007
D030

D0064240

Fig. 3509 - Connector positions

Table 736
Sys- P/N Description Characteristics/notes Position Wiring
tem
B037 Fuse (7.5A) 40-1204
B038 Fuse (7.5A) 40-1204

40-918
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 3510
D023 Wiring connector 40-1204
40-1220

Fig. 3510
D030 Wiring connector 40-1204
40-1186

Fig. 3511
I027 Windscreen wash- 40-1204
er pump switch

Fig. 3513
Fig. 3512
I028 Windscreen wiper 40-1204
switch

Fig. 3515

Fig. 3514

40-919
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I029 Rear screen wiper 40-1204
switch

Fig. 3517

Fig. 3516
M005 Windscreen wiper 40-1204
intermittent timer

Fig. 3518
N005 02941435 Rear screen wiper 40-1204
motor

40-920
Wiring diagrams

D030

N006

D0064290

Fig. 3519 - Connector positions

Table 737
Sys- P/N Description Characteristics/notes Position Wiring
tem
D030 Wiring connector 40-1204
40-1186

Fig. 3519

40-921
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
N006 Windscreen wiper 40-1186
motor

Fig. 3520

40.3.62 - S020D - Windscreen wipers - Version with high-visibility cab - Version with
digital instrument panel (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

40-922
Wiring diagrams

I008
J005 J004
N004 N003
M M

10 9 5 6 2 3 7 8 NC NO 85 86 30 NC NO 85 86 30 2 1 2 1

B026

B015

B020

B030
B024
C004

C004

C009
30A
75A

15A

30A
3A
+30

+15

+30
D008
6 2 5 3

D023

6 2 5 3
B037

B038
7.5A
7.5A

C007
C007

C007

C007
C007

D030

2 4 1 3

31 T I 53M 53S 15 6 5 1 3 2 8 7 3 2 4 1 2 3 8 7 6 5 1 3 2 8 7 2 1
53

31

31b

53a

M
D0063020
N005
M005 N006
I028 I027 I029

Fig. 3520 - Windscreen wipers - Version with high-visibility cab - Version with digital instrument panel - System
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D008 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D008 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D008 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D023 (F) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D023 (M) - Wiring connector (Wiring loom 0.016.0373.4/30)
l D030 (M) - Wiring connector (Wiring loom 0.015.6272.4/40)
l D0320 (F) - Wiring connector (Wiring loom 0.011.3597.3)
l I008 - Road lights switch
l I027 - Windscreen washer pump switch
l I028 - Windscreen wiper switch
l I029 - Rear window wiper switch
l J004 - Relay
l J005 - Relay

40-923
 Wiring diagrams
l M005 - Windscreen wiper intermittent timer
l N003 - Windscreen washer pump
l N004 - Rear window washer pump
l N005 - Rear window wiper motor
l N006 - Windscreen wiper motor

B026
B030
A
J005

B015
J004

B020 B024

D008

C004

I008
B

D0064280

Fig. 3520 - Windscreen wipers - Version with high-visibility cab - Version with digital instrument panel - Connec-
tor positions
Table 738
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221

40-924
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B024 Fuse (7.5A) 40-1205
B024 Fuse (7.5A) 40-1221
B026 Fuse (30A) 40-1205
B026 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 3520
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3520
I008 Road lights switch 40-1205
40-1221
J004 Relay 40-1205
40-1221

Fig. 3520
J005 Relay 40-1205
40-1221

Fig. 3520

40-925
 Wiring diagrams

N004

N003

C009

D0064210

Fig. 3520 - Connector positions

Table 739
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1205
40-1221

Fig. 3520

40-926
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
N003 Windscreen wash- 40-1205
er pump 40-1221

Fig. 3520
N004 Rear screen wash- 40-1205
er pump 40-1221

Fig. 3520

40-927
 Wiring diagrams

D023

D008

D0064220

Fig. 3520 - Connector positions

Table 740
Sys- P/N Description Characteristics/notes Position Wiring
tem
D008 Wiring connector 40-1205
40-1220
40-1221
40-1220

Fig. 3520

40-928
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D023 Wiring connector 40-1204
40-1220

Fig. 3520

40-929
 Wiring diagrams

M005
I029
N005

I028

D023 B037-B038

I027

C007
D030

D0064240

Fig. 3520 - Connector positions

Table 741
Sys- P/N Description Characteristics/notes Position Wiring
tem
B037 Fuse (7.5A) 40-1204
B038 Fuse (7.5A) 40-1204

40-930
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C007 Earthing point 7 40-1204

Fig. 3520
D023 Wiring connector 40-1204
40-1220

Fig. 3520
D030 Wiring connector 40-1204
40-1186

Fig. 3520
I027 Windscreen wash- 40-1204
er pump switch

Fig. 3520
Fig. 3520
I028 Windscreen wiper 40-1204
switch

Fig. 3520

Fig. 3520

40-931
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I029 Rear screen wiper 40-1204
switch

Fig. 3520

Fig. 3520
M005 Windscreen wiper 40-1204
intermittent timer

Fig. 3520
N005 02941435 Rear screen wiper 40-1204
motor

40-932
Wiring diagrams

D030

N006

D0064290

Fig. 3520 - Connector positions

Table 742
Sys- P/N Description Characteristics/notes Position Wiring
tem
D030 Wiring connector 40-1204
40-1186

Fig. 3520

40-933
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
N006 Windscreen wiper 40-1186
motor

Fig. 3520

40.3.63 - S021 - Transmission (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)
E002 E003 I015 I010
I011 J006 J004 J002 J003 H002
DOUBLE TRACTION

OBSTRUCTION

WHEEL SPEED

DIFFERENTIAL
+12/30

+12/30

HI-LO

SEAT
+12V

GND

GND

4 3 2 1 15 21 14 17 18 1 8 13 22 18 14 NC NO 86 30 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30 1 2 3 4 7 8 2 1 3 5 4 6 7 8 2 3

D013
C004
C004
C004

2 3 12 7 5 9

C003
B011

B010
7.5A

5A

B015

B021

B020

B006

B025
B030
7.5A
15A

30A

30A
10A

3A

B024
7.5A
+30

+15

+30
C004
C004

C003
D012b

D012a

D012

1 2 3
D007

D011
F

9 1 2 3 7 8 10 11
K007 B A A A A A A A A B B
K018

B1 B3 A7 B2 C5 A6 A2 A1 D1 D1 A2

K020 K016 L006 L008 K017 L007 K015

pos freq freq

t P

1 4 2 2 1 2 1 1 2 1 2 1 2 1 1 2 3
D019
D022

C004

3 1 2 6 7 10 8 4 9 5 11

18 1 2 8 4 19 14 13 12 24 9 15 7 20 21 22 23 5 25 26 2 1 1 1 2 3 1 2 3 1 2 1 2 1 2 10 9 5 6 2 3 7 8
REVERSE SPEED SENSOR
+30

+30

-31

SEAT SENSOR

-31

OIL TEMPERATURE
EV REVERSE +

EV REVERSE -
COMFORT CLUTCH

+5V

WHEEL SPEED

+15V

EV PROP +

EV PROP -
EV ON-OFF FRONT
CLUTCH PEDAL

CLUTCH PEDAL
DIG. CLUTCH S.

PRESS. SWITCH

freq
P P
K009

K019 I022 K010 L002 L001 L004 D0063030

I008
H003

Fig. 3521 - Transmission - System

l D007 (M) - Wiring connector (Wiring loom 0.015.1418.4/30)
l D007 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D007 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D007 (M) - Wiring connector (Wiring loom 0.015.1418.4/30)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D012 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D012 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D012a (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D012a (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D012b (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D012b (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D013 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D013 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D013 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D013 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D019 (M) - Wiring connector (Wiring loom 0.015.1998.4/10)
l D019 (F) - Wiring connector (Wiring loom 0.015.7023.4/50)

40-934
Wiring diagrams
E002 E003 I015 I010
I011 J006 J004 J002 J003 H002

DOUBLE TRACTION

OBSTRUCTION

WHEEL SPEED

DIFFERENTIAL
+12/30

+12/30

HI-LO

SEAT
+12V

GND

GND
4 3 2 1 15 21 14 17 18 1 8 13 22 18 14 NC NO 86 30 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30 1 2 3 4 7 8 2 1 3 5 4 6 7 8 2 3

D013
C004
C004
C004

2 3 12 7 5 9

C003
B011

B010
7.5A

5A

B015

B021

B020

B006

B025
B030
7.5A
15A

30A

30A
10A

3A

B024
7.5A
+30

+15

+30
C004
C004

C003
D012b

D012a

D012

1 2 3
D007

D011
F

9 1 2 3 7 8 10 11
K007 B A A A A A A A A B B
K018

B1 B3 A7 B2 C5 A6 A2 A1 D1 D1 A2

K020 K016 L006 L008 K017 L007 K015

pos freq freq

t P

1 4 2 2 1 2 1 1 2 1 2 1 2 1 1 2 3
D019
D022

C004
3 1 2 6 7 10 8 4 9 5 11

18 1 2 8 4 19 14 13 12 24 9 15 7 20 21 22 23 5 25 26 2 1 1 1 2 3 1 2 3 1 2 1 2 1 2 10 9 5 6 2 3 7 8
REVERSE SPEED SENSOR
+30

+30

-31

SEAT SENSOR

-31

OIL TEMPERATURE
EV REVERSE +

EV REVERSE -
COMFORT CLUTCH

+5V

WHEEL SPEED

+15V

EV PROP +

EV PROP -
EV ON-OFF FRONT
CLUTCH PEDAL

CLUTCH PEDAL
DIG. CLUTCH S.

PRESS. SWITCH

freq
P P
K009

K019 I022 K010 L002 L001 L004 D0063030

I008
H003

Fig. 3521 - Transmission - System

l D022 (M) - Wiring connector (Wiring loom 0.015.1998.4/10)
l D022 (F) - Wiring connector (Wiring loom 0.015.1418.4/30)
l E002 - Instrument panel
l E003 - Instrument panel
l H002 - Main gear lever - Hi/Lo buttons and clutch button
l H003 - Shuttle lever
l I008 - Road lights switch
l I010 - Differential lock control switch
l l011 - Clutch pedal switch
l I015 - 4WD control switch
l I022 - 4WD engagement control switch
l J002 - Relay
l J003 - Relay
l J004 - Relay
l J006 - Relay
l K007 - Operator present sensor
l K009 - Transmission oil filter clogging pressure switch
l K010 - Wheel speed sensor
l K015 - Engine speed sensor
l K016 - Shuttle sensor
l K017 - Oil temperature sensor
l K018 - Clutch oil pressure switch
l K019 - PALL filter clogging sensor
l K020 - Clutch pedal position sensor
l L001 - Differential lock control solenoid valve
l L002 - 4WD control solenoid valve
l L004 - Hi/Lo gear control solenoid valve
l L006 - Forward gear selection solenoid valve
l L007 - Reverse gear selection solenoid valve
l L008 - Proportional solenoid valve

40-935
 Wiring diagrams

B030
J003 B025

J002 J006
B015 A
B006
J004
B020
B024
B010 B021
B011

D007 E002

E003 C004
D012
D012b

D012a

A
I011

I008
B

D0064480

Fig. 3522 - Transmission - Connector positions

Table 743
Sys- P/N Description Characteristics/notes Position Wiring
tem
B006 Fuse (7.5A) 40-1209
B006 Fuse (7.5A) 40-1221
B010 Fuse (5A) 40-1209
B010 Fuse (5A) 40-1221
B011 Fuse (7.5A) 40-1209
B011 Fuse (7.5A) 40-1221
B015 Fuse (15A) 40-1209
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1209
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1209

40-936
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B021 Fuse (10A) 40-1221
B024 Fuse (7.5A) 40-1209
B024 Fuse (7.5A) 40-1221
B025 Fuse (30A) 40-1209
B025 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1209
40-1221

Fig. 3523
D007 Wiring connector 40-1209
40-1195
40-1221
40-1195

Fig. 3524
D012 Configuration con- 40-1209
nector 40-1221

Fig. 3525
Configuration con- 40-1209
nector 40-1221

Fig. 3525
Configuration con- 40-1209
nector 40-1221

Fig. 3525

40-937
 Wiring diagrams
Table 744
Sys- P/N Description Characteristics/notes Position Wiring
tem
E002 Instrument panel 40-1209
40-1221

Fig. 3526
E003 Instrument panel 40-1209
40-1221

Fig. 3527
I008 Road lights switch 40-1209
40-1221
I011 Clutch pedal switch 40-1221
1

Fig. 3530
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I011 Clutch pedal switch 40-1209
1

Fig. 3530
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
J002 Relay 40-1209
40-1221

Fig. 3531

40-938
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J003 Relay 40-1209
40-1221

Fig. 3532
J004 Relay 40-1209
40-1221

Fig. 3533
J006 Relay 40-1209
40-1221

Fig. 3534

40-939
 Wiring diagrams

I010
C003
I015

H002

D013

B
K007

D011

D0064490

Fig. 3535 - Connector positions

Table 745
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1209
40-1221

Fig. 3536

40-940
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1209
40-1214
40-1221
40-1214

Fig. 3537
D013 Wiring connector 40-1209
40-1209
40-1221
40-1221

Fig. 3538
H002 Main gear lever - 40-1209
Hi/Lo buttons and 40-1221
transmission split

Fig. 3539
I010 Differential lock 40-1209
40-1221
I015 4WD control switch 40-1209
40-1221
K007 Operator present 40-1209
sensor 40-1221

Fig. 3544

40-941
 Wiring diagrams

G19
D022
D007

X54
H003
G8

X53

X55
K020
G19
X54

X55

D0049450
D0064520

Fig. 3545 - Connector positions

Table 746
Sys- P/N Description Characteristics/notes Position Wiring
tem
D007 Wiring connector 40-1209
40-1195
40-1221
40-1195

Fig. 3545
D022 Wiring connector 40-1201
40-1195

Fig. 3546

40-942
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
H003 Shuttle lever 40-1195

Fig. 3547
K020 Clutch pedal posi- Pin 1 = power (Nominal 5.0V) 40-1195
tion sensor Pin 2 = earth
Pin 4 = analog signal

40-943
 Wiring diagrams

D011

L002

K010
L001
L004

D0064500

Fig. 3549 - Connector positions

Table 747
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1209
40-1214
40-1221
40-1214

Fig. 3549

40-944
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
K010 Wheels speed sen- This cannot be checked using an 40-1214
sor ordinary tester; use the ART.

Fig. 3550
L001 Differential lock 40-1214
control solenoid
valve

Fig. 3551
L002 4WD control sole- 40-1214
noid valve

Fig. 3552
L004 Hi/Lo drive control 40-1214
solenoid valve

Fig. 3553

40-945
 Wiring diagrams

G22

ECO

G23

G20
X65

X67

K009
X66

D019

I022
D0064510

Fig. 3554 - Connector positions

Table 748
Sys- P/N Description Characteristics/notes Position Wiring
tem
D019 Wiring connector 40-1214
40-1201

Fig. 3555

40-946
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I022 4WD engagement 40-1214
control switch

Fig. 3556
K009 Transmission oil Normally open contact 40-1214
filter clogging pres- Calibration pressure: 0.5 to 0.4
bar absolute pressure

40-947
 Wiring diagrams

D019

D022

K019

L007
L008
L006
K018
K017
K016
K015
D0064530

Fig. 3558 - Connector positions

40-948
Wiring diagrams
Table 749
Sys- P/N Description Characteristics/notes Position Wiring
tem
D019 Wiring connector 40-1214
40-1201

Fig. 3558
D022 Wiring connector 40-1201
40-1195

Fig. 3558
K015 Engine speed sen- 40-1201
sor

Fig. 3559
K016 Shuttle sensor This cannot be checked using an 40-1201
ordinary tester; use the ART.

Fig. 3560
K017 Oil temperature Resistance between pins 1 and 2 40-1201
sensor at 0±1 °C: 7351 Ohms
at 20±1 °C: 2812 Ohms
at 40±1 °C: 1199 Ohms
at 60±1 °C: 560.2 Ohms
at 80±1 °C: 283.2 Ohms
K018 Clutch oil pressure Normally closed (NC) contact 40-1201
Switching pressure: 4 bar
K019 PALL filter clogging Normally open contact (NO) 40-1201
sensor Differential switching pressure:
2.4 bar
Reset pressure: 1.8 bar

40-949
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
L006 Forward gear se- 40-1201
lection solenoid

Fig. 3564
L007 Reverse gear se- 40-1201
lection solenoid

Fig. 3565
L008 Solenoid-operated 40-1201
proportional valve

Fig. 3566

40-950
Wiring diagrams
40.3.64 - S021A - Transmission - Version with analog instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

E009 E008 I008 I010

J004 J002
HIDR./TRANSM.

DIFFERENTIAL
+15

+15

-31

A A B
10 12 12 B1 B6 NC NO 85 86 30 NC NO 85 86 30 10 9 5 6 2 3 7 8 7 8 2 3

D013
C004
C004

C004
2 3 5

C003
B015

B021

B020

B025
B018

B030
15A

30A

30A

30A
10A

3A

B024
7.5A
+15

+30
D011

B A A
B1 A7 A6

1 1 2

D0065230
K009

L001

Fig. 3567 - Transmission - Version with analog instrument panel - System

l D011 (M) - Wiring connector (Wiring loom 0.016.1999.4/10)
l D011 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l E008 - Instrument panel
l E009 - Instrument panel
l I008 - Road lights switch
l I010 - Differential lock control switch
l J002 - Relay
l J004 - Relay
l K009 - Transmission oil filter clogging pressure switch

40-951
 Wiring diagrams
l L001 - Differential lock control solenoid valve

B030

B025
J002
A
B015
J004

B018 B024
B020 B021

C004

E008
E009

I008
B

D0065630

Fig. 3568 - Transmission - Version with analog instrument panel - Connector positions
Table 750
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1238
B018 Fuse (15A) 40-1238
B020 Fuse (3A) 40-1238
B021 Fuse (10A) 40-1238
B024 Fuse (7.5A) 40-1238
B025 Fuse (30A) 40-1238
B030 Fuse (30A) 40-1238

40-952
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1238

Fig. 3569
E008 Instrument panel 40-1238
E009 Instrument panel 40-1238
I008 Road lights switch 40-1238

Fig. 3570 Fig. 3571

J002 Relay 40-1238

Fig. 3572
J004 Relay 40-1238

Fig. 3573

40-953
 Wiring diagrams

I010
C003

D013

D011

D0065640

Fig. 3574 - Connector positions

Table 751
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1238

Fig. 3575

40-954
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1233
40-1238

Fig. 3576
D013 Wiring connector 40-1238
40-1238

Fig. 3577
I010 Differential lock 40-1238
control switch

Fig. 3578
Fig. 3579

40-955
 Wiring diagrams

D011

L001

D0065650

Fig. 3580 - Connector positions

Table 752
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1233
40-1238

Fig. 3580

40-956
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
L001 Differential lock 40-1233
control solenoid
valve

Fig. 3581

G22

G23

G20
X65

X67

K009
X66

D0065660

Fig. 3582 - Connector positions

40-957
 Wiring diagrams
Table 753
Sys- P/N Description Characteristics/notes Position Wiring
tem
K009 Transmission oil Normally open contact 40-1233
filter clogging pres- Calibration pressure: 0.5 to 0.4
bar absolute pressure

40-958
Wiring diagrams
40.3.65 - S021D - Transmission - Version with digital instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
E002 E003 I010
J004
DOUBLE TRACTION

OBSTRUCTION

DIFFERENTIAL
+12/30

+12/30

+12V

GND

GND
15 21 14 17 18 8 13 14 NC NO 85 86 30 7 8 2 3

D013
C004
C004

2 3 5 9

C003
B010
5A

B015

B021

B020

B030
15A

30A
10A

3A

B024
7.5A
+30

+30
+15

C003
D011

B A A A A
B1 A6 A1 D1 B1
C004

1 1 2 10 9 5 6 2 3 7 8
P
K009

L001
I008 D0064820

Fig. 3584 - Transmission - Version with digital instrument panel - System

l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D013 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D013 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D013 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)

40-959
 Wiring diagrams
l D013 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l E002 - Instrument panel
l E003 - Instrument panel
l I008 - Road lights switch
l I010 - Differential lock control switch
l J004 - Relay
l K009 - Transmission oil filter clogging pressure switch
l L001 - Differential lock control solenoid valve

B030

B015 A

J004
B020
B024
B010 B021

E002

E003 C004

I008
B

D0064481

Fig. 3585 - Transmission - Version with digital instrument panel - Connector positions
Table 754
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1205
B010 Fuse (5A) 40-1221

40-960
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1205
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1205
B021 Fuse (10A) 40-1221
B024 Fuse (7.5A) 40-1205
B024 Fuse (7.5A) 40-1221
B030 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1221
C004 Earthing point 4 40-1205
40-1221

Fig. 3586
E002 Instrument panel 40-1205
40-1221

Fig. 3587
E003 Instrument panel 40-1205
40-1221

Fig. 3588
I008 Road lights switch 40-1205
40-1221
J004 Relay 40-1205
40-1221

Fig. 3591

40-961
 Wiring diagrams

I010
C003

D013

D011

D0064491

Fig. 3592 - Connector positions

Table 755
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1205
40-1221

Fig. 3593

40-962
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1205
40-1212
40-1221
40-1212

Fig. 3594
D013 Wiring connector 40-1205
40-1205
40-1221
40-1221

Fig. 3595
I010 Differential lock 40-1205
40-1221

40-963
 Wiring diagrams

D011

L001

D0064501

Fig. 3598 - Connector positions

Table 756
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1205
40-1212
40-1221
40-1212

Fig. 3598

40-964
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
L001 Differential lock 40-1212
control solenoid
valve

Fig. 3599

G22

ECO

G23

G20
X65

X67

K009
X66

D0064511

Fig. 3600

40-965
 Wiring diagrams
Table 757
Sys- P/N Description Characteristics/notes Position Wiring
tem
K009 Transmission oil Normally open contact 40-1212
filter clogging pres- Calibration pressure: 0.5 to 0.4
bar absolute pressure

40-966
Wiring diagrams
40.3.66 - S022 - PTO (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
I004 I005
E003 E002 J004
I006 I007

1 2 2 3 7 8 2 3 7 8 2 1 NC NO 85 86 30

PTO SYNCRO
FRONT PTO

REAR PTO

D013
PTO 1000
PTO ECO

PTO 540

+12/30

+12/30

+12V
GND

GND

C009

C003

C004
4 1 3 2
13 16 8 9 24 10 11 15 21 13 14

C003
C004

B030
B015

B021

B020
B010

15A

30A
10A

3A
5A
+30

+30
+15
C009

C004

B024
7.5A
D011

A B B A A A B
B3 C3 A4 A8 A1 D1 D1

10 9 5 6 2 3 7 8
C003
C009

C009

I008
C004

2 3 2 1 2 3 4 1 4 1 14 9 2 1 17 6 7 12 15
REAR PTO SWITCH
FRONT PTO LED

REAR PTO LED

+15
REAR PTO EV

FRONT PTO EV
GND

D+
FRONT PTO SWITCH

D005

2 9 8
I023 L003 I021 I003 I002
D006

M003
2 1 9

2 1

L005
A003

D0062870

Fig. 3602 - PTO - System

l A003 - Alternator “D+”
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D006 (M) - Wiring connector (Wiring loom 0.008.0913.3)
l D006 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)

40-967
 Wiring diagrams
l D013 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D013 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l E002 - Instrument panel
l E003 - Instrument panel
l I002 - 540 PTO control switch
l I003 - 1000 PTO control switch
l I004 - Front PTO control switch
l I005 - Rear PTO control switch
l I006 – LH rear PTO control switch (on fender)
l I007 – RH rear PTO control switch (on fender)
l I008 - Road lights switch
l I021 - PTO control switch ECO
l I023 - PTO control switch ECO
l J004 - Relay
l L003 - Rear PTO control solenoid valve
l L005 - Front PTO control solenoid valve
l M003 - Rear PTO control unit

40-968
Wiring diagrams

B030

B015
A
J004

B020
B010 B024
B021

E002

E003 C004

D005

I008

D0064410

Fig. 3603 - PTO - Connector positions

Table 758
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1209
B015 Fuse (15A) 40-1209
B020 Fuse (3A) 40-1209
B021 Fuse (10A) 40-1209
B024 Fuse (7.5A) 40-1209
B030 Fuse (30A) 40-1209

40-969
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1209

Fig. 3604
D005 Wiring connector 40-1234
40-1236
40-1209
40-1209

Fig. 3605
E002 Instrument panel 40-1209

Fig. 3606
E003 Instrument panel 40-1209

Fig. 3607
I008 Road lights switch 40-1209

Fig. 3608 Fig. 3609

J004 Relay 40-1209

Fig. 3610

40-970
Wiring diagrams

I005
I004
C003

I007
M003
D013

D011

C009
I003
I002
I006
D0064420

Fig. 3611 - Connector positions

Table 759
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1209

Fig. 3612

40-971
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1209

Fig. 3613
D011 Wiring connector 40-1209
40-1214

Fig. 3614
D013 Wiring connector 40-1209
40-1209

Fig. 3615
I002 540 PTO control 40-1209
1
switch

Fig. 3616
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally Fig. 3617
open contact (NO)
I003 1000 PTO control 40-1209
1
switch

Fig. 3617
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally Fig. 3618
open contact (NO)

40-972
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I004 Front PTO control 40-1209
switch

Fig. 3620
Fig. 3619
I005 Rear PTO control 40-1209
switch

Fig. 3621
Fig. 3620
I006 LH rear PTO con- Resistance between Pin 1 and 40-1209
trol switch (on Pin 2 with button pressed: 3.9
fender) Ohms

Fig. 3622
I007 Rh rear PTO con- Resistance between Pin 1 and 40-1209
trol switch (on Pin 2 with button pressed: 3.9
fender) Ohms

Fig. 3623
M003 Rear PTO ECU 40-1209

Fig. 3624

40-973
 Wiring diagrams

D011

AA

L003

D0064430

Fig. 3625 - Connector positions

Table 760
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1209
40-1214

Fig. 3625

40-974
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
L003 Rear PTO control Pin 1 = earth 40-1214
solenoid valve Pin 2 = power
Impedance between Pin1 and
Pin2: ~ 8 Ohm (at 20 °C)

Fig. 3626

G22

ECO

I023
A

G23

G20
X65

X67

I021

X66

D0064460

Fig. 3627 - Connector positions

40-975
 Wiring diagrams
Table 761
Sys- P/N Description Characteristics/notes Position Wiring
tem
I021 P.T.O. engagement 40-1214
switch ECO

CB A
Fig. 3628
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 2 and pin 3: normally
open contact (NO)
I023 P.T.O. engagement Between pin 2 and pin 3: normally 40-1214
switch ECO closed contact (NC)
Between pin 1 and pin 4: normally
open contact (NO)
With switch free of levers

40-976
Wiring diagrams

D005

A003

D0064470

Fig. 3631 - Connector positions - Version with front battery

40-977
 Wiring diagrams
Table 762
Sys- P/N Description Characteristics/notes Position Wiring
tem
A003 01183630 Alternator “D+” 40-1234
40-1236

Fig. 3632
D005 Wiring connector 40-1234
40-1236
40-1209
40-1209

Fig. 3632

40-978
Wiring diagrams
D005

A003

L005
D006
D006440

L005
D006

Fig. 3633 - Connector positions - Version with lateral battery

40-979
 Wiring diagrams
Table 763
Sys- P/N Description Characteristics/notes Position Wiring
tem
A003 01183630 Alternator “D+” 40-1234
40-1236

Fig. 3633
D005 Wiring connector 40-1234
40-1236
40-1209
40-1209

Fig. 3633
D006 Wiring connector 40-1236
40-1180

Fig. 3634
L005 Front PTO control 40-1180
solenoid valve

40-980
Wiring diagrams
40.3.67 - S022A - PTO - Version with analog instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001)
E008 I004 I005
J004 J002

2 3 7 8 4 5 2 3 7 8 4 5 NC NO 85 86 30 NC NO 85 86 30
FRONT SIDE PTO
PTO SYNCRO

REAR PTO
+15

D013
-31

B1 B9 B
12
B B8
10

4 1 3 2

C004
C003
C004

B030

B018
B015

B021

B020

B025
15A

30A
10A

15A

30A
3A

+30
+15
C009
D011

C004

B A A A B A
A4 A1 D1 B1 C3 A7
D005

2 9
C004

B024
7.5A
D006

2 1

2 3 2 1 2 1 10 9 5 6 2 3 7 8

I021 L003 L005

D0065010
I008

Fig. 3635 - PTO - Version with analog instrument panel - System

l D005 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D005 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D006 (M) - Wiring connector (Wiring loom 0.008.0913.3)
l D006 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D011 (M) - Wiring connector (Wiring loom 0.016.1999.4/10)
l D011 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D013 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l E008 - Instrument panel
l I004 - Front PTO control switch
l I005 - Rear PTO control switch
l I008 - Road lights switch

40-981
 Wiring diagrams
l I021 - PTO control switch ECO
l J002 - Relay
l J004 - Relay
l L003 - Rear PTO control solenoid valve
l L005 - Front PTO control solenoid valve

B030

J002
B025
A
B015 J004

B018 B024
B020 B021

C004

D005

E008

I008

D0065690

Fig. 3636 - PTO - Version with analog instrument panel - Connector positions
Table 764
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1238
B018 Fuse (15A) 40-1238
B020 Fuse (3A) 40-1238
B021 Fuse (10A) 40-1238
B024 Fuse (7.5A) 40-1238

40-982
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B025 Fuse (30A) 40-1238
B030 Fuse (30A) 40-1238
C004 Earthing point 4 40-1238

Fig. 3637
D005 Wiring connector 40-1238
40-1238
40-1234
40-1236

Fig. 3638
E008 Instrument panel 40-1238
I008 Road lights switch 40-1238

Fig. 3639 Fig. 3640

J002 Relay 40-1238

Fig. 3641
J004 Relay 40-1238

Fig. 3642

40-983
 Wiring diagrams

I005
I004
C003

D013

D011

C009

D0065700

Fig. 3643 - Connector positions

Table 765
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1238

Fig. 3644

40-984
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1238

Fig. 3645
D011 Wiring connector 40-1233
40-1238

Fig. 3646
D013 Wiring connector 40-1238
40-1238

Fig. 3647
I004 Front PTO control 40-1238
switch

Fig. 3649
Fig. 3648
I005 Rear PTO control 40-1238
switch

Fig. 3650

40-985
 Wiring diagrams

D011

L003

D0065710

Fig. 3651 - Connector positions

Table 766
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1233
40-1238

Fig. 3651

40-986
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
L003 Rear PTO control Pin 1 = earth 40-1233
solenoid valve Pin 2 = power
Impedance between Pin1 and
Pin2: ~ 8 Ohm (at 20 °C)

Fig. 3652

I021

D0065720

Fig. 3653 - Connector positions

40-987
 Wiring diagrams
Table 767
Sys- P/N Description Characteristics/notes Position Wiring
tem
I021 P.T.O. engagement 40-1233
switch ECO

CB A
Fig. 3654
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 2 and pin 3: normally
open contact (NO)

40-988
Wiring diagrams

D005

L005
D006
D0065730

Fig. 3656 - Connector positions

40-989
 Wiring diagrams
Table 768
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1238
40-1238
40-1234
40-1236

Fig. 3656
D006 Wiring connector 40-1236
40-1180

Fig. 3657
L005 Front PTO control 40-1180
solenoid valve

40-990
Wiring diagrams
40.3.68 - S022D - PTO - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001)
I004 I005
E003 E002 J004
I006 I007

1 2 2 3 7 8 2 3 7 8 2 1 NC NO 85 86 30

PTO SYNCRO
FRONT PTO

REAR PTO

D013
PTO 1000
PTO ECO

PTO 540

+12/30

+12/30

+12V
GND

GND

C009

C003

C004
4 1 3 2
13 16 8 9 24 10 11 15 21 13 14

C003
C004

B030
B015

B021

B020
B010

15A

30A
10A

3A
5A
+30

+30
+15
C009

C004

B024
7.5A
D011

A B B A A A B
B3 C3 A4 A8 A1 D1 D1

10 9 5 6 2 3 7 8
C003
C009

C009

I008
C004

2 3 2 1 2 3 4 1 4 1 14 9 2 1 17 6 7 12 15
REAR PTO SWITCH
FRONT PTO LED

REAR PTO LED

+15
REAR PTO EV

FRONT PTO EV
GND

D+
FRONT PTO SWITCH

D005

2 9 8
I023 L003 I021 I003 I002
D006

M003
2 1

2 1 D+

L005
A003

D0062870

Fig. 3658 - PTO - Version with digital instrument panel - System

l A003 - Alternator “D+”
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D006 (M) - Wiring connector (Wiring loom 0.008.0913.3)
l D006 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)

40-991
 Wiring diagrams
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D013 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D013 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l E002 - Instrument panel
l E003 - Instrument panel
l I002 - 540 PTO control switch
l I003 - 1000 PTO control switch
l I004 - Front PTO control switch
l I005 - Rear PTO control switch
l I006 – LH rear PTO control switch (on fender)
l I007 – RH rear PTO control switch (on fender)
l I008 - Road lights switch
l I021 - PTO control switch ECO
l I023 - ECO PTO control switch
l J004 - Relay
l L003 - Rear PTO control solenoid valve
l L005 - Front PTO control solenoid valve
l M003 - Rear PTO control unit

40-992
Wiring diagrams

B030

B015
A
J004

B020
B010 B024
B021

E002

E003 C004

D005

I008

D0064410

Fig. 3659 - PTO - Version with digital instrument panel - Connector positions
Table 769
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1205
B015 Fuse (15A) 40-1205
B020 Fuse (3A) 40-1205
B021 Fuse (10A) 40-1205
B024 Fuse (7.5A) 40-1205
B030 Fuse (30A) 40-1205

40-993
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1205

Fig. 3660
D005 Wiring connector 40-1234
40-1236
40-1205
40-1205

Fig. 3661
E002 Instrument panel 40-1205

Fig. 3662
E003 Instrument panel 40-1205

Fig. 3663
I008 Road lights switch 40-1205

Fig. 3664 Fig. 3665

J004 Relay 40-1205

Fig. 3666

40-994
Wiring diagrams

I005
I004
C003

I007
M003
D013

D011

C009
I003
I002
I006
D0064420

Fig. 3667 - Connector positions

Table 770
Sys- P/N Description Characteristics/notes Position Wiring
tem
I002 540 PTO control 40-1205
1
switch

Fig. 3668
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally Fig. 3669
open contact (NO)

40-995
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I003 1000 PTO control 40-1205
1
switch

Fig. 3669
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally Fig. 3670
open contact (NO)
I004 Front PTO control 40-1205
switch

Fig. 3671
Fig. 3671
I005 Rear PTO control 40-1205
switch

Fig. 3672
Fig. 3671
I006 Lh rear PTO control Resistance between Pin 1 and 40-1205
switch (on fender) Pin 2 with button pressed: 3.9
Ohms

Fig. 3673
I007 Rh rear PTO con- Resistance between Pin 1 and 40-1205
trol switch (on Pin 2 with button pressed: 3.9
fender) Ohms

Fig. 3674

40-996
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1205

Fig. 3675
C009 Earthing point 9 40-1205

Fig. 3676
D011 Wiring connector 40-1205
40-1212

Fig. 3677
D013 Wiring connector 40-1205
40-1205

Fig. 3678
M003 Rear PTO ECU 40-1205

Fig. 3679

40-997
 Wiring diagrams

D011

AA

L003

D0064430

Fig. 3680 - Connector positions

Table 771
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1205
40-1212

Fig. 3680

40-998
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
L003 Rear PTO control Pin 1 = earth 40-1212
solenoid valve Pin 2 = power
Impedance between Pin1 and
Pin2: ~ 8 Ohm (at 20 °C)

Fig. 3681

G22

ECO

I023
A

G23

G20
X65

X67

I021

X66

D0064460

Fig. 3682 - Connector positions

40-999
 Wiring diagrams
Table 772
Sys- P/N Description Characteristics/notes Position Wiring
tem
I021 P.T.O. engagement 40-1212
switch ECO

CB A
Fig. 3683
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 2 and pin 3: normally
open contact (NO)
I023 P.T.O. engagement Between pin 2 and pin 3: normally 40-1212
switch ECO closed contact (NC)
Between pin 1 and pin 4: normally
open contact (NO)
With switch free of levers

40-1000
Wiring diagrams

D005

A003

L005
D006
D0064440

Fig. 3686 - Connector positions

40-1001
 Wiring diagrams
Table 773
Sys- P/N Description Characteristics/notes Position Wiring
tem
A003 01183630 Alternator “D+” 40-1234
40-1236

Fig. 3687
D005 Wiring connector 40-1234
40-1236
40-1205
40-1205

Fig. 3687
D006 Wiring connector 40-1236
40-1180

Fig. 3688
L005 Front PTO control 40-1180
solenoid valve

40-1002
Wiring diagrams
40.3.69 - S023 - Can Bus (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)

E003 E002 M002

P003

-31 ELECTR.

-31 ELECTR.
CAN RES

CAN H

+12/30

+12/30

CAN H.
CAN L

CAN L
+12V
GND

GND

+15
13 4 3 2 8 15 21 14 4 3 1 2 12 13 14 2 1

C009
C004

C004
B021

B022
7.5A
10A
B011
B010

7.5A
5A

+15
+30

C004
D007

1 2 3 4 5

1 2 3 4 1 2 8 9 10 11 15
CAN H

+15
+30

+30

-31

-31

CAN L

P007 D0062880
H003

Fig. 3689 - Can Bus - System

l D007 (M) - Wiring connector (Wiring loom 0.015.1418.4/30)
l D007 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D007 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D007 (M) - Wiring connector (Wiring loom 0.015.1418.4/30)
l E002 - Instrument panel
l E003 - Instrument panel
l H003 - Shuttle lever
l M002 - Engine ECU
l P003 - CAN BUS diagnostics port
l P007 - CAN BUS auxiliary socket

40-1003
 Wiring diagrams

A
B021

B010

B011
B022

D007
E002

E003 C004

P003
B

D0064380

Fig. 3690 - Can bus - Connector positions

Table 774
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1209
B010 Fuse (5A) 40-1221
B011 Fuse (7.5A) 40-1209
B011 Fuse (7.5A) 40-1221
B021 Fuse (10A) 40-1209
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1209
B022 Fuse (7.5A) 40-1221

40-1004
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1209
40-1221

Fig. 3691
D007 Wiring connector 40-1209
40-1195
40-1221
40-1195

Fig. 3692
E002 Instrument panel 40-1209
40-1221

Fig. 3693
E003 Instrument panel 40-1209
40-1221

P003 CAN BUS diagnos- 40-1209

tics socket 40-1221

Fig. 3694

40-1005
 Wiring diagrams

M002

C009

D0064390

Fig. 3695 - Connector positions

Table 775
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1209
40-1221

Fig. 3696

40-1006
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
M002 02959599 Engine control unit 40-1209
40-1221

Fig. 3697

P007
D007

H003
G8

X53

G19
X54

X55

D0064400

Fig. 3698 - Connector positions

40-1007
 Wiring diagrams
Table 776
Sys- P/N Description Characteristics/notes Position Wiring
tem
D007 Wiring connector 40-1209
40-1195
40-1221
40-1195

Fig. 3698
H003 Shuttle lever 40-1195
40-1195

Fig. 3699
P007 CAN BUS auxiliary 40-1195
socket

Fig. 3700

40.3.70 - S023A - Can bus - Version with analog instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

M002

P003
-31 ELECTR.

-31 ELECTR.
CAN H.

CAN L

+15

1 2 4 3 12 13 14 2 1
C004

C009
B021

B022
7.5A
10A

D0065410
+15

Fig. 3701 - Can bus - Version with analog instrument panel - System

40-1008
Wiring diagrams
l M002 - Engine ECU
l P003 - CAN BUS diagnostics port

B021 B022

C004

P003

D0065670

Fig. 3702 - Can bus - Version with analog instrument panel - Connector positions
Table 777
Sys- P/N Description Characteristics/notes Position Wiring
tem
B021 Fuse (10A) 40-1238
B022 Fuse (7.5A) 40-1238

40-1009
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1238

Fig. 3703
P003 CAN BUS diagnos- 40-1238
tics socket

Fig. 3704

40-1010
Wiring diagrams

M002

C009

D0065680

Fig. 3705 - Connector positions

Table 778
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1238

Fig. 3706

40-1011
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
M002 02959599 Engine control unit 40-1238

Fig. 3707

40.3.71 - S023D - Can bus - Version with digital instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

E003 E002 M002

P003

-31 ELECTR.

-31 ELECTR.
CAN RES

CAN H

+12/30

+12/30

CAN H.
CAN L

CAN L
+12V
GND

GND

+15
13 4 3 2 8 15 21 14 4 3 1 2 12 13 14 2 1

C009
C004

C004
B021

B022
7.5A
B010

10A
5A

+15
+30

D0064830

Fig. 3708 - Can bus - Version with digital instrument panel - System
l E002 - Instrument panel
l E003 - Instrument panel
l M002 - Engine ECU
l P003 - CAN BUS diagnostics port

40-1012
Wiring diagrams

A
B021

B010

B022

E002

E003 C004

P003
B

D0064381

Fig. 3709 - Can bus - Version with digital instrument panel - Connector positions
Table 779
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1205
B010 Fuse (5A) 40-1221
B021 Fuse (10A) 40-1205
B021 Fuse (10A) 40-1221
B022 Fuse (7.5A) 40-1205
B022 Fuse (7.5A) 40-1221

40-1013
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1205
40-1221

Fig. 3710
E002 Instrument panel 40-1205
40-1221

Fig. 3711
E003 Instrument panel 40-1205
40-1221

Fig. 3712
P003 CAN BUS diagnos- 40-1205
tics socket 40-1221

Fig. 3713

40-1014
Wiring diagrams

M002

C009

D0064390

Fig. 3714 - Connector positions

Table 780
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1205
40-1221

Fig. 3715

40-1015
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
M002 02959599 Engine control unit 40-1205
40-1221

Fig. 3716

40.3.72 - S024 - Brakes (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
E003

E002

E004b
E004a

E004
J002 J004 J006 I013
TRAILER PRESSURE
BRAKES OIL LEVEL

F009
HAND BRAKE

PARK BRAKE

+12/30

+12/30
+12V
GND

GND

13 8 7 12 22 26 14 21 15 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30 2 1 + - G 1 2 3 4 1 2

C004
C004

C004

C004

C004
C004

C003
B010
B006

B025

B030

B009
B020
B021

B015

B024
7.5A

30A

30A

15A

15A

7.5A
5A
3A
10A
C004

D011
+30
+15
D005

D011

C008

9 10 B
A5
A
D6
A
A8
A
A1
A
D1
B
D1
B
D8
A
D4
C004
A
B8
D021

1 2 1 2 10 9 5 6 2 3 7 8 1 2 1 2
STOP
-31

P P

P
P006 F008
K013

K002 D010
K008

I008 K025
D018

1 2

1 2

D0063040
L009

Fig. 3717 - Brakes - System

40-1016
Wiring diagrams
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D010 (F) - Park Brake switch (Wiring loom 0.015.7021.4/70)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D018 (M) - Wiring connector (Wiring loom 0.016.1001.4/20)
l D018 (F) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D021 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D021 (F) - Wiring connector (Wiring loom 0.014.1645.4/10)
l E002 - Instrument panel
l E003 - Instrument panel
l E004 - Trailer pressure indicator
l E004a - Trailer pressure indicator
l E004b- Trailer pressure indicator
l F008 - LH rear light
l F009 - RH rear light
l I008 - Road lights switch
l I013 - Brake pedal switch
l J002 - Relay
l J004 - Relay
l J006 - Relay
l K002 - Brake fluid level sensor
l K008 - Park Brake pressure switch
l K013 - Hydraulic trailer braking valve pressure switch
l K025 - Compressed air pressure sensor
l L009 - Trailer parking brake solenoid valve

40-1017
 Wiring diagrams
B030

B025
J002
J006
B015
A
B020
J004

B006
B009
B021 B024
B010

E002 C004
I013
E003

D005 E004
E004a
E004b

I008

D0064300

Fig. 3718 - Brakes - Connector positions

Table 781
Sys- P/N Description Characteristics/notes Position Wiring
tem
B006 Fuse (7.5A) 40-1209
B009 Fuse (15A) 40-1209
B010 Fuse (5A) 40-1209
B015 Fuse (15A) 40-1209
B020 Fuse (3A) 40-1209
B021 Fuse (10A) 40-1209
B024 Fuse (7.5A) 40-1209
B025 Fuse (30A) 40-1209
B030 Fuse (30A) 40-1209

40-1018
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1209

Fig. 3719
D005 Wiring connector 40-1234
40-1236
40-1209
40-1209

Fig. 3720
E002 Instrument panel 40-1209

Fig. 3721
E003 Instrument panel 40-1209

Fig. 3722
E004 Trailer pressure in- Pin S = input from sensor 40-1209
dicator Pin + = 15V power supply
Pin - = earth
Trailer pressure in- Pin S = input from sensor 40-1209
dicator Pin + = 15V power supply
Pin - = earth
Trailer pressure in- Pin S = input from sensor 40-1209
dicator Pin + = 15V power supply
Pin - = earth
I008 Road lights switch 40-1209

Fig. 3724 Fig. 3725

40-1019
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I013 Brake pedal switch 40-1209
1

Fig. 3726
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally Fig. 3727
open contact (NO)
J002 Relay 40-1209

Fig. 3728
J004 Relay 40-1209

Fig. 3729
J006 Relay 40-1209

Fig. 3730

40-1020
Wiring diagrams

C003
F009

C008

D010

D011

K008

D0064310

F008

Fig. 3731 - Connector positions

Table 782
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1209

Fig. 3732

40-1021
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C008 Earthing point 8 40-1209

Fig. 3733
D010 Park Brake switch 40-1209

Fig. 3734
D011 Wiring connector 40-1209
40-1214

Fig. 3735
F008 LH rear light 40-1209

Fig. 3736
F009 RH rear light 40-1209

Fig. 3737
K008 Park Brake pres- Normally open contact (NO) 40-1209
Switching pressure: 15 bar

40-1022
Wiring diagrams

P006

D018

A K013

D021

D0064320

Fig. 3739 - Connector positions

Table 783
Sys- P/N Description Characteristics/notes Position Wiring
tem
D018 Wiring connector 40-1214
40-1232

Fig. 3740
D021 Wiring connector 40-1214
40-1191
K013 Hydraulic trailer Normally closed (NC) contact 40-1214
Switching pressure: 11 bar

40-1023
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
P006 Trailer socket 40-1214

Fig. 3742

40-1024
Wiring diagrams

D011

D0064330

Fig. 3743 - Connector positions

Table 784
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1209
40-1214

Fig. 3743

40-1025
 Wiring diagrams

L009
D018

D0064340

Fig. 3744 - Connector positions

Table 785
Sys- P/N Description Characteristics/notes Position Wiring
tem
D018 Wiring connector 40-1214
40-1232

Fig. 3744
L009 Trailer parking Pin 1 = power 40-1232
brake control sole- Pin 2 = earth
noid valve Impedance between Pin1 and
Pin2: ~ 8 Ohm (at 20 °C)

40-1026
Wiring diagrams

D021

K025

G23

X77

D0064350

Fig. 3745 - Connector positions

Table 786
Sys- P/N Description Characteristics/notes Position Wiring
tem
D021 Wiring connector 40-1214
40-1191
K025 Compressed air Power 12V DC 40-1191
pressure sensor Resistance at 0 bar 10-13 Ohm
Resistance at 6 bar 119-129 Ohm

40-1027
 Wiring diagrams

K002 D005

D0064370

Fig. 3746 - Connector positions - Version with lateral battery

40-1028
Wiring diagrams

K002 D005

D0064360

Fig. 3747 - Connector positions - Version with front battery

40-1029
 Wiring diagrams
Table 787
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
40-1236
40-1209
40-1209

Fig. 3747
K002 Brake fluid level 40-1234
sensor 40-1236

Fig. 3748

40-1030
Wiring diagrams
40.3.73 - S024A - Brakes - Version with analog instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

E008
E009

E004b
E004a

E004
J002 J004 I013
TRAILER PRESSURE

F009
BRALE OIL LEV.

+15
-31

A
B1 A6 A9 12 NC NO 85 86 30 NC NO 85 86 30 2 1 + - G 1 2 3 4 1 2

C004
C004

C004

C004

C004
C004

B025

B030

B009
B020
B021

B015

B024
30A

30A

15A

15A

7.5A
3A
10A

C003
+30
+15
C004

D011
C009

C004
D005
D011

A A A A A
D6 A1 D1 B1 D4

10 9
A
B8
D021

1 2 2 1 10 9 5 6 2 3 7 8 3 6 1 2
-31

STOP

P
P006 F008
K013

I017 K002
I008 K025 D0065250

Fig. 3749 - Brakes - Version with analog instrument panel - System

l D005 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D005 (M) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D011 (M) - Wiring connector (Wiring loom 0.016.1999.4/10)
l D011 (F) - Wiring connector (Wiring loom 0.016.2002.4/60)
l D021 (M) - Wiring connector (Wiring loom 0.016.1999.4/10)
l D021 (F) - Wiring connector (Wiring loom 0.014.1645.4/10)
l E004 - Trailer pressure indicator
l E004a - Trailer pressure indicator
l E004b- Trailer pressure indicator
l E008 - Instrument panel
l E009 - Instrument panel
l F008 - LH rear light
l F009 - RH rear light
l I008 - Road lights switch
l I013 - Brake pedal switch
l I017 - Parking brake switch
l J002 - Relay

40-1031
 Wiring diagrams
l J004 - Relay
l K002 - Brake fluid level sensor
l K013 - Hydraulic trailer braking valve pressure switch
l K025 - Compressed air pressure sensor
l P006 - Trailer socket

B030

J002

B015 B025
A
B020
J004

B009 B021 B024

C004
I013

D005
E004
E004a
E004b

E008

E009

I008

D0065740

Fig. 3750 - Brakes - Version with analog instrument panel - Connector positions
Table 788
Sys- P/N Description Characteristics/notes Position Wiring
tem
B009 Fuse (15A) 40-1238
B015 Fuse (15A) 40-1238
B020 Fuse (3A) 40-1238
B021 Fuse (10A) 40-1238
B024 Fuse (7.5A) 40-1238

40-1032
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B025 Fuse (30A) 40-1238
B030 Fuse (30A) 40-1238
C004 Earthing point 4 40-1238

Fig. 3751
D005 Wiring connector 40-1238
40-1238
40-1234
40-1236

Fig. 3752
E004 Trailer pressure in- Pin S = input from sensor 40-1238
dicator Pin + = 15V power supply
Pin - = earth
Trailer pressure in- Pin S = input from sensor 40-1238
dicator Pin + = 15V power supply
Pin - = earth
Trailer pressure in- Pin S = input from sensor 40-1238
dicator Pin + = 15V power supply
Pin - = earth
E008 Instrument panel 40-1238
E009 Instrument panel 40-1238
I008 Road lights switch Drawing D0037210.eps 40-1238

Fig. 3754
I013 Brake pedal switch Drawing D0020570.eps 40-1238
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
J002 Relay 40-1238

Fig. 3756

40-1033
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J004 Relay 40-1238

Fig. 3757

40-1034
Wiring diagrams

C003
F009

I017

D011

C009

D0065750

F008

Fig. 3758 - Connector positions

Table 789
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1238

Fig. 3759

40-1035
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1238

Fig. 3760
D011 Wiring connector 40-1233
40-1238

Fig. 3761
F008 LH rear light 40-1238

Fig. 3762
F009 RH rear light 40-1238

Fig. 3763
I017 Parking brake 40-1238
switch

40-1036
Wiring diagrams

D011

D0065760

Fig. 3764 - Connector positions

Table 790
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1233
40-1238

Fig. 3764

40-1037
 Wiring diagrams

P006

G22

A K013

G23

G20
X65

X67

D021

X66

D0065770

Fig. 3765 - Connector positions

Table 791
Sys- P/N Description Characteristics/notes Position Wiring
tem
D021 Wiring connector 40-1233
40-1191
K013 Hydraulic trailer Normally closed (NC) contact 40-1233
Switching pressure: 11 bar
P006 Trailer socket 40-1233

Fig. 3767

40-1038
Wiring diagrams

D021

K025

G23

X77

D0064350

Fig. 3768 - Connector positions

Table 792
Sys- P/N Description Characteristics/notes Position Wiring
tem
D021 Wiring connector 40-1233
40-1191
K025 Compressed air Power 12V DC 40-1191
pressure sensor Resistance at 0 bar 10-13 Ohm
Resistance at 6 bar 119-129 Ohm

40-1039
 Wiring diagrams

K002 D005

D0064370

Fig. 3769 - Connector positions - Version with lateral battery

40-1040
Wiring diagrams
Table 793
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1238
40-1238
40-1236

Fig. 3769
K002 Brake fluid level 40-1236
sensor

Fig. 3770

40-1041
 Wiring diagrams

K002 D005

D0064360

Fig. 3771 - Connector positions - Version with front battery

40-1042
Wiring diagrams
Table 794
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1238
40-1238
40-1234

Fig. 3771
K002 Brake fluid level 40-1234
sensor

Fig. 3771

40-1043
 Wiring diagrams
40.3.74 - S024D - Brakes - Version with digital instrument panel (R3 EVO 100 -> 16001, R3
EVO 110 -> 5001, R3 EVO 85 -> 16001)
E003

E002

E004b
E004a

E004
J002 J004 I013
TRAILER PRESSURE
BRAKES OIL LEVEL

F009
HAND BRAKE

+12/30

+12/30
+12V
GND

GND

13 8 7 12 22 14 21 15 NC NO 85 86 30 NC NO 85 86 30 2 1 + - G 1 2 3 4 1 2

C004

C004
C004

C004

C004
C004

C003
B010

B025

B030

B009
B020
B021

B015

B024
30A

30A

15A

15A

7.5A
5A
3A
10A
C004

D011
+30
+15
D005

D011

C008

C004
A A A A B B A
9 10 D6 A8 A1 D1 D1 D8 D4
A
B8
D021

1 2 1 2 10 9 5 6 2 3 7 8 3 6 1 2

-31

STOP
P

K002 D010
P
P006 F008
K013

I008 K025

D0064840

Fig. 3772 - Brakes - Version with digital instrument panel - System

l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D005 (M) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D010 (F) - Park Brake switch (Wiring loom 0.015.7021.4/70)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D011 (F) - Wiring connector (Wiring loom 0.015.7021.4/70)
l D021 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D021 (F) - Wiring connector (Wiring loom 0.014.1645.4/10)
l E002 - Instrument panel
l E003 - Instrument panel
l E004 - Trailer pressure indicator
l E004a - Trailer pressure indicator
l E004b- Trailer pressure indicator
l F008 - LH rear light
l F009 - RH rear light

40-1044
Wiring diagrams
l I008 - Road lights switch
l I013 - Brake pedal switch
l J002 - Relay
l J004 - Relay
l K002 - Brake fluid level sensor
l K013 - Hydraulic trailer braking valve pressure switch
l K025 - Compressed air pressure sensor
l P006 - Trailer socket

B030

J002

B015
B025 A
B020
J004

B009
B021 B024
B010

E002 C004
I013
E003

D005 E004
E004a
E004b

I008

D0064301

Fig. 3773 - Brakes - Version with digital instrument panel - Connector positions
Table 795
Sys- P/N Description Characteristics/notes Position Wiring
tem
B009 Fuse (15A) 40-1205
B010 Fuse (5A) 40-1205

40-1045
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B015 Fuse (15A) 40-1205
B020 Fuse (3A) 40-1205
B021 Fuse (10A) 40-1205
B024 Fuse (7.5A) 40-1205
B025 Fuse (30A) 40-1205
B030 Fuse (30A) 40-1205
C004 Earthing point 4 40-1205

Fig. 3774
D005 Wiring connector 40-1234
D005 Wiring connector 40-1236
D005 Wiring connector 40-1205
D005 Wiring connector 40-1205

Fig. 3775
E002 Instrument panel 40-1205

Fig. 3776
E003 Instrument panel 40-1205

Fig. 3777
E004 Trailer pressure in- Pin S = input from sensor 40-1205
dicator Pin + = 15V power supply
Pin - = earth
Trailer pressure in- Pin S = input from sensor 40-1205
dicator Pin + = 15V power supply
Pin - = earth
Trailer pressure in- Pin S = input from sensor 40-1205
dicator Pin + = 15V power supply
Pin - = earth

40-1046
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I008 Road lights switch 40-1205

Fig. 3779 Fig. 3780

I013 Brake pedal switch 40-1205
1

Fig. 3781
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally Fig. 3782
open contact (NO)
J002 Relay 40-1205

Fig. 3783
J004 Relay 40-1205

Fig. 3784

40-1047
 Wiring diagrams

C003
F009

C008

D010

D011

D0064311

F008

Fig. 3785 - Connector positions

Table 796
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1205

Fig. 3786

40-1048
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C008 Earthing point 8 40-1205

Fig. 3787
D010 Park Brake switch 40-1205

Fig. 3788
D011 Wiring connector 40-1205
40-1212

Fig. 3789
F008 LH rear light 40-1205

Fig. 3790
F009 RH rear light 40-1205

Fig. 3791

40-1049
 Wiring diagrams

P006

A K013

D021

D0064321

Fig. 3792 - Connector positions

Table 797
Sys- P/N Description Characteristics/notes Position Wiring
tem
D021 Wiring connector 40-1212
40-1191
P006 Trailer socket 40-1212

Fig. 3793
K013 Hydraulic trailer Normally closed (NC) contact 40-1212
Switching pressure: 11 bar

40-1050
Wiring diagrams

D011

D0064330

Fig. 3795 - Connector positions

40-1051
 Wiring diagrams
Table 798
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1205
40-1212

Fig. 3795

D021

K025

G23

X77

D0064350

Fig. 3796 - Connector positions

Table 799
Sys- P/N Description Characteristics/notes Position Wiring
tem
D021 Wiring connector 40-1212
40-1191
K025 Compressed air Power 12V DC 40-1191
pressure sensor Resistance at 0 bar 10-13 Ohm
Resistance at 6 bar 119-129 Ohm

40-1052
Wiring diagrams

K002 D005

D0064370

Fig. 3797 - Connector positions - Version with lateral battery

40-1053
 Wiring diagrams
Table 800
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1236
D005 Wiring connector 40-1205
D005 Wiring connector 40-1205

Fig. 3797
K002 Brake fluid level 40-1236
sensor

Fig. 3798

40-1054
Wiring diagrams

K002 D005

D0064360

Fig. 3799 - Connector positions - Version with front battery

40-1055
 Wiring diagrams
Table 801
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1234
D005 Wiring connector 40-1205
D005 Wiring connector 40-1205

Fig. 3799
K002 Brake fluid level 40-1234
sensor

Fig. 3799

40.3.75 - S025 - Negatives (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)

C007

C003 C008
C004
C009

C005
C001

C006

C002

F0150490

Fig. 3800 - Connector positions

40-1056
Wiring diagrams

C007
C008
C009
C004
C003

C005

C002

C006

C001

F0150500

Fig. 3801 - Connector positions

Table 802
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative 40-1241
terminal
C002 Earthing point 2 40-1241
C003 Earthing point 3 40-1209
40-1221
C004 Earthing point 4 40-1209
40-1221
C005 Earthing point 5 40-1242
C006 Earthing point 6 40-1242
C007 Earthing point 7 40-1226
40-1244
40-1204
C008 Earthing point 8 40-1209
40-1221
C009 Earthing point 9 40-1209
40-1221

40-1057
 Wiring diagrams
40.3.76 - S025A - Negatives - Version with analog instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

C007

C009
C004
C003

C005

C002

C006

C001

F0150501

Fig. 3802 - Negatives - Version with analog instrument panel - Positions

40-1058
Wiring diagrams

C007

C003
C004
C009

C005
C001

C006

C002

F0150491

Fig. 3803 - Negatives - Version with analog instrument panel - Positions

Table 803
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative Version with front battery 40-1241
terminal

Fig. 3804
C001 Battery negative Version with lateral battery 40-1241
terminal

Fig. 3805

40-1059
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C002 Earthing point 2 40-1241

Fig. 3806
C003 Earthing point 3 40-1238

Fig. 3807
C004 Earthing point 4 40-1238

Fig. 3808
C005 Earthing point 5 40-1242

Fig. 3809
C006 Earthing point 6 40-1242

Fig. 3810
C007 Earthing point 7 40-1228
40-1242
40-1204

Fig. 3811

40-1060
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1238

Fig. 3812

40.3.77 - S025D - Negatives - Version with digital instrument panel (R3 EVO 100 -> 16001,
R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

C007

C003 C008
C004
C009

C005
C001

C006

C002

F0150490

Fig. 3813 - Negatives - Version with digital instrument panel - Connector positions

40-1061
 Wiring diagrams

C007
C008
C009
C004
C003

C005

C002

C006

C001

F0150500

Fig. 3814 - Negatives - Version with digital instrument panel - Connector positions
Table 804
Sys- P/N Description Characteristics/notes Position Wiring
tem
C001 Battery negative 40-1241
terminal
C002 Earthing point 2 40-1241
C003 Earthing point 3 40-1205
C003 Earthing point 3 40-1221

Fig. 3815
C004 Earthing point 4 40-1205
C004 Earthing point 4 40-1221

Fig. 3816

40-1062
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C005 Earthing point 5 40-1242

Fig. 3817
C006 Earthing point 6 40-1242

Fig. 3818
C007 Earthing point 7 40-1228
C007 Earthing point 7 40-1242
C007 Earthing point 7 40-1204

Fig. 3819
C008 Earthing point 8 40-1205
C008 Earthing point 8 40-1221

Fig. 3820
C009 Earthing point 9 40-1205
C009 Earthing point 9 40-1221

Fig. 3821

40-1063
 Wiring diagrams
40.3.78 - S026 - Steering column lights switch – Version with cab without front lift (U.S.A.)
(R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
E003 E002 F020 F008 F021 F009
I016

DIRECTION INDICATOR

DIRECTION INDICATOR

DIRECTION INDICATOR
POSITION BEAM

31

31

31

31
FULL BEAM

2°TRAILER
1°TRAILER

+12/30

+12/30

+12V
GND

GND

D044

D043
13 8 9 10 11 12 8 21 15 14 1 3 2 17 18 10 8 5

3 1 2 4 5 3 2 1 4 5

C004
C004

C003
C009
J004 H001
M004

DIR.LAMP RH
LT

LT
DIR.LAM P LT

TRAILER RH
HAZARD RH
RIGHT

HAZARD IN
LEFT

RH DIR.IN

LT DIR.IN

HAZARD

TRAILER
HAZARD
LIGHT

+15
+30

+30

-31
NC NO 85 86 30 31 b
31 56d b
56 56a 56 L R 49a A1 B1 B4 A6 B2 B3 A8 A4 A2 B7 B6 A5 A3 B8

C004
C004

C004

B007
B030

B010
B020

B021

B032
B015

B009
B012

B013
30A

15A
20A
15A

15A

15A

20A
10A
3A

5A
+15

+30

B016
B024

B023

7.5A
7.5A

7.5A
C004

C004
C004

C009

7 4 1 5 2 10 9 5 6 2 3 7 8 1 2 1 2

I009
F007a F007
I008
C004
C004

C003
D004

D011
D014

10 5 3 4 14 9 8 13 1 2
B B B B B B A
1 4 6 3 2 5 B4 A1 C1 B6 B7 B8 D8

D0063470

TO SISTEM 2/2 TO SISTEM 2/2 TO SISTEM 2/2

Fig. 3822 - Steering column lights switch - Version with cab without front lift - System (1/2)

40-1064
Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004
C004

C003
D004

D014

D011
10 5 3 4 14 9 8 13 1 2
A B B B B B B
1 4 6 3 2 5 D8 C1 A1 B4 B6 B7 B8

D038
D040

D037
D039
1 2 1 2 1 2 1 2 1 2
1 3 4 7 5 6 2

+58 lLEFT
3 4 3 4

DIR. RIGHT
-31

+58 RH
+30

+15
DIR. LEFT
E001 F005 F002 F003 F004

P006

3 2 1 1 2 3
-31

-31
F.D.

FS.
58

58

D0063460
F014 F015

Fig. 3823 - Steering column lights switch - Version with cab without front lift - System (2/2)
l D004 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D004 (F) - Wiring connector (Wiring loom 0.014.8107.4/30)
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D014 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D043 (M) - Wiring connector (Wiring loom 0.013.4909.4)
l D043 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D014 (M) - Wiring connector (Wiring loom 0.013.4909.4)
l D044 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l E001 - Horn
l E002 - Instrument panel
l E003 - Instrument panel
l F002 - RH high beam headlight
l F003 - RH low beam headlight
l F004 - LH low beam headlight
l F005 - LH high beam headlight
l F007 - Number plate light
l F007a - Number plate light
l F008 - LH rear sidelight and direction indicator
l F009 - LH rear sidelight and direction indicator
l F014 - RH front sidelight and direction indicator
l F015 - LH front sidelight and direction indicator
l F020 - LH rear light (hazard warning)
l F021 - RH rear light (hazard warning)
l H001 - Lights selector switch

40-1065
 Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004
C004

C003
D004

D014

D011
10 5 3 4 14 9 8 13 1 2
A B B B B B B
1 4 6 3 2 5 D8 C1 A1 B4 B6 B7 B8

D038
D040

D037
D039
1 2 1 2 1 2 1 2 1 2
1 3 4 7 5 6 2

+58 lLEFT
3 4 3 4

DIR. RIGHT
-31

+58 RH
+30

+15
DIR. LEFT
E001 F005 F002 F003 F004

P006

3 2 1 1 2 3
-31

-31
F.D.

FS.
58

58

D0063460
F014 F015

Fig. 3823 - Steering column lights switch - Version with cab without front lift - System (2/2)
l I008 - Road lights switch
l I009 - Top work lights switch
l I016 - Hazard warning lights switch
l J004 - Relay
l M004 - Hazard warning lights flasher unit
l P006 - Trailer socket

40-1066
Wiring diagrams
J004

B030 B021
B032
B023
B015
B016 A
B007

B020

B009 B024
B010 B012 B013

E002 D004

E003
D014 C004

H001

I016
M004

I009
I008
B

D0064910

Fig. 3824 - Steering column lights switch - Version with cab without front lift - Connector positions
Table 805
Sys- P/N Description Characteristics/notes Position Wiring
tem
B007 Fuse (20A) 40-1221
B009 Fuse (15A) 40-1221
B010 Fuse (5A) 40-1221
B012 Fuse (15A) 40-1221
B013 Fuse (15A) 40-1221
B015 Fuse (15A) 40-1221
B016 Fuse (7.5A) 40-1209
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1221
B023 Fuse (7.5A) 40-1221
B024 Fuse (7.5A) 40-1221

40-1067
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B030 Fuse (30A) 40-1221
B032 Fuse (20A) 40-1221
C004 Earthing point 4 40-1221

Fig. 3825
D004 Wiring connector 40-1221
D004 Wiring connector 40-1193

Fig. 3826
D014 Wiring connector 40-1221
D014 Wiring connector 40-1224

Fig. 3827
E002 Instrument panel 40-1221

Fig. 3828
E003 Instrument panel 40-1221

Fig. 3829
H001 Lights selector 40-1221
switch

40-1068
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I008 Road lights switch 40-1221

Fig. 3830 Fig. 3831

I009 Upper worklights 40-1221
switch

Fig. 3832
J004 Relay 40-1221

Fig. 3833
I016 Hazard warning 0
1
40-1221
lights switch
5 17
18
10
8 1 2 3
5 1 7 18

Pin 1 2 3 5 8 10 17 18
Pos

Fig. 3834
Fig. 3835
M004 Hazard warning 40-1221
lights ECU

Fig. 3836

40-1069
 Wiring diagrams

F021
C003

D0064800
D043
F009

D011
F020

C009 D044
F007a
F008
F007

Fig. 3837 - Connector positions

Table 806
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1221

Fig. 3838

40-1070
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1221

Fig. 3839
D011 Wiring connector 40-1221
D011 Wiring connector 40-1214

Fig. 3840
D043 Wiring connector 40-1221
D043 Wiring connector 40-1187
D044 Wiring connector 40-1221
D044 Wiring connector 40-1187
F007 Number plate light 40-1221

Fig. 3841
Number plate light 40-1221

Fig. 3842
F008 LH rear sidelight 40-1187
and direction indi-
cator

Fig. 3843

40-1071
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F009 RH rear sidelight 40-1187
and direction indi-
cator

Fig. 3844
F020 LH rear light (haz- 40-1187
ard warning)
F021 RH rear light (haz- 40-1187
ard warning)

40-1072
Wiring diagrams

D011

D0064640

Fig. 3845 - Connector positions

Table 807
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1221
D011 Wiring connector 40-1214

Fig. 3845

40-1073
 Wiring diagrams

P006

G22

ECO

A
S
G23

G20
X65

X67

D0064630

Fig. 3846 - Connector positions

Table 808
Sys- P/N Description Characteristics/notes Position Wiring
tem
P006 Trailer socket 40-1214

Fig. 3847

40-1074
Wiring diagrams

D039

D014
D040
D037

D038

D0064650

Fig. 3848 - Connector positions

Table 809
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1221
D014 Wiring connector 40-1224

Fig. 3848
D037 Wiring connector 40-1224
D037 Wiring connector 40-1251
D038 Wiring connector 40-1224
D038 Wiring connector 40-1251
D039 Wiring connector 40-1224
D040 Wiring connector 40-1224

40-1075
 Wiring diagrams

D039
F014 D040

D037
D038

F015

D0064660

Fig. 3849 - Connector positions

Table 810
Sys- P/N Description Characteristics/notes Position Wiring
tem
D037 Wiring connector 40-1224
D037 Wiring connector 40-1251
D038 Wiring connector 40-1224
D038 Wiring connector 40-1251
D039 Wiring connector 40-1224
D040 Wiring connector 40-1224
F014 04411921.4 Front RH sidelight 40-1250
and direction indi-
cator
F015 04411920.4 Front LH sidelight 40-1251
and direction indi-
cator

40-1076
Wiring diagrams

D004

F003

F004
F002

F005

E001

D0064670

Fig. 3850 - Connector positions

Table 811
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1221
D004 Wiring connector 40-1193

Fig. 3850

40-1077
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F002 Rh high beam 40-1193
headlight

Fig. 3851
F003 Rh low beam head- 40-1193
light
F003 Rh low beam head- 40-1193
light

Fig. 3852
F004 Lh low beam head- 40-1193
light
F004 Lh low beam head- 40-1193
light

Fig. 3853
F005 Lh high beam 40-1193
headlight

Fig. 3854
E001 Horn 40-1193

Fig. 3855

40-1078
Wiring diagrams
40.3.79 - S026D - Steering column lights switch - Version with cab without front lift - Ver-
sion with digital instrument panel (USA) (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3
EVO 85 -> 16001)
E003 E002 F020 F008 F021 F009
I016

DIRECTION INDICATOR

DIRECTION INDICATOR

DIRECTION INDICATOR
POSITION BEAM

31

31

31

31
FULL BEAM

2°TRAILER
1°TRAILER

+12/30

+12/30

+12V
GND

GND

D044

D043
13 8 9 10 11 12 8 21 15 14 1 3 2 17 18 10 8 5

3 1 2 4 5 3 2 1 4 5

C004
C004

C003
C009
J004 H001
M004

DIR.LAMP RH
LT

LT
DIR.LAM P LT

TRAILER RH
HAZARD RH
RIGHT

HAZARD IN
LEFT

RH DIR.IN

LT DIR.IN

HAZARD

TRAILER
HAZARD
LIGHT

+15
+30

+30

-31
NC NO 85 86 30 31 b
31 56d b
56 56a 56 L R 49a A1 B1 B4 A6 B2 B3 A8 A4 A2 B7 B6 A5 A3 B8

C004
C004

C004

B007
B030

B010
B020

B021

B032
B015

B009
B012

B013
30A

15A
20A
15A

15A

15A

20A
10A
3A

5A
+15

+30

B016
B024

B023

7.5A
7.5A

7.5A
C004

C004
C004

C009

7 4 1 5 2 10 9 5 6 2 3 7 8 1 2 1 2

I009
F007a F007
I008
C004
C004

C003
D004

D011
D014

10 5 3 4 14 9 8 13 1 2
B B B B B B A
1 4 6 3 2 5 B4 A1 C1 B6 B7 B8 D8

D0063470

TO SISTEM 2/2 TO SISTEM 2/2 TO SISTEM 2/2

Fig. 3856 - Steering column lights switch - Version with cab without front lift - Version with digital instrument
panel (USA) - System (1/2)

40-1079
 Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004
C004

C003
D004

D014

D011
10 5 3 4 14 9 8 13 1 2
A B B B B B B
1 4 6 3 2 5 D8 C1 A1 B4 B6 B7 B8

D038
D040

D037
D039
1 2 1 2 1 2 1 2 1 2
1 3 4 7 5 6 2

+58 lLEFT
3 4 3 4

DIR. RIGHT
-31

+58 RH
+30

+15
DIR. LEFT
E001 F005 F002 F003 F004

P006

3 2 1 1 2 3
-31

-31
F.D.

FS.
58

58

D0063460
F014 F015

Fig. 3857 - Steering column lights switch - Version with cab without front lift - Version with digital instrument
panel (USA) - System (2/2)
l D004 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D004 (F) - Wiring connector (Wiring loom 0.015.7310.4)
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D014 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D039 (F) - Wiring connector (Wiring loom 04411923.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D040 (F) - Wiring connector (Wiring loom 04411923.4)
l D043 (M) - Wiring connector (Wiring loom 0.013.4909.4)
l D043 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D014 (M) - Wiring connector (Wiring loom 0.013.4909.4)
l D044 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l E001 - Horn
l E002 - Instrument panel
l E003 - Instrument panel
l F002 - RH high beam headlight
l F003 - RH low beam headlight
l F004 - LH low beam headlight
l F005 - LH high beam headlight
l F007 - Number plate light
l F007a - Number plate light
l F008 - LH rear sidelight and direction indicator
l F009 - LH rear sidelight and direction indicator
l F014 - RH front sidelight and direction indicator
l F015 - LH front sidelight and direction indicator

40-1080
Wiring diagrams
l F020 - LH rear light (hazard warning)
l F021 - RH rear light (hazard warning)
l H001 - Lights selector switch
l I008 - Road lights switch
l I009 - Top work lights switch
l I016 - Hazard warning lights switch
l J004 - Relay
l M004 - Hazard warning lights flasher unit
l P006 - Trailer socket

D039

D014
D040
D037

D038

D0064650

Fig. 3858 - Steering column lights switch - Version with cab without front lift - Version with digital instrument
panel (USA) - Connector positions

40-1081
 Wiring diagrams
Table 812
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1221
40-1224

Fig. 3859
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250
D040 Wiring connector 40-1224
40-1250

40-1082
Wiring diagrams

D039
F014 D040

D037
D038

F015

D0064660

Fig. 3860 - Connector positions

Table 813
Sys- P/N Description Characteristics/notes Position Wiring
tem
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250
D040 Wiring connector 40-1224
40-1250
F014 04411921.4 RH front sidelight 40-1250
and direction indi-
cator
F015 04411920.4 LH front sidelight 40-1251
and direction indi-
cator

40-1083
 Wiring diagrams

D004

F003

F004
F002

F005

E001

D0064670

Fig. 3861 - Connector positions

Table 814
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1221
40-1218

Fig. 3862

40-1084
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
E001 Horn 40-1218

Fig. 3863
F002 RH high beam 40-1218
headlight

Fig. 3864
F003 RH low beam head- 40-1218
light
RH low beam head- 40-1218
light

Fig. 3865
F004 LH low beam head- 40-1218
light
LH low beam head- 40-1218
light

Fig. 3866
F005 LH high beam 40-1218
headlight

Fig. 3867

40-1085
 Wiring diagrams

F021
C003

D0064800
D043
F009

D011
F020

C009 D044
F007a
F008
F007

Fig. 3868 - Connector positions

Table 815
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1221

Fig. 3869

40-1086
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1221

Fig. 3869
D011 Wiring connector 40-1221
40-1212

Fig. 3870
D043 Wiring connector 40-1221
40-1187
D044 Wiring connector 40-1221
40-1187
F007 Number plate light 40-1221

Fig. 3871
Number plate light 40-1221

Fig. 3872
F008 LH rear sidelight 40-1187
and direction indi-
cator

Fig. 3873

40-1087
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F009 RH rear sidelight 40-1187
and direction indi-
cator

Fig. 3874
F020 LH rear light (haz- 40-1187
ard warning)
F021 RH rear light (haz- 40-1187
ard warning)

40-1088
Wiring diagrams
J004

B030 B021
B032
B023
B015
B016 A
B007

B020

B009 B024
B010 B012 B013

E002 D004

E003
D014 C004

H001

I016
M004

I009
I008
B

D0064910

Fig. 3875 - Connector positions

Table 816
Sys- P/N Description Characteristics/notes Position Wiring
tem
B007 Fuse (20A) 40-1221
B009 Fuse (15A) 40-1221
B010 Fuse (5A) 40-1221
B012 Fuse (15A) 40-1221
B013 Fuse (15A) 40-1221
B015 Fuse (15A) 40-1221
B016 Fuse (7.5A) 40-1221
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1221
B023 Fuse (7.5A) 40-1221
B024 Fuse (7.5A) 40-1221

40-1089
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B030 Fuse (30A) 40-1221
B032 Fuse (20A) 40-1221
C004 Earthing point 4 40-1221

Fig. 3876
D004 Wiring connector 40-1221
40-1218

Fig. 3876
D014 Wiring connector 40-1221
40-1224

Fig. 3876
E002 Instrument panel 40-1221

Fig. 3877
E003 Instrument panel 40-1221

Fig. 3878
H001 Lights selector 40-1221
switch

40-1090
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I008 Road lights switch 40-1221

Fig. 3879 Fig. 3880

I009 Top work lights 40-1221
switch

Fig. 3881
I016 Hazard warning 0
1
40-1221
lights switch
5 17
18
10
8 1 2 3
5 1 7 18

Pin 1 2 3 5 8 10 17 18
Pos

Fig. 3882
Fig. 3883
J004 Relay 40-1221

Fig. 3884
M004 Hazard warning 40-1221
lights ECU

40-1091
 Wiring diagrams

P006

G22

ECO

A
S
G23

G20
X65

X67

D0064630

Fig. 3885 - Connector positions

Table 817
Sys- P/N Description Characteristics/notes Position Wiring
tem
P006 Trailer socket 40-1212

Fig. 3886

40-1092
Wiring diagrams

D011

D0064640

Fig. 3887 - Connector positions

Table 818
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1221
40-1212

Fig. 3887

40-1093
 Wiring diagrams
40.3.80 - S027 - Steering column lights switch – Version with cab with front lift (U.S.A.)
(R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)
E003 E002 F020 F008 F021 F009
I016

DIRECTION INDICATOR

DIRECTION INDICATOR

DIRECTION INDICATOR
POSITION BEAM

31

31

31

31
FULL BEAM

2°TRAILER
1°TRAILER

+12/30

+12/30

+12V
GND

GND

D044

D043
13 8 9 10 11 12 8 21 15 14 1 3 2 17 18 10 8 5

3 1 2 4 5 3 1 2 4 5

C004
C004

C003
C009
J004 H001
M004

DIR.LAMP RH
LT

LT
DIR.LAM P LT

TRAILER RH
HAZARD RH
RIGHT

HAZARD IN
LEFT

RH DIR.IN

LT DIR.IN

HAZARD

TRAILER
HAZARD
LIGHT

+15
+30

+30

-31
NC NO 85 86 30 31 31b 56d 56b 56a 56 L R 49a A1 B1 B4 A6 B2 B3 A8 A4 A2 B7 B6 A5 A3 B8

C004
C004

C004

B007
B030

B010
B015

B020

B021

B032

B009
B012

B013
30A

15A
20A
15A

15A

15A

20A
10A
3A

5A
+15

+30

B016
B024

B023

7.5A
7.5A

7.5A
C004

C004

C009
C004

10 9 5 6 2 3 7 8

1 2 1 2

I008 F007a F007

7 4 1 5 2 8 6 3

I009
C004
C004

C003
D004

D014

D011

10 5 3 4 14 9 8 13 1 2
B B B B B B A
1 4 8 10 6 3 2 5 7 9 B4 A1 C1 B6 B7 B8 D8

D0063480
TO SISTEM 2/2 TO SISTEM 2/2 TO SISTEM 2/2

Fig. 3888 - Steering column lights switch - Version with cab with front lift (U.S.A.) - System (1/2)

40-1094
Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004
C004

C003
D004

D014

D011
10 5 3 4 14 9 8 13 1 2
A B B B B B B
1 4 8 10 6 3 2 5 7 9 D8 C1 A1 B4 B6 B7 B8

1 2 1 2 1 2 1 2 1 2

D038
D040

D037
D039
1 3 4 7 5 6 2

+58 lLEFT
DIR. RIGHT
-31

+58 RH
+30

+15
DIR. LEFT
1 2 3 4 3 4 1 2

E001 F005 F002 F003 F004

P006

1 2 3 4 3 2 1 1 2 3 4 3 2 1
-31
F.D.

-31

FS.
58

58

D0063490
F014 F015
D041 D042

Fig. 3889 - Steering column lights switch - Version with cab with front lift (U.S.A.) - System (2/2)
l D004 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D004 (F) - Wiring connector (Wiring loom 0.014.8107.4/30)
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D014 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D041 (F) - RH front light on arm (Wiring loom 04411923.4)
l D042 (F) - LH front light on arm (Wiring loom 04411923.4)
l D043 (M) - Wiring connector (Wiring loom 0.013.4909.4)
l D043 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D014 (M) - Wiring connector (Wiring loom 0.013.4909.4)
l D044 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l E001 - Horn
l E002 - Instrument panel
l E003 - Instrument panel
l F002 - RH high beam headlight
l F003 - RH low beam headlight
l F004 - LH low beam headlight
l F005 - LH high beam headlight
l F007 - Number plate light
l F007a - Number plate light
l F008 - LH rear sidelight and direction indicator
l F009 - LH rear sidelight and direction indicator
l F014 - RH front sidelight and direction indicator
l F015 - LH front sidelight and direction indicator
l F020 - LH rear light (hazard warning)

40-1095
 Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004
C004

C003
D004

D014

D011
10 5 3 4 14 9 8 13 1 2
A B B B B B B
1 4 8 10 6 3 2 5 7 9 D8 C1 A1 B4 B6 B7 B8

1 2 1 2 1 2 1 2 1 2

D038
D040

D037
D039
1 3 4 7 5 6 2

+58 lLEFT
DIR. RIGHT
-31

+58 RH
+30

+15
DIR. LEFT
1 2 3 4 3 4 1 2

E001 F005 F002 F003 F004

P006

1 2 3 4 3 2 1 1 2 3 4 3 2 1
-31
F.D.

-31

FS.
58

58

D0063490
F014 F015
D041 D042

Fig. 3889 - Steering column lights switch - Version with cab with front lift (U.S.A.) - System (2/2)
l F021 - RH rear light (hazard warning)
l H001 - Lights selector switch
l I008 - Road lights switch
l I009 - Top work lights switch
l I016 - Hazard warning lights switch
l J004 - Relay
l M004 - Hazard warning lights flasher unit
l P006 - Trailer socket

40-1096
Wiring diagrams
J004

B030 B021
B032
B023
B015
B016 A
B007

B020

B009 B024
B010 B012 B013

E002 D004

E003
D014 C004

H001

I016
M004

I009
I008
B

D0064910

Fig. 3890 - Steering column lights switch - Version with cab with front lift (U.S.A.) - Connector positions
Table 819
Sys- P/N Description Characteristics/notes Position Wiring
tem
B007 Fuse (20A) 40-1221
B009 Fuse (15A) 40-1221
B010 Fuse (5A) 40-1221
B012 Fuse (15A) 40-1221
B013 Fuse (15A) 40-1221
B015 Fuse (15A) 40-1221
B016 Fuse (7.5A) 40-1209
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1221
B023 Fuse (7.5A) 40-1221
B024 Fuse (7.5A) 40-1221

40-1097
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
B030 Fuse (30A) 40-1221
B032 Fuse (20A) 40-1221
C004 Earthing point 4 40-1221

Fig. 3891
D004 Wiring connector 40-1221
D004 Wiring connector 40-1193

Fig. 3892
D014 Wiring connector 40-1221
D014 Wiring connector 40-1224

Fig. 3893
E002 Instrument panel 40-1221

Fig. 3894
E003 Instrument panel 40-1221

Fig. 3895
H001 Lights selector 40-1221
switch

40-1098
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I008 Road lights switch 40-1221

Fig. 3896 Fig. 3897

I009 Upper worklights 40-1221
switch

Fig. 3898
I016 Hazard warning 0
1
40-1221
lights switch
5 17
18
10
8 1 2 3
5 1 7 18

Pin 1 2 3 5 8 10 17 18
Pos

Fig. 3899
Fig. 3900
M004 Hazard warning 40-1221
lights ECU

Fig. 3901
J004 Relay 40-1221

Fig. 3902

40-1099
 Wiring diagrams

F021
C003

D0064800
D043
F009

D011
F020

C009 D044
F007a
F008
F007

Fig. 3903 - Connector positions

Table 820
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1221

Fig. 3904

40-1100
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1221

Fig. 3905
D011 Wiring connector 40-1221
D011 Wiring connector 40-1214

Fig. 3906
D043 Wiring connector 40-1221
D043 Wiring connector 40-1187
D044 Wiring connector 40-1221
D044 Wiring connector 40-1187
F007 Number plate light 40-1221

Fig. 3907
Number plate light 40-1221

Fig. 3908
F008 LH rear sidelight 40-1187
and direction indi-
cator

Fig. 3909

40-1101
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F009 RH rear sidelight 40-1187
and direction indi-
cator

Fig. 3910
F020 LH rear light (haz- 40-1187
ard warning)
F021 RH rear light (haz- 40-1187
ard warning)

40-1102
Wiring diagrams

D011

D0064640

Fig. 3911 - Connector positions

Table 821
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1221
D011 Wiring connector 40-1214

Fig. 3911

40-1103
 Wiring diagrams

P006

G22

ECO

A
S
G23

G20
X65

X67

D0064630

Fig. 3912 - Connector positions

Table 822
Sys- P/N Description Characteristics/notes Position Wiring
tem
P006 Trailer socket 40-1214

Fig. 3913

40-1104
Wiring diagrams

D039

D014
D040
D037

D038

D0064650

Fig. 3914 - Connector positions

Table 823
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1221
D014 Wiring connector 40-1224

Fig. 3914
D037 Wiring connector 40-1224
D037 Wiring connector 40-1251
D038 Wiring connector 40-1224
D038 Wiring connector 40-1251
D039 Wiring connector 40-1224
D040 Wiring connector 40-1224

40-1105
 Wiring diagrams

D039
D040
F014

D037
D038
D041

F015

D042

D0064680

Fig. 3915 - Connector positions

Table 824
Sys- P/N Description Characteristics/notes Position Wiring
tem
D037 Wiring connector 40-1224
D037 Wiring connector 40-1251
D038 Wiring connector 40-1224
D038 Wiring connector 40-1251
D039 Wiring connector 40-1224
D040 Wiring connector 40-1224
D041 Rh front light on 40-1250
arms
D042 LH front light on 40-1251
arms
F014 04411921.4 Front RH sidelight 40-1250
and direction indi-
cator
F015 04411920.4 Front LH sidelight 40-1251
and direction indi-
cator

40-1106
Wiring diagrams

D004

F003

F004
F002

F005

E001

D0064670

Fig. 3916 - Connector positions

Table 825
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1221
D004 Wiring connector 40-1193

Fig. 3916

40-1107
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F002 Rh high beam 40-1193
headlight

Fig. 3917
F003 Rh low beam head- 40-1193
light
F003 Rh low beam head- 40-1193
light

Fig. 3918
F004 Lh low beam head- 40-1193
light
F004 Lh low beam head- 40-1193
light

Fig. 3919
F005 Lh high beam 40-1193
headlight

Fig. 3920
E001 Horn 40-1193

Fig. 3921

40-1108
Wiring diagrams
40.3.81 - S027D - Steering column lights switch - Version with cab without front lift - Ver-
sion with digital instrument panel (USA) (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3
EVO 85 -> 16001)
E003 E002 F020 F008 F021 F009
I016

DIRECTION INDICATOR

DIRECTION INDICATOR

DIRECTION INDICATOR
POSITION BEAM

31

31

31

31
FULL BEAM

2°TRAILER
1°TRAILER

+12/30

+12/30

+12V
GND

GND

D044

D043
13 8 9 10 11 12 8 21 15 14 1 3 2 17 18 10 8 5

3 1 2 4 5 3 1 2 4 5

C004
C004

C003
C009
J004 H001
M004

DIR.LAMP RH
LT

LT
DIR.LAM P LT

TRAILER RH
HAZARD RH
RIGHT

HAZARD IN
LEFT

RH DIR.IN

LT DIR.IN

HAZARD

TRAILER
HAZARD
LIGHT

+15
+30

+30

-31
NC NO 85 86 30 31 31b 56d 56b 56a 56 L R 49a A1 B1 B4 A6 B2 B3 A8 A4 A2 B7 B6 A5 A3 B8

C004
C004

C004

B007
B030

B010
B015

B020

B021

B032

B009
B012

B013
30A

15A
20A
15A

15A

15A

20A
10A
3A

5A
+15

+30

B016
B024

B023

7.5A
7.5A

7.5A
C004

C004

C009
C004

10 9 5 6 2 3 7 8

1 2 1 2

I008 F007a F007

7 4 1 5 2 8 6 3

I009
C004
C004

C003
D004

D014

D011

10 5 3 4 14 9 8 13 1 2
B B B B B B A
1 4 8 10 6 3 2 5 7 9 B4 A1 C1 B6 B7 B8 D8

D0063480
TO SISTEM 2/2 TO SISTEM 2/2 TO SISTEM 2/2

Fig. 3922 - Steering column lights switch - Version with cab without front lift - Version with digital instrument
panel (USA) - System (1/2)

40-1109
 Wiring diagrams

TO SISTEM 1/2 TO SISTEM 1/2 TO SISTEM 1/2

C004
C004

C003
D004

D014

D011
10 5 3 4 14 9 8 13 1 2
A B B B B B B
1 4 8 10 6 3 2 5 7 9 D8 C1 A1 B4 B6 B7 B8

1 2 1 2 1 2 1 2 1 2

D038
D040

D037
D039
1 3 4 7 5 6 2

+58 lLEFT
DIR. RIGHT
-31

+58 RH
+30

+15
DIR. LEFT
1 2 3 4 3 4 1 2

E001 F005 F002 F003 F004

P006

1 2 3 4 3 2 1 1 2 3 4 3 2 1
-31
F.D.

-31

FS.
58

58

D0063490
F014 F015
D041 D042

Fig. 3923 - System (2/2)

l D004 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D004 (F) - Wiring connector (Wiring loom 0.015.7310.4)
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D014 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D014 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D037 (F) - Wiring connector (Wiring loom 04411923.4)
l D038 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D038 (F) - Wiring connector (Wiring loom 04411923.4)
l D039 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D039 (F) - Wiring connector (Wiring loom 04411923.4)
l D040 (M) - Wiring connector (Wiring loom 0.016.0664.4)
l D040 (F) - Wiring connector (Wiring loom 04411923.4)
l D041 (M) - Wiring connector (Wiring loom 0.014.3927.4/40)
l D041 (F) - Wiring connector (Wiring loom 04411923.4)
l D041 (F) - RH front light on arm (Wiring loom 04411923.4)
l D042 (M) - Wiring connector (Wiring loom 0.014.3927.4/40)
l D042 (F) - Wiring connector (Wiring loom 04411923.4)
l D042 (F) - LH front light on arm (Wiring loom 04411923.4)
l D043 (M) - Wiring connector (Wiring loom 0.013.4909.4)
l D043 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D014 (M) - Wiring connector (Wiring loom 0.013.4909.4)
l D044 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l E001 - Horn
l E002 - Instrument panel
l E003 - Instrument panel
l F002 - RH high beam headlight
l F003 - RH low beam headlight
l F004 - LH low beam headlight
l F005 - LH high beam headlight
l F007 - Number plate light

40-1110
Wiring diagrams
l F007a - Number plate light
l F008 - LH rear sidelight and direction indicator
l F009 - LH rear sidelight and direction indicator
l F014 - RH front sidelight and direction indicator
l F015 - LH front sidelight and direction indicator
l F020 - LH rear light (hazard warning)
l F021 - RH rear light (hazard warning)
l H001 - Lights selector switch
l I008 - Road lights switch
l I009 - Top work lights switch
l I016 - Hazard warning lights switch
l J004 - Relay
l M004 - Hazard warning lights flasher unit
l P006 - Trailer socket

J004

B030 B021
B032
B023
B015
B016 A
B007

B020

B009 B024
B010 B012 B013

E002 D004

E003
D014 C004

H001

I016
M004

I009
I008
B

D0064910

Fig. 3924 - Steering column lights switch - Version with cab without front lift - Version with digital instrument

40-1111
 Wiring diagrams
panel (USA) - Connector positions
Table 826
Sys- P/N Description Characteristics/notes Position Wiring
tem
B007 Fuse (20A) 40-1221
B009 Fuse (15A) 40-1221
B010 Fuse (5A) 40-1221
B012 Fuse (15A) 40-1221
B013 Fuse (15A) 40-1221
B015 Fuse (15A) 40-1221
B016 Fuse (7.5A) 40-1221
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1221
B023 Fuse (7.5A) 40-1221
B024 Fuse (7.5A) 40-1221
B030 Fuse (30A) 40-1221
B032 Fuse (20A) 40-1221
C004 Earthing point 4 40-1221

Fig. 3925
D004 Wiring connector 40-1221
40-1218

Fig. 3926
D014 Wiring connector 40-1221
40-1224

Fig. 3927
E002 Instrument panel 40-1221

Fig. 3928

40-1112
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
E003 Instrument panel 40-1221

Fig. 3929
H001 Lights selector 40-1221
switch
I008 Road lights switch Drawing D0037210.eps 40-1221

Fig. 3930
I009 Top work lights 40-1221
switch

Fig. 3931
I016 Hazard warning Drawing D0015410.eps 40-1221
lights switch

Fig. 3932
J004 Relay 40-1221

Fig. 3933

40-1113
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
M004 Hazard warning 40-1221
lights ECU

Fig. 3934

F021
C003

D0064800
D043
F009

D011
F020

C009 D044
F007a
F008
F007

Fig. 3935 - Connector positions

40-1114
Wiring diagrams
Table 827
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1221

Fig. 3936
C009 Earthing point 9 40-1221

Fig. 3937
D011 Wiring connector 40-1221
40-1212

Fig. 3938
D043 Wiring connector 40-1221
40-1187
D044 Wiring connector 40-1221
40-1187
F007 Number plate light 40-1221

Fig. 3939
Number plate light 40-1221

Fig. 3940

40-1115
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F008 LH rear sidelight 40-1187
and direction indi-
cator

Fig. 3941
F009 RH rear sidelight 40-1187
and direction indi-
cator

Fig. 3942
F020 LH rear light (haz- 40-1187
ard warning)
F021 RH rear light (haz- 40-1187
ard warning)

40-1116
Wiring diagrams

D011

D0064640

Fig. 3943 - Connector positions

Table 828
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1221
40-1212

Fig. 3943

40-1117
 Wiring diagrams

P006

G22

ECO

A
S
G23

G20
X65

X67

D0064630

Fig. 3944 - Connector positions

Table 829
Sys- P/N Description Characteristics/notes Position Wiring
tem
P006 Trailer socket 40-1212

Fig. 3945

40-1118
Wiring diagrams

D039

D014
D040
D037

D038

D0064650

Fig. 3946 - Connector positions

Table 830
Sys- P/N Description Characteristics/notes Position Wiring
tem
D014 Wiring connector 40-1221
40-1224

Fig. 3946
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250

40-1119
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D040 Wiring connector 40-1224
40-1250

D039
D040
F014

D037
D038
D041

F015

D042

D0064680

Fig. 3947 - Connector positions

Table 831
Sys- P/N Description Characteristics/notes Position Wiring
tem
D037 Wiring connector 40-1224
40-1251
D038 Wiring connector 40-1224
40-1251
D039 Wiring connector 40-1224
40-1250
D040 Wiring connector 40-1224
40-1250
D041 Wiring connector 40-1250
40-1192
D041 Rh front light on 40-1250
arms

40-1120
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D042 Wiring connector 40-1192
40-1251
D042 LH front light on 40-1251
arms
F014 04411921.4 RH front sidelight 40-1250
and direction indi-
cator
F015 04411920.4 LH front sidelight 40-1251
and direction indi-
cator

D004

F003

F004
F002

F005

E001

D0064670

Fig. 3948 - Connector positions

40-1121
 Wiring diagrams
Table 832
Sys- P/N Description Characteristics/notes Position Wiring
tem
D004 Wiring connector 40-1221
40-1218

Fig. 3948
E001 Horn 40-1218

Fig. 3949
F002 RH high beam 40-1218
headlight

Fig. 3950
F003 RH low beam head- 40-1218
light

Fig. 3951
F003 RH low beam head- 40-1218
light

Fig. 3951
F004 LH low beam head- 40-1218
light

Fig. 3952

40-1122
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
F004 LH low beam head- 40-1218
light

Fig. 3952
F005 LH high beam 40-1218
headlight

Fig. 3953

40-1123
 Wiring diagrams
40.3.82 - S028 - PTO (U.S.A.) (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)
I004 I005
E003 E002 J004
I006 I007

1 2 2 3 7 8 2 3 7 8 2 1 NC NO 85 86 30

PTO SYNCRO
EV PTO ANT.

FRONT PTO

REAR PTO
PTO 1000
PTO ECO

PTO 540

D013
+12/30

+12/30

+12V
GND

GND

19 13 16 8 9 24 10 11 15 21 13 14
4 1 3 9 2

C004
B010
5A

C003
C004

+30

B030
B015

B021

B020
15A

30A
10A

3A

+30
+15
C009

C004

B024
7.5A
D011

B A A B B A A A B
B2 A7 B3 C3 A4 A8 A1 D1 D1

10 9 5 6 2 3 7 8
C003

2 3 1

I008
C004
C009

C009

K012
14 9 2 1 17 6 11 7 15 12 18
REAR PTO SWITCH
FRONT PTO LED

ABILITAZ. SENS.
REAR PTO LED

+15

PTO SPEED
REAR PTO EV

FRONT PTO EV
GND

D+
FRONT PTO SWITCH

D005

2 9 8
2 3 2 1 2 3 4 1 4 1
D006

I023 L003 I021 I003 I002 M003

2 1 9

2 1

L005
A003

D0063500

Fig. 3954 - PTO - System

l A003 - Alternator “D+”
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D006 (M) - Wiring connector (Wiring loom 0.008.0913.3)
l D006 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)

40-1124
Wiring diagrams
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D013 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D013 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l E002 - Instrument panel
l E003 - Instrument panel
l I002 - 540 PTO control switch
l I003 - 1000 PTO control switch
l I004 - Front PTO control switch
l I005 - Rear PTO control switch
l I006 – LH rear PTO control switch (on fender)
l I007 – RH rear PTO control switch (on fender)
l I008 - Road lights switch
l I021 – Groundspeed PTO control switch
l I023 - ECO PTO control switch
l J004 - Relay
l K012 - Rear PTO speed sensor (USA version)
l L003 - Rear PTO control solenoid valve
l L005 - Front PTO control solenoid valve
l M003 - Rear PTO control unit

40-1125
 Wiring diagrams

B030

B015
A
J004

B020
B010 B024
B021

E002

E003 C004

D005

I008

D0064410

Fig. 3955 - PTO - Connector positions

Table 833
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1221
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1221
B024 Fuse (7.5A) 40-1221
B030 Fuse (30A) 40-1221

40-1126
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1221

Fig. 3956
D005 Wiring connector 40-1221
40-1221
40-1234
40-1236

Fig. 3957
E002 Instrument panel 40-1221

Fig. 3958
E003 Instrument panel 40-1221

Fig. 3959
I008 Road lights switch 40-1221

Fig. 3960 Fig. 3961

J004 Relay 40-1221

Fig. 3962

40-1127
 Wiring diagrams

I005
I004
C003

I007
M003
D013

D011

C009
I003
I002
I006
D0064420

Fig. 3963 - Connector positions

Table 834
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1221

Fig. 3964

40-1128
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1221

Fig. 3965
D011 Wiring connector 40-1221
40-1214

Fig. 3966
D013 Wiring connector 40-1221
40-1221

Fig. 3967
I002 540 PTO control 40-1221
1
switch

Fig. 3968
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally Fig. 3969
open contact (NO)
I003 1000 PTO control 40-1221
1
switch

Fig. 3969
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally Fig. 3970
open contact (NO)

40-1129
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I004 Front PTO control 40-1221
switch

Fig. 3972
Fig. 3971
I005 Rear PTO control 40-1221
switch

Fig. 3974
Fig. 3973
I006 LH rear PTO con- Resistance between Pin 1 and 40-1221
trol switch (on Pin 2 with button pressed: 3.9
fender) Ohms

Fig. 3975
I007 RH rear PTO con- Resistance between Pin 1 and 40-1221
trol switch (on Pin 2 with button pressed: 3.9
fender) Ohms

Fig. 3976
M003 Rear PTO ECU 40-1221

Fig. 3977

40-1130
Wiring diagrams

D011

K012

L003

D0064780

Fig. 3978 - Connector positions

Table 835
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1221
40-1214

Fig. 3978

40-1131
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
K012 Rear PTO speed Pin 1 = earth 40-1214
sensor (USA ver- Pin 2 = analog signal:
sion) 0 Volt with sensor covered by
metal
12 Volt with sensor exposed
Pin 3 = 12 V power input
L003 Rear PTO control Pin 1 = earth 40-1214
solenoid valve Pin 2 = power
Impedance between Pin1 and
Pin2: ~ 8 Ohm (at 20 °C)

40-1132
Wiring diagrams

G22

ECO

I023
A

G23

G20
X65

X67

I021

X66

D0064460

Fig. 3981 - Connector positions

Table 836
Sys- P/N Description Characteristics/notes Position Wiring
tem
I021 P.T.O. engagement 40-1214
switch ECO
CB A

Fig. 3982
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 2 and pin 3: normally
open contact (NO)
I023 P.T.O. engagement Between pin 2 and pin 3: normally 40-1214
switch ECO closed contact (NC)
Between pin 1 and pin 4: normally
open contact (NO)
With switch free of levers

40-1133
 Wiring diagrams

40-1134
Wiring diagrams

D005

A003

L005
D006
D0064440

Fig. 3985 - Connector positions - Version with lateral battery

40-1135
 Wiring diagrams
Table 837
Sys- P/N Description Characteristics/notes Position Wiring
tem
A003 01183630 Alternator “D+” 40-1234
40-1236

Fig. 3986
D005 Wiring connector 40-1221
40-1221
40-1234
40-1236

Fig. 3986
D006 Wiring connector 40-1236
40-1180

Fig. 3987
L005 Front PTO control 40-1180
solenoid valve

40-1136
Wiring diagrams

D005

A003

D0064470

Fig. 3988 - Connector positions - Version with front battery

40-1137
 Wiring diagrams
Table 838
Sys- P/N Description Characteristics/notes Position Wiring
tem
D005 Wiring connector 40-1221
40-1221
40-1234
40-1236

Fig. 3988
A003 01183630 Alternator “D+” 40-1234
40-1236

Fig. 3988

40-1138
Wiring diagrams
40.3.83 - S028D - PTO (U.S.A.) - Version with digital instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
I004 I005
E003 E002 J004
I006 I007

1 2 2 3 7 8 2 3 7 8 2 1 NC NO 85 86 30

PTO SYNCRO
EV PTO ANT.

FRONT PTO

REAR PTO
PTO 1000
PTO ECO

PTO 540

D013
+12/30

+12/30

+12V
GND

GND

19 13 16 8 9 24 10 11 15 21 13 14
4 1 3 9 2

C004
B010
5A

C003
C004

+30

B030
B015

B021

B020
15A

30A
10A

3A

+30
+15
C009

C004

B024
7.5A
D011

B A A B B A A A B
B2 A7 B3 C3 A4 A8 A1 D1 D1

10 9 5 6 2 3 7 8
C003

2 3 1

I008
C004
C009

C009

K012
14 9 2 1 17 6 11 7 15 12 18
REAR PTO SWITCH
FRONT PTO LED

ABILITAZ. SENS.
REAR PTO LED

+15

PTO SPEED
REAR PTO EV

FRONT PTO EV
GND

D+
FRONT PTO SWITCH

D005

2 9 8
2 3 2 1 2 3 4 1 4 1
D006

I023 L003 I021 I003 I002 M003

2 1 9

2 1

L005
A003

D0063500

Fig. 3989 - PTO (U.S.A.) - Version with digital instrument panel - System
l A003 - Alternator “D+”
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D006 (M) - Wiring connector (Wiring loom 0.008.0913.3)
l D006 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)

40-1139
 Wiring diagrams
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D013 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D013 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l E002 - Instrument panel
l I002 - 540 PTO control switch
l I003 - 1000 PTO control switch
l I004 - Front PTO control switch
l I005 - Rear PTO control switch
l I006 – LH rear PTO control switch (on fender)
l I007 – RH rear PTO control switch (on fender)
l I008 - Road lights switch
l I021 – Groundspeed PTO control switch
l I023 - ECO PTO control switch
l J004 - Relay
l K012 - Rear PTO speed sensor (USA version)
l L003 - Rear PTO control solenoid valve
l L005 - Front PTO control solenoid valve
l M003 - Rear PTO control unit

40-1140
Wiring diagrams

B030

B015
A
J004

B020
B010 B024
B021

E002

E003 C004

D005

I008

D0064410

Fig. 3990 - PTO (U.S.A.) - Version with digital instrument panel - Connector positions
Table 839
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1221
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1221
B024 Fuse (7.5A) 40-1221
B030 Fuse (30A) 40-1221

40-1141
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1221

Fig. 3991
D005 Wiring connector 40-1221
40-1221
40-1234
40-1236

Fig. 3992
E002 Instrument panel 40-1221

Fig. 3993
E003 Instrument panel 40-1221

Fig. 3994
I008 Road lights switch 40-1221

Fig. 3995 Fig. 3996

J004 Relay 40-1221

Fig. 3997

40-1142
Wiring diagrams

I005
I004
C003

I007
M003
D013

D011

C009
I003
I002
I006
D0064420

Fig. 3998 - Connector positions

Table 840
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1221

Fig. 3999

40-1143
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C009 Earthing point 9 40-1221

Fig. 4000
D011 Wiring connector 40-1221
40-1212

Fig. 4001
D013 Wiring connector 40-1221
40-1221

Fig. 4002
I002 P.T.O. engagement 40-1221
switch 540

Fig. 4003 Fig. 4004

Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)
I003 1000 PTO control 40-1221
switch

Fig. 4004
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 3 and pin 4: normally
open contact (NO)

40-1144
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
I004 Front PTO control 40-1221
switch

Fig. 4006
Fig. 4005
I005 Rear PTO control 40-1221
switch

Fig. 4007
Fig. 4006
I006 Lh rear PTO control Resistance between Pin 1 and 40-1221
switch (on fender) Pin 2 with button pressed: 3.9
Ohms

Fig. 4008
I007 Rh rear PTO con- Resistance between Pin 1 and 40-1221
trol switch (on Pin 2 with button pressed: 3.9
fender) Ohms

Fig. 4009
M003 Rear PTO ECU 40-1221

Fig. 4010

40-1145
 Wiring diagrams

D011

K012

L003

D0064780

Fig. 4011 - Connector positions

Table 841
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1221
40-1212

Fig. 4011

40-1146
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
K012 Rear PTO speed Pin 1 = earth 40-1212
sensor (USA ver- Pin 2 = analog signal:
sion) 0 Volt with sensor covered by
metal
12 Volt with sensor exposed
Pin 3 = 12 V power input
L003 Rear PTO control Pin 1 = earth 40-1212
solenoid valve Pin 2 = power
Impedance between Pin1 and
Pin2: ~ 8 Ohm (at 20 °C)

40-1147
 Wiring diagrams

D005

A003

L005
D006
D0064440

Fig. 4014 - Connector positions

40-1148
Wiring diagrams
Table 842
Sys- P/N Description Characteristics/notes Position Wiring
tem
A003 01183630 Alternator “D+” 40-1234
40-1236

Fig. 4015
D005 Wiring connector 40-1221
40-1221
40-1234
40-1236

Fig. 4015
D006 Wiring connector 40-1236
40-1180

Fig. 4016
L005 Front PTO control 40-1180
solenoid valve

40-1149
 Wiring diagrams

D005

A003

D0064470

Fig. 4017 - Connector positions

40-1150
Wiring diagrams
Table 843
Sys- P/N Description Characteristics/notes Position Wiring
tem
A003 01183630 Alternator “D+” 40-1234
40-1236

Fig. 4017
D005 Wiring connector 40-1221
40-1221
40-1234
40-1236

Fig. 4017

40-1151
 Wiring diagrams

G22

ECO

I023
A

G23

G20
X65

X67

I021

X66

D0064460

Fig. 4018 - Connector positions

Table 844
Sys- P/N Description Characteristics/notes Position Wiring
tem
I021 P.T.O. engagement 40-1212
switch ECO
CB A

Fig. 4019
Between pin 1 and pin 2: normally
closed contact (NC)
Between pin 2 and pin 3: normally
open contact (NO)
I023 P.T.O. engagement Between pin 2 and pin 3: normally 40-1212
switch ECO closed contact (NC)
Between pin 1 and pin 4: normally
open contact (NO)
With switch free of levers

40-1152
Wiring diagrams

40.3.84 - S029 - Brakes (U.S.A.) (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 ->
20001)

40-1153
 Wiring diagrams
E003
E002

E004b
E004a

E004
J002 J004 J006
TRAILER PRESSURE
BRAKES OIL LEVEL

HAND BRAKE

PARK BRAKE

+12/30

+12/30
+12V
GND

GND

13 8 7 12 22 26 14 21 15 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30 2 1 + - G

C004

C004

C004

C004
C004

C003
B010
B006

B025

B030
B020
B021

B015

B024
7.5A

30A

30A

15A

7.5A
5A
3A
10A
C004

D011
+30
+15
D005

D011

C008

B A A A A B A
9 10 A5 D6 A8 A1 D1 D1 D8
A
B8

D021
1 2 1 2 10 9 5 6 2 3 7 8

P P

P
K013

K002 D010
K008

I008 K025
D018

1 2

1 2

D0063510
L009

Fig. 4022 - Brakes - System

l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D010 (F) - Park Brake switch (Wiring loom 0.016.0484.4/60)
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D018 (M) - Wiring connector (Wiring loom 0.016.1001.4/20)
l D018 (F) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D021 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D021 (F) - Wiring connector (Wiring loom 0.014.1645.4/10)
l E002 - Instrument panel
l E003 - Instrument panel
l E004 - Trailer pressure indicator

40-1154
Wiring diagrams
E003
E002

E004b
E004a

E004
J002 J004 J006
TRAILER PRESSURE
BRAKES OIL LEVEL

HAND BRAKE

PARK BRAKE

+12/30

+12/30
+12V
GND

GND

13 8 7 12 22 26 14 21 15 NC NO 85 86 30 NC NO 85 86 30 NC NO 85 86 30 2 1 + - G

C004

C004

C004

C004
C004

C003
B010
B006

B025

B030
B020
B021

B015

B024
7.5A

30A

30A

15A

7.5A
5A
3A
10A
C004

D011
+30
+15
D005

D011

C008

B A A A A B A
9 10 A5 D6 A8 A1 D1 D1 D8
A
B8

D021
1 2 1 2 10 9 5 6 2 3 7 8

P P

P
K013

K002 D010
K008

I008 K025
D018

1 2

1 2

D0063510
L009

Fig. 4022 - Brakes - System

l E004a - Trailer pressure indicator
l E004b- Trailer pressure indicator
l I008 - Road lights switch
l J002 - Relay
l J004 - Relay
l J006 - Relay
l K002 - Brake fluid level sensor
l K008 - Park Brake pressure switch
l K013 - Hydraulic trailer braking valve pressure switch
l K025 - Compressed air pressure sensor
l L009 - Trailer parking brake solenoid valve

40-1155
 Wiring diagrams
B030

B025
J002
J006
B015
A
B020 J004

B006
B021 B024
B010

E002
C004
E003

D005 E004
E004a
E004b

I008

D0064750

Fig. 4023 - Brakes - Connector positions

Table 845
Sys- P/N Description Characteristics/notes Position Wiring
tem
B006 Fuse (7.5A) 40-1221
B010 Fuse (5A) 40-1221
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1221
B024 Fuse (7.5A) 40-1221
B025 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1221

40-1156
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1221

Fig. 4024
D005 Wiring connector 40-1221
D005 Wiring connector 40-1221
D005 Wiring connector 40-1234
D005 Wiring connector 40-1236

Fig. 4025
E002 Instrument panel 40-1221

Fig. 4026
E003 Instrument panel 40-1221

Fig. 4027
E004 Trailer pressure in- Pin S = input from sensor 40-1221
dicator Pin + = 15V power supply
Pin - = earth
Trailer pressure in- Pin S = input from sensor 40-1221
dicator Pin + = 15V power supply
Pin - = earth
Trailer pressure in- Pin S = input from sensor 40-1221
dicator Pin + = 15V power supply
Pin - = earth
I008 Road lights switch 40-1221

Fig. 4029 Fig. 4030

40-1157
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J002 Relay 40-1221

Fig. 4031
J004 Relay 40-1221

Fig. 4032
J006 Relay 40-1221

Fig. 4033

40-1158
Wiring diagrams

C003

C008

D010

D011

K008

D0064760

Fig. 4034 - Connector positions

Table 846
Sys- P/N Description Characteristics/notes Position Wiring
tem
C003 Earthing point 3 40-1221

Fig. 4035

40-1159
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C008 Earthing point 8 40-1221

Fig. 4036
D010 Park Brake switch 40-1221

Fig. 4037
D011 Wiring connector 40-1221
D011 Wiring connector 40-1214

Fig. 4038
K008 Park Brake pres- Normally open contact (NO) 40-1221
Switching pressure: 15 bar

40-1160
Wiring diagrams

D018

A K013

D021

D0064770

Fig. 4040 - Connector positions

Table 847
Sys- P/N Description Characteristics/notes Position Wiring
tem
D018 Wiring connector 40-1214
D018 Wiring connector 40-1232

Fig. 4041
D021 Wiring connector 40-1214
40-1191
K013 Hydraulic trailer Normally closed (NC) contact 40-1214
Switching pressure: 11 bar

40-1161
 Wiring diagrams

D011

D0064330

Fig. 4043 - Connector positions

40-1162
Wiring diagrams
Table 848
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1221
D011 Wiring connector 40-1214

Fig. 4043

L009
D018

D0064340

Fig. 4044 - Connector positions

40-1163
 Wiring diagrams
Table 849
Sys- P/N Description Characteristics/notes Position Wiring
tem
D018 Wiring connector 40-1214
D018 Wiring connector 40-1232

Fig. 4044
L009 Trailer parking Pin 1 = power 40-1232
brake control sole- Pin 2 = earth
noid valve Impedance between Pin1 and
Pin2: ~ 8 Ohm (at 20 °C)

D021

K025

G23

X77

D0064350

Fig. 4045 - Connector positions

40-1164
Wiring diagrams
Table 850
Sys- P/N Description Characteristics/notes Position Wiring
tem
D021 Wiring connector 40-1214
40-1191
K025 Compressed air Power 12V DC 40-1191
pressure sensor Resistance at 0 bar 10-13 Ohm
Resistance at 6 bar 119-129 Ohm

K002 D005

D0064360

Fig. 4046 - Connector positions - Version with front battery

40-1165
 Wiring diagrams

K002 D005

D0064370

Fig. 4047 - Connector positions - Version with lateral battery

40-1166
Wiring diagrams
Table 851
Sys- P/N Description Characteristics/notes Position Wiring
tem
K002 Brake fluid level 40-1234
sensor 40-1236

Fig. 4048
D005 Wiring connector 40-1221
40-1221
40-1234
40-1236

Fig. 4048

40-1167
 Wiring diagrams
40.3.85 - S029D - Brakes (U.S.A.) - Version with digital instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)
E003

E002

E004b
E004a

E004
J002 J004
TRAILER PRESSURE
BRAKES OIL LEVEL

HAND BRAKE

PARK BRAKE

+12/30

+12/30
+12V
GND

GND

13 8 7 12 22 26 14 21 15 NC NO 85 86 30 NC NO 85 86 30 2 1 + - G

C004

C004

C004
C004
C004

B010

B025

B030

B024
B020
B021

B015
30A

30A

15A

7.5A
5A
3A
10A
C004

D011
+30
+15
D005

D011

C008

A
9 10 D6
A
B8
D021

1 2 10 9 5 6 2 3 7 8
1 2
P

P
K002 D010
K013

I008 K025

D0064850

Fig. 4049 - Brakes (U.S.A.) - Version with digital instrument panel - Systems
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (M) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D005 (F) - Wiring connector (Wiring loom 0.016.2000.4/20)
l D005 (F) - Wiring connector (Wiring loom 0.016.2001.4/10)
l D010 (F) - Park Brake switch (Wiring loom 0.016.0484.4/60)
l D011 (F) - Wiring connector (Wiring loom 0.016.0484.4/60)
l D011 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D021 (M) - Wiring connector (Wiring loom 0.015.7023.4/50)
l D021 (F) - Wiring connector (Wiring loom 0.014.1645.4/10)
l E002 - Instrument panel
l E004 - Trailer pressure indicator
l E004a - Trailer pressure indicator
l E004b- Trailer pressure indicator
l I008 - Road lights switch
l J002 - Relay
l J004 - Relay

40-1168
Wiring diagrams
l K002 - Brake fluid level sensor
l K013 - Hydraulic trailer braking valve pressure switch
l K025 - Compressed air pressure sensor

B030

B025
J002

B015
A
B020 J004

B021 B024
B010

E002
C004
E003

D005 E004
E004a
E004b

I008

D0064751

Fig. 4050 - Brakes (U.S.A.) - Version with digital instrument panel - Connector positions
Table 852
Sys- P/N Description Characteristics/notes Position Wiring
tem
B010 Fuse (5A) 40-1221
B015 Fuse (15A) 40-1221
B020 Fuse (3A) 40-1221
B021 Fuse (10A) 40-1221
B024 Fuse (7.5A) 40-1221
B025 Fuse (30A) 40-1221
B030 Fuse (30A) 40-1221

40-1169
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
C004 Earthing point 4 40-1221

Fig. 4051
D005 Wiring connector 40-1221
40-1221
40-1234
40-1236

Fig. 4052
E002 Instrument panel 40-1221

Fig. 4053
E003 Instrument panel 40-1221

Fig. 4054
E004 Trailer pressure in- Pin S = input from sensor 40-1221
dicator Pin + = 15V power supply
Pin - = earth
Trailer pressure in- Pin S = input from sensor 40-1221
dicator Pin + = 15V power supply
Pin - = earth
Trailer pressure in- Pin S = input from sensor 40-1221
dicator Pin + = 15V power supply
Pin - = earth
I008 Road lights switch 40-1221

Fig. 4056 Fig. 4057

40-1170
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
J002 Relay 40-1221

Fig. 4058
J004 Relay 40-1221

Fig. 4059

40-1171
 Wiring diagrams

C008

D010

D011

D0064761

Fig. 4060 - Connector positions

Table 853
Sys- P/N Description Characteristics/notes Position Wiring
tem
C008 Earthing point 8 40-1221

Fig. 4061
D010 Park Brake switch 40-1221

40-1172
Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1221
40-1212

Fig. 4062

A K013

D021

D0064771

Fig. 4063 - Connector positions

Table 854
Sys- P/N Description Characteristics/notes Position Wiring
tem
D021 Wiring connector 40-1212
40-1191

40-1173
 Wiring diagrams
Sys- P/N Description Characteristics/notes Position Wiring
tem
K013 Hydraulic trailer Normally closed (NC) contact 40-1212
Switching pressure: 11 bar

D011

D0064330

Fig. 4065 - Connector positions

40-1174
Wiring diagrams
Table 855
Sys- P/N Description Characteristics/notes Position Wiring
tem
D011 Wiring connector 40-1221
40-1212

Fig. 4065

D021

K025

G23

X77

D0064350

Fig. 4066 - Connector positions

Table 856
Sys- P/N Description Characteristics/notes Position Wiring
tem
D021 Wiring connector 40-1212
40-1191
K025 Compressed air Power 12V DC 40-1191
pressure sensor Resistance at 0 bar 10-13 Ohm
Resistance at 6 bar 119-129 Ohm

40-1175
 Wiring diagrams

K002 D005

D0064360

Fig. 4067 - Connector positions - Version with front battery

40-1176
Wiring diagrams
Table 857
Sys- P/N Description Characteristics/notes Position Wiring
tem
K002 Brake fluid level 40-1234
sensor

Fig. 4068
D005 Wiring connector 40-1221
40-1221
40-1234

Fig. 4068

40-1177
 Wiring diagrams

K002 D005

D0064370

Fig. 4069 - Connector positions - Version with lateral battery

40-1178
Wiring diagrams
Table 858
Sys- P/N Description Characteristics/notes Position Wiring
tem
K002 Brake fluid level 40-1236
sensor

Fig. 4069
D005 Wiring connector 40-1221
40-1221
40-1236

Fig. 4069

40-1179
 Wiring diagrams
40.4 - Wiring harnesses
40.4.1 - 0.008.0913.3 - Front PTO

D006
L005

M1
1

L1
2

D006
L005

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue

Z Viola/Violet B Bianco/White

N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray
D0047871

Fig. 4070 - Front PTO

Table 859
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D006 Wiring connector
L005 Front PTO control solenoid valve

40.4.2 - 0.009.7853.3/20 - Air conditioning condenser fan - Version with standard cab

40-1180
Wiring diagrams

K024

K023
1

P015
3 2 1

D028
J014 2 1

4 3

D0063070

Fig. 4071 - Air conditioning condenser fan - Version with standard cab (1/2)
Table 860
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D028 Wiring connector
J014 Control relay for air conditioning cooler fan
K023 Air conditioning pressure switch
K024 Air conditioning pressure switch
P015 Air conditioning condenser fan

K024

K023
P015
BIANCO

WHITE

3 2 1 1
AN 2.5 AN 1

30

J014
N 2.5
A 2.5

85 87 86
CB 1
VN 1
CB 1

N1
V1

87

A 2.5
V1
N 2.5
N1

2 1
D028 4 3
AN 2.5
VN 1

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue

Z Viola/Violet B Bianco/White

N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray
D0063080

Fig. 4072 - Air conditioning condenser fan - Version with standard cab (2/2)

40-1181
 Wiring diagrams
40.4.3 - 0.010.2147.2 - Heating - Version with standard cab

P014 O003

D027

H005
D0063090

Fig. 4073 - Heating - Version with standard cab (1/2)

Table 861
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D027 Wiring connector
D027 Wiring connector
H005 Blower speed selector switch
O003 Resistor
P014 Electric fan

40-1182
Wiring diagrams

N 2.5
C 2.5 D027

N 2.5
M R 2.5

P014

MN 1.5

MN 1.5
RN 1.5

R 2.5
C 2.5
LR 1

LR 1
L M H B L
TF 3
2

O003 0

H005

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue

Z Viola/Violet B Bianco/White

N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray D0063100

Fig. 4074 - Heating - Version with standard cab (2/2)

40.4.4 - 0.010.2153.2 - Air conditioning - Version with standard cab

40-1183
 Wiring diagrams

P014 O003

D027

J013

D026 H005

K022
D0063120

Fig. 4075 - Air conditioning - Version with standard cab (1/2)

Table 862
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D026 Wiring connector
D026 Wiring connector
D027 Wiring connector
D027 Wiring connector
H005 Blower speed selector switch
J013 Compressor relay
K022 Air conditioning temperature thermostat
O003 Resistor
P014 Electric fan

40-1184
Wiring diagrams

N 2.5
C 2.5 D027
BV 0.5
NZ 0.5
CB 1 D026
B 0.5

N 2.5
P014 M R 2.5
B 0.5
B 0.5
K022

MN 1.5

MN 1.5
RN 1.5

BV 0.5
NZ 0.5
R 2.5

C 2.5
B 0.5

CB 1
LR 1

LR 1

C1
L M H B L 30 85 86 87
TF 3
2

O003 0

TABELLA COLORI / COLOURS TABLE

J013
H005
M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue

Z Viola/Violet B Bianco/White

N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray
D0063130

Fig. 4076 - Air conditioning - Version with standard cab (2/2)

40-1185
 Wiring diagrams
40.4.5 - 0.010.4516.3 - Windscreen wiper - Version with standard cab

G-R 1

M-N 1

N006 D030

V-N 1

R-N 1

R-N 1 G-R 1
G-R 1 V-N 1
(+AZZ) (+MOT) (+MOT) (AZZ.)

R-N 1
V-N 1 M-N 1
(+AZZ)
(AZZ.) (GND)
3 2 1

6 5 4

M-N 1
TABELLA COLORI / COLOURS TABLE (GND)

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray
D0006743

Fig. 4077 - Windscreen wiper - Version with standard cab

Table 863
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D030 Wiring connector
D030 Wiring connector
N006 Windscreen wiper motor

40-1186
Wiring diagrams
40.4.6 - 0.011.3597.3 - Windscreen wiper - Version with high-visibility cab

G-R 1

M-N 1

N006 D030

V-N 1

R-N 1

R-N 1 G-R 1 G-R 1 V-N 1

(+AZZ) (+MOT)

V-N 1 M-N 1 M-N 1 R-N 1

(AZZ.) (GND)

TABELLA COLORI / COLOURS TABLE

G-R (+MOT) G M Marrone/Brown C Arancio/Orange
M-N (GND) M
WIRES WIPER V Verde/Green A Azzurro/Blue
R-N (+AZZ) V-N
Z Viola/Violet B Bianco/White
V-N (AZZ.) N
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray D0006834

Fig. 4078 - Windscreen wiper - Version with high-visibility cab

Table 864
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D030 Wiring connector
N006 Windscreen wiper motor

40-1187
 Wiring diagrams
40.4.7 - 0.013.4909.4 - Rear lights (U.S.A.)
RH rear lights (U.S.A.)

F021

D043
5

F009
4
3
2
1

D0063140

Fig. 4079 - RH rear lights (U.S.A.) (1/2)

Table 865
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D043 Wiring connector
F009 RH rear sidelight and direction indicator
F021 RH rear light (hazard warning)

GN 1

L1
F009
GN 1
5

L1
4 N1

N1
D043 2

N1
1

A1
TABELLA COLORI / COLOURS TABLE 3

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
N1
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow A1
F021
R Rosso/Red H Grigio/Gray

D0063150

Fig. 4080 - RH rear lights (U.S.A.) (2/2)

40-1188
Wiring diagrams
LH rear lights (U.S.A.)

F020

D044
5

F008
4
3
2
1

D0063160

Fig. 4081 - LH rear lights (U.S.A.) (1/2)

Table 866
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D044 Wiring connector
F008 LH rear sidelight and direction indicator
F020 LH rear light (hazard warning)

GN 1

L1
F008
GN 1
5

L1
4 N1

N1
D044 2

N1
1

A1
3
TABELLA COLORI / COLOURS TABLE
M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue N1

Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
A1
F020
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray
D0063170

Fig. 4082 - LH rear lights (U.S.A.) (2/2)

40-1189
 Wiring diagrams
40.4.8 - 0.013.6327.4 - LH rotating beacon

2
D031 F019
1

D0063200

Fig. 4083 - LH rotating beacon (1/2)

Table 867
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D031 Wiring connector
D031 Wiring connector
F019 Rotating beacon

N 1.5
2

VR 1.5
2
F019
D031 N 1.5
1
VR 1.5 1

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray
D0063210

Fig. 4084 - LH rotating beacon (2/2)

40.4.9 - 0.013.6327.4 - RH rotating beacon

2
D032 F018
1

D0063180

Fig. 4085 - RH rotating beacon (1/2)

40-1190
Wiring diagrams
Table 868
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D032 Wiring connector
D032 Wiring connector
F018 Rotating beacon

N 1.5
2

VR 1.5
2
F018
D032 N 1.5
1
VR 1.5 1

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

D0063190

Fig. 4086 - RH rotating beacon (2/2)

40.4.10 - 0.014.1645.4/10 - Compressed air pressure sensor

D021 K025
1
1

D021 1
BZ 1
1 K025

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray D0048071

Fig. 4087 - Compressed air pressure sensor

Table 869
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D021 Wiring connector
K025 Compressed air pressure sensor

40-1191
 Wiring diagrams
40.4.11 - 0.014.3927.4/40 - LH auxiliary work lights - Version with high-visibility cab

D042 30 F017

V 1.5
2
D042 M 1.5
F017
1

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray D0036794

Fig. 4088 - LH auxiliary work lights - Version with high-visibility cab

Table 870
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D042 Wiring connector
F017 Lh auxiliary worklight

40.4.12 - 0.014.3927.4/40 - RH auxiliary work lights - Version with high-visibility cab

D041 30 F016

V 1.5
2
D041 M 1.5 F016
1

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray D0036793

Fig. 4089 - RH auxiliary work lights - Version with high-visibility cab

40-1192
Wiring diagrams
Table 871
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D041 Wiring connector
F016 Rh auxiliary worklight

40.4.13 - 0.014.8107.4/30 - Hood lights (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO
85 -> 20001)

F001

E001

1
2

D004

F005 F004
F002 F003

F006

D0063220

Fig. 4090 - Hood lights (1/2)

Table 872
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D004 Wiring connector
D004 Wiring connector
E001 Horn
F001 Rh front worklight (on hood)
F002 Rh high beam headlight
F003 Rh low beam headlight
F003 Rh low beam headlight
F004 Lh low beam headlight
F004 Lh low beam headlight
F005 Lh high beam headlight
F006 Lh front worklight (on hood)

40-1193
 Wiring diagrams

1
F003
2

2
F004

1
F002
2
H 1.5
LOW BEAM LIGHTS RH 1

H 1.5 1
LOW BEAM LIGHTS LT 2

VN 1.5
F005
HIGH BEAM LIGHTS RH 3
2

VN 1.5
HIGH BEAM LIGHTS LT 4 1
Z1
E001
2 1
HORN 5
F006
RV 1.5
CORNER LIGHTS LT 6 2 1
RV 1.5 F001
2
D004
CORNER LIGHTS RH 7

N 1.5
-31 8

N 1.5
-31 9

R1
+30 10

N 1.5
-31 11

N 1.5
-31 12

N 1.5
-31 13

N 1.5
-31 14

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

D0063230

Fig. 4091 - Hood lights (2/2)

40-1194
Wiring diagrams
40.4.14 - 0.014.9195.4/20 - Preheating

A001 J001b

125

T001a B004 J001a

D0036762

Fig. 4092 - Preheat

Table 873
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
A001 Preheating device
B004 Fuse
J001a Preheating relay
J001b Preheating relay
T001a Battery positive terminal

40-1195
 Wiring diagrams
40.4.15 - 0.015.1418.4/30 - Cab shuttle (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO
85 -> 20001)

12
D007
11
5 10
4
9
6 8
7 7
3 6
8 2
9 1
10
11
12

P007
1
2
3

1
4

2
3
4

D022
H003

3k
K020

D0047681

Fig. 4093 - Cab shuttle

Table 874
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D007 Wiring connector
D007 Wiring connector
D022 Wiring connector
H003 Shuttle lever
K020 Clutch pedal position sensor
P007 CAN BUS auxiliary socket

40-1196
Wiring diagrams
40.4.16 - 0.015.1435.4/20 - RH auxiliary work lights - Version with standard cab (R3 EVO
100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)

D041 F016

CV 1.5

D041 F016
1

N1

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

D0036782

Fig. 4094 - RH auxiliary work lights - Version with standard cab

Table 875
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D041 Wiring connector
F016 Rh auxiliary worklight

40-1197
 Wiring diagrams
40.4.17 - 0.015.1435.4/20 - LH auxiliary work lights - Version with standard cab (R3 EVO
100 -> 20001, R3 EVO 110 -> 1001, R3 EVO 85 -> 20001)

D042 F017

CV 1.5

2
D042 F017
1

N1

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray

D0036783

Fig. 4095 - LH auxiliary work lights - Version with standard cab

Table 876
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D042 Wiring connector
F017 Lh auxiliary worklight

40-1198
Wiring diagrams
40.4.18 - 0.015.1983.4/10 - Power supplies 1

60A

N001

B001

D0036772 D001

Fig. 4096 - Power supplies 1

Table 877
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
B001 Fuse
D001 Wiring connector
D001 Wiring connector
N001 Starter motor “+30”

40-1199
 Wiring diagrams
40.4.19 - 0.015.1983.4/10 - Power supplies 2

60A

N001

B002

D0036773 D002

Fig. 4097 - Power supplies 2

Table 878
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
B002 Fuse
D002 Wiring connector
D002 Wiring connector
N001 Starter motor “+30”

40-1200
Wiring diagrams
40.4.20 - 0.015.1983.4/10 - Power supplies 3

60A

N001

B003

D0036774 D003

Fig. 4098 - Power supplies 3

Table 879
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
B003 Fuse
D003 Wiring connector
D003 Wiring connector
N001 Starter motor “+30”

40-1201
 Wiring diagrams
40.4.21 - 0.015.1998.4/10 - Drivetrain shuttle (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001,
R3 EVO 85 -> 20001)
K017
2 1

K018

1
K015 K016 L006 L007 L008

3 2 1 2 1 2 1 2 1

D022
D019
AMP

1
1 2

K019 D0063240

Fig. 4099 - Drivetrain shuttle (1/2)

Table 880
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D019 Wiring connector
D022 Wiring connector
K015 Engine speed sensor
K016 Shuttle sensor
K017 Oil temperature sensor
K018 Clutch oil pressure switch
K019 PALL filter clogging sensor
L006 Forward gear selection solenoid
L007 Reverse gear selection solenoid
L008 Solenoid-operated proportional valve

40-1202
Wiring diagrams

D022
1 2 3 4 5 6 7 8 9 10 11 11 D019

N-1

VN-1

RN-1
Z-1
C-1
MB-1

BN-1
L-1

A-1

B-1

VB-1
K017
1 2
SU2

1
T P

1.ZN-1
L007

MB-1
2
K019
MB-1
P
K018
2 1 1 2

2.N-1
N-1

K016 L008

N-1
1 2 3

F
1 2

SU1
K015
L006
N-1
TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue

Z Viola/Violet B Bianco/White

N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray
D0063250

Fig. 4100 - Drivetrain shuttle (2/2)

40.4.22 - 0.015.6123.4 - Rear wiper - Version with standard cab (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001)

D036 N005

N 1 (-31)
HN 1 (53)

D036 N005

TABELLA COLORI / COLOURS TABLE

M Marrone/Brown C Arancio/Orange
V Verde/Green A Azzurro/Blue
Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray D0047711

Fig. 4101 - Rear wiper - Version with standard cab

Table 881
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D036 Wiring connector
N005 Rear screen wiper motor

40-1203
 Wiring diagrams
40.4.23 - 0.015.6272.4/40 - Cab roof - Version with high-visibility cab
F011
P012 D034 P011
O001
P009
D034
P008

F013
G001
K021
D031

P013 D035

D035
D028

F012

N005

J012

J010 F010 D025

D024
J011

M005
E007 D032
E006
I030 D023
P010
I025

O002
37
D030
03
H004
I029 B034 B040
G002
04

I028
05 07
06

I027 I026
I024
C007 D0047751

Fig. 4102 - Cab roof - Version with high-visibility cab

Table 882
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
B034 Fuse (15A)
B035 Fuse (5A)
B036 Fuse (20A)
B037 Fuse (7.5A)
B038 Fuse (7.5A)
B039 Fuse (10A)
B040 Fuse (10A)
C007 Earthing point 7
D023 Wiring connector
D024 Wiring connector
D025 Wiring connector
D028 Wiring connector
D030 Wiring connector
D031 Wiring connector
D032 Wiring connector
D034 Wiring connector
D034 Wiring connector
D035 Wiring connector
D035 Wiring connector

40-1204
Wiring diagrams
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
E006 Climate control LED
E007 Climate control panel lighting
F010 Rh front worklight (on cab roof)
F011 Lh rear worklight (on cab roof)
F012 Rh rear worklight (on cab roof)
F013 Lh front worklight (on cab roof)
Table 883
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
G001 Interior roof light
G002 Spot light
H004 Blower speed selector switch
H004 Blower speed selector switch
06 I024 Front worklights switch
I025 Rotating beacon switch
07 I026 Rear worklights switch
05 I027 Windscreen washer pump switch
04 I028 Windscreen wiper switch
03 I029 Rear screen wiper switch
I030 A/C activation switch
J010 Max. fan speed relay
J011 Compressor and A/C 1st speed start relay
J012 3rd fan speed relay
K021 Air conditioning temperature thermostat
M005 Windscreen wiper intermittent timer
N005 Rear screen wiper motor
O001 Lh resistor
37 O002 Rh resistor
P008 Radio (power supply)
P009 Lh loudspeaker
P010 Rh loudspeaker
P011 Radio (loudspeakers)
P012 Rh fan
P013 Lh fan

40-1205
 Wiring diagrams
40.4.24 - 0.015.7021.4/70 - Central - Version with digital instrument panel (R3 EVO 100 ->
16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

MF5
40A FT1-2-3 B029
MF4
40A START B028

PK1 PK2
+15
START FAN SPEED J008 J009
COMPRESSOR
MU1

MU4

RELAY
B030
COMPRESSOR

30A
MK3
FT 5-6-7-8

FAN SPEED
RELAY

B025

B026

B027
MK1

20 A B032
30A
30A

30A

POWER
B031 B033
MU6
MU3

30A +15
MF1

20 A
MK3 MF3

SOCKET
MK1

+15 +15
HI/LO J002 J003 J004
F14-15 F11-12-13

+15 ROOF +15

FAN SPEED J005 J006 J007
MK4

MK6

FT5.6.7.8 MU6
M11

B006 B016

B010 B020
B011 B021
B005 B015

B009 B019

B012 B022
B013 B023
STOLL SOCKET
B007 B017
B008 B018

B014 B024
RELAY

L R
+15 +15 +15 +15 +15 +15 +15 +15
M20

7.5A 7.5A 7.5 A 10A 3A 15 A 15 A 7.5 A 7.5 A 15 A

COMPRESSOR

STOP(EU)
STOP +30
+15 +30 +30 USA +30 +30 +30
10 A 7.5 A 20 A 15 A 15 A 5A 7.5A 15 A 15 A 15 A
M1

M10

D0063290

Fig. 4103 - Fusebox

40-1206
Wiring diagrams
I015 I010 I005 I004 P004a
I014 R F

P004
1
3 2 1 8 3 2 1 8 3 2 1 8 3 2 1 8 3 2 1 8
2
6 5 4 7 6 5 4 7 6 5 4 7 6 5 4 7 6 5 4 7

P002a
D013 P002b
K006 H002
4 5 6
LEVA HI/LO
M003 K005 P002
1 2 3
18

D011
13
7

4 5 6
2 3
12

C003

1
AMP
6 1

F
4 3 2 1

D013 85-100 3-LO/4-HI

HI(VIOLA)
LO(BIANCO)
110 3-HI/4-LO

I001
AMP

2
1
I007

3
AMP

2
1
F009

2
4
1
3
8

7
I016

4
5
2

17 18
3 10
I018

15
30

50
1

2
P005

I013

4
3
2
1
K007

3
AMP

2
D004

1
C004 N004
1

N003
1

E004
+ 2

-
G

E004a
E004b C009
M002
D007
S
D012b S C008 F

ECU MOTORE
D009 R

D012a R
M001
D010

3
D012
AMP

2
M

1
M F

D008 E003 K008

5k
I002 D010

3
4
5

2
3

1
2
1
D014 E002 I003 I017

4
1

3k

3
R001

2
1
M004 P003
4
1
2
5

4
4

I008
3

AMP
3

2
6

2
3

D005
1
1

7
1

4
2

D003 I011
4

3 10

6
3

SUPPLY FREE
2

I019
1

7
8
1

1 2 3 1 2 1 2

D002
2

AMP

AMP

AMP
SUPPLY FREE
3

I009

I006
8
TOP

I012

F007a
F007
1

4
D001 TOP
8

5
1

1 2
4

SUPPLY FREE

6
3 4
2

5
3

F008
56b
56a 31b

49a
H001
L
56 31
56d

D0063280

Fig. 4104 - Central - Version with digital instrument panel

Table 884
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
B005 Fuse (10A)
B006 Not used
B007 Fuse (20A)
B008 Fuse (15A)
B009 Fuse (15A)
B010 Fuse (5A)
B011 Not used
B012 Fuse (15A)
B013 Fuse (15A)
B014 Not used
B015 Fuse (15A)
B016 Fuse (7.5A)
B017 Not used
B018 Not used
B019 Fuse (15A)
B020 Fuse (3A)
B021 Fuse (10A)
B022 Fuse (7.5A)
B023 Fuse (7.5A)
B024 Fuse (7.5A)
B025 Fuse (30A)
B026 Fuse (30A)
B027 Fuse (30A)
B028 Fuse (40A)
B029 Fuse (40A)
B030 Fuse (30A)
B031 Fuse (30A)
B032 Fuse (20A)
B033 Fuse (20A)
C003 Earthing point 3

40-1207
 Wiring diagrams
Table 885
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
C004 Earthing point 4
C008 Earthing point 8
C009 Earthing point 9
D001 Wiring connector
D002 Wiring connector
D003 Wiring connector
D004 Wiring connector
D005 Wiring connector
D005 Wiring connector
D007 Not used
D008 Wiring connector
D009 Wiring connector
D010 Not used
D010 Park Brake switch
D011 Wiring connector
D012 Not used
R D012a Not used
S D012b Not used
D013 Wiring connector
D013 Wiring connector
D014 Wiring connector
E002 Instrument panel
E003 Instrument panel
E004 Trailer pressure indicator
E004a Trailer pressure indicator
E004b Trailer pressure indicator
F007 Number plate light
F007a Number plate light
F008 LH rear light
F009 RH rear light
Table 886
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
H001 Lights selector switch
HI/LO LEVER H002 Not used
I001 Engine speed memory button
I002 540 PTO control switch
I003 1000 PTO control switch
I004 Front PTO control switch
I005 Rear PTO control switch
I006 Lh rear PTO control switch (on fender)
I007 Rh rear PTO control switch (on fender)
I008 Road lights switch
TOP I009 Top work lights switch
I010 Differential lock control switch
I011 Clutch pedal switch
I012 Lower front work lights switch
I013 Brake pedal switch
I014 Not used
I015 Not used
I016 Hazard warning lights switch
I017 Not used
I018 Starter switch
I019 Not used
J002 Relay
J003 Not used
J004 Relay
J005 Relay
J006 Not used

40-1208
Wiring diagrams
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
J007 Relay
J008 Relay
J009 Relay
Table 887
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
K005 Hand throttle position sensor
K006 Accelerator pedal position sensor
K007 Not used
K008 Not used
M M001 Engine control unit
F M002 Engine control unit
M003 Rear PTO ECU
M004 Hazard warning lights ECU
N003 Windscreen washer pump
N004 Rear screen washer pump
P002 Auxiliary power socket (25A)
P002a Auxiliary power socket (25A)
P002b Auxiliary power socket (25A)
P003 CAN BUS diagnostics socket
P004 Cigar lighter
P004a Cigar lighter
P005 Pneumatic seat compressor
R001 Diagnostics socket

40.4.25 - 0.015.7021.4/70 - Central wiring (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3
EVO 85 -> 20001)
I015 I010 I005 I004 P004a
I014 R F

P004
1
3 2 1 8 3 2 1 8 3 2 1 8 3 2 1 8 3 2 1 8
2
6 5 4 7 6 5 4 7 6 5 4 7 6 5 4 7 6 5 4 7

P002a
D013 P002b
K006 H002
4 5 6
LEVA HI/LO
M003 K005 P002
1 2 3
18

D011
13
7
4 5 6
2 3

12

C003
1
AMP

6 1
R

4 3 2 1

D013 85-100 3-LO/4-HI

HI(VIOLA)
LO(BIANCO)
110 3-HI/4-LO

I001
AMP
2
1

I007
3

AMP
2
1

F009
2
4
1
3
8

I016
1

4
5
2

17 18
3 10

I018
15

30
50

2
P005

I013
4
3
2
1

K007
3

AMP
2

D004
1

C004 N004
1

N003
1

E004
+ 2

-
G

E004a
E004b C009
M002
D007
S
D012b S C008 F
ECU MOTORE

D009 R

D012a R
M001
D010
3

D012
AMP
2

M
1

M F

D008 E003 K008

5k

I002 D010
3
4

5
2
3

1
2
1

D014 E002 I003 I017

4

1
3k

R001
2
1

M004 P003
4
1
2
5

4
4

I008
3

AMP
3

2
6

2
3

D005
1
1

7
1

4
2

D003 I011
4

3 10

6
3

SUPPLY FREE
2

I019
1

7
8
1

1 2 3 1 2 1 2

D002
2

AMP

AMP

AMP

SUPPLY FREE
3

I009
7

I006
8

TOP

I012
F007a
F007
1

D001 TOP
8

5
1

1 2
4

SUPPLY FREE
3

3 4
2

5
3

F008

56b
56a 31b

49a
H001
L
56 31
56d

D0063280

Fig. 4105 - Central wiring loom (1/2)

Table 888
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
B005 Fuse (10A)
B006 Fuse (7.5A)

40-1209
 Wiring diagrams
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
B007 Fuse (20A)
B008 Fuse (15A)
B009 Fuse (15A)
B010 Fuse (5A)
B011 Fuse (7.5A)
B012 Fuse (15A)
B013 Fuse (15A)
B014 Not used
B015 Fuse (15A)
B016 Fuse (7.5A)
B017 Not used
B018 Fuse (15A)
B019 Fuse (15A)
B020 Fuse (3A)
B021 Fuse (10A)
B022 Fuse (7.5A)
B023 Fuse (7.5A)
B024 Fuse (7.5A)
B025 Fuse (30A)
B026 Fuse (30A)
B027 Fuse (30A)
B028 Fuse (40A)
B029 Fuse (40A)
B030 Fuse (30A)
Table 889
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
B031 Fuse (30A)
B032 Fuse (20A)
B033 Fuse (20A)
C003 Earthing point 3
C004 Earthing point 4
C008 Earthing point 8
C009 Earthing point 9
D001 Wiring connector
D002 Wiring connector
D003 Wiring connector
D004 Wiring connector
D005 Wiring connector
D005 Wiring connector
D007 Wiring connector
D008 Wiring connector
D009 Wiring connector
D010 Not used
D010 Wiring connector
D011 Wiring connector
D012 Configuration connector
R D012a Configuration connector
S D012b Configuration connector
D013 Wiring connector
D013 Wiring connector
D014 Wiring connector
Table 890
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
E002 Instrument panel
E003 Instrument panel
E004 Trailer pressure indicator
E004a Trailer pressure indicator

40-1210
Wiring diagrams
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
E004b Trailer pressure indicator
F007 Number plate light
F007a Number plate light
F008 LH rear light
F009 RH rear light
H001 Lights selector switch
HI/LO LEVER H002 Main gear lever - Hi/Lo buttons and transmission split
I001 Engine speed memory button
I002 P.T.O. engagement switch 540
I003 P.T.O. engagement switch 1.000
I004 Front PTO control switch
I005 Rear PTO control switch
I006 Lh rear PTO control switch (on fender)
I007 Rh rear PTO control switch (on fender)
I008 Road lights switch
TOP I009 Upper worklights switch
I010 Differential lock control switch
I011 Clutch pedal switch
I012 Lower front worklights switch
I013 Brake pedal switch
I014 Not used
I015 4WD control switch
I016 Hazard warning lights switch
I017 Not used
I018 Starter switch
I019 Corner lights switch

Table 891
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
J002 Relay
J003 Relay
J004 Relay
J005 Relay
J006 Relay
J007 Relay
J008 Relay
J009 Relay
K005 Hand throttle position sensor
K006 Accelerator pedal position sensor
K007 Operator present sensor
K008 Park Brake pressure brake
M M001 Engine ECU
F M002 Engine ECU
M003 Rear PTO ECU
M004 Hazard warning lights ECU
N003 Windscreen washer pump
N004 Rear screen washer pump
P002 Auxiliary power socket (25A)
P002a Auxiliary power socket (25A)
P002b Auxiliary power socket (25A)
P003 CAN BUS diagnostics socket
P004 Cigar lighter
P004a Cigar lighter
P005 Pneumatic seat compressor
R001 Diagnostics socket

40-1211
 Wiring diagrams

MF5
40A FT1-2-3 B029
MF4
40A START B028

PK1 PK2
+15
START FAN SPEED J008 J009
COMPRESSOR
MU1

MU4

30A
RELAY
MK3
COMPRESSOR B030
FT 5-6-7-8

FAN SPEED
RELAY

B025

B026

B027
MK1

20 A B032
30A
30A

30A

POWER
B031 B033
MU6
MU3

30A +15
MF1

20 A
MK3 MF3

SOCKET
MK1

+15 +15
HI/LO J002 J003 J004
F14-15 F11-12-13

+15 ROOF +15

FAN SPEED J005 J006 J007
MK4

MK6

FT5.6.7.8 MU6
M11

B006 B016

B010 B020
B011 B021
B005 B015

B009 B019

B012 B022
B013 B023
STOLL SOCKET

B007 B017
B008 B018

B014 B024
RELAY

L R
+15 +15 +15 +15 +15 +15 +15 +15
M20

7.5A 7.5A 7.5 A 10A 3A 15 A 15 A 7.5 A 7.5 A 15 A

COMPRESSOR

STOP(EU)
STOP +30
+15 +30 +30 USA +30 +30 +30
10 A 7.5 A 20 A 15 A 15 A 5A 7.5A 15 A 15 A 15 A
M1

M10

D0063290

Fig. 4106 - Central wiring loom (2/2)

40-1212
Wiring diagrams
40.4.26 - 0.015.7023.4/50 - Driveline - Version with digital instrument panel (R3 EVO 100
-> 16001, R3 EVO 110 -> 5001, R3 EVO 85 -> 16001)

K014

4
AMP

3
2
1
D018
K013

AMP
I
I023 2 1

ECO

AMP
1 2 3

AMP
1

AMP
3 2 1

I
I022

ECO
I021

3
AMP

2
S
S

1
P006 AMP

K009

1
1

A
2

6
7
3

5
4

D015

AMP

1
AM
P

90°

D021 D019
A
I020
AMP

2
0° 180°

1
K012 USA STOLL
D017 270°
1

AMP

2
2

AMP

USA STOLL

1
3

D011

2 1 3 5 4
AMP

H/L
D020 1

AMP
1 2 1 2
1 2 3

D016 7-8
AMP

AMP
1

AMP

K011
2

7-8
AMP
3

K010 L004 L002

H/L
1 2
1 2
AMP
AMP

L003 L001

D0063060

Fig. 4107 - Driveline - Version with digital instrument panel

Table 892
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D011 Wiring connector
D011 Wiring connector
D015 Wiring connector
D015 Wiring connector
7-8 D016 Not used
STOLL D017 Not used
D018 Not used
D019 Not used
D020 Not used
A D021 Wiring connector
I020 Start enable switch (transmission in neutral)
S I021 P.T.O. engagement switch ECO
I022 Not used
ECO I023 P.T.O. engagement switch ECO
K009 Transmission oil filter clogging pressure switch
K010 Not used
K011 Services circuit alarm pressure switch
USA K012 Rear PTO speed sensor (USA version)
I K013 Hydraulic trailer braking valve pressure switch
K014 Fuel level sensor
L001 Differential lock control solenoid valve
L002 Not used
L003 Rear PTO control solenoid valve
H/L L004 Not used
P006 Trailer socket

40-1213
 Wiring diagrams
D015

CHARGE AIR PRESSURE SIGNAL (M24)

CHARGE AIR PRESSURE +5V (M25)
CHARGE AIR PRESSURE GND (M23)

CHARGE AIR PRESSURE TEMP.(M4)

WATER TEMPERATURE (M8)

WATER TEMPERATURE (M9)

FUEL TEMP (M5 - ANAL)

ATTUATOR (M18)
ATTUATOR (M17)
ATTUATOR (M19)

ATTUATOR (M15)
ATTUATOR (M14)

PICK-UP+ (M13)
12 PICK-UP- (M12)
23
14
18
17
19

15

25
13
24
5

4
XSCH
RN0.75
A-A5 FUEL TEMP (M5 - ANAL5
BN0.75
A-B4 PICK-UP- (M12)
VN0.75
A-C7 CHARGE AIR PRESSURE GND (M23)
LR0.75
A-B6 ATTUATOR (M14)
V0.75 A-C2 ATTUATOR (M18)
B 0.75 ATTUATOR (M17)
A-C1
M 0.75
A-C3 ATTUATOR (M19)
CB0.75
A-B1 WATER TEMPERATURE (M8)
RG0.75
A-B7 ATTUATOR (M15)
HN0.75
B-C4 WATER TEMPERATURE (M9)
Z0.75
B-C5 CHARGE AIR PRESSURE +5V (M25)
HR0.75
A-B5 PICK-UP+ (M13)
H0.75
A-C8 CHARGE AIR PRESSURE SIGNAL (M24)
N 0.75 N0.75

L004
1 A-C4 SCREEN
-31 -31 HB0.75
A-A4 CHARGE AIR PRESSURE TEMP.(M4)
EV LO EV LO 2

N 0.75 S.U.1

L003
-31 -31 1

PTO POSTER. Rear PTO 2

K011 SERBIZI SERVICE

LR 1

CV 0.75
B-A3 CONSENSO CAMBIO GEAR START CONSENT
MB 1.5
+15 +15 1 LR 1

K010
A-A2 SERVIZI SERVICE
GIRI RUOTE WHEEL SIGNAL 2
RV 0.75
N 0.75 S.U.1 B-C3 PTO POSTER. Rear PTO
-31 -31 3

B-D4

HR 0.75
A-A6 EV DF EV DF
N 0.75 S.U.1

L002
B-D5
-31 -31 1

D011
EV DT EV DT 2 B-C2

N1 CN 0.75 EV LO EV LO

D018
-31 B-A2
-31 2

S.U.3 BN 0.75 +15

EV RIMORCHIO EV TRAILER 1 A-A7 +15

I020
CONS.MARCIA GEAR CONSENT 1
BR 0.5
N 0.75 S.U.1 A-B2 VEL.RUOTE WHEEL SIGNAL
-31 -31 2
AR 1
A-C5 EV DT EV DT

CV 1
3 FARO LAV.PIATT. PLATFORM W.L.

L001
FARO LAV.PIATT. PLATFORM W.L. B-A6
EV DF EV DF 2
N 0.75 S.U.1 CV 1
-31 -31 1 FARO LAV.PIATT. PLATFORM W.L. FARO LAV.PIATT. PLATFORM W.L.
2 B-A7

D020 LAMPAGGIANTE FLASHER 1

N 1.5
GV 1.5

V 1.5
B-A8 LAMPAGGIANTE FLASHER

-31 -31 4 B-A5 EV RIMORCHIO TRAIELR BRAKE EV

-31 -31 5 N 1.5 N1.5(W2) A-A1 -31 -31

D021 FREN.RIM.PNEUM. AIR TRAIELR PRESS.

S.U.1
N1.5(W2)

N1.5(W2)
A-A8 -31 -31

A-D1 -31 -31

S.U.1 N1.5(W2) B-D1

-31 -31
B-D2

K013 FREN.RIM.IDR. HYDR.TRAILER PRESS.

V 0.75

S 0.75
A-D6 FREN.RIM.PNEUM. AIR TRAIELR PRESS.

A-B8 FREN.RIM.IDR. HYDR.TRAILER PRESS.

SL 0.75

I023
PTO ECO PTO ECO 2 B-B2 SEGNALE SENS.USA USA SENS.SIGNAL
N 0.75
-31 -31 3 VB 0.75
A-A3 PTO ECO PTO ECO
S.U.1

HG 0.75
B-A4 PTO SynCRO PTO Syncro

I021
PTO Syncro PTO Syncro 2
B-B3
N 0.75 S.U.1
-31 -31 3
S.U.1 B-C6

S.U.1
B-C7
S.U.1

S.U.1 B-D3

AN 0.75
SPIA DT DT LIGHT 1 B-B1 TRASM.IDRAUL. TRANSM.HYDRAUL

I022 -31 -31 2

N 0.75 AR 0.75
S.U.1

A-B3 SPIA DT DT LIGHT

3 HN 0.75
A-C6 SPIA LIGHT

C 0.75
A-D7 LIVELLO LEVEL

K012 VR0.75
B-C8 STOLL STOLL

AN 1
P006
N 0.75
N 0.75 B-B5 DIREZIONI SX LEFT DIECTIONS EU
-31 SENSORE USA -31 USA SENSOR
TABELLA COLORI / COLOURS TABLE
-31 2
S.U.1

-31 2 S.U.T6 AN 1
A1 DIREZIONI SX LEFT DIECTIONS 1 -31 -31 1
K014
SPIA LIGHT 4 RIGHT DIRECTION EU A1
SEGNALE SENS.USA USA SENS.SIGNAL 3 A-D2 DIREZIONI DX S.U.T2
C1
BN 0.75
DIREZIONI DX RIGHT DIRECTION 4 +30 +30 4
LIVELLO LEVEL 3
G1
M Marrone/Br own C Arancio/Orang e
1 S.U.T3 G1
+15 SENSORE USA +15 USA SENSOR +58 SX +58 SINISTRA EU 5 5
1
A-D3 +58 SX +58 SINISTRA DIR.RIGHT DIR.RIGHT
S.U.T4 RN 1.5
RN 1.5 6 6
A-D4 STOP STOP EU STOP STOP 58 RH +58 RH
V Verde/Green A Azzurr o/Blue
S.U.T1 GN 1
+58 SX +58 LEFT 7 +15 +15 7
+58 DX +58 RH EU
GN 1
S.U.T7 N 1.5 Z Viola/Violet B Bianco/White
S.U.1

A-D5

K009 IDRAULICA HYDRAULIC

AN 1

-31 -31 2
N 0.75
B-B4 +15 RIMORCHIO USA +15USA TRAILER
GN 1
AG1
-31 -31 3

2
DIR.LEFT

58 LEFT
DIR.LEFT

58 LEFT
3

2
N Nero/Blac k L Blu/Dark Blue
STOLL STOLL 1 B-A1 +30 RIMMORCHIO USA +30 USA TRAILER
A1
S Rosa/Pink G Giallo/Y ello w
VERSION EU VERSION U.S.A.
X1

G1
R Rosso/Red H
D019 TRASMISSIONI TRANSMISSION
AN 1

D017
B-B6

B-B7
DIREZIONI DX

+58 DX
RIGHT DIRECTION USA

+58 RH USA
RN 1.5
Grigio/Gra y

AG1
B-B8 +58 SX +58 LT USA
BN 1.5
EV 1 EV 1 1 B-C1 DIREZIONI SX LEFT DIECTIONS USA

D016 EV 2 EV 2 2

3
N1 B-D8 -31 EU -31 EU
N 1.5

-31 -31
N 1.5
A-D8 -31 USA -31 USA

VA 1
B-D6 EV 1 EV 1

VS 1 B-D7 EV 2 EV 2

D0063300

Fig. 4108

40.4.27 - 0.015.7023.4/50 - Drivetrain (R3 EVO 100 -> 20001, R3 EVO 110 -> 1001, R3 EVO
85 -> 20001)

K014

4
AMP

3
2
1
D018
K013
AMP

I
I023 2 1

ECO
AMP

1 2 3
AMP

1
AMP

3 2 1
I

I022
ECO

I021
3

AMP
2

S
S
1

P006 AMP

K009
1
1

A
2

6
7
3

5
4

D015
AMP

AM
P

90°

D021 D019
A
I020
AMP
2

0° 180°
1

K012 USA STOLL

D017 270°
1

AMP
2
2

AMP

USA STOLL
1
3

D011

2 1 3 5 4
AMP

H/L

D020 1
AMP

1 2 1 2
1 2 3

D016 7-8
AMP

AMP
1

AMP

K011
2

7-8
AMP
3

K010 L004 L002

H/L
1 2
1 2
AMP
AMP

L003 L001

D0063060

Fig. 4109 - Drivetrain (1/2)

Table 893
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D011 Wiring connector

40-1214
Wiring diagrams
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D011 Wiring connector
D015 Wiring connector
7-8 D016 Not used
STOLL D017 Not used
D018 Wiring connector
D019 Wiring connector
D020 Not used
A D021 Wiring connector
I020 Start enable switch (transmission in neutral)
S I021 P.T.O. engagement switch ECO
I022 4WD engagement control switch
ECO I023 P.T.O. engagement switch ECO
K009 Transmission oil filter clogging pressure switch
K010 Wheels speed sensor
K011 Services circuit alarm pressure switch
USA K012 Rear PTO speed sensor (USA version)
I K013 Hydraulic trailer braking valve pressure switch
K014 Fuel level sensor
L001 Differential lock control solenoid valve
L002 4WD control solenoid valve
L003 Rear PTO control solenoid valve
H/L L004 Hi/Lo drive control solenoid valve
P006 Trailer socket

D015
CHARGE AIR PRESSURE SIGNAL (M24)
CHARGE AIR PRESSURE +5V (M25)
CHARGE AIR PRESSURE GND (M23)

CHARGE AIR PRESSURE TEMP.(M4)

WATER TEMPERATURE (M8)

WATER TEMPERATURE (M9)

FUEL TEMP (M5 - ANAL)

ATTUATOR (M18)
ATTUATOR (M17)
ATTUATOR (M19)

ATTUATOR (M15)
ATTUATOR (M14)

PICK-UP+ (M13)
12 PICK-UP- (M12)
23
14
18
17
19

15

25
13
24
5

4
XSCH

RN0.75
A-A5 FUEL TEMP (M5 - ANAL5
BN0.75
A-B4 PICK-UP- (M12)
VN0.75
A-C7 CHARGE AIR PRESSURE GND (M23)
LR0.75
A-B6 ATTUATOR (M14)
V0.75 A-C2 ATTUATOR (M18)
B 0.75 ATTUATOR (M17)
A-C1
M 0.75
A-C3 ATTUATOR (M19)
CB0.75
A-B1 WATER TEMPERATURE (M8)
RG0.75
A-B7 ATTUATOR (M15)
HN0.75
B-C4 WATER TEMPERATURE (M9)
Z0.75
B-C5 CHARGE AIR PRESSURE +5V (M25)
HR0.75
A-B5 PICK-UP+ (M13)
H0.75
A-C8 CHARGE AIR PRESSURE SIGNAL (M24)
N 0.75 N0.75

L004
1 A-C4 SCREEN
-31 -31 HB0.75
A-A4 CHARGE AIR PRESSURE TEMP.(M4)
EV LO EV LO 2

N 0.75 S.U.1

L003
-31 -31 1

PTO POSTER. Rear PTO 2

K011 SERBIZI SERVICE

LR 1

CV 0.75
B-A3 CONSENSO CAMBIO GEAR START CONSENT
MB 1.5
+15 +15 1 LR 1

K010
A-A2 SERVIZI SERVICE
GIRI RUOTE WHEEL SIGNAL 2
RV 0.75
N 0.75 S.U.1 B-C3 PTO POSTER. Rear PTO
-31 -31 3

B-D4

HR 0.75
A-A6 EV DF EV DF
N 0.75 S.U.1

L002
B-D5
-31 -31 1

D011
EV DT EV DT 2 B-C2

N1 CN 0.75 EV LO EV LO

D018
-31 B-A2
-31 2

S.U.3 BN 0.75 +15

EV RIMORCHIO EV TRAILER 1 A-A7 +15

I020
CONS.MARCIA GEAR CONSENT 1
BR 0.5
N 0.75 S.U.1 A-B2 VEL.RUOTE WHEEL SIGNAL
-31 -31 2
AR 1
A-C5 EV DT EV DT

CV 1
3 FARO LAV.PIATT. PLATFORM W.L.

L001
FARO LAV.PIATT. PLATFORM W.L. B-A6
EV DF EV DF 2
N 0.75 S.U.1 CV 1
-31 -31 1 FARO LAV.PIATT. PLATFORM W.L. FARO LAV.PIATT. PLATFORM W.L.
2 B-A7

D020 LAMPAGGIANTE FLASHER 1

N 1.5
GV 1.5

V 1.5
B-A8 LAMPAGGIANTE FLASHER

-31 -31 4 B-A5 EV RIMORCHIO TRAIELR BRAKE EV

-31 -31 5 N 1.5 N1.5(W2) A-A1 -31 -31

D021 FREN.RIM.PNEUM. AIR TRAIELR PRESS.

S.U.1
N1.5(W2)

N1.5(W2)
A-A8 -31 -31

A-D1 -31 -31

S.U.1 N1.5(W2) B-D1

-31 -31
B-D2

K013 FREN.RIM.IDR. HYDR.TRAILER PRESS.

V 0.75

S 0.75
A-D6 FREN.RIM.PNEUM. AIR TRAIELR PRESS.

A-B8 FREN.RIM.IDR. HYDR.TRAILER PRESS.

SL 0.75

I023
PTO ECO PTO ECO 2 B-B2 SEGNALE SENS.USA USA SENS.SIGNAL
N 0.75
-31 -31 3 VB 0.75
A-A3 PTO ECO PTO ECO
S.U.1

HG 0.75
B-A4 PTO SynCRO PTO Syncro

I021
PTO Syncro PTO Syncro 2
B-B3
N 0.75 S.U.1
-31 -31 3
S.U.1 B-C6

S.U.1
B-C7
S.U.1

S.U.1 B-D3

AN 0.75
SPIA DT DT LIGHT 1 B-B1 TRASM.IDRAUL. TRANSM.HYDRAUL

I022 -31 -31 2

N 0.75 AR 0.75
S.U.1

A-B3 SPIA DT DT LIGHT

3 HN 0.75
A-C6 SPIA LIGHT

C 0.75
A-D7 LIVELLO LEVEL

K012 VR0.75
B-C8 STOLL STOLL

AN 1
P006
N 0.75
N 0.75 B-B5 DIREZIONI SX LEFT DIECTIONS EU
-31 SENSORE USA -31 USA SENSOR
TABELLA COLORI / COLOURS TABLE
-31 2
S.U.1

-31 2 S.U.T6 AN 1
A1 DIREZIONI SX LEFT DIECTIONS 1 -31 -31 1
K014
SPIA LIGHT 4 RIGHT DIRECTION EU A1
SEGNALE SENS.USA USA SENS.SIGNAL 3 A-D2 DIREZIONI DX S.U.T2
C1
BN 0.75
DIREZIONI DX RIGHT DIRECTION 4 +30 +30 4
LIVELLO LEVEL 3
G1
M Marrone/Br own C Arancio/Orang e
1 S.U.T3 G1
+15 SENSORE USA +15 USA SENSOR +58 SX +58 SINISTRA EU 5 5
1
A-D3 +58 SX +58 SINISTRA DIR.RIGHT DIR.RIGHT
S.U.T4 RN 1.5
RN 1.5 6 6
A-D4 STOP STOP EU STOP STOP 58 RH +58 RH
V Verde/Green A Azzurr o/Blue
S.U.T1 GN 1
+58 SX +58 LEFT 7 +15 +15 7
+58 DX +58 RH EU
GN 1
S.U.T7 N 1.5 Z Viola/Violet B Bianco/White
S.U.1

A-D5

K009 IDRAULICA HYDRAULIC

AN 1

-31 -31 2
N 0.75
B-B4 +15 RIMORCHIO USA +15USA TRAILER
GN 1
AG1
-31 -31 3

2
DIR.LEFT

58 LEFT
DIR.LEFT

58 LEFT
3

2
N Nero/Blac k L Blu/Dark Blue
STOLL STOLL 1 B-A1 +30 RIMMORCHIO USA +30 USA TRAILER
A1
S Rosa/Pink G Giallo/Y ello w
VERSION EU VERSION U.S.A.
X1

G1
R Rosso/Red H
D019 TRASMISSIONI TRANSMISSION
AN 1

D017
B-B6

B-B7
DIREZIONI DX

+58 DX
RIGHT DIRECTION USA

+58 RH USA
RN 1.5
Grigio/Gra y

AG1
B-B8 +58 SX +58 LT USA
BN 1.5
EV 1 EV 1 1 B-C1 DIREZIONI SX LEFT DIECTIONS USA

D016 EV 2 EV 2 2

3
N1 B-D8 -31 EU -31 EU
N 1.5

-31 -31
N 1.5
A-D8 -31 USA -31 USA

VA 1
B-D6 EV 1 EV 1

VS 1 B-D7 EV 2 EV 2

D0063300

Fig. 4110 - Drivetrain (2/2)

40-1215
 Wiring diagrams
40.4.28 - 0.015.7266.4/40 - Air conditioning condenser fan - Version with high-visibility
cab ()

P015
J014 J015
A B

K023

D028

B A

P016
D0047701

Fig. 4111 - Air conditioning condenser fan - Version with high-visibility cab (1/2)
Table 894
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D028 Wiring connector
J014 Control relay for air conditioning cooler fan
J015 Control relay for auxiliary air conditioning cooler fan
K023 Air conditioning pressure switch
P015 Air conditioning condenser fan
P016 Auxiliary air conditioning condenser fan

40-1216
Wiring diagrams
P015 P016
K023 A B A B
1 2 3 5 6

N-1.5

N-1.5
N-1

SU1 SU2
MN-1.5

MN-1.5
AN-1.5
AN-1.5

AN-1.5

AN-1.5
N-1.5

VN-1
N-1.5

A-1.5
L-1.5

CB-1
V-1

C-1
TABELLA COLORI / COLOURS TABLE
1 2 3 4 5 6 7 8 M Marrone/Brown C Arancio/Orange 2 4 6 8 2 4 6 8
V Verde/Green A Azzurro/Blue
D028 Z Viola/Violet B Bianco/White
J014 J015
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray
D0063310

Fig. 4112 - Air conditioning condenser fan - Version with high-visibility cab (2/2)
40.4.29 - 0.015.7266.4/40 - Air conditioning condenser fan - Version with standard cab ()

P015
J014 J015
A B

K023

D028

B A

P016
D0047701

Fig. 4113 - Air conditioning condenser fan - Version with standard cab (1/2)

40-1217
 Wiring diagrams
Table 895
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D028 Wiring connector
J014 Control relay for air conditioning cooler fan
J015 Control relay for auxiliary air conditioning cooler fan
K023 Air conditioning pressure switch
P015 Air conditioning condenser fan
P016 Auxiliary air conditioning condenser fan

P015 P016
K023 A B A B
1 2 3 5 6

N-1.5

N-1.5
N-1

SU1 SU2
MN-1.5

MN-1.5
AN-1.5
AN-1.5

AN-1.5

AN-1.5
N-1.5

VN-1
N-1.5

A-1.5
L-1.5

CB-1
V-1

C-1

TABELLA COLORI / COLOURS TABLE

1 2 3 4 5 6 7 8 M Marrone/Brown C Arancio/Orange 2 4 6 8 2 4 6 8
V Verde/Green A Azzurro/Blue
D028 Z Viola/Violet B Bianco/White
J014 J015
N Nero/Black L Blu/Dark Blue
S Rosa/Pink G Giallo/Yellow
R Rosso/Red H Grigio/Gray
D0063310

Fig. 4114 - Air conditioning condenser fan - Version with standard cab (2/2)

40-1218
Wiring diagrams
40.4.30 - 0.015.7310.4 - Hood lights (R3 EVO 100 -> 16001, R3 EVO 110 -> 5001, R3 EVO
85 -> 16001)

E001

1
2
B A B A

F005 F004
F002 F003
B A B A

D004

D0064690

Fig. 4115 - Hood lights

Table 896
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D004 Wiring connector
D004 Wiring connector
D004 Wiring connector
E001 Horn
F002 Rh high beam headlight
F003 Rh low beam headlight
F003 Rh low beam headlight
F004 Lh low beam headlight
F004 Lh low beam headlight
F005 Lh high beam headlight

40-1219
 Wiring diagrams
1
F003
2

1
F004
2

1
D004 F002
H 1.5 2
ANABBAGLIANTI DX LOW BEAM LIGHTS RH 1
ANABBAGLIANTI SX LOW BEAM LIGHTS LT H 1.5 1
2
VN 1.5
F005
ABBAGLIANTI DX HIGH BEAM LIGHTS RH 2
3

ABBAGLIANTI SX HIGH BEAM LIGHTS LT VN 1.5

4 1

CLACSON HORN Z1 E001

5 2

RV 1.5
6
RV 1.5
7

N 1.5
-31 -31 8

N 1.5
-31 -31 9

R1
+30 +30 10 TABELLA COLORI / COLOURS TABLE
M Marrone/Brown C Arancio/Orange
-31 -31 11
V Verde/Green A Azzurro/Blue
12 Z Viola/Violet B Bianco/White
N Nero/Black L Blu/Dark Blue
N 1.5
-31 -31 13 S Rosa/Pink G Giallo/Yellow
N 1.5 R Rosso/Red H Grigio/Gray
-31 -31 14

D0064700

Fig. 4116 - Hood lights

40.4.31 - 0.016.0373.4/30 - Cab power supply

D023

D009

D025

D024

D008
D0047661

Fig. 4117 - Cab power supply

Table 897
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D008 Wiring connector
D008 Wiring connector
D009 Wiring connector
D009 Wiring connector
D023 Wiring connector

40-1220
Wiring diagrams
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D023 Wiring connector
D023 Wiring connector
D024 Wiring connector
D024 Wiring connector
D024 Wiring connector
D025 Wiring connector

40.4.32 - 0.016.0484.4/60 - Central (U.S.A.)

I015 I010 I005 I004
I014 R F

6
2

5
1

4
8

7
3

6
2

5
1

4
8

7
3

6
2

5
1

4
8

7
3

6
2

5
1

4
8

7 6
3 2

5
1

4
8

7
P004a
P004
1

D013 P002a
H002 P002b
K006 M003 K005
1
4 5 6
2 3
LEVA HI/LO
18 13
P002
D011
7

4 5 6
2 3
12
R

C003
F

1
AMP
6 1

D013
4 3 2 1

85-100 3-LO/4-HI
HI(VIOLA)
LO(BIANCO)

I001
AMP
110 3-HI/4-LO
2
1

I007

3
AMP

2
1
D043

5
4

4
AMP

3
3

2
2

1
1
7
8

I016
1

4
2

5
18 17
3
10

I018
15

30
50

2
P005

K007

3
AMP

2
D004

1
C004 N004
1

N003
1

E004
+ 2

-
G

E004a
E004b C009 M002
F

D007
S
D012b S C008
M001

ECU MOTORE
D009 R
D012a R
D010 M

3
D012
AMP

2
1
M F

D008 E003 K008

5k

I002 D010

3
4
5

2
3

1
2
1
D014 E002 I003 I017

4
1
3k

3
R001

2
1
M004 P003
4
4

AMP
3

I008
2

D005
2

1
1

7
1

4
2

D003 I011
4

6
3

SUPPLY FREE
10

9
2

I019
1

7
8
1

1 2 3 1 2 1 2

D002
2

1 2 3 4 5
AMP

AMP

AMP
3

SUPPLY FREE

I009
AMP
7

I006
8

TOP
F007a
F007

I012
1

1 2 3 4 5
8

TOP
2

5
1

D001
4

6
2

D044

SUPPLY FREE
3

56b
56a 31b

49a

L
H001
56 31
56d

D0063320

Fig. 4118 - Central (U.S.A.) (1/2)

Table 898
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
B005 Fuse (10A)
B006 Fuse (7.5A)
B007 Fuse (20A)
B008 Fuse (15A)
B009 Fuse (15A)
B010 Fuse (5A)
B011 Fuse (7.5A)
B012 Fuse (15A)
B013 Fuse (15A)
B014 Not used
B015 Fuse (15A)
B016 Fuse (7.5A)
B017 Not used
B018 Fuse (15A)
B019 Fuse (15A)
B020 Fuse (3A)
B021 Fuse (10A)
B022 Fuse (7.5A)
B023 Fuse (7.5A)
B024 Fuse (7.5A)
B025 Fuse (30A)
B026 Fuse (30A)

40-1221
 Wiring diagrams
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
B027 Fuse (30A)
B028 Fuse (40A)
B029 Fuse (40A)
B030 Fuse (30A)
B031 Fuse (30A)
Table 899
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
B032 Fuse (20A)
B033 Fuse (20A)
C003 Earthing point 3
C004 Earthing point 4
C008 Earthing point 8
C009 Earthing point 9
D001 Wiring connector
D002 Wiring connector
D003 Wiring connector
D004 Wiring connector
D005 Wiring connector
D005 Wiring connector
D007 Wiring connector
D008 Wiring connector
D009 Wiring connector
D010 Wiring connector
D010 Not used
D011 Wiring connector
D012 Configuration connector
R D012a Configuration connector
S D012b Configuration connector
D013 Wiring connector
D013 Wiring connector
D014 Wiring connector
D043 Wiring connector
D044 Wiring connector
E002 Instrument panel
Table 900
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
E003 Instrument panel
E004 Trailer pressure indicator
E004a Trailer pressure indicator
E004b Trailer pressure indicator
F007 Number plate light
F007a Number plate light
H001 Lights selector switch
HI/LO LEVER H002 Main gear lever - Hi/Lo buttons and transmission split
I001 Engine speed memory button
I002 P.T.O. engagement switch 540
I003 P.T.O. engagement switch 1.000
I004 Front PTO control switch
I005 Rear PTO control switch
I006 Lh rear PTO control switch (on fender)
I007 Rh rear PTO control switch (on fender)
I008 Road lights switch
TOP I009 Upper worklights switch
I010 Differential lock control switch
I011 Clutch pedal switch
I012 Lower front worklights switch
I014 Not used
I015 4WD control switch

40-1222
Wiring diagrams
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
I016 Hazard warning lights switch
I017 Not used
I018 Starter switch
I019 Corner lights switch
J002 Relay
J003 Relay
Table 901
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
J004 Relay
J005 Relay
J006 Relay
J007 Relay
J008 Relay
J009 Relay
K005 Hand throttle position sensor
K006 Accelerator pedal position sensor
K007 Operator present sensor
K008 Park Brake pressure brake
M M001 Engine ECU
F M002 Engine ECU
M003 Rear PTO ECU
M004 Hazard warning lights ECU
N003 Windscreen washer pump
N004 Rear screen washer pump
P002 Auxiliary power socket (25A)
P002a Auxiliary power socket (25A)
P002b Auxiliary power socket (25A)
P003 CAN BUS diagnostics socket
P004 Cigar lighter
P004a Cigar lighter
P005 Pneumatic seat compressor
R001 Diagnostics socket

40-1223
 Wiring diagrams

MF5
40A FT1-2-3 B029
MF4
40A START B028

PK1 PK2
+15
START FAN SPEED J008 J009
COMPRESSOR
MU1

MU4

30A
RELAY
MK3
COMPRESSOR B030
FT 5-6-7-8

FAN SPEED
RELAY

B025

B026

B027
MK1

20 A B032
30A
30A

30A

POWER
B031 B033
MU6
MU3

30A +15
MF1

20 A
MK3 MF3

SOCKET
MK1

+15 +15
HI/LO J002 J003 J004
F14-15 F11-12-13

+15 ROOF +15

FAN SPEED J005 J006 J007
MK4

MK6

FT5.6.7.8 MU6
M11

B006 B016

B010 B020
B011 B021
B005 B015

B009 B019

B012 B022
B013 B023
STOLL SOCKET

B007 B017
B008 B018

B014 B024
RELAY

L R
+15 +15 +15 +15 +15 +15 +15 +15
M20

7.5A 7.5A 7.5 A 10A 3A 15 A 15 A 7.5 A 7.5 A 15 A

COMPRESSOR

STOP(EU)
STOP +30
+15 +30 +30 USA +30 +30 +30
10 A 7.5 A 20 A 15 A 15 A 5A 7.5A 15 A 15 A 15 A
M1

M10

D0063290

Fig. 4119 - Central (U.S.A.) (2/2)

40-1224
Wiring diagrams
40.4.33 - 0.016.0664.4 - Front lights

D014

D037 D039
D038 D040

L.H. SIDE R.H. SIDE

D0036482

Fig. 4120 - Front lights (1/2)

Table 902
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
D014 Wiring connector
D014 Wiring connector
D037 Wiring connector
D038 Wiring connector
D039 Wiring connector
D040 Wiring connector

40-1225
 Wiring diagrams

D014
1 2 3 4 5 6 7 8 9 10

N1.5

G1
A1

GN1

CV1

CV1
AN1

N1.5
H1

H1

TABELLA COLORI / COLOURS TABLE D038 D037 D040 D039

M Marrone/Brown C Arancio/Orange

V Verde/Green A Azzurro/Blue

Z Viola/Violet B Bianco/White

N Nero/Black L Blu/Dark Blue

S Rosa/Pink G Giallo/Yellow

R Rosso/Red H Grigio/Gray
D0063330

Fig. 4121 - Front lights (2/2)

40-1226
Wiring diagrams
40.4.34 - 0.016.0865.4/10 - Cab roof - Version with standard cab (R3 EVO 100 -> 20001, R3
EVO 110 -> 1001, R3 EVO 85 -> 20001)

I026 I027 I025

D029 I029
1 2 3 4
5 6 7 8
4
8
3
7
2
6
1
5
3
1
4
2

D028 I
53M
I-6

53S
15

M005 31

G001
A H

1 8
B038

B040
B037
B034

B036

B039
B035

4 3 2 1

1 2 3 4
5 6 7 8 E005
5 A RADIO

I024 I028
7.5 A

7.5 A

10 A
10 A

30 A

10 A

D026
P008
1 2
4 3 2 1

D027
C007
2 1
3
6
2
5
1
4

D030

D023
3
6
5
2
4
1

D024 D0047771

Fig. 4122 - Cab roof - Version with standard cab (1/2)

Table 903
CODE STAMPED ON INTERCONNECTION DESCRIPTION
CONNECTOR CODE
B034 Fuse (10A)
B035 Fuse (5A)
B036 Fuse (30A)
B037 Fuse (7.5A)
B038 Fuse (7.5A)
B039 Fuse (10A)
B040 Fuse (10A)
C007 Earthing point 7
D023 Wiring connector