Deutz-Fahr Agrokid 210 / 220 / 230 Tractor Service & Repair Manual

WORKSHOP MANUAL AGROKID 210 ->20001 AGROKID 220 ->ZKDS2102V0MD20001 AGROKID 220 ->ZKDS2902V0MD20001 AGROKID 230 ->ZKDS2202V0MD20001 AGROKID 230 ->ZKDS3002V0MD20001

III CONTENTS 0 - INTRODUCTION 0.1 - Introduction 0-2 0.1.1 - Safety notes 0-2 0.1.2 - General safety rules 0-2 0.1.3 - Safety precautions for removal and refitting operations 0-3 0.1.4 - Lifting instructions 0-4 0.1.5 - Tightening torques 0-5 0.1.6 - Threadlockers, adhesives, sealants and lubricants 0-8 0.1.7 - Conversion factors 0-10 10 - TECHNICAL CHARACTERISTICS 10.1 - Transmission 10-2 10.1.1 - Transmission 10-2 10.1.2 - Rear PTO and Mid PTO 10-8 10.2 - Rear axle 10-13 10.2.1 - Brakes and rear axle assembly 10-13 10.3 - Front axle 10-14 10.3.1 - Front axle 10-14 10.4 - Hydraulic system 10-17 10.4.1 - Gear pump 10-17 10.4.2 - Differential lock control assembly 10-18 10.4.3 - Steering circuit 10-20 10.4.4 - Power steering valve 10-22 10.4.5 - Remote control valve 10-23 20 - CALIBRATIONS AND ELECTRONIC DIAGNOSIS 20.1 - Diagnostic tool screens 20-2 20.1.1 - Baruffaldi electromagnetic clutch 20-2 20.1.2 - Operator seated sensor ECU (p/n 2.8519.106.0) 20-8 30 - METHOD OF INTERVENTION 30.1 - B0 - Engine 30-2 30.1.1 - PREPARATION FOR DISASSEMBLY 30-2 30.1.2 - Engine - Separation from the transmission 30-3 30.1.3 - Engine 30-10 30.1.4 - Compression test 30-11 30.1.5 - engine block, crankshaft, pistons and sump 30-13 30.1.6 - Inspection of the engine monobloc 30-23 30.1.7 - Inspection of the crankshaft 30-23 30.1.8 - Fan - alternator drivebelt 30-26 30.1.9 - A/C fan - compressor drivebelt 30-29 30.1.10 - Crankshaft pulley 30-32 30.1.11 - Flywheel bearing 30-33 30.1.12 - Timing gears and flywheel 30-33 30.1.13 - Inspection of the flywheel and ring gear 30-44 30.1.14 - Inspection of the pistons, piston rings and gudgeon pins 30-45 30.1.15 - Inspection of the connecting rods 30-47 30.1.16 - Inspection of the camshaft 30-48

IV CONTENTS 30.1.17 - Inspection of the camshaft 30-49 30.1.18 - Inspection of the idler gear 30-50 30.1.19 - Inspection of the valves, valve guides and valve seats 30-50 30.1.20 - Valve clearances 30-53 30.1.21 - Inspection of the rocker arms and rocker shaft 30-55 30.1.22 - Cylinder head and valve train components 30-55 30.1.23 - Inspection of the cylinder head 30-62 30.1.24 - Inspection of the valve springs 30-62 30.1.25 - Inspection of the valve pushrods 30-62 30.1.26 - Renewal of the jets 30-62 30.1.27 - Lubrication System 30-63 30.1.28 - Inspection of the lubrication system 30-65 30.1.29 - Fuel System 30-66 30.1.30 - Inspection and adjustment of the fuel system 30-69 30.1.31 - Inspection of the fuel lift pump 30-71 30.1.32 - Injection pump 30-71 30.1.33 - Inspection of the fuel injection pump camshaft 30-78 30.1.34 - Inspection of the fuel injection pump camshaft 30-79 30.1.35 - Fuel injection nozzle 30-80 30.1.36 - Maintenance of the injector nozzles 30-82 30.1.37 - Governor 30-83 30.1.38 - Cooling system 30-85 30.1.39 - Inspection of the cooling system 30-87 30.1.40 - Engine air intake pipe 30-89 30.1.41 - Intake and exhaust systems 30-90 30.1.42 - Inspection of the air intake and exhaust system 30-91 30.2 - C0 - Engine accessories 30-93 30.2.1 - Engine cooling system radiator 30-93 30.2.2 - Expansion tank 30-96 30.2.3 - Fan 30-97 30.2.4 - Air cleaner assembly 30-98 30.2.5 - Fuel ﬁlter 30-99 30.2.6 - Fuel tank - Fuel tank ﬂoat switch 30-99 30.2.7 - Auxiliary fuel tank 30-103 30.2.8 - Engine stop keyswitch 30-104 30.2.9 - Exhaust pipe - tractor with cab 30-106 30.2.10 - Engine stop keyswitch 30-107 30.2.11 - Alternator 30-109 30.2.12 - Alternator 30-112 30.2.13 - Starter motor 30-116 30.2.14 - Starter motor 30-118 30.2.15 - Disassembly of the starter motor 30-120 30.3 - D0 - Transmission 30-127 30.3.1 - Clutch plate 30-127 30.3.2 - Checking clutch plate wear 30-128 30.3.3 - Clutch release bearing 30-128 30.3.4 - Clutch release forks 30-129 30.3.5 - Clutch housing 30-131

V CONTENTS 30.3.6 - Disassembly of the gearbox input shaft 30-135 30.3.7 - Disassembly of the main shaft 30-137 30.3.8 - Disassembly of the secondary shaft 30-138 30.3.9 - Gearbox and shuttle assembly - complete unit 30-141 30.3.10 - Gearbox and shuttle assembly - complete unit 30-142 30.3.11 - Range gearbox and differential assembly - complete unit 30-146 30.3.12 - Gearbox input shaft - oil seal renewal 30-148 30.3.13 - Bevel gear pair 30-149 30.3.14 - Disassembly of 4WD output shaft and groundspeed PTO 30-153 30.3.15 - Creeper - synchronizer renewal 30-155 30.3.16 - PTO output shaft. 30-157 30.3.17 - Disassembly of the PTO output shaft. 30-158 30.3.18 - Removal of the PTO output shaft 30-158 30.3.19 - Parking brake 30-160 30.3.20 - Adjustment of the bevel gear pair 30-162 30.4 - E0 - Rear axle 30-166 30.4.1 - Left-hand rear axle 30-166 30.4.2 - Disassembly of LH/RH rear axle 30-168 30.4.3 - Rear differential 30-172 30.4.4 - Disassembly of the rear differential 30-175 30.4.5 - Rear axle brake discs 30-176 30.5 - F0 - Front axle 30-178 30.5.1 - Front support 30-178 30.5.2 - Front axle - complete assembly 30-182 30.5.3 - Steering cylinders 30-184 30.5.4 - Steering cylinders disassembly 30-186 30.5.5 - Steering knuckle housing and axle shaft 30-188 30.5.6 - Disassembly of the bevel gear pair 30-190 30.5.7 - Propeller shaft - Front axle drive shaft 30-198 30.5.8 - Planetary reduction gear 30-199 30.5.9 - Disassembly of the planetary reduction gear 30-200 30.6 - G0 - Bodywork - Cab - Platform 30-205 30.6.1 - Cab 30-205 30.6.2 - Hood and side panels 30-212 30.6.3 - Cab access steps 30-216 30.6.4 - Adjustable front fenders 30-217 30.6.5 - Cab door lock - tie-rod 30-217 30.6.6 - Instrument panel 30-219 30.6.7 - Left-hand rear cab pillar - screenwash reservoir 30-220 30.6.8 - Right-hand console 30-221 30.6.9 - Left-hand console 30-222 30.6.10 - Instrument panel 30-223 30.6.11 - Centre console 30-224 30.6.12 - RH rear cab pillar trim 30-225 30.6.13 - A/C system air intake ﬁlters 30-225 30.6.14 - Cab roof 30-226 30.6.15 - Seat 30-230 30.6.16 - Air conditioning system - Standard roof version 30-231

VI CONTENTS 30.6.17 - Air conditioning compressor 30-233 30.6.18 - Condenser 30-235 30.6.19 - Receiver-dryer 30-236 30.6.20 - Evaporator assembly 30-237 30.6.21 - Air conditioner fan 30-238 30.6.22 - Bistable pressure switch for compressor clutch engagement/disengagement 30-239 30.6.23 - Steering wheel 30-240 30.6.24 - Adjustment of the lift control valve levers 30-241 30.6.25 - Remote valve control levers 30-243 30.7 - H0 - Hydraulic system 30-244 30.7.1 - Pump for hydraulic lift and auxiliary services and power steering system 30-244 30.7.2 - Transmission oil ﬁlter assembly 30-245 30.7.3 - Power steering valve - Complete assembly 30-246 30.7.4 - Power steering disassembly 30-248 30.7.5 - Pressure relief valve - lift control valve 30-260 30.7.6 - Lift locking shut-off valve 30-261 30.7.7 - Remote control valve 30-262 30.7.8 - Remote control valve 30-262 30.7.9 - Control rods 30-264 30.7.10 - Double/single acting conversion valve 30-265 30.8 - L0 - Electrical system 30-267 30.8.1 - Battery 30-267 30.8.2 - Fuse and relay assembly 30-268 30.8.3 - Electrostatic unit 30-269 30.8.4 - Parking brake switch 30-270 30.8.5 - Adjustment of the parking brake switch 30-271 30.8.6 - Brake lights switches 30-272 30.8.7 - Adjustment of the brake light switches 30-273 30.8.8 - Steering column switch 30-273 30.8.9 - Control buttons - RH console 30-273 30.9 - M0 - Front PTO 30-276 30.9.1 - Pump - clutch assembly - brake 30-276 30.9.2 - PTO output shaft 30-279 30.9.3 - Solenoid valve 30-281 30.10 - N0 - Front lift 30-283 30.10.1 - Front lift - version with front PTO - 30-283 30.10.2 - Cylinder 30-285 30.11 - R0 - Rear lift 30-287 30.11.1 - Rear lift - complete assembly 30-287 30.11.2 - Rear lift - complete assembly 30-289 30.11.3 - Adjustment of the rear lift 30-294 30.11.4 - Lift cylinders 30-296 30.11.5 - Lift cylinders 30-297 30.11.6 - Renewal of the rear lift bush 30-298 30.11.7 - Lift arms 30-299 30.11.8 - Hydraulic lift control valve 30-301 30.11.9 - Disassembly of the lift control valve 30-302

VII CONTENTS 30.11.10 - Three-point linkage with mechanical adjustment 30-307 30.12 - S0 - Wheels 30-309 30.12.1 - Front wheels 30-309 30.12.2 - Rear wheels 30-309 30.13 - V0 - Ballast - towing hitches 30-310 30.13.1 - Support and towing hitch 30-310 40 - WIRING DIAGRAMS 40.1 - Introduction 40-2 40.1.1 - Structure of the unit 40-2 40.1.2 - Wiring and components index 40-6 40.1.3 - Introduction 40-6 40.1.4 - Basic electronics for mechanics (1/2) 40-9 40.1.5 - Basic electronics for mechanics (2/2) 40-11 40.1.6 - Electrical and electronic components (1/2) 40-18 40.1.7 - Electrical and electronic components (2/2) 40-26 40.2 - Components 40-31 40.2.1 - Components 40-31 40.3 - Systems 40-35 40.3.1 - Earthing points 40-35 40.3.2 - Starting 40-37 40.3.3 - Control unit - Fan 40-39 40.3.4 - Steering column lights switch 40-40 40.3.5 - Instrument panel 40-43 40.3.6 - Cab 40-45 40.3.7 - Aereo cab 40-48 40.3.8 - PTO 40-51 40.3.9 - Front axle differential lock 40-53 40.3.10 - Brakes 40-55 40.4 - Wiring harnesses 40-57 40.4.1 - Wiring harnesses 40-57 40.4.2 - Positions of front wiring connectors 40-58 40.4.3 - Front PTO wiring - 0.014.2645.4 40-61 40.4.4 - Positions of front PTO wiring connectors. 40-61 40.4.5 - Front lights wiring - 0.014.7599.4 40-63 40.4.6 - Positions of front light wiring connectors 40-64 40.4.7 - Compressor wiring - 0.014.7601.4 40-65 40.4.8 - Positions of compressor wiring connectors 40-65 40.4.9 - Front wiring with cab 40-66 40.4.10 - Positions of front wiring connectors with cab 40-68 40.4.11 - Central wiring - 0.012.6949.4 40-71 40.4.12 - Positions of central wiring connectors 40-75 40.4.13 - Solenoid valve wiring - 0.014.1482.4 40-80 40.4.14 - Positions of solenoid valve wiring connectors 40-81 40.4.15 - Rear wiring - 0.013.1452.4/10 40-82 40.4.16 - Positions of rear wiring connectors 40-84 40.4.17 - Remote valve wiring - 0.012.6955.4 40-86

VIII CONTENTS 40.4.18 - Rear lights wiring - 0.014.7602.4 40-86 40.4.19 - Positions of rear light wiring connectors 40-87 40.4.20 - Aereo cab wiring - 0.014.7593.4 40-89 40.4.21 - Positions of aereo-cab wiring connectors 40-91 40.4.22 - Cab power supply - 0.014.7594.4 40-92 40.4.23 - Positions of cab power supply wiring connectors 40-93 40.4.24 - Air conditioning system - 0.014.7596.4 40-94 40.4.25 - Position of air conditioner wiring connectors 40-95 40.4.26 - Cab earth wiring - 0.015.0031.4 40-96 40.4.27 - Positions of cab earth wiring connectors 40-97 40.4.28 - Worklights-number plate light- flashing light - 0.014.7595.4 40-98 40.4.29 - Positions of worklight, number plate and flashing light wiring connectors 40-99 40.4.30 - Flashing light wiring - 0.014.7591.4 40-101 40.4.31 - Positions of flashing light wiring connectors 40-101 40.4.32 - Windscreen wipers - 0.014.7598.4 40-102 40.4.33 - Positions of windscreen wiper wiring connectors 40-103 40.4.34 - Radio wiring - 0.014.7600.4 40-104 40.4.35 - Positions of radio-loudspeaker wiring connectors 40-105

0-1 0 - INTRODUCTION

0-2 INTRODUCTION 0.1 - INTRODUCTION The purpose of this workshop manual is to provide instruction for repair technicians and a practical guide to improving the quality of repairs. This manual enables repair technicians to acquire a thorough knowledge of the machine, indicating the correct methods for fault diagnosis, for working in safety and for accurate dimensional checks and visual inspections. The instructions also indicate the products to use, the tightening torques and the adjustment data. The technical material contained in this manual is reserved to Authorised Dealers and Service Centres who will be duly informed of any technical changes to the machines in question through the issue of documents regarding modifications, updates and supplements for optional equipment. All technicians and their colleagues are expressly forbidden from reproducing any part of this manual in any form or from communicating the contents to third parties without the express written permission of the Manufacturer, who remains the sole owner of this document with all rights reserved in accordance with applicable laws. 0.1.1 - Safety notes To ensure that machines entrusted to Authorised Service Centres for repair or overhaul continue to function correctly, it is very impor- tant that all repair work is carried out in the prescribed manner. The procedures for checks and repairs indicated in this manual are safe and effective. Some of the operations described require the use of special tools and equipment; these tools have been specifally designed for the intended purpose and may be ordered directly from the Manufacturers. DO NOT USE MAKESHIFT TOOLS; not only is there a risk of personal injury, but such tools are rarely suited to the purpose for which they are used. In potentially hazardous situations, always give priority to personal safety and take the necessary actions to eliminate the danger 0.1.2 - General safety rules l Even if you have a thorough knowledge of the machine as regards its components, operation and controls, always take special care when carrying out the following operations; Remember that the machine you are working on is in need of repair or overhaul and consequently may not always behave as expected. l Before starting work, clean the tractor thoroughly to remove all mud, dust and road dirt. Also clean the cab to remove all traces of oil, snow and ice from the access steps and grab rails. l When climbing up to or down from the cab, always ensure you maintain three points of contact at a time (foot or handholds) in order to keep your balance and prevent accidental falls. l Always take special care when carrying out fault diagnosis operations; these operations often require two persons, who must never stand in front of the wheels when the engine is running. l When carrying out checks and repairs, wear close-fitting clothing, safety goggles and protective gloves that are suitable for the task (cleaning, draining fluids, repairs). When working near moving parts, long hair should be gathered up and tied back safely under a cap to prevent the risk of entanglement and severe injury. l Do not allow anyone who is not directly involved in the work to come near the tractor; ensure that they remain at a safe dis- tance. l Keep well clear of moving parts; when the engine is running, some moving parts are not easily visible and therefore present a risk of entanglement, even if protected by safety guards. l Ensure that the area is well ventilated before starting the engine in order to avoid the formation of dangerous concentrations of toxic gases; always connect suitable fume extraction equipment to the exhaust pipe. l Do not start the engine with the safety guards removed under any circumstances; all repair and adjustment operations must be carried out with the engine stopped. l Do not top up fuel, oil or coolant levels when the engine is running. l Never smoke and ensure there are no naked flames nearby when topping up fuel or oil. Always remove the battery from the machine before recharging. l Before checking or removing the battery, stop the engine and remove the key from the starter switch. l Remove the battery and recharge in a well-ventilated area where the temperature exceeds 0°C. l When checking or recharging the battery, do not smoke or allow naked flames in the vicinity as the hydrogen gas given off by the battery is highly explosive. l The liquid (electrolyte) contained in the battery is very harmful if it comes into contact with the skin and the eyes; for this rea- son, always wear gloves and safety goggles with side shields when checking or topping up the battery. Should any electrolyte accidentally come into contact with your skin, wash the affected areas immediately with plenty of fresh water; if electrolyte comes into contact with your clothing, this should be removed as soon as possible. In case of accidental ingestion of electrolyte, drink copious amounts of water, milk or vegetable oil and take antacids such as magnesium, bicarbonate, etc. and seek medical attention immediately. l Before working on the electrical systems, always disconnect the battery terminals.

Deutz-Fahr Agrokid 210 / 220 / 230 Tractor Service & Repair Manual

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