Claas Ares 816 826 836 Workshop

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J1 – LIFT AND FRONT POWER TAKE-

OFF

J2 – PNEUMATIC BRAKING

Chapter J

Ares 806 60 05 030 493 – 09.2004 publication


CONTENTS

J1 – LIFT AND FRONT POWER TAKE-OFF

FRONT LIFT
CHARACTERISTICS....................................................................................................................................................... J1.2
EXPLODED VIEWS OF 3 500 AND 6 600 DAN FRONT LIFTS ..................................................................................... J1.3
TIGHTENING TORQUES................................................................................................................................................ J1.4

MEASUREMENT AND CHECKING POINTS


CHECKING THE CYLINDER PRESSURE...................................................................................................................... J1.5

"INSPECTION RESULTS" SHEET


CHECKING THE CYLINDER PRESSURE...................................................................................................................... J1.6

FRONT POWER TAKE-OFF


CHARACTERISTICS....................................................................................................................................................... J1.7
EXPLODED VIEW OF THE FRONT POWER TAKE-OFF ASSEMBLY.......................................................................... J1.8
EXPLODED VIEW OF THE UNIT ................................................................................................................................. J1.10
REMOVING THE PTO HOUSING................................................................................................................................. J1.11
EXPLODED VIEW OF THE CLUTCH ........................................................................................................................... J1.13
REMOVING THE CLUTCH ........................................................................................................................................... J1.14
REFITTING THE CLUTCH ............................................................................................................................................ J1.14

MEASUREMENT AND CHECKING POINTS


CHECKING THE CLUTCH FEED PRESSURE............................................................................................................. J1.15

"INSPECTION RESULTS" SHEET


CHECKING THE CLUTCH FEED PRESSURE............................................................................................................. J1.16

Ares 806 – 09.2004 – GB


J2 – PNEUMATIC BRAKING

HOW IT WORKS
MEASUREMENT AND CHECKING POINTS.................................................................................................................. J2.3
WITH THE ENGINE RUNNING, AND TRAILER CONNECTED, NO ACTION OF BRAKES.......................................... J2.4
WITH THE ENGINE RUNNING AND TRAILER CONNECTED, SERVICE BRAKES APPLIED..................................... J2.6
WITH THE ENGINE RUNNING AND TRAILER CONNECTED, HAND BRAKE APPLIED............................................. J2.8

MAIN COMPONENTS
PNEUMATIC CIRCUIT LAYOUT ON GTA 3230........................................................................................................... J2.10
COMPRESSOR............................................................................................................................................................. J2.11
PRESSURE REGULATOR............................................................................................................................................ J2.11
TANK ............................................................................................................................................................................. J2.11
TRAILER CONTROL VALVE ........................................................................................................................................ J2.12
SOLENOID VALVE........................................................................................................................................................ J2.12
PRINCIPAL CONTROL VALVE..................................................................................................................................... J2.13
BLEEDING THE HYDRAULIC AND PNEUMATIC TRAILER BRAKING SYSTEM....................................................... J2.13

TOOLS
LIFT, FRONT POWER TAKE-OFF AND PNEUMATIC BRAKING TOOLS .................................................................. J2.15

Ares 806 – 09.2004 – GB


A0 – INJECTION SHEET CHECKING
PROCEDURE

A0.1 Ares 806 – 09.2004 – GB


Checking procedure

The purpose of this procedure is to check a number of points before and after measuring on the power bench. It is suited
to engines with electronic control (TIER 2).
Failing to carry out these tests may lead to an incorrect power reading.
Always check the following points before starting a PTO power test.
Reminder: Wait until the running-in period has elapsed (minimum 100 hours) before testing an engine on the power bench.
This period is necessary to ensure that measuring is carried out under the right conditions.

1. Visual checks
Make sure that the supply and return circuit lines are
correctly fitted (not trapped or kinked on fitting, etc.).
Check that the engine serial n° read with Métadiag is the
same as the one indicated on the engine identification
plate and if there are any error codes.

2. Engine oil
Check the level:
l
I Normal level.
II Readjust the level as soon as possible. ll
lll
III Readjust the level before starting up the engine again.
221hsm01 Fig. 1

3. Hydraulic /transmission oil level


Check the level:
Mark (K): Minimum level.
Mark (J): Maximum level.
J
10 l

Fig. 2: Quadrishift.
Fig. 3: Full Powershift.
A level above level (J) affects engine power and
increases temperature. Example: Overfilling will greatly K
affect performance in road transport at high speed.

341hpn09 Fig. 2

J
13 l

542hsn03 Fig. 3

A0.2 Ares 806 – 09.2004 – GB


Checking procedure

4. Battery
Check the voltage with the engine off (between 12 and 13 V). Alternator-generated power consumption can reach 1,5 kW.

5. Coolers
Check that all radiators/coolers are clean.

6. Diesel filters
Change the filters. Fit the pressure gauge.
Unit reference: 60 05 00 55 21.
See measurement sheet for values.

161msm14 Fig. 4

161msm15 Fig. 5

7. Air filter
Check condition and replace if necessary.

Ares 806 – 09.2004 – GB A0.3


Checking procedure

8. Turbocharger pressure
Fit the pressure gauge.
Unit reference: 60 05 00 55 21.
See measurement sheet for values.

141msm01 Fig. 6

141msm02 Fig. 7

9. Hydraulic pressure
Fit the pressure gauge(s). See appendix for pressure connections.

A0.4 Ares 806 – 09.2004 – GB


Checking procedure

10. Fit the dynamometer


Ensure that the bench is correctly calibrated and that the
universal joint is aligned.

002msm01 Fig. 8

11. Twinshift/Quadrishift/shuttle reverser position (according to equipment)


To limit transmission power take-off, make sure that: the reverser is in neutral, the Twinshift is set to speed 2 and the
Quadrishift to speed 1.
Mechanical doubler: Hare position.
Make sure that the handbrake is applied.

12. Air conditioning/Ventilation


Make sure that the air conditioning and ventilation are switched off.

13. Front power take-off


Make sure that the front power take-off is disengaged.

Ares 806 – 09.2004 – GB A0.5


Checking procedure

14. Hydraulic pressure


Check hydraulic pressure by referring to the appendix. Make sure that no hydraulic application is running. If hydraulic
pressure is not within the specifications, the PTO power test results will be affected.

15. Check the maximum off-load speed


Ares 816/826: 2 354 ± 50.
Ares 836: 2 275 + 25/ 0.

16. Engage the PTO at the 1 000 rpm position


17. Set the engine to maximum speed for 1 min
18. Measure the power (see injection sheet)
19. After measuring, check the tractor temperature
Engine: 90°C.
Transmission: 60-65°C.

20. Leave the engine running between 1 500 and 1 600 rpm for 3 to 5 minutes, then idle before
switching off
If the results do not match the manufacturer's data following these operations, a flowmeter will need to be installed and the
values compared to the injection sheets.

A0.6 Ares 806 – 09.2004 – GB


Measurement sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:

Tractor type: ...........................................................................................................................................................................

Serial n°: ................................................................................................................................................................................

Engine serial n°: .....................................................................................................................................................................

Total operating hours: ............................................................................................................................................................

Date of operation: ..................................................................................................................................................................

Transmission type: .................................................................................................................................................................

Start of test End of test Reference values (bar)

Hydraulic pressure in HP circuit


See appendix
Hydraulic pressure in LP circuit
Outside temperature —
Transmission temperature 60 °C ß 65 °C
Engine temperature > 87 °C
Diesel temperature

Engine speed 1 000 1 100 1 200 1 300 1 400 1 500 1 600 1 700 1 800 1 900 2 000 2 100 2 200

Measurement (kW)
Measurement (N.m).
(power take-off)
Measurement (l/h)
Measurement of boost pressure
(bar)
Measurement of diesel supply pressure
at filter outlet (bar)
Boost pressure (bar)
0,36 0,39 0,51 0,65 0,79 0,85 0,87 0,91 0,94 0,97 1,02 1,04 1,00
Ares 816
Boost pressure (bar) Ares 826 0,39 0,50 0,66 0,87 1,05 1,16 1,21 1,27 1,32 1,36 1,40 1,40 1,37
Boost pressure (bar)
— 0,47 0,61 0,78 0,93 1,02 1,13 1,21 1,23 1,24 1,23 1,22 1,18
Ares 836
Diesel supply pressure at filter
0,25 ß 0,30
outlet (bar) Ares 816-826
Diesel supply pressure at filter
0,50
outlet (bar) Ares 836

Ares 806 – 09.2004 – GB A0.7


Pressure connection (appendix)

100 l/min LS circuit

2
1

396hsm01 Fig. 9

Parts list 2 14 cm³ pump pressure = 25 bar (nominal speed).


1 19 cm³ pump pressure = 17 bar (nominal speed). 3 Steering pressure = 50 bar (nominal speed).

A0.8 Ares 806 – 09.2004 – GB


Pressure connection (appendix)

110 l/min LS circuit (Quadrishift and Full Powershift)

HP

BP

396hsm02 Fig. 10

Parts list
1 High-pressure pump output pressure = 30 bar at 1 000 rpm. 2 Booster pump output pressure = 5 bar at 1 000 rpm.

Ares 806 – 09.2004 – GB A0.9


Notes

A0.10 Ares 806 – 09.2004 – GB


FUEL INJECTION DATA SHEET
ARES 816 - H 4412
DPS 6068 HRT 70 engine FUEL SUPPLY LINE DATA
Nominal speed 2 200 rpm
1 Main fuel tank: 300 litres 5 Stanadyne rotary injection pump
Secondary fuel tank: 80 litres DE 10 -5807.
Electronically controlled.
2 Mechanical supply pumps.
6 Stanadyne staggered injection injectors
3 Initial fuel filter: 10 microns
9.5 mm holder body (type 35107).
4 Final fuel filter: 2 microns Set pressure on injector: 250 bar.
7 Radiator.

DYNAMIC TIMING
Electronic management.

TEST CONDITIONS
– Refer to inspection procedure.

NOTE
– Reference values: measurements made on a tractor equipped with pneumatic braking, ambient temperature of 25 °C
with the visco-coupler free.

Supply system
Suction

Supply system
Supply pump pressure

Discharge line

Return line

161hsm02

Ares 806 – 09.2004 – EN


ENGINE TESTS AT PTO ARES 816 – H 4412
Position 1 000 rpm
kW POWER bhp
110 150
CURVE INTERPRETATION
Engine speed rpm 1300 2000 3 2200
100 136
Power take-off speed rpm 650 2 1000 1100
90 123 kW 77.7 98.5 91.2
POWER
bhp 105.6 133.9 124.0
80 109
TORQUE
N.m 1 1142 940 792
(Power take-off output)
70 95
CONSUMPTION PER HOUR l/h 21.5 29.4 29.7
60 82
g/kW.h 230 249 271
SPECIFIC CONSUMPTION
50 68 g/bhp.h 169 183 199
1000 1200 1400 1600 1800 2000 2200 rpm
N.m TORQUE 1 Maximum torque 2 Pow er take-off standardized speed 3 Nominal engine speed
1300 maximum torque – nominal speed torque
1250
Torque feedback = x 100 = 44.2 %
nominal speed torque
1200
1150 ENGINE TESTS AT POWER TAKE-OFF
1100 Rear Power Take-off (total reduction)
Engine Gearbox
1050 axle Position 540 Position 540 ECO Position 1000 Position 1000 ECO
1000
950
6068 HRT 70 GTA 1042 GPA 42 3.50 2.82 2.00 _
900
850 SPEEDS Idle Nominal Max no load
800 P ower
(rpm) Engine P ower take-o ff Engine
take-o ff
Engine P o wer take-o ff
750
700 540 840 Æ 860 240 Æ 246 2200 629 2304 Æ 2404 658 Æ 687
1000 1200 1400 1600 1800 2000 2200 rpm 840 Æ 860 298 Æ 305 817 Æ 852
Pow er take- 540 ECO 2200 780 2304 Æ 2404
l/h CONSUMPTION PER HOUR off position
35
1000 840 Æ 860 420 Æ 430 2200 1100 2304 Æ 2404 1152 Æ 1202
1000 ECO _ _ _ _ _ _ _ _ _ _

30
REFERENCE VALUES - Power Take-off position 1000 rpm
Engine rpm 1000 1200 1400 1600 1800 2000 2100 2200
25 SPEED
PTO rpm 500 600 700 800 900 1000 1050 1100

20 kW 53.2 71.6 83.5 93.1 98.2 98.5 96.3 91.2


POWER * _
bhp 72.3 97.3 113.5 126.6 133.5 133.9 130.9 124.0
15
TORQUE **
1000 1200 1400 1600 1800 2000 2200 rpm _ N.m 1016 1140 1138 1112 1042 940 876 792
(pow er take-off output)
g/kW.h SPECIFIC CONSUMPTION g/bhp.h
290 213 _ l/h 16.0 19.6 23.4 25.6 27.7 29.4 29.9 29.7
CONSUMPTION PER
280 206 HOUR
_ l/h _ _ _ _ _ _ _ _
270 198
g/kW.h 250 227 233 229 234 249 259 271
SPECIFIC
_
260 191 CONSUMPTION ***
g/bhp.h 184 167 171 168 172 183 190 199
250 184
Torque at Power t ake-of f outlet (N.m)
* P o wer (W) = torque (N.m) x speed (rad/s) ** Equivalent engine torque (N.m) =
Power t ake-off reduction
240 177
Ho urly co nsumptio n (l/h) x 1000 000
Injectio n flo w (mm3) = 1bhp = 0.7355 kW
Number of engine cylinders x engine speed(rpm) x 30
230 169 1rpm = 0.1047 rad/s
Hourly consumption (l/h) x diesel fuel density (0.840) 1kW = 1.3596 bhp
*** Specific consumptio n
1rad/s = 9.5510 rpm
220 162 (g/kW.h o r g/bhp,h) = P ower (kW or bhp)
1000 1200 1400 1600 1800 2000 2200 rpm

Ares 806 – 09.2004 – EN


FUEL INJECTION DATA SHEET
ARES 826 QUADRISHIFT – H 4422
DPS 6068 HRT 71 engine FUEL SUPPLY LINE DATA
Nominal speed 2 200 rpm
1 Main fuel tank: 300 litres 5 Stanadyne rotary injection pump
Secondary fuel tank: 80 litres DE 10 -5807. Electronically controlled.
2 Mechanical supply pumps. 6 Stanadyne staggered injection injectors
9.5 mm holder body (type 35107).
3 Initial fuel filter: 10 microns
Set pressure on injector: 250 bar.
4 Final fuel filter: 2 microns
7 Radiator.

DYNAMIC TIMING
Electronic management.

TEST CONDITIONS
– Refer to inspection procedure.

NOTE
– Reference values: measurements made on a tractor without pneumatic braking, ambient temperature of 25 °C with the
visco-coupler free.

Supply system
Suction

Supply system
Supply pump pressure

Discharge line

Return line

161hsm02

Ares 806 – 09.2004 – EN


ENGINE TESTS AT PTO ARES 826 QUADRISHIFT – H 4422
Position 1 000 rpm
kW POWER bhp
130 177
CURVE INTERPRETATION
120 163 Engine speed rpm 1400 2000 3 2200
110 150 Power take-off speed rpm 700 2 1000 1100
100 136 kW 97.9 113.1 103.7
POWER
bhp 133.1 153.8 141.0
90 123
TORQUE
N.m 1 1336 1080 900
80 109 (Power take-off output)
70 95 CONSUMPTION PER HOUR l/h 25.8 32.3 32.9
60 82 g/kW.h 219 237 263
SPECIFIC CONSUMPTION
50 68 g/bhp.h 161 174 193
1000 1200 1400 1600 1800 2000 2200 rpm
N.m TORQUE 1 Maximum torque 2 Pow er take-off standardized speed 3 Nominal engine speed
1500 maximum torque – nominal speed torque
Torque feedback = x 100 = 48.4 %
nominal speed torque
1400
ENGINE TESTS AT POWER TAKE-OFF
1300
Rear Power Take-off (total reduction)
Engine Gearbox
1200 axle Position 540 Position 540 ECO Position 1000 Position 1000 ECO

1100 6068HRT71 GTA 1044 GPA 44 3.50 2.82 2.00 _

1000 Idle Nominal Max no load


SPEEDS
P ower
900 (rpm) Engine P ower take-o ff Engine Engine P o wer take-o ff
take-o ff

800 540 840 Æ 860 240 Æ 246 2200 629 2304 Æ 2404 658 Æ 687
1000 1200 1400 1600 1800 2000 2200 rpm 840 Æ 860 298 Æ 305 817 Æ 852
Pow er take- 540 ECO 2200 780 2304 Æ 2404
l/h CONSUMPTION PER HOUR off position
40
1000 840 Æ 860 420 Æ 430 2200 1100 2304 Æ 2404 1152 Æ 1202
1000 ECO _ _ _ _ _ _ _ _ _ _

35

REFERENCE VALUES - Power Take-off position 1000 rpm


30
Engine rpm 1000 1200 1400 1600 1800 2000 2100 2200
SPEED
25 PTO rpm 500 600 700 800 900 1000 1050 1100

kW 58.0 78.7 97.9 105.9 111.9 113.1 110.3 103.7


20 POWER * _

bhp 78.9 107.0 133.1 144.0 152.1 153.8 150.0 141.0


15
TORQUE **
1000 1200 1400 1600 1800 2000 2200 rpm _ N.m 1106 1252 1336 1264 1186 1080 1002 900
(pow er take-off output)
g/kW.h SPECIFIC CONSUMPTION g/bhp.h
280 206 _ l/h 15.7 20.6 25.8 28.4 30.7 32.3 32.9 32.9
CONSUMPTION PER
270 199 HOUR
_ l/h _ _ _ _ _ _ _ _
260 191
g/kW.h 226 218 219 223 228 237 248 263
SPECIFIC
_
250 184 CONSUMPTION ***
g/bhp.h 166 160 161 164 168 174 182 193
240 176
Torque at Power t ake-of f outlet (N.m)
* P o wer (W) = torque (N.m) x speed (rad/s) ** Equivalent engine torque (N.m) =
Power t ake-off reduction
230 169
Ho urly co nsumptio n (l/h) x 1000 000
Injectio n flo w (mm3) = 1bhp = 0.7355 kW
Number of engine cylinders x engine speed(rpm) x 30
220 161 1rpm = 0.1047 rad/s
Hourly consumption (l/h) x diesel fuel density (0.840) 1kW = 1.3596 bhp
*** Specific consumptio n
1rad/s = 9.5510 rpm
210 154 (g/kW.h o r g/bhp,h) = P ower (kW or bhp)
1000 1200 1400 1600 1800 2000 2200 95

Ares 806 – 09.2004 – EN


FUEL INJECTION DATA SHEET
ARES 826 FULL-POWERSHIFT – H 4322
DPS 6068 HRT 71 engine FUEL SUPPLY LINE DATA
Nominal speed 2 200 rpm
1 Main fuel tank: 300 litres 5 Stanadyne rotary injection pump
Secondary fuel tank: 80 litres DE 10 -5807.
Electronically controlled.
2 Mechanical supply pumps.
6 Stanadyne staggered injection injectors
3 Initial fuel filter: 10 microns
9.5 mm holder body (type 35107).
4 Final fuel filter: 2 microns Set pressure on injector: 250 bar.
7 Radiator.

DYNAMIC TIMING
Electronic management.

TEST CONDITIONS
– Refer to inspection procedure.

NOTE
– Reference values: measurements made on a tractor without pneumatic braking, ambient temperature of 25 °C with the
visco-coupler free.

Supply system
Suction

Supply system
Supply pump pressure

Discharge line

Return line

161hsm02

Ares 806 – 09.2004 – EN


ENGINE TESTS AT PTO ARES 826 FULL-POWERSHIFT – H 4322
Position 1 000 rpm
kW POWER bhp
130 177
CURVE INTERPRETATION
120 163 Engine speed rpm 1400 2000 3 2200
110 150 Power take-off speed rpm 670 2 1000 1052

100 136 kW 96.3 111.0 100.7


POWER
bhp 130.9 150.9 136.9
90 123
TORQUE
N.m 1 1374 1108 914
80 109 (Power take-off output)
70 95 CONSUMPTION PER HOUR l/h 25.9 32.4 32.9
60 82 g/kW.h 222 241 270
SPECIFIC CONSUMPTION
50 68 g/bhp.h 163 177 199
1000 1200 1400 1600 1800 2000 2200 rpm
N.m TORQUE 1 Maximum torque 2 Pow er take-off standardized speed 3 Nominal engine speed
1500 maximum torque – nominal speed torque
Torque feedback = x 100 = 50.3 %
nominal speed torque
1400
ENGINE TESTS AT POWER TAKE-OFF
1300
Rear Power Take-off (total reduction)
Engine Gearbox
1200 axle Position 540 Position 540 ECO Position 1000 Position 1000 ECO

1100 6068 HRT 71 GBA 31 GPA 34 3.69 2.68 2.09 _

1000 Idle Nominal Max no load


SPEEDS
Pow er
900 (rpm) Engine Power take-off Engine Engine Power take-off
take-off
800 540 840 Æ 860 228 Æ 233 2200 596 2265 Æ 2285 614 Æ 619
1000 1200 1400 1600 1800 2000 2200 rpm Power
540 ECO 840 Æ 860 313 Æ 321 2200 821 2265 Æ 2285 845 Æ 853
l/h CONSUMPTION PER HOUR take-off
40 position 1000 840 Æ 860 402 Æ 411 2200 1053 2265 Æ 2285 1084 Æ 1093
1000 ECO _ _ _ _ _ _ _ _ _ _

35

REFERENCE VALUES - Power Take-off position 1000 rpm


30
Engine rpm 1000 1400 1500 1600 1800 2000 2100 2200
SPEED
25 PTO rpm 478 670 717 765 900 1000 1004 1052

kW 55.0 96.3 102.5 104.5 110.5 111.0 107.1 100.7


20 POWER * _
bhp 74.8 130.9 139.4 142.1 150.2 150.9 145.6 136.9
15
TORQUE **
1000 1200 1400 1600 1800 2000 2200 rpm _ N.m 1098 1374 1365 1309 1221 1108 1018 914
(pow er take-off output)
g/kW.h SPECIFIC CONSUMPTION g/bhp.h
290 213 _ l/h 15.8 25.9 27.5 28.4 30.7 32.4 32.9 32.9
CONSUMPTION PER
280 206 HOUR
_ l/h _ _ _ _ _ _ _ _
270 198
g/kW.h 237 222 222 225 231 241 255 270
SPECIFIC
260 191 _
CONSUMPTION ***
g/bhp.h 174 163 163 165 170 177 188 199
250 184
To rque at P o wer take-off outlet (N.m)
* P o wer (W) = torque (N.m) x speed (rad/s) ** Equivalent engine torque (N.m) =
P o wer take-o ff reductio n
240 177
Ho urly co nsumptio n (l/h) x 1000 000
Injectio n flo w (mm3) = 1bhp = 0.7355 kW
Number of engine cylinders x engine speed(rpm) x 30
230 169 1rpm = 0.1047 rad/s
Hourly consumption (l/h) x diesel fuel density (0.840) 1kW = 1.3596 bhp
*** Specific consumptio n
1rad/s = 9.5510 rpm
220 162 (g/kW.h o r g/bhp,h) = P ower (kW or bhp)
1000 1200 1400 1600 1800 2000 2200 rpm

Ares 806 – 09.2004 – EN


FUEL INJECTION DATA SHEET
ARES 836 – H 4432
DPS 6068 HRT 72 engine FUEL SUPPLY LINE DATA
Nominal speed 2 200 rpm
1 Main fuel tank: 300 litres 5 Stanadyne rotary injection pump
Secondary fuel tank: 80 litres VP 44 0 470 506680.
Electronically controlled.
2 Electric supply pumps.
6 Stanadyne conventional injectors
3 Initial fuel filter: 30 microns
9.5 mm holder body (type 35101).
4 Final fuel filter: 5 microns Set pressure on injector: 250 bar.
2 7 Radiator.

DYNAMIC TIMING
3 Electronic management.

TEST CONDITIONS
– Refer to inspection procedure.

7 NOTE
– Reference values: measurements made on a tractor without pneumatic braking, ambient temperature of 25 °C with the
visco-coupler free.

Supply system 1
Suction

Supply system
Supply pump pressure

Discharge line

Return line

161hsm01

Ares 806 – 09.2004 – EN


ENGINE TESTS AT PTO ARES 836 – H 4432
Position 1 000 rpm
kW POWER bhp
150 204
CURVE INTERPRETATION
140 190 rpm 3
Engine speed 1700 2090 2200
130 177
Power take-off speed rpm 813 2 1000 1052
120 163 kW 133.7 131.0 123.1
POWER
110 150 bhp 181.8 178.1 167.4
100 136 TORQUE
N.m 1 1570 1246 1117
(Power take-off output)
90 123

80 109 CONSUMPTION PER HOUR l/h 34.0 36.5 36.0

70 96 g/kW.h 215 235 247


SPECIFIC CONSUMPTION
60 82 g/bhp.h 158 173 182
1000 1200 1400 1600 1800 2000 2200 rpm
N.m TORQUE 1 Maximum torque 2 Pow er take-off standardized speed 3 Nominal engine speed
1700 maximum torque – nominal speed torque
Torque feedback = x 100 = 40.6 %
nominal speed torque
1600
ENGINE TESTS AT POWER TAKE-OFF
1500
Rear Power Take-off (total reduction)
Engine Gearbox
1400 axle Position 540 Position 540 ECO Position 1000 Position 1000 ECO

1300 6068HRT72 GTA 1044 GPA 44 3.50 2.82 2.09 _

1200 Idle Nominal Max no load


SPEEDS
P ower
1100 (rpm) Engine P ower take-o ff Engine Engine P o wer take-o ff
take-o ff

1000 540 840 Æ 860 240 Æ 246 2200 629 2265 Æ 2285 647 Æ 653
1000 1200 1400 1600 1800 2000 2200 rpm 840 Æ 860 298 Æ 305 803 Æ 810
Pow er take- 540 ECO 2200 780 2265 Æ 2285
l/h CONSUMPTION PER HOUR off position
40
1000 840 Æ 860 402 Æ 411 2200 1052 2265 Æ 2285 1083 Æ 1093
1000 ECO _ _ _ _ _ _ _ _ _ _

35

REFERENCE VALUES - Power Take-off position 1000 rpm


30
Engine rpm 1000 1200 1400 1600 1800 2000 2090 2200
SPEED
25 PTO rpm 478 574 670 765 861 957 1000 1052

kW 66.8 88.5 108.3 124.7 136.6 132.5 131.0 123.1


20 POWER * _

bhp 90.8 120.3 147.2 169.5 185.7 180.1 178.1 167.4


15
TORQUE **
1000 1200 1400 1600 1800 2000 2200 rpm _ N.m 1334 1472 1543 1556 1516 1321 1246 1117
(pow er take-off output)
g/kW.h SPECIFIC CONSUMPTION g/bhp.h
260 191 _ l/h 18.2 23.0 28.3 31.9 35.4 36.1 36.5 36.0
CONSUMPTION PER
HOUR
_ l/h _ _ _ _ _ _ _ _
250 184

g/kW.h 229 219 220 216 218 230 235 247


SPECIFIC
240 176 _
CONSUMPTION ***
g/bhp.h 168 161 162 159 160 169 173 182
230 169 Torque at Power t ake-of f outlet (N.m)
* P o wer (W) = torque (N.m) x speed (rad/s) ** Equivalent engine torque (N.m) =
Power t ake-off reduction
Ho urly co nsumptio n (l/h) x 1000 000
220 161 Injectio n flo w (mm3) = 1bhp = 0.7355 kW
Number of engine cylinders x engine speed(rpm) x 30
1rpm = 0.1047 rad/s
Hourly consumption (l/h) x diesel fuel density (0.840) 1kW = 1.3596 bhp
*** Specific consumptio n
1rad/s = 9.5510 rpm
210 154 (g/kW.h o r g/bhp,h) = P ower (kW or bhp)
1000 1200 1400 1600 1800 2000 2200 rpm

Ares 806 – 09.2004 – EN


A1 – INJECTION FEED
Engine DPS 6068 HRT 70

Engine DPS 6068 HRT 71

Engine DPS 6068 HRT 72

Ares 806 – 09.2004 – GB


Identification

Injection pumps identification

TRACTOR ARES 816 ARES 826 ARES 836


Type 4412 4422 4232

Engine 6068HRT70 6068HRT71 6068HRT72


Injection pump STANADYNE BOSCH
Model DE 10 VP 44
Type DE 10 5807
Injection order 1-5-3-6-2-4
Injector STANADYNE
Model Pencil-type 9 mm *2
Reference 35107 RE 507766 35101 RE 506688
Injector calibration pressure
250
(bar)
New injector opening pressure 255 to 260 bar
Minimum acceptable opening
235 bar
pressure of a worn injector
Maximum opening pressure
7 bar
difference between cylinders

STANADYNE injection pump BOSCH injection pump

161hsm01c 161hsm02c

A1.2 Ares 806 – 09.2004 – GB


Tightening torques (DE 10)

0,5 daN.m

2,7 daN.m
3 daN.m

2,7 daN.m
4 daN.m

19,5 daN.m

2,5 daN.m

9,5 daN.m
2,7 daN.m

0,6 daN.m

161msm01

Ares 806 – 09.2004 – GB A1.3


Tightening torques (VP 44)

0,5 daN.m

2,7 daN.m

4 daN.m
7 daN.m

2,7 daN.m

2,7 daN.m

0,6 daN.m

4,8 daN.m

161hsm03c

A1.4 Ares 806 – 09.2004 – GB


Operating principles

Pre-filter
Filters: 149 microns

ARES 816 and 826

Note: The original strainer (6) is to be replaced by a


removable strainer on the first compulsory service
(first 100 hours). 6
- Clean around the strainer located between the cab and
the main tank.
- Loosen the clips to free the strainer from the tubing.
- Collect any diesel still in the feed pipe.
- Open the strainer by unscrewing parts (B) and (C).
- Clean the 2 parts of the strainer.
- Reassemble.
- Drain the feed circuit.
161hpn05

IMPORTANT: Be careful not to introduce any


impurities into the diesel circuit during this operation.

161hpn01

Ares 806 – 09.2004 – GB A1.5


Operating principles

Fuel filter

1 2 1 2

3 3

A B

161hsm13c

Parts list
A Final filter B Primary filter
1 Fuel outlet 3 Drain screw
2 Fuel inlet 4 Filter

A1.6 Ares 806 – 09.2004 – GB


Operating principles

Injection pump
STANADYNE injection pump (DE 10)

161msm02

Parts list
A Fuel inlet. F Fuel control solenoid.
B Drive shaft. G Pump distributor.
C Transfer pump. H Distributor rotor.
D Cam ring. I Fuel temperature sensor.
E Pipe coupling for injector. J Fuel return.

Ares 806 – 09.2004 – GB A1.7


Operating principles

Injection pump
BOSCH injection pump (VP 44)

161hsm04c

Parts list
A Drive shaft. E High-pressure solenoid valve.
B Fuel pump. F Pump control unit (UCE).
C High-pressure radial piston pump. G Timing device.
D Distributor shaft. H Timing solenoid valve.

A1.8 Ares 806 – 09.2004 – GB


Operating principles

Injectors
Parts list
1 Injector nozzle.
2 Carbon deposit arrestor seal.
3 Needle.
4 Injector body.
5 Seal. 11 20
6 Injection pipe coupling.
7 Needle guide. 14
8 Union nut.
9 Spring retainer. 15
12
10 Adjustable spring.
11 Stroke adjustment screw. 13
12 Locknut.
13 Union. 10
14 Locknut.
15 Pressure adjustment screw.
16 Clamp. 16 18 19
17 Olive. 9
18 Filter basket.
19 Injection pipe.
20 Cap.
7

5 6 17
4
8

161msm03

Ares 806 – 09.2004 – GB A1.9


Operating principles

Situation of the different sensors (DE 10)

B
A

161msm04

Parts list
A Engine oil pressure sensor: 1,5 daN.m.
B Pump control solenoid.
C Engine control unit.
D Crankshaft position sensor: 1,4 daN.m.
E Fuel temperature sensor: 1,3 to 1,8 daN.m.
F Engine coolant temperature sensor: 1,5 daN.m.
G Manifold air temperature sensor: 1 daN.m.

A1.10 Ares 806 – 09.2004 – GB


Operating principles

Situation of the different sensors (VP 44)

161hsm05c

Parts list
A Engine coolant temperature sensor: 1,5 daN.m.
B Engine oil pressure sensor: 1,5 daN.m.
C Fuel pressure sensor: 1,3 to 1,8 daN.m.
D Electric transfer pump connector.
E Pump position sensor.
F Crankshaft position sensor: 1,4 daN.m.
G Engine control unit.
H Coolant temperature sensor (thermostat housing): 1,5 daN.m.
I Manifold air temperature sensor: 1 daN.m.

Ares 806 – 09.2004 – GB A1.11


Checks/Adjustments

Accelerator control adjustment

161msm05

Make sure that: 2 - The angular detector values:


1 - The adjustment measurement (A) satisfies the - Raised pedal (in idling speed stop): Maximum 0,9 V.
following 2 conditions: - Pedal fully depressed: Minimum 3,1 V.
- The pedal shoe effort must be between 3 and 5 daN. The voltage will be measured with ignition switched on.
- The pedal must return easily to the high position. Use the cable n° 60 05 005 577 to measure the output
voltage.

A1.12 Ares 806 – 09.2004 – GB


Checks/Adjustments

Adjusting the engine injector


B F
For any operation assembling/dismantling the injectors,
use tool n° 60 05 005 579 combined with a sliding D A 0,5 daN.m
hammer.
- Unscrew the protection cover (F). C 1 daN.m
- Loosen and remove the locking nut (A) of the needle
rise adjustment screw.
- Loosen locking nut (C) of the injection pressure
adjustment screw, use tool n° 60 05 005 574.
- Connect the injector to the tester then adjust the
pressure to the specified value by turning the pressure
adjustment screw (D). E
- Tighten the locknut (A) and check the pressure.
Carry out the adjustment again if necesssary.
WARNING: It is recommended to aim for the
maximum value in the adjustment because after
operating for some time the pressure drops slightly
before stabilising. Repeat the adjustment in order to
obtain a reliable result.
- Gently turn the needle rise adjustment screw (B) until it
reaches the seat of the spring (E).
- Unscrew the needle rise adjustment screw a 7/8 turn.
- Tighten the locknut (A) at torque.
WARNING: The injector nozzle must never be
pointing towards the person performing the 161msm06

adjustment. The jet escaping from a port can pierce


clothing and skin, and cause serious infections. It is
recommended to contain the jet within a transparent
container.

Ares 806 – 09.2004 – GB A1.13


Checks/Adjustments

Supply pressure check


- Fit the tool (1) n° 60 05 005 521.
- Start the engine.
The fuel pump must maintain the minimum pressure A B
indicated below. If the pressure is low, change the filters
and start the check again.
Pressures and flows (see injections sheets, chapter A0).
Parts list
A Output .
B Input.
C Primary filter.
D Final filter.

A B

D
161msm07

A1.14 Ares 806 – 09.2004 – GB


Removal/refitting

Fuel filter replacement


To replace the fuel filter:
- Loosen retaining ring (A) and remove the filter
body (B).
- Retain the holding ring (A) and put it in place on the A
new filter.
- Put the new filter in place, aligning the filter locators B
with the oblong holes in the mounting flange for the
filter head.
- Tighten the retaining ring (A) until it locks.
- Bleed the fuel filter.
Note: The holding ring is in the correct position when
no further resistance is felt during tightening.
Change both at the same time. Polarising slot on cartridge
and filter (no possibility of inversion).
161msm08

Injection system bleeding


1st case F
After changing the fuel filter
- Undo the drain screw on the front of the filter head.
- Activate the mechanical feed pump.
- Tighten up the drain screw again. The engine should
start.

2nd case
After complete draining of the circuit
- Perform operations from 1 to 3 described under
the 1st case.
- Loosen the return pipe (F) until all the air is eliminated,
then tighten it up again.
- Whilst turning the engine using the starter motor,
161msm09
loosen the couplings (H) until the fuel escaping from
the coupling is free of air bubbles. Retighten the union
while turning the starter.
- Repeat the procedure for the other injectors until the
engine starts.

161msm10

Ares 806 – 09.2004 – GB A1.15


Removal/refitting

Injection pump removal (DE 10)


IMPORTANT: Before any work is done on the injection
pump, it is IMPERATIVE to position the timing axle B A
n° 60 05 005 575 in aperture (E), as well as the
flywheel timing axle n° 60 05 005 576 using flywheel
turning tool n° 60 05 005 501 turning the gear to the
left when facing the tractor. Make sure that these
timing pins remain in place until reassembly.
IMPORTANT: Never use steam or cold water to clean
a hot or operating injection pump.
D
IMPORTANT: Take care not to turn the injection pump
couplings when loosening the injection pipes, as this E
may cause internal damage to the pump.
C
- Blank off all the couplings and apertures as soon as
dismantling takes place (pump and pipes), do not use
fraying materials. 161msm11
- Disconnect electrical connections.
- Disconnect the fuel return pipe (A).
- Disconnect the fuel supply pipe (B).
- Disconnect the injection pipes (C).
- Dismantle the diesel filter.
- Remove the pump gear access plate.
- Remove the nut and washer securing the injection
pump drive pinion to the pump shaft.
- Attach special tool n° 60 05 005 514 to the gear.
- Remove the three nuts (D) securing the pump to the
engine front plate.
- Turn the screw of tool n° 60 05 005 514 clockwise until
the pump shaft separates from the drive gear.
- Disengage the pump from the three studs by pulling it
backwards.

A1.16 Ares 806 – 09.2004 – GB


Removal/refitting

Injection pump removal (VP 44)


IMPORTANT: Before carrying out any work on the E
injection pump, it is ESSENTIAL to fit timing pin
n° 60 05 005 578 near to screws (E), and flywheel
timing pin n° 60 05 005 576 with the aid of flywheel
turner n° 60 05 005 501 while rotating the pinion to the
left when facing the tractor. Make sure that these
timing pins remain in place until reassembly.
IMPORTANT: Never use steam or cold water to clean
a hot or operating injection pump.
D
IMPORTANT: Take care not to turn the injection pump
A
couplings when loosening the injection pipes, as this
may cause internal damage to the pump. B
- Blank off all the couplings and apertures as soon as C
dismantling takes place (pump and pipes), do not use
fraying materials. 161hsm06c
- Disconnect electrical connections.
- Disconnect the fuel return pipe (A).
- Disconnect the fuel supply pipe (B).
- Disconnect the injection pipes (C).
- Dismantle the diesel filter.
- Remove the pump gear access plate.
- Remove the 4 screws and washers (E) attaching the
injection pump driving pinion to the pump shaft.
- Disengage the pump from the three studs by pulling it
backwards.

Ares 806 – 09.2004 – GB A1.17


Removal/refitting

Injection pump installation (DE 10)


E 19,5 daN.m
WARNING: Before replacing the pump, make sure
that the pump timing pin and the flywheel timing pin
have remained in place. If not repeat the operation
indicated prior to the pump removal.
- Fit a new seal on the front face of the injection pump
attachment flange.
- Slide the injection pump onto the mounting studs,
whilst at the same time inserting the pump shaft into
the drive pinion.
- Hand-tighten the nuts (D).
- After firmly engaging the drive pinion against the
tapered part of the shaft, fit the washer and nut (E).
- Tighten nut (E) to 19,5 daN.m.
- Remove the pump timing and flywheel pins.
- Torque-tighten the nuts (D) to 2,5 daN.m.
- Tighten the injection pipes (C), then the return (A) and B A
supply (B) pipes.
- Connect up the various electric cables which were
disconnected prior to removal of the pump.
- Bleed the air from the fuel circuit.
IMPORTANT: Never remove the pump and flywheel
timing pins before the pump and gear are fastened.

C
161msm12

A1.18 Ares 806 – 09.2004 – GB


Removal/refitting

Injection pump installation (VP 44) 4,8 daN.m

WARNING: Before replacing the pump, make sure E


that the pump timing pin and the flywheel timing pin
have remained in place. If not repeat the operation
indicated prior to the pump removal.
- Fit a new seal on the front face of the injection pump
attachment flange.
- Slide the injection pump onto the mounting studs while
inserting the pump hub into the driving pinion.
- Hand-tighten the nuts (D).
- After engaging the driving pinion with the pump hub, fit
screws (E) and washers.
- Torque tighten the screws (E) to 4,8 daN.m.
- Remove the pump timing and flywheel pins.
- Torque-tighten the nuts (D) to 7 daN.m.
- Tighten the injection pipes (C), then the return (A) and
supply (B) pipes.
- Connect up the various electric cables which were
disconnected prior to removal of the pump.
- Bleed the air from the fuel circuit. 7 daN.m
IMPORTANT: Never remove the pump and flywheel D
timing pins before the pump and gear are fastened. A
B
C

161hsm07c

Ares 806 – 09.2004 – GB A1.19


Diagnostics
N.B.: Before carrying out any diagnostic operations, check that the quality and quantity of fuel is adequate.

Sheet n° 1 "Engine start-up defect"

The engine is started


but does not run

No active Connect Metadiag and Anomaly


codes switch ignition on codes active

Correct Check the presence Incorrect If the codes comprise a


of fuel in the injectors SPN 637, diagnose them first

Repair according to the code


See sheet (see chapter G7)
"Checking the
fuel supply
system"

Check for
clogging of Incorrect Repair or
intake replace the
exhaust components
Correct

Check Incorrect
compression Problem of pistons, rings,
liners or valve guides
Correct

Check the Incorrect Repair or


injectors replace the
injectors
Correct

Have the pump


repaired

161hsm08c

A1.20 Ares 806 – 09.2004 – GB


Diagnostics

Sheet n° 2 "Irregular engine operation"


Beforehand, check for: - Transmission problems;
- Air leak on the intake manifold; - Engine accessory problems;
- Mechanical problems; - Electromagnetic disturbance.

The engine is misfiring and/or


does not operate regularly

No active Connect Metadiag and Anomaly


codes switch ignition on codes active

Wrap a cloth around the injector union. See sheet


Slowly loosen and observe If the codes
No "Checking the comprise a
a change in engine speed. fuel supply
Perform the operation for each cylinder. (on all the cylinders) SPN 637,
system" diagnose them
Misfiring on a single cylinder?
first
Yes

Check the Incorrect Replace Repair according


cylinder the cylinder to the code
head gasket head gasket (see chapter G7)
Correct

Check the Incorrect Repair or


fuel inlet replace the
pipe pipe
Correct

Check Incorrect Apply some oil on the piston ring area Correct
compression through the injector bore.
Repeat the compression test.
Incorrect
Correct

Repair or Incorrect Check the Problem of pistons, rings,


Check the Incorrect
replace the clearance on liners or valve guides
injectors the valves
injectors
Correct
Correct

Adjust the
clearance and Check Correct
Have the pump perform the valve
repaired test again lifting
Incorrect

Wear on
camshaft boss,
rollers, rocker
arm rods

161hsm09c

Ares 806 – 09.2004 – GB A1.21


Diagnostics

Sheet n° 3 "Grey or black smoke emission"

The engine emits too much smoke,


black or grey, at the exhaust

No active Connect Metadiag and Anomaly


codes switch ignition on codes active

Look for a possible clogging at If the codes


Yes intake or exhaust comprise a
or a possible air leak SPN 637,
diagnose them
Correct

first

Repair according
Repair or replace the Inspect the turbocharger: to the code
defective components - compressor inlet/outlet, (see chapter G7)
Correct - turbine inlet/outlet, Incorrect
- internal/external central body,
- end float,
- supercharging pressure.

Check the Repair or


Incorrect Correct replace the
clearance on
the valves defective
components

Adjust the Repair or


clearance and Check the Incorrect replace the
perform the fuel return defective
test again pipe components
Correct

Incorrect Repair or
Check the replace the
injectors injectors
Correct

Have the pump


repaired

161hsm10c

A1.22 Ares 806 – 09.2004 – GB


Diagnostics

Sheet n° 4 "White smoke emission"

The engine emits too much white


smoke at the exhaust

No active Connect Metadiag and Anomaly


codes switch ignition on codes active

Yes Look for a possible failure of the cylinder If the codes


head gasket. comprise a
SPN 637,
diagnose them
No

first

Repair according
to the code
(see chapter G7)

See sheet
"Cylinder head Check Incorrect Problem of pistons, rings,
gasket inspection compression liners or valve guides
procedure"
Correct

Check the Incorrect Repair or


injectors replace the
injectors
Correct

Have the pump


repaired

161hsm11c

Ares 806 – 09.2004 – GB A1.23


Diagnostics

Sheet n° 5 "Check the fuel feed circuit"

The engine operates


irregularly

No active Connect Metadiag and Anomaly


codes switch ignition on codes active

If the codes
No Look for possible presence Yes comprise a
of air in the supply system. SPN 637,
diagnose them
first

Incorrect Check fuel supply pressure Correct Bleed the Repair according
and flowrate system to the code
(see chapter G7)

Repair or
replace any
defective part
in the system.

Inspect the fuel pipes


Incorrect Inspect the fuel inlet pipes Correct Correct Incorrect
before injection betwwen
between the injector
the final filter outlet
and the pump
and the injection pump

Repair or Repair or
Have the pump
replace the replace the
repaired
pipe(s) pipe(s)

161hsm12c

A1.24 Ares 806 – 09.2004 – GB


A2 – ENGINE TIER II
Engine DPS 6068 HRT 70
Engine DPS 6068 HRT 71
Engine DPS 6068 HRT 72

Ares 806 – 09.2004 – GB


General specifications

Identification of the engines


Engine 6068 HRT 70 6068 HRT 71 6068 HRT 72
Number of cylinders 6
115 128,5 141,5
Nominal power ECE R 24 in kW (ch)
(157) (175) (192)

Manufacturer's plate
The plate (C) is on the right-hand side of the engine and
includes the following information:
First line

CD ............... Production plant code (CD = Saran)


6068............. Type of engine
6 = Number of cylinders
068 = Capacity (068 = 6,8 litres) C
H .................. Intake
D = Naturally aspirated
T = Over-supply
H = Turbocharged and air-air aftercooled
617251......... Serial number 101msn01 Fig. 1

Second line

6068............. See above.


H .................. See above.
RT ................ RENAULT Agriculture application
70................. Application issue

A2.2 Ares 806 – 09.2004 – GB


General specifications

Engines 6 cylinders

Engine 6068 HRT 70 6068 HRT 71 6068 HRT 71

Make DPS
Injection Direct
Air intake Turbo
Cooling Liquid
Number of cylinders 6
Injection order 5-3-6-2-4
Bore (in mm) 106,5
Travel (in mm) 127
Cubic capacity (cm3) 6788
Compression ratio 17/1
Compression pressure (in bar) 24
Rated speed (rpm) 2 200
Idle speed (rpm) 850 ± 10
Maximum rev speed off-load (rpm) 2325 ± 10
Lubrication circuit (I)* Minimum 14/maximum 17
Cooling circuit (I)** 23 with heating
* Lubricant: Corresponding to standard SAE 15W40 - ACEA E5 - API CH-4.
** Fluid: Coolant volume – Reference GLACEOL RX GF (– 37°C) or corresponding to type D standards.

Crankshaft rotation direction Identification of the sides of the engine


Clockwise when facing the end of the water pump. To distinguish the "right hand" side from the "left hand"
side, stand facing the end of the crankshaft (at the rear of
Identification of the front of the engine the engine).
The end of the water pump is the «front» of the engine.
Identification of cylinder No 1
The first cylinder, on the water pump side, corresponds to
cylinder No 1.

1
2
3
4
5
6

101hsm00 Fig. 2

Ares 806 – 09.2004 – GB A2.3


DIMENSIONAL SPECIFICATIONS

Cylinder head and valves


A

130hsm00 Fig. 3

A.
– Minimum acceptable cylinder head thickness: 104,87 mm.
– Maximum acceptable cylinder head thickness: 105,13 mm.
– Maximum acceptable cylinder head rework: 0,76 mm.
Minimum cylinder head thickness after rework: 104,11 mm.
B. Cylinder head flatness over entire length: 0,08 mm.

A2.4 Ares 806 – 09.2004 – GB


DIMENSIONAL SPECIFICATIONS

C G
D H

F J

E I

131hsm00 Fig. 4

Intake Exhaust
C. G.
Ø Valve stem minimum: 7,864 mm. Ø Valve stem minimum: 7,848 mm.
Ø Valve stem maximum: 7,884 mm. Ø Valve stem maximum: 7,884 mm.
D. H.
Minimum clearance between stem and guide: 0,05 mm. Minimum clearance between stem and guide: 0,05 mm.
Maximum clearance between stem and guide: 1,10 mm. Maximum clearance between stem and guide: 1,10 mm.
Wear limit: 0,15 mm. Wear limit: 0,15 mm.
E. I.
Minimum valve withdrawal: 0,61 mm. Minimum valve withdrawal: 1,22 mm.
Maximum valve withdrawal: 1,11 mm. Maximum valve withdrawal: 1,72 mm.
Withdrawal wear limit: 1,63 mm. Withdrawal wear limit: 2,26 mm.
F. J.
Ø Valve head minimum: 46,47 mm. Ø Valve head minimum: 42,37 mm.
Ø Valve head maximum: 46,73 mm. Ø Valve head maximum: 42,63 mm.

Ares 806 – 09.2004 – GB A2.5


DIMENSIONAL SPECIFICATIONS

131hsm01 Fig. 5

Parts list
Adm. : Intake. A Uncompressed length: 54 mm. Length compressed to 24 daN:
Ech. : Exhaust. 46 mm. Length compressed to 68 daN: 34,5 mm.
LU. : Wear limit.

A2.6 Ares 806 – 09.2004 – GB


DIMENSIONAL SPECIFICATIONS
Cylinder block

0,025 → 150

337,896 → 337,972
Ø 84,46 → 84,48

111hsm00 Fig. 6

Parts list
A Ø without bush of bearing n° 1. Minimum: 59,96 mm. B Ø without bush of bearing n° 1.
Maximum: 59,98 mm. Ø without bush of other bearings. Minimum: 55,96 mm.
Minimum: 55,98 mm. Maximum: 56,01 mm. Maximum: 55,98 mm.

Ares 806 – 09.2004 – GB A2.7


General specifications
Liners and pistons
Ø 126,33 → 126,35

6,022 → 6,058 Ø 106,48 → 106,52 0,3 → 0,1*

Ø 120,61 → 120,69

Ø 5,952 → 5,988

Ø 120,70 → 120,75

Ø 0,1 → 0,14

10

Ø 115,724 → 115,748

E
Ø 71,64 → 71,70

Ø 115,75 → 115,80

A C
Ø 106,38 → 106,40
19

6068H = Ø 41,285 → 41,295 B D

0,08 → 0,30

0,09 → 0,14

121hsm00 Fig. 7

Compare A, B, C, D to determine whether the liner is tapered or out-of-round.

Parts list
Maximum ovalization: 0,05 mm. E Clearance on first fit between 0,025 —> 0,075 mm.
Maximum taper: 0,05 mm. Clearance on 2nd fit between 0 —> 0,075 mm.
Wear limit: 0,1 mm.

* Maximum gap between nearest two points of two liners = 0,05 mm.

A2.8 Ares 806 – 09.2004 – GB


General specifications

Connecting rods
After measuring A, B and C (bearing bush removed), the maximum difference must be 0,038 mm.

121hsm01 Fig. 8

Parts list
Bearing bush/crank pin clearance: Maximum bore ovalization:
Minimum 0,050 mm. LU: 0,038 mm.
Maximum 0,127 mm. Repair bushes available: 0,25 mm.
LU: 1,152 mm. LU: Wear limit.

* Measurement taken with bush mounted.

Ares 806 – 09.2004 – GB A2.9


General specifications

Crankshaft, bearings and flywheel

0,05 → 0,25

101hsm06 Fig. 9

Parts list
Bearing bush/crank pin clearance: Maximum bore ovalization:
Minimum 0,050 mm. LU: 0,038 mm.
Maximum 0,127 mm. Repair bushes available: 0,25 mm.
LU: 1,152 mm. LU: Wear limit.

* Measurement taken with bush mounted.

A2.10 Ares 806 – 09.2004 – GB


General specifications

Camshaft

Adm : 6,93 → 7,42 – LU = 6,68


Ech : 6,76 → 7,26 – LU = 6,50
3,935 → 3,985 – LU = 3,83

Ø 55,872 → 55,898 – LU = 55,85

A = 0,08 → 0,23 – LU = 0,38

B = 0,08 → 0,14 C = 0,06 → 0,11

111hsm09 Fig. 10

Parts list
Adm. Intake. A Axial clearance.
Ech. Exhaust. B Bearing clearance.
LU Wear limit. C Clearance of bearing n° 1 with bush.

* Measurement taken with bush mounted.

Ares 806 – 09.2004 – GB A2.11


General specifications

Distribution

A = 0,095 → 0,145
Ø 69,802 → 69,832

Ø 69,757 → 69,777

0,08 → 0,75

0,08 → 0,75

B = 0,075 → 0,125

0,005 → 0,68

A = 0,095 → 0,145

0,07 → 0,6 0,06 → 0,58


Ø 44,437 → 44,463
Ø 44,489 → 44,539

0,06 → 0,65

0,007 → 0,65

0,08 → 0,6

B = 0,026 → 0,102

132hsm00 Fig. 11

Parts list
A Axial clearance. B Clearance.

A2.12 Ares 806 – 09.2004 – GB


General specifications

Lubrication
Oil pump
Oil pump delivery at maximum speed, at 3 bar pressure .......................................................................................... 70 l/min
Minimum oil pressure at tick-over, with the oil at 90°C ................................................................................... 1 bar minimum
Minimum oil pressure at maximum off-load speed, with the oil at 90°C
– All engine types ........................................................................................................................................... 3 bar minimum
Bypass valve spring.
– Spring length (off-load) ............................................................................................................................................. 51 mm
– Spring force at a length of 29 mm .......................................................................................................................... 8,7 daN
B = Ø 16,05 → 16,10

A = Ø 16,02 → 16,03

35,97 → 36,05
D = 0,04 → 0,165
C = Ø 12,35 → 12,36

A = Ø 12,31 → 12,33

D = 0,04 → 0,165

0,131 → 0,211
1
0,21
1→
0,13

220hsm00 Fig. 12

Parts list
A Shaft. B Bush. C Bore. D Axial clearance.

Ares 806 – 09.2004 – GB A2.13


General specifications

Cooling
Thermostat
Thermostat opening temperature ................................................................................................................ 82 °C (80-84 °C)
Temperature for full opening of the thermostat.............................................................................................................. 94 °C
Cooling system pressure .............................................................................................................................................0,7 bar
Water pump and fan drive support

250hsm00 Fig. 13

A2.14 Ares 806 – 09.2004 – GB


General specifications

Turbocharger
Type of turbocharger ........................................................................................................................................................ CZ.
Normal turbocharger pressure at full load nominal speed .........................................................................................0,83 bar

165hsm00 Fig. 14

Ares 806 – 09.2004 – GB A2.15


Tightening torques
Front chassis / engine link
See figure.
30 ± 5 daN.m

Engine/transmission link
A - 2 M22 x 90 screws: 56 ± 10 daN.m.
B - 4 M16 x 85 screws: 23 ± 4 daN.m.
C - 4 M22 x 110 screws: 56 ± 10 daN.m.
D - 1 M16 x 60 screws: 23 ± 4 daN.m.
P - Guide pin

30 ± 5 daN.m

101msm02 Fig. 15

10

101msm03 Fig. 16

A2.16 Ares 806 – 09.2004 – GB


Tightening torques

3 daN.m*

101hsm07 Fig. 17

* If fitting, resistance = 3,4 daN.m.

Ares 806 – 09.2004 – GB A2.17


Tightening torques

101hsm08 Fig. 18

* Plus 3 punches.

A2.18 Ares 806 – 09.2004 – GB


Tightening torques
Crankshaft with straight front end
Oiled screw.

Crankshaft with tapering front end


2 daN.m
New oiled screw.

101msm04 Fig. 19

50 daN.m

101msm05 Fig. 20

Ares 806 – 09.2004 – GB A2.19


Checks/Adjustments

Checking compression
2 1
N.B.: before starting the test, make sure that the
battery is fully charged and that the injector area is
perfectly clean.
Start the engine and run it at idle speed during 10
to 15 minutes.
Remove the injectors.
Mount tool n° 60 05 005 516 (1), (Fig. 21 and 22) with
seal (3) on a compression tester.
Disconnect the power connector from the injection pump.
Turn the engine using the starter motor during a few
seconds.
The compression value should be 24 bar minimum. It
must be measured on each cylinder. The difference
between the min. and the max. value should be inferior
to 3,5 bar. Check at crankshaft minimal speed at 150 rpm
131hsm02 Fig. 21
when cold or 200 rpm when hot.

Check of engine oil pressure


Remove the oil pressure probe and install pressure gauge
No. 77 01 388 204 (1) on the block, (Fig. 24). 1
Before checking the pressure, run the engine. 3
At idle speed and with a temperature of 93°C, the
pressure gauge should indicate a minimum pressure
of 1 bar.
At full load nominal speed and with a service temperature
of 105°C, the pressure gauge should indicate a pressure
between 2,6 and 3,3 bar.

131hsm14 Fig. 22

101hsm01 Fig. 23

A2.20 Ares 806 – 09.2004 – GB


Checks/Adjustments

Check of valve lift (Engine cold)


N.B.: The lift valve measure enables detection of cam
wear.
1 Turn the engine and position the valves as indicated in
the following paragraph ("Valve clearance").
2 Cancel the valve clearance.
3 Place a dial gauge on the valve spring cup or on the
valve cap and then set on "0".
4 Turn the engine and observe the dial gauge until the
valve opens at maximum. Check the values read with the
specifications at the beginning of this chapter.
5 Measure the valve lift as explained above and adjust the
clearance.
6 If the specifications are not followed, remove and check
the camshaft condition.
131hsm03 Fig. 24

Valve clearance (Engine cold)


Using tool No. 60 05 005 501 (1) turn the flywheel in its
normal direction (clockwise when viewed from the water
pump) until piston No. 1 (at the front) is at top dead centre
(TDC) of its compression stroke. Engage adjustment pin
n° 60 05 005 576 in the flywheel bore (2).
N.B.: When piston No. 1 is at TDC of its compression
stroke, the valve springs of cylinder No. 1 are not
pressurised. 1
Valve clearance
2
Refer to the chapter "Dimensional specifications".
Loosen the blocking locknuts (A) and adjust the valve
clearance as indicated next page.

111hsm01 Fig. 25

131hsm04 Fig. 26

Ares 806 – 09.2004 – GB A2.21


Checks/Adjustments

Valve adjustment sequence


6-cylinder engine
Adjust the clearance on the exhaust valves of
cylinders 1, 3 and 5 and on the intake valves of A
cylinders 1, 2 and 4.
Rotate the cranshaft through 360° to bring piston n° 6 to
TDC of its compression stroke and refit the adjustment
pin.
Adjust the clearance of the exhaust valves No. 2, 4 and 6,
and the intake valves No. 3, 4 and 6.
A Front of engine.
B Exhaust valve.
C Intake valve.
D Piston No. 1 at TDC (compression stroke).
D Piston No. 6 at TDC (compression stroke).
E Piston No. 4 at TDC (compression stroke). 131hsm05 Fig. 27

Checking the turbocharger pressure


Remove the plug (1) and install pressure gauge No.
60 05 005 521 on the intake manifold.
Before checking, run the engine.
Observe the pressure gauge.
The lift pressure should be, when the engine is running at
full load and reaches nominal speed:
– Engine 6068 HRT 70 ....................................... 0,63 bar
– Engine 6068 HRT 71 ....................................... 0,80 bar
– Engine 6068 HRT 72 ....................................... 0,97 bar
1
If the pressure is too low, check the following points:
– Air filter clogging.
– Leak at the intake circuit, between the turbocharger
and cylinder head. 101msm06 Fig. 28

– Faulty turbocharger.

A2.22 Ares 806 – 09.2004 – GB


Checks/Adjustments

Check of the belt and the


tensioner spring
Check of the belt condition
1 Inspect the stops (A) and (B) of the tensioner.
2 If the tensioner stop, located on the swivel arm, contacts
the fixed stop (B), check the mounting support (alternator,
tensioner, etc.) and the belt length.

Replace the belt if necessary.

Check of the tensioner spring force


A
A belt force gauge does not provide accurate 2
B
measurement of the belt force when a spring-operating
automatic tensioner is used. Measure the tensioner spring
force with a torque wrench proceeding as follows:
1 Loosen the tension on the belt using a nut spinner and
251hsm00 Fig. 29
a socket on the tension arm. Remove the belt from the
pulleys.
2 Release the tension exerted on the tension arm and
remove the nut spinner.
3 Scribe a mark (A) on the tensioner swivel arm as shown
in the figure.
4 Measure 21 mm from (A) and scribe a mark (B) on the
tensioner mounting base.
5 Swivel the arm using a torque wrench to align the A
markings (A), (B) and (C). B
6 Note the measure on the torque wrench and compare it
to the specification below.

Change the tensioner if required.

Spring force: 1,8 à 2,2 daN.

251hsm01 Fig. 30

251hsm02 Fig. 31

Ares 806 – 09.2004 – GB A2.23


Checks/Adjustments

Procedure for checking the viscous fan coupling

Speed of the
Ambient Engine speed / pulley driving Minimum fan
Engine speed Maximum slip
Optional temperature in viscous fan the viscous fan speed in
at full load tolerated in %
°C coupling ratio coupling in rpm (B)
rpm (A)

Without air-
conditioning with or
25 2 200 1,12 2464 1602 35
without pneumatic
braking
With air-conditioning
with or without 25 2 200 1,34 2948 1916 35
pneumatic braking

Preliminary checks
– Coolant level in the chamber and cleanliness of all the
radiators (water, oil and air).
– Belt condition.
– Operation of the thermostat(s).
– Operation of the temperature probe.
N.B.: The rotation speed of the pulley (A) is given as
an indication for when a check is carried out.
N.B.: When the engine is cold, slippage on the
viscous fan coupling is approximately 7%. Allow the
engine to warm up properly before measuring.

Checking the viscous fan coupling


– Place the tractor on the power bench at 2 200 rpm at
full load for 30 minutes minimum.
– Check with an electronic rev counter th speed of the
101msm07 Fig. 32
fan (B) and compare it with the values in the table
above.
– The measured slip must correspond to (or can be
slightly different from) the values described above. In
all cases, if the slip exceeds 35 %, consider changing
the viscous fan coupling.
Note: The fan speeds indicated in the above table
were measured at an ambient temperature of 25 °C.
During the inspection, if the temperature is lower
than 25 °C (for example 20 °C), reduce "reasonably"
the speeds of fan (B) and vis-versa if the ambient
temperature is higher than 25 °C.

A2.24 Ares 806 – 09.2004 – GB


Removal/refitting

Preliminary operations
Cab
– Apply the handbrake.
– Set the gearbox lever to neutral.

Electricity
– Disconnect the battery.

Sheet metal elements


– Remove the lateral, frontal and upper covers.
– Remove the exhaust pipe (according to the engine
type).
– Remove the exhaust/battery support assembly*.

Transmission shaft
– Remove the protective casing.
101hsm02 Fig. 33
– Disconnect and remove the transmission shaft.

Drains
(according to intervention)
– Drain the cooling system.
– Drain the engine casing.

Front weights
– Remove the removable ballast weights.

Tractor adjustment
– Chock the rear wheels.
– Neutralize the tilt angle by fixing the front axle.

* According to equipment.

Ares 806 – 09.2004 – GB A2.25


Removal/refitting

Separate engine/front axle


Elements to be separated or removed
• Disconnect all wiring harnesses connected to the
engine:
– Starter.
– Earth and supply cables.
– Engine shutdown solenoid valve.
– Coolant temperature sensor.
– Engine oil pressure sensor.
– Engine/cab link, 2 connectors.
– Cold starting aid.
– Alternator.
– Cooling compressor*. 4
• Cut the plastic clamps and pull back the electrical
harnesses at the front of the tractor towards the cab 251hsm03 Fig. 34
front.
• Loosen the clamps (2) and remove the air intake pipe.
• Disconnect the various hydraulic lines, steering
cylinder, transmission oil cooler, front differential lock C
system.
• Disconnect the cooling hoses (4).
N.B.: For tractors fitted with a suspended front axle,
disconnect the 2 hydraulic lines and the 3 electrical
connections (C), (angle sensor).

Do not remove the probe, just disconnect


the connector.

451hsm47 Fig. 35

* According to equipment.

A2.26 Ares 806 – 09.2004 – GB


Removal/refitting

Tractors fitted with air conditionning


N.B.: It is not necessary to disconnect the piping of
the cooling circuit (if it is necessary to remove the
cooling circuit, refer to chapter "Heating-Air
conditioning".
– Slide the condenser laterally (5) to remove it and to
remove the dehydrator (6).
– Position the assembly on a trolley.

The handling of the various cooling


circuit components should be carefully
performed to prevent the leak risks of the
cooling fluid. Once the assembly is re-installed,
check the circuit sealing using the specified
electronic leak detector (see chapter "Heating/air
conditioning"). 6 5
– Install the splitting carriages under the engine and 641hsm20 Fig. 36

under the front main ballast weight.


N.B.: Adjust the various stops of the splitting
assembly in order to perform a proper separation of
the front axle and to facilitate the assembly
recoupling.
– Remove the attachments (7) (2 screws and 4 nuts) of
the chassis.
– Separate the front axle.
For safety reasons, use a hoist and slings adapted to the 7
engine weight: Minimum 600 kg.

101hsm03 Fig. 37

Ares 806 – 09.2004 – GB A2.27


Removal/refitting

Separate engine/gearbox
12
Elements to be removed or separated to enable engine
removal:
– Starter (use a hinged socket wrench "FACOM
series 66").
– Muffler (according to equipment).
– Hydraulic unit. 9
– Protection screen (9), chassis and insulating plate.
– Diesel fuel piping (10), supply and return.
– Heating piping (11).
– Hydraulic piping of the differential lock system
(according to equipment). 10

Tractors fitted with air conditionning 11


– Compressor (12) (without disconnecting the piping).
N.B.: It is not necessary to disconnect the piping of 101hsm04 Fig. 38

the cooling circuit (if it is necessary to remove the


cooling circuit, refer to chapter "Heating-Air
conditioning".
– Install the splitting carriage under the transmission.
N.B.: Adjust the various stops of the uncoupling
assembly to separate properly the engine to facilitate
the assembly recoupling.
– Fasten on the shackles (13) chains and slings adapted
to the engine weight.

For safety reasons, use a hoist and slings


adapted to the engine weight: Minimum
600 kg.

101hsm05 Fig. 39

13 13

131hsm06 Fig. 40

A2.28 Ares 806 – 09.2004 – GB


Removal/refitting

– Remove the engine/clutch casing attachments (14).


– To have access to the two upper securing screws (15),
it is necessary to tilt the cab on the rear studs.
– To perform this operation, remove the bolts of the rear
stud and tilt the cab towards the rear using the tools
specified in the chapter "Cab".
For the suspension cabs "Hydrostable", remove the upper
securing screws of the front dampers and perform the
lifting using the tools specified in the chapter "Cab". 14

For safety reasons, chock the cab.

14
– Unscrew the 10 securing screws (14), on the engine
flywheel casing side while lifting the engine.
– Use a 3/4" 22 12 point-socket for the screws(A) and
a 16 12 point-socket for the screws (B). 111hsm02 Fig. 41

15

111hsm03 Fig. 42

A A

B B

A A
111hsm04 Fig. 43

Ares 806 – 09.2004 – GB A2.29


Removal/refitting

Engine installation specifications


56 ± 10 daN.m 8,5 ± 1 daN.m
Chassis shimming
23 ± 4 daN.m 23 ± 4 daN.m
– Couple the chassis to the engine without fitting the
lower mounting screws.
– Torque tighten the attachment bolts in (A) to the
recommended torque.
– Measure with a set of shims the dimension (X).
The theoretical dimension is 8,34 ± 0,81 mm.
The shimming required corresponds to the value
read + 0,1 mm.
– Install the two lower screws after shimming and torque
tighten them to the recommended torque.

56 ± 10 daN.m 56 ± 10 daN.m
111hsm05 Fig. 44

35 ± 6 daN.m

X
35 ± 6 daN.m

250hsm00 Fig. 45

A2.30 Ares 806 – 09.2004 – GB


Removal/refitting

Cylinder head
Remove the cylinder head
Remove the intake and exhaust manifolds. C
Remove the injectors using special tool
No.60 05 005 503 (1).
N.B.: The injectors must be removed to prevent
damaging them when removing the cylinder head.
Mark all the parts before removing them, in order to
help assembly in their initial location.
Remove the rocker arm assembly.
Remove the cylinder head fitting bolts, and remove the A B C
cylinder head.
Important: After removing the cylinder head, never
turn the crankshaft unless all the liners are held (C)
using bolts (A) and washers (B).

Injector seating cleaning


Remove the carbon deposit in the injector housings using
tool No. 60 05 005 519 (2).
Important: Always turn the tool clockwise, even when
removing it, in order to prevent from blunting it.

131hsm07 Fig. 46

131hsm08 Fig. 47

Ares 806 – 09.2004 – GB A2.31


Removal/refitting

Removing the valves and their springs


1 Compress the valve springs with a compressor tool (1)
to free the half-cones (A).
N.B.: On the local level, build part (2) using a washer
and a bolt with specifications identical to that of a
rocker arm pump securing screw. 1
Bolt reference: 60 05 021 506.
2 Release the tension on the springs. Remove the
rotators (B) and the valve springs (C). Mark each element
in order to reassemble it in its respective location. 2
3 Remove the valves. Mark them for refitting.
4 Remove the valve stem seals (D) from the valve guide
shoulders.

Checking the cylinder head gasket face


The maximum distortion defect is 0,08 mm.
In case of major distortion, rectify the cylinder head gasket 131hsm09 Fig. 48
face.
N.B.: The cylinder head gasket face can be rectified
by 0,76 mm maximum. Always check valve
withdrawal after rectifying the cylinder head.

D
C
B
A

131hsm10 Fig. 49

131hsm11 Fig. 50

A2.32 Ares 806 – 09.2004 – GB


Removal/refitting

Refitting the cylinder head


1 Clean the threaded holes on the cylinder block using the
special tap No.60 05 005 517 (1). Remove any dust and
liquid residue using compressed air. 1
2 Lubricate the rockers (3) on the camshaft before
reinstalling them in their housings.
3 Fit a new dry cylinder head gasket (no sealing
compound).
Important: Check that all rockers are in place before
fitting the cylinder head.
4 Insert 2 centring studs in housings (A).
N.B.: Build locally with 2 screws reference
n° 60 05 012 886 and 2 centring studs.
Important: If the centering studs are not fitted in
place, the O-ring crimped in the cylinder head seal
(passage of lubrication oil from the rocker arm) may
110hsm00 Fig. 51
be damaged when the cylinder head is moved onto
the engine block to align the bolt bores.
5 Fit the cylinder head correctly on the centring studs, and
lower it onto the cylinder block.

Tightening method
1 Apply a LITTLE graphite grease to the threads and 3
under the head of each screw before fitting.
2 Remove the centring studs and fit all the cylinder head
bolts.
3 Tighten the cylinder head bolts to the tightening torque
specified, according to the sequence indicated, starting
with bolt No.1.
Refer to the chapter "Tightening torques".
A Centring stud housing.
B Front of engine.

110hsm01 Fig. 52

A A

111hsm08 Fig. 53

Ares 806 – 09.2004 – GB A2.33


Removal/refitting

Angular tightening method


To ensure that the 60° angle is achieved (4th stage), A B
60˚
proceed as follows:

Stage A A B

Make a first mark on the socket and a second 60° in an


anticlockwise direction from the first.

Stage B
Scribe a mark on the cylinder head opposite each bolt.
C D
Stage C
Fit the socket onto the bolt while ensuring that the first
60˚ A
mark is aligned with the reference mark on the cylinder A
B
head.

Stage D
Tighten all the bolts (in sequence) until the second mark 131hsm12 Fig. 54
on the socket is aligned with the mark on the cylinder
head.
Important: The angular tightening method eliminates
the obligation to retighten the cylinder head bolts C
after the first hours of service.
A Reference mark.
B Mark at 60°.

Reassembling the rocker arm (only after


reassembling the cylinder head)
1 Assemble the rocker stems in their original position.
N.B.: The ends of the valve stems are hardened.
Fitting protective caps is therefore unnecessary.
2 Assemble the rocker arm on the engine. D
Important: Align the orifice (C) on the rocker arm with
the lubrication orifice (D) on the cylinder head.
131hsm13 Fig. 55
3 Lubricate all the rockers with engine oil.
4 Tighten the attachment studs to the recommended
torque in the chapter "Tightening torques".

A2.34 Ares 806 – 09.2004 – GB


Removal/refitting

Camshaft
Removing the camshaft
N.B.: Removing the cylinder head from the engine is
not required to remove the camshaft. A

1 Remove the rocker arm and stems.


2 Remove the distributor casing.
3 Turn the engine gear train until the bolts (A) can be
removed.
4 Using a wire (C) push the followers through all the
lubrication bores located on the rockers.
Important: If the camshaft followers fall into the
engine casing, you must remove the cylinder head.
5 Remove the support plate (D) from the slot located
behind the camshaft pinion.
6 Slowly extract the camshaft to extract it from the cylinder 120hsm08 Fig. 56
block.
7 Clean the camshaft, then inspect the camshaft cams
and bearings. If required, change the camshaft.

120hsm09 Fig. 57

120hsm10 Fig. 58

Ares 806 – 09.2004 – GB A2.35


Removal/refitting

Cylinder block
Changing the camshaft bush
Removal A
1 Remove the camshaft.
2 Remove the Torx bolt (A) and fit the taper end stud (B)
of the tool No.5531.
3 Install the 2 other flat end studs (C) from tool No. 5531
and the disassembly/assembly plate (D) of tool No.5520.
4 Insert the bush extractor (E) from tool No.5520 into the
camshaft bore as shown in the photo.
5 Tighten the hex head nut (F) until the bush is released
Fig. 59
from the bore. 120hsm11

6 Clean and inspect the bush bore. If the bore is


damaged, change the cylinder block.
D C
Refitting
Important: Fit the bush while ensuring that all
lubrication holes in the bush and cylinder block are
opposite each other. B C

1 Mark the orientation of the lubrication holes (G) on the


E
front face of the block and on the bush, in order to facilitate
alignment of the bush during installation.
2 Apply high temperature grease on the inside/outside
diameters of the new bush, and on the inside diameter of F
the bore in the block.
120hsm12 Fig. 60
3 Fit the tool in place with the bush as shown in the
picture. With the bush (J) engaged, tighten the screw (H)
until the flange (K) contacts the cylinder block face.
4 Remove the tool and check for proper alignment of the
lubrication hole. If the holes are not aligned, remove and
discard the bush. Fit a new bush.
G

120hsm13 Fig. 61

120hsm14 Fig. 62

A2.36 Ares 806 – 09.2004 – GB


Removal/refitting

Liners
Disassembling the liners 1
Important: Before disassembly, number the liners
and the pistons. Mark the FRONT part of the liner to
ensure its proper reassembly position.
Extract the liners from the cylinder block using tool
n° 60 05 005 504 (1).
Important: After removing the cylinder head, never
turn the crankshaft unless all the liners are held (C)
using bolts (A) and washers (B).

Checking the ovalization and tapering of


the liners
Refer to the chapter "Dimensional specifications".

120hsm00 Fig. 63

A B C

120hsm01 Fig. 64

120hsm02 Fig. 65

Ares 806 – 09.2004 – GB A2.37


Removal/refitting

Measurement of the liner protrusion


Important: First fit the liners without seals to check
liner protrusion. When correctly installed, the liners
can be rotated easily by hand. If not, remove the liners
and polish the lower liner guide in order to achieve
frictionless rotation of the liners.
1 Fit the liners without seals and secure them at 4 points.
Tighten the screws to 7 daN.m. 1
2 Measure the protrusion of the liners, using the checking
tool No.77 01 388 180 (1).
• Calibrate the control tool:
– Fit the calibration rule on the base.
– Calibrate the dial gauge to zero.
– Remove the rule.
• Fitting the control tool.
– Position the checking tool on the cylinder to check. 120hsm03 Fig. 66
• Measure the liner overlapping in 4 points.
Refer to the chapter "Dimensional specifications".
3 If the overlap or the tolerance differ from the values
indicated, smear abrasive paste on the cylinder block
shoulder (2) supporting the liner flange (3), fit the liner,
and turn to the right and left until achieving proper
overlapping (to this effect, use the special tool
No.60 05 005 504)
4 If the overlap is insufficient, fit a shim under the flange. 2 3
Two thicknesses of shims are available: 0,05 and
0,10 mm.
Important: Use only one shim per cylinder. If a liner
requires more than one shim, fit a new liner or a new
cylinder block.

120hsm04 Fig. 67

A2.38 Ares 806 – 09.2004 – GB


Removal/refitting

Fitting the rectangular section seal


Smear the new seal with soap, slide it onto the liner until A B
it is supported on its shoulder. The seal must be
compressed at minimum 0,13 mm.
1 Liner.
2 Rectangular section seal.
A Incorrect fitting.
B Correct fitting. 1 1

Fitting liner O-rings 2 2


Smear the new O-rings with soap and fit them in their
respective grooves.
A Rectangular section seal.
B Red and white O-ring.
C Black O-ring.
D Liner.
E Cylinder block. 120hsm05 Fig. 68

Refitting the liners


Slide the liner with the shim and the rectangular section
seal in its housing in the cylinder block. Seat the liners
using the tool No.60 05 005 504 (1).
Block the liners with the large washers and the bolts. A
Important: When reassembling, match the marks
B
scribed before removing the liners.
C

120hsm06 Fig. 69

120hsm07 Fig. 70

Ares 806 – 09.2004 – GB A2.39


Removal/refitting

Pistons and connecting rods


Before disassembling, mark the connecting rod and the
cap with the cylinder the connecting rod is fitted to.

Changing connecting rod bushes


Engines 6068 H A
Use the tool No. 60 05 00 532 for a 41 mm pin.
Removal
1 Fit on one of the ends of the connecting rod bush the
extractor shaft (A). Turn the shaft (A) until the tapered C
parts of the shaft are parallel with the tapered parts of the
bush (C). 120hsm15 Fig. 71
2 Opposite the extractor shaft (A), install the receiver
plate (B).
3 Using a hydraulic press, (c) press the bush from the
connecting rod until the extractor shaft (A) falls into the
receiving plate (B).
Important: If the bush is badly worn out, the extractor
shaft (A) can contact the inside diameter of the
connecting rod bore. When extracting the bush,
ensure you do not damage the connecting rod bore.
4 Clean, inspect, and measure the inside diameter of the
B
connecting rod pin bore.
Refitting
1 First slide the bush (C) on the shaft (A), then the 120hsm16 Fig. 72
part (D). Apply grease on the outside diameters of the
bushes (C) and (D), as well as in the connecting rod bore.
2 Insert the shaft (A) into the connecting rod pin bore, C
ensuring that the pilot bush (D) is guided in the connecting
rod bore, and that the taper of the bush (C) is aligned with
the taper of the shaft (A).
3 Install the receiving plate (B) on the other end of the
connecting rod.
4 Using a hydraulic press, push the bush into the
connecting rod bore, until the rim is flush or just under the
connecting rod face.
Important: check that the bush lubrication orifice (A) A
D
is aligned with the connecting rod's.
120hsm17 Fig. 73

120hsm18 Fig. 74

A2.40 Ares 806 – 09.2004 – GB


Removal/refitting

Checking the piston heads and skirts


Check that the pistons are not scratched and show no A B
trace of seizing or overheating.
Measure the diameter of the piston at 19 mm from the 60 05 005 507
bottom of the skirt, perpendicularly to the piston pin.
Compare the dimension measured with the initial
dimension. Refer to the chapter "Dimensional
specifications".

Compression ring groove


Use gauge n° 60 05 005 507 (6068) to check the wear on
the compression ring groove.
1
1 Piston.
a Piston can be used.
b Piston to be changed.

Compression and oil ring grooves


121hsm02 Fig. 75
Use a new ring and a set of shims to determine the
clearance, which should not exceed 0,20 mm. If the
clearance exceeds this dimension, change the piston.

121hsm03 Fig. 76

Ares 806 – 09.2004 – GB A2.41


Removal/refitting

Fitting piston rings


Fit the piston rings using the ring extender
No.77 01 388 110. The "·" punch marks, one for the top
compression ring (n° 1) and two for the compression ring
(n° 2), must be directed towards the piston head. 77 01 388 110

N.B.: Ring n°s 1 and 2 can also be identified by the


"Top", "T" or "·" marks. During their installation,
check that the rings are correctly positioned.

Fitting the oil ring


Fit the oil ring (3) in the lower groove, on the expander.
Check that the opening of the oil ring is opposite the
opening on the expander.

121hsm04 Fig. 77

121hsm05 Fig. 78

121hsm06 Fig. 79

A2.42 Ares 806 – 09.2004 – GB


Removal/refitting

Piston/connecting rods assembly


N.B.: Reassemble the pistons on the connecting rods A B C
they were removed from.
1 Lubricate the piston pin and bush with clean engine oil.
2 Assemble the pistons and connecting rods, while
checking that the marks "FRONT" (front) (A) on the side A
or the upper face of the piston and on the same side of the
connecting rod are located on the same side.
Important: If the mark "FRONT" is not visible on the
side or the upper face of the piston, fit the piston on
its connecting rod while ensuring that the
combustion chamber offset on the piston is located
on the side opposite the camshaft. The long side of
the connecting rod must be fitted on the camshaft
side.
1. Camshaft side.
Fig. 80
2. Liner bore pin. 121hsm07

3. Combustion chamber offset.

3 Insert the piston pin (B) in the piston pin bore. Install
new circlips (C) while directing the circlip cutting edge
opposite the piston pin. Check that the circlips are
properly pushed into the piston pin bore grooves.

Ring spacing
The figure here shows where the ring openings must be
located.
A Piston head.
B Top compression ring opening.
C Oil ring opening.
D Expander opening.
E Compression ring opening.
F Slit in the expander. 1 2 3
G Front of engine.
121hsm08 Fig. 81

B E

A
F

C D

121hsm09 Fig. 82

Ares 806 – 09.2004 – GB A2.43


Removal/refitting

Inspecting the connecting rod and the cap


1 Inspect the connecting rods and the caps to ensure that
they are neither worn nor damaged. Search for chips and
scratches in the connecting zone (A).
A
Important: Do not scratch the connecting surfaces of
the connecting rod and cap. This is absolutely vital on
Précision JointTM connecting rods to guarantee
correct coupling. Never rub these surfaces (C) with a
metallic brush nor any other tool. The contact
surfaces must be preserved.
2 Inspect the cap bolt holes (B) and the adjacent surfaces.
In the presence of any defect, change the connecting rod B
and the cap.
Important: Never swap connecting rods and caps. C
A Coupling zone.
B Cap holes.
121hsm10 Fig. 83
C Précision JointTM surfaces.

Fitting the bearing in the cap


N.B.: Owing to the manufacturing process, the 2 parts
(Précision JointTM connecting rod and cap) both
comprise a notch, whereas the separate bearing has C
a single pin. Only one notch on the cap is used for the
bearing pin.
1 Fit the carried over bearing in the connecting rod cap
with the pin (A) in the notch (B).
2 Apply clean engine oil to the carried over bearing. Fit the B
cap on the connecting rod with the pins on the same side.
A Pin.
B Notch.
A
C Additional notch (not used).

121hsm11 Fig. 84

A2.44 Ares 806 – 09.2004 – GB


Removal/refitting

Reassembling pistons and connecting rods


N.B.: The pistons must be reassembled in the liners
they were extracted from. A
1 Smear the pistons and rings with clean engine oil. Fit the
pistons into the liners using the ring compressor
No. 8111 (1).
N.B.: Check for each piston that the mark "FRONT"
(A) on the upper face of the piston is turned towards
the front of the cylinder block.
2 Push the piston into the liner until the upper ring is fully
inside it.

Assembling the cap onto the connecting rod


1 Smear the half-bearings with clean engine oil, then
assemble the cap onto the connecting rod with the 1
pins (A) on the same side. The notch (C) is not used.
121hsm12 Fig. 85
Important: Ensure that the cap is correctly aligned on
the connecting rod with the junction surfaces
perfectly coupled.
2 Dip the connecting rod bolts in clean engine oil and fit
them.
C
Important: Never use the connecting rod bolts more
than once for the final assembly of the engine. When
connecting rod bolts have been tightened at final
torque, do not reuse them.
3 Tighten the bolts alternately at 5,8 daN.m, then turn
each bolt at a 90-100 degree angle. B

Tightening method
1 Position the wrench in parallel the engine axis (A). A
2 Tighten the bolt until the wrench is perpendicular to the
engine axis (B).

121hsm11 Fig. 86

90˚

121hsm13 Fig. 87

Ares 806 – 09.2004 – GB A2.45


Removal/refitting

Measuring piston overlap


Use the checking tool No.77 01 388 180 (1).
1 Calibrate the control tool.
– Fit the calibration rule on the base.
– Calibrate the dial gauge to zero.
– Remove the rule.
2 Fitting the control tool.
– Position the checking tool on the cylinder to check.
3 Measuring the piston overlap.
– Bring the piston to the top dead centre using the dial
gauge and the engine displacement tool.
– Read directly the piston overlap value in respect of the
gasket face of the engine block.
– Move the apparatus on the longitudinal axis of the
engine, and record a second value.
– Calculate the average over the 2 values.
121hsm14 Fig. 88
4 Check values indicated in the chapter "Dimensional
specifications".
5 If the overlap exceeds the dimension specified, check
all the parts involved to determine its cause.
1 Piston at TDC.
2 Liner bore pin.

121hsm15 Fig. 89

1 2

121hsm16 Fig. 90

A2.46 Ares 806 – 09.2004 – GB


Removal/refitting

Crankshaft, bearings, and flywheel


Fitting bearing bushes
1 Install the bearing bushes. Check that the bearing bush
tags (A) are engaged in the slots (B) in the cylinder block
and the bearing seats. Also check that the bearing bush A
lubrication holes (C) are aligned with the oil passages in C
the block (D). During assembly, apply a thick layer of
clean engine oil:
– On all cylinder block bearings. B
– On both sides of the bearings.
– On the outside diameter of the journals.
D
2 Fit the thrust bearing (E) in the rear bearing (F) of the
cylinder block after dipping them in clean engine oil.
A Tags in the bearing bush.
B Slot in the block.
C Lubrication holes in the bearing bush. 121hsm17 Fig. 91

D Oil passages in the block.


E Rear thrust bearing bush.

121hsm18 Fig. 92

121hsm19 Fig. 93

Ares 806 – 09.2004 – GB A2.47


Removal/refitting

Assembling bearing caps


1 Apply a layer of clean engine oil on the bearing bushes.
Fully dip clean engine oil and position them on the bearing
caps.
Important: Check that the bearing caps are installed
A
in their initial location. The numbers (B) stamped on
the caps must be identical to those stamped on the
block rail groove. The arrows (C) on the cap must be
turned towards the block camshaft side.
2 Install the bearing caps in order to ensure that the
brackets (A) of the cap and the cylinder block are all on
the same side of the cylinder block. A
3 Fit all bolts and tighten them manually.
4 Tighten all the bolts on the bearing caps to 13,5 daN.m
EXCEPT the rear (thrust) bearing cap bolts.
5 Before tightening the rear bearing cap bolts, align the
upper and lower bearing bushes as follows: Using a lever, 121hsm20 Fig. 94
set the tool between a crankshaft balancer mass and a
partition of the cylinder block. Then push the crankshaft
forward then backward to align the stop bearing bushes.
6 Tighten the bolts on the rear (thrust) bearing cap
to 13,5 daN.m.
7 Turn the crankshaft manually. If it does not rotate easily,
disassemble the parts and determine its cause.
8 Check axial play (see specifications at the beginning of
this chapter).
3 4 5
Rectifying the crankshaft B
If the journals show ovality, if they are tapered, scratched
C
or damaged in any way, rectify them and fit the repair
dimension bearing bushes 0,25 mm.
Important: Have the crankshaft rectified only by a
skilled person, on a machine enabling to comply with
specified tolerances.
121hsm21 Fig. 95

A2.48 Ares 806 – 09.2004 – GB


Removal/refitting

Removing the flywheel


1 Remove the two securing screws and replace them with
studs (1), then remove the other securing screws.
N.B.: Build locally with two screws reference
n° 60 05 021 489 and 2 studs. 1 A
2 Insert 2 screws (reference n° 60 05 021 489) into the
tapped holes (A) to push the flywheel off the crankshaft
and simplify handling.
Note: As the flywheel is heavy, appropriate lifting
equipment is required to prevent accidents.

Changing the flywheel ring gear


1 Extract the ring gear from the flywheel using a brass drift A
1
and a hammer.
2 Heat the new ring gear to 150 °C in an oil bath, in an
appropriate oven or using a flame.
121hsm22 Fig. 96
Note: The oil and oil vapours are flammable
from 190°C. Use a thermometer to ensure that a
temperature of 180°C is not exceeded. Heat the oil in
a well ventilated room. Beware when handling hot oil:
Danger of burns !
Important: If heated using a flame, check that the heat
is applied evenly over the entire circumference of the
ring gear.
3 Shrink on the ring gear to fit it correctly onto the flywheel
shoulder. The edge (A) of the teeth must be turned
towards the engine.
N.B.: Check that the ring gear is supported all around
the flywheel shoulder.

121hsm23 Fig. 97

121hsm24 Fig. 98

Ares 806 – 09.2004 – GB A2.49


Removal/refitting

Reassembling the engine flywheel casing


1 Clean the gasket faces of the cylinder block and
flywheel casing.
2 Install the casing seal (1) and the seal (2) (no sealing
compound). 2
3 Fit the flywheel casing onto the cylinder block and
tighten the securing bolts to the following tightening
torques:

Tightening torques with lubrication


Refer to the chapter "Tightening torques".

Reassembling the flywheel


1 Fit the flywheel onto the studs, and slide it against the
crankshaft.
Important: Always change the flywheel bolts when it 1
has been removed.
121hsm25 Fig. 99
2 Apply Loctite Frenetanch (242) to the threads of
screws (E) and begin to screw the bolts into the
crankshaft. Remove the centering studs and screw the
last 2 bolts. Refer to the chapter "Tightening torques".

121hsm26 Fig. 100

A2.50 Ares 806 – 09.2004 – GB


Removal/refitting

Changing the rear bearing seal


Removal
1 Fit and centre tool No.60 05 005 509 (1) on the rear end
of the crankshaft. Then use stop ring pliers and place the
tool's ring narrow shoulder (2) behind the rim and the
inside cage of the seal. 1
2 Hold the parts assembled using a clamp (3), then
tighten the bolt (4) slowly until the inside cage of the joint
is extracted. 2
3 Cut and remove the sealing lip (5) which is now
121hsm27 Fig. 101
accessible.
4 Using a punch and a hammer, push the outside cage of
the seal towards the engine until the cage swivels.
5 Extract the seal cage (6) using a slide hammer.

4
121hsm28 Fig. 102

121hsm29 Fig. 103

121hsm30 Fig. 104

6
121hsm31 Fig. 105

Ares 806 – 09.2004 – GB A2.51


Removal/refitting

Refitting
1 Apply a fine layer of Loctite (518) on the edge of the
crankshaft flange.
2 Secure the guide No.60 05 005 510 (A) at the end of the
crankshaft using bolts.
1
3 Position the new rear bearing seal (1) on the guide A
ensuring that the seal opening is turned towards the
engine.
4 Slide the fitting tool (B) onto the guide (A) and tighten
nut (C) gradually until the tool is bearing on the guide.

121hsm32 Fig. 106

121hsm33 Fig. 107

A2.52 Ares 806 – 09.2004 – GB


Removal/refitting

Changing the front


bearing seal
D
Tapered end crankshaft.
C
Refitting the front bearing seal
– Inspect and clean the distributor casing seal bore.
Check that it has no dents, nor burrs. Use tool
reference n° 77 111 32 517.
– Tighten screw (C) on the end of the crankshaft.
– Apply a fine layer of clean engine oil on the seal lips,
and position it on the guide (D).
101msm09 Fig. 108
Important: Do not apply oil to the outside diameter of
the seal.
– Place tool (E) on its guide (D) and engage nut (F). E
– Slide sleeve (G) right up to the casing (this guides the
seal from the outside when it passes the tapering part
of the crankshaft)
– Tighten nut (F) until the seal is up against the timing
cover.

101msm10 Fig. 109

F
101msm11 Fig. 110

101msm12 Fig. 111

Ares 806 – 09.2004 – GB A2.53


Removal/refitting

Disassembly of the distributor casing


1 Drain the cooling system and the oil in the casing.
2 Remove the closing plate (A) of the cooler.
3 Remove the pulley and the fan bracket (B).
4 Remove the crankshaft pulley.
5 Remove the water pump by-pass tube (F).
6 Unlock the bolts (C) of the oil casing to remove the
distributor casing.
7 Remove the nuts (E) and the bolts (D).
8 Remove the remaining bolts after marking them.
A

111hsm10 Fig. 112

111hsm11 Fig. 113

111hsm12 Fig. 114

A2.54 Ares 806 – 09.2004 – GB


Removal/refitting

Camshaft, balancer shafts and


distributor
Measuring the clearance between the pinion
teeth
Use a comparator to measure the clearance between the
pinion teeth and compare the values measured with the
"Specifications". If the clearance between the teeth is not
correct, change the pinions.
A Camshaft pinion/upper intermediate pinion.
B Injection pump pinion/upper intermediate pinion.
C Upper intermediate pinion/crankshaft pinion.
D Crankshaft pinion/lower intermediate pinion.
E Oil pump pinion/lower intermediate pinion.
F Balancer shaft/hydraulic pump pinion.
G Balancer shaft/lower intermediate pinion.
111hsm13 Fig. 115
H Camshaft/power take-off.

Disassembly of the balancer shafts


Important: Upon disassembly, mark the left and right
balancer shafts to ensure correct reassembly.
A mark "R" for right and "L" for left are engraved on the
face of the rear bearing of the balancer shaft, in order to
help their identification. The journals of the shafts have
been resurfaced in a specific direction and there is a risk
of premature wear of the shafts and bushes if the right and A
left shafts are reversed.
1 Remove the lower intermediate pinion and the oil pump
pinion.
2 Remove the counterweights (A) on the balancer shafts,
according to equipment.
3 Loosen the bolts (B) and extract the balancer shafts
from the cylinder block.
N.B.: Do not damage the journals, nor the bushes 111hsm14 Fig. 116

when removing the balancer shafts.

111hsm15 Fig. 117

Ares 806 – 09.2004 – GB A2.55


Removal/refitting

Removing the front plate


To remove the front plate, first remove the following C
components:
– The distributor casing.
A
– The camshaft.
– The balancer shafts.
– The upper intermediate pinion.
D
– The injection pump.
– The lower intermediate pinion.
– The oil pump.
B
– The auxiliary hydraulic pump.
111hsm16 Fig. 118
1 Remove the 4 flush-head screws TORX® (A) from the
front plate.
2 Remove the 6 threaded studs (B) and (C).
3 Remove the front plate (D).
N.B.: When changing the front plate, refer to Chapter
"A1" to carry over the distributor mark for the
injection pump onto the new plate.
4 Remove the oil by-pass valve and the spring (E).

Disassembly/Assembly of the camshaft


pinion
1 Extract the pinion using a hydraulic press.
2 Inspect and check the camshaft and change if required. 111hsm15 Fig. 119
3 For reassembly, support the camshaft under the first
journal (bearing) and place the set under a hydraulic
press.
4 Smear the camshaft nose and the pinion bore with high
temperature grease.
5 Fit the Woodruff key in the camshaft nose.
6 Install the pinion in order to ensure that the mark (A) is
opposite the distributor casing. Then push the pinion onto
the camshaft nose.

111hsm17 Fig. 120

111hsm18 Fig. 121

A2.56 Ares 806 – 09.2004 – GB


Removal/refitting

Disassembly/assembly of the crankshaft


pinion
1 Lock the flywheel using the timing pin
B
No.60 05 005 576.
2 Remove the distributor casing, the oil pump, the upper
and lower intermediate pinions, and the front plate.
3 Use an appropriate extractor, then remove the
crankshaft pinion.
4 For disassembly, heat the pinion at 148 °C, in the oven.
If the heat of a flame is used, ensure the pinion is heated
all around its circumference.
DO NOT OVERHEAT.
111hsm19 Fig. 122
5 Install the guide (B) of tool No.5534 on the crankshaft
nose and tighten the bolts.
6 Fit the pinion (heated at 148 °C) on the crankshaft nose.
Ensure that the key (D) is properly aligned with the groove D
of the key in the pinion.
7 Place the edge (C) of tool No.5534 on its guide (B) and C
E
tighten the nut (E) until the pinion is pushed against the
crankshaft flange. Let the pinion cool down before
removing the tool.

Changing the pinion pins


1 Insert the flexible pins in the lower idle pinion pins (A)
and upper idle pinion pins (B) while observing the
protrusion value (C) in respect of the pin. 111hsm20 Fig. 123
C = 2,79 to 4,83 mm.
2 Fit the stop washer (D) and the upper pinion pin. Push C
the pin (B) in the front plate until the washer is completely
C
pushed and locked.
Important: The greasing holes for the upper pin must
be aligned properly to enable adequate lubrication of
the upper intermediate pinion bush.

A B
111hsm21 Fig. 124

111hsm22 Fig. 125

Ares 806 – 09.2004 – GB A2.57


Removal/refitting

Disassembly/reassembly of the auxiliary


drive bearing
1 Remove the oil pipe (A).
2 Remove the bearing (B) by unscrewing the bolts (C).
3 Repair or change the bearing if required.
4 Fit a new seal on the bearing and install the assembly
on the engine.
B
5 Tighten the bolts to 9,5 daN.m.
6 Connect the oil pipe.

Reassembly of the front plate


1 If not done yet, using a brass scraper, remove any A
C
sealing compound fitted previously.
Important: Ensure there is no oil, remaining sealing
compound or cleaning products on the cylinder block
and the front plate.
111hsm23 Fig. 126
2 Apply a continuous bead of Loctite (515) (E) to the
cylinder block as illustrated opposite.
3 Position the bead in the middle of the assembled
surfaces and right around the bolt holes.
4 Install the front plate (D) and tighten the bolts (A) and
the studs (B) and (C) to the torque specified in the chapter
"Tightening torques".
N.B.: Do not forget to install the by-pass valve before
assembling the front plate. E

111hsm24 Fig. 127

111hsm16 Fig. 128

A2.58 Ares 806 – 09.2004 – GB


Removal/refitting

Reassembly of the balancer shafts


1 Smear with clean engine oil the balancer shaft bushes
in the cylinder block, as well as the shaft journals.
Important: Do not swap the shafts. If the pinions are
removed from the shafts on removal, and if they are
swapped over, fit new bushes.
2 Fit the balancer shafts and the stop plates, and tighten
the bolts (B) to 4 daN.m.
3 Fit the counterweights (A) onto the balancer shafts on
the bladed side (C). The counterweights must be opposed
to the keys (D).

111hsm15 Fig. 129

111hsm14 Fig. 130

D
111hsm25 Fig. 131

Ares 806 – 09.2004 – GB A2.59


Removal/refitting

Assembling the upper distributor


1 Bring piston n° 1 to TDC using flywheel rotator
n° 60 05 005 501 and adjustment pin n° 60 05 005 576.
2 Fit the camshaft and the injection pump.
3 Rotate the camshaft until the mark (A) is aligned with the
timing tool n° 60 05 005 511 (1).
4 Use timing tool n° 60 05 005 511 to align the timing
mark for injection pump pinion (B) with the timing tool.
Important: Use timing mark "4" for four-cylinder
engines and "S6" for 6-cylinder engines.
5 Smear the shaft and the pinion sleeve with high
temperature grease.
6 Fit the upper intermediate pinion (C) on its shaft, while
ensuring that neither the camshaft pinion nor that of the
injection pump turn.
7 Fit the washer and the bolt, tighten it to 7 daN.m.
Fig. 132
8 Check the pinion distribution again. 111hsm26

111hsm27 Fig. 133

A2.60 Ares 806 – 09.2004 – GB


Removal/refitting

Assembling the lower distribution


1 Bring piston n° 1 to TDC using flywheel rotator
n° 60 05 005 501 and adjustment pin n° 60 05 005 576.
2 Fit the oil pump and the balancer shafts.
3 Turn the right-hand balancer shaft until mark (A) is
aligned with timing tool n° 60 05 005 511 (1).
4 Fit the lower intermediate pinion without turning the
balancer shaft.
N.B.: Fit the stop washer while turning the "X" mark in
the opposite direction to the pinion.
Tighten the bolt to 7 daN.m (oil the bolt).
Repeat operation 3 with the left-hand balancer shaft.
Fit the oil pump pinion on its shaft. Tighten the nut
to 5 daN.m and lock it with 3 punches.
Check the timing of the two balancer shafts again.
Important: When adjusting the balancer shafts, the 111hsm28 Fig. 134
key groove on the shafts must be in the high position
(12 o'clock), with the 2 pinion marks turned inwards
towards the end of the crankshaft.

Fitting the distributor casing


1 Check that the casing gasket faces and the front plate
are clean.
2 Fit the cover (C) providing access to the injection pump
pinion using a new seal (D) if required. Tighten the screws
D
to 0,6 daN.m.
3 Install the gasket seal (A) and cut it in the lower part to
ensure it contacts the oil casing seal.
4 Install the distributor casing (B). Smear the bolt (E) with
sealing compound. Tighten the bolts and nuts to 3,5
daN.m.

111hsm29 Fig. 135

A B C

E D
111hsm30 Fig. 136

Ares 806 – 09.2004 – GB A2.61


Removal/refitting

Lubrication
Removing the cooler
1 Drain the engine block and remove the Plug (A) to drain
the cooling fluid remaining in the casing (D).
2 Remove the closing plate (B) and the elbowed
adapter (C).
3 Remove the casing (D) and the cooler (E).

Inspecting the oil cooler


1 Check that the oil cooler (E) is not damaged, nor
clogged, or that it has no leaks which could mix the oil and
the cooling fluid.
2 Rinse the oil cooler to eliminate all the debris which
could be in the harness.
3 Test the oil cooler under pressure in a liquid using
compressed air if you suspect that oil and cooling fluid are
221hsm02 Fig. 137
mixing. The oil cooler should present no leak under a
pressure of 1,4 to 1,7 bar for at least 30 seconds.
4 Inspect the oil cooler casing (D).
5 Change any parts required. Do not attempt to repair the
oil cooler.

Installing the oil cooler


1 Lubricate the new O-rings (F) with clean engine oil.
2 Install the oil cooler (E) in the oil cooler casing (D). E
3 Apply Loctite Frenetanch (242) to the bolts securing
the oil cooler to the oil cooler casing. Tighten the bolts
to 1,2 daN.m. D

221hsm00 Fig. 138

221hsm03 Fig. 139

A2.62 Ares 806 – 09.2004 – GB


Removal/refitting

Remove / install the oil pressure regulator


flap
Tool reference n° 60 05 005 573.
Removal
1 Remove the distributor casing.
2 Install the extractor (A), on the oil pressure valve (B). A B
Check that the tabs (D) are properly engaged in the valve
indicators (C).
3 Install the sleeve (E) on the extractor until it is
completely recovered.
4 Screw the slide-hammer (F) on the extractor and
remove the valve. C
N.B.: To remove the extractor valve, turn the extractor
on the valve till the tabs come out of the indicators D
and remove the extractor.

221hsm04 Fig. 140

221hsm05 Fig. 141

221hsm06 Fig. 142

Ares 806 – 09.2004 – GB A2.63


Removal/refitting

Refitting
N.B.: It is recommended to install the valve only after
having installed the front plate. The retaining studs of
the plate protect the valve.
1 Position the fitting tool (A) in the valve (B).
A B
2 Using a hammer, fit the valve in the engine block
bore (C) until it is seated correctly.

Replacing the by-pass (Fig. 146)


1 Remove the distributor casing and the front plate.
2 Remove the by-pass (1) and the spring (2) and check
their condition.
3 Check the spring strength (2) for a length
of 29 mm: 87,8 N.
4 Fit the by-pass and the spring.
5 Fit the front plate and the distributor cover.
221hsm07 Fig. 143

A B

221hsm08 Fig. 144

221hsm09 Fig. 145

A2.64 Ares 806 – 09.2004 – GB


Removal/refitting

Disassembly of the oil pump


1 Remove the oil casing and the distributor cover.
2 Remove the nut (A) and remove the pinion (B) from the
oil pump tapered shaft. To remove the oil pump pinion, C
unscrew the nut by several turns, and apply a force
between the front plate and the pinion on both sides of the
D D
pinion using a small lever. If the method indicated above
is not successful, unscrew the bolts on the oil pump body
and hit the nut at the end of the shaft using a small lead
head hammer, while applying a force on the pinion until it
comes off of the tapered shaft.
3 Remove the suction strainer (C) from the oil pump, by
B
unscrewing the 2 bolts (D).
4 Remove the other 2 bolts (D) and the cover (E).
A
5 The bolt (F) of the lower intermediate pinion must be
removed to remove the body of the oil pump (G).

221hsm10 Fig. 146

D
E

221hsm11 Fig. 147

Ares 806 – 09.2004 – GB A2.65


Removal/refitting

Reassembling the oil pump

7
5

6
7
8
1

221hsm12 Fig. 148

Parts list
1 Cylinder block seal. 4 Outlet pipe. 7 Bolts, (4).
2 Ring (outlet pipe). 5 Strainer . 8 Drive pinion.
3 Ring (strainer pipe). 6 Pump casing. 9 Nut.

1 Fit the new seal (1) in the cylinder block. 5 Tighten the four bolts (7) to 3,5 daN.m and the bolt of the
2 Fit the new O-rings (2) and (3) in the pump body at the lower intermediate pinion to 8 daN.m according to the
discharge pipe and on the strainer tube (5). sequence indicated in the diagram.
3 Fit the drive shaft and the intermediate pinion in the 6 Fit the pump drive pinion (8) and tighten the nut (9)
pump body (6). The two pinions must rotate freely. to 5 daN.m.
4 Install the pump cover and the suction strainer on the 7 Lock the nut with three punches.
pump body.

A2.66 Ares 806 – 09.2004 – GB


Removal/refitting

Fitting the oil sump


1 Apply a coat of Loctite (515) (or equivalent sealing
compound) on the gasket face of the oil sump, at the
location where the flywheel casing, the front plate and the
distributor cover are fitted on the cylinder block.
2 Choose and fit the seal matching the oil sump used.
3 Fit the oil sump and tighten the various bolts refering to
the chapter "Tightening torques".

Fitting the filler tube on the oil sump


N.B.: This type of tube is also used as oil fill tube.
1 Remove the filler tube.
2 Clean the oil casing gasket face.
3 Apply a coat of Loctite (515) sealing compound, then fit
the filler tube.
4 Tighten the screws to 5 daN.m.
221hsm13 Fig. 149

221hsm14 Fig. 150

Ares 806 – 09.2004 – GB A2.67


Removal/refitting

Cooling
Water pump

A
B
C
D

E
F
G
H

251hsm04 Fig. 151

Parts list
A Casing. D Body. G Shaft.
B Turbine. E Bearing. H Inside stop ring.
C Sealing joint. F Outside stop ring.

Disassembly of the water pump


1 Drain the coolant.
2 Remove the piping (J) connecting the thermostat casing
to the water pump.
3 Remove the inlet elbow (K).
4 Remove the water pump (D). J
5 Remove the water pump pulley.

251hsm05 Fig. 152

251hsm06 Fig. 153

A2.68 Ares 806 – 09.2004 – GB


Removal/refitting

Disassembly of the water pump


1 Remove the inside stop ring of the pump body front
bore.
2 Support the front face of the water pump body and press
the shaft on the turbine side (A) until the latter is pulled off
the shaft, and the shaft/bearing assembly is removed from
the body. Discard the turbine. A
3 Push out the seal (B) from the pump body.
4 Support the inside bearing bush and press the shaft (C)
to extract the bearing. Discard the bearing.

251hsm07 Fig. 154

251hsm08 Fig. 155

251hsm09 Fig. 156

Ares 806 – 09.2004 – GB A2.69


Removal/refitting

Reassembling the water pump


1 Clean and inspect carefully the assembly surface of the
water pump in the distributor casing before installing it.
2 Install the outside circlip (C) in the groove of the
shaft (B) using appropriate circlip pliers.
3 Fit the bearing (A) on the shaft against the circlip, using A
an appropriate mandrel supported on the bearing inside
bush. C
B
Important: Do not press the end of the bearing shaft.
Push only the outside bush of the bearing when fitting
the bearing and shaft asembly in the body.
4 Fit the bearing and shaft assembly in the body by
251hsm10 Fig. 157
pushing until it reaches the bottom of the body bore using
a mandrel (D).
5 Fit the large inside circlip in the front bore groove of the
pump body.
N.B.: The water pumps are fitted with a single part D
water sealing gasket.
6 Install the seal (dry) on the water pump shaft and in the
body while pushing it in properly in the body using the tool
provided with the seal kit.
7 Support the front nose of the water pump shaft.
Important: When installing the turbine, press only the
brass bush (E), otherwise the turbine could crack.
8 Using an appropriate mandrel, install the turbine on the 251hsm11 Fig. 158

shaft according to the dimensions specified below. Gap


between the turbine and the end of the shaft: At the same
level ± 0,13 mm as the end of the shaft.
9 Turn the turbine a full turn by hand, and check the
clearance between the turbine and the body using a set of
feeler gauges. Minimum clearance between the body and
the turbine = 0,27 mm.

251hsm12 Fig. 159

251hsm13 Fig. 160

A2.70 Ares 806 – 09.2004 – GB


Removal/refitting

Removal/refitting of the automatic belt


tensioner (spring-operated)
Note: the thread of the bolt (A) of the automatic
tensioner is a left-hand thread.
1 Loosen the tension on the belt using a wrench and a
socket.
2 Remove the poly V belt from the pulleys.
3 Remove the belt tensioner. A
4 Install the tensioner and tighten the bolts to 5 daN.m.

Removal/refitting of the hub and


inspection of the fan support
1 Support the rear of the fan hub (A) and drive out the
shaft (B) with the mandrel and a hydraulic press.
2 Clean and inspect the bearing/shaft bore.
3 If one of the parts is damaged or worn, replace the
251hsm14 Fig. 161
assembly.
N.B.: The support should be installed taking care to
align the holes:
– D and 1. 3
– E and 3.
E

B A
251hsm15 Fig. 162

Ares 806 – 09.2004 – GB A2.71


Removal/refitting

Checking and replacing the thermostat


1 Drain part of the coolant from the system.
2 Remove the tube (A) connecting the thermostat cover to
the water pump.
3 Remove the thermostat cover (B).
4 Extract the thermostat (C).
5 In hot water, check the thermostat opening and closing B
temperatures (see chapters "Specifications and
diagnostic".
6 Remove and discard the old seals (D) and (E). Clean A
the seal faces on the cover (B) and the cylinder head.
7 Install the new seal (E) on the cylinder head, while
maintaining in place using centering studs (F). 251hsm16 Fig. 163

8 Install the thermostat (C) in its cover (B) while


maintaining the thermostat (F) in place using a G
screwdriver. Tighten the 2 bolts to 7 daN.m.
9 Lubricate the new seal (D) with universal grease before E
installing it on the thermostat cover (B).
10 Fit the tube (A) connecting the thermostat cover (B) to B
the water pump, then tighten the clamps (H).
H
11 Fill the cooling system to check there are no leaks.
Important: When filling the cooling system, bleed any C
air present. Loosen the temperature probe (J) at the
back of the cylinder head to bleed the air when filling
the system. Tighten the probe when all the air has A D G
been bled from the system. 251hsm17 Fig. 164

251hsm18 Fig. 165

251hsm19 Fig. 166

A2.72 Ares 806 – 09.2004 – GB


Removal/refitting

1
4
5

3 2

251hsm20 Fig. 167 251hsm21 Fig. 168

Changing the drive belt


1 Inspect the moulded end pieces (2) and (3) on the belt
tensioner (1). 1 7
2 If the stop (2) on the tensioner swivel arm contacts the
fixed stop (3), check the condition of the various pulleys
on which the belt passes. If the pulleys seem normal, 2 5
replace the belt.
3 To change, loosen the belt tension using a wrench
placed on the pulley (B).
4 Remove the old belt from the pulleys, then cut it. 3
6
5 Slip the new belt between fan (4) and the cooling
nozzle (5).
A
6 Install the new belt so that it passes correctly over all the 4
pulleys (see drawing opposite).
7 Tighten the belt with the tensioner (B). Remove the
wrench. 251hsn03 Fig. 169

Parts list (Fig. 169 and 170)


A With air conditioning, without air compressor.
B With air conditioning and air compressor.
1 Alternator. 5
7
2 Tensioner roller.
3 Water pump.
4 Crankshaft. 1 8
5 Refrigeration or air compressor.
6 Return roller.
7 Fan pulley.
2
8 Air compressor.
6
3

4
B

251hsn04 Fig. 170

Ares 806 – 09.2004 – GB A2.73


Removal/refitting

Turbocharger
Checking the shaft radial clearance
1 Fit on the turbocharger a comparator fitted onto a
support with a graduated extension, and fit the graduated
extension on the shaft of the compressor, by passing it
through the lubrication orifice.
2 Push and pull alternately the compressor shaft.
3 With equal pressure applied to both ends of the shaft,
the clearance should not exceed the values indicated in
the chapter "Dimensional specifications".

Checking the shaft axial clearance


1 Using a comparator contacting the shaft, measure axial
clearance.
2 Move the shaft axially by hand in the 2 directions and
compare the value read with the values specified in the
"Dimensional specifications" chapter.

Reconditioning the turbocharger


Important: It is difficult to recondition a turbocharger
without the necessary tools and training. Do not
disassemble a turbocharger completely.

251hsm22 Fig. 171

A2.74 Ares 806 – 09.2004 – GB


Diagnostic Sheets

"Excessive oil consumption" sheet


Prior to this procedure, check the sealing on the outside pipes and the cap seals.

221hsm15 Fig. 172

Ares 806 – 09.2004 – GB A2.75


Diagnostic Sheets

Inspection procedure of the


cylinder head gasket
Before removing the cylinder head, perform the following
checks:

Visual check
– Presence of coolant on the cylinder head gasket.
– Presence of coolant in the crankcase.
– Insufficient coolant level.
– High oil level.
– Presence of cooling liquid in the engine breather (A).

Pressurized test of the cooling A


system
Before the test, warm the engine. 131hsm16 Fig. 173

Let the engine cool down, and remove the


radiator cap cautiously.

0,7 bar
If no leak is visible, but if pressure drops, there may
be an internal coolant leak or an internal leak in the
seal between the block and the cylinder head.

131hsm15 Fig. 174

A2.76 Ares 806 – 09.2004 – GB


Diagnostic Sheets

"Engine oil pressure too high" sheet


Prior to this procedure, check the level and quality of oil and the oil filter.

221hsm16 Fig. 175

Ares 806 – 09.2004 – GB A2.77


Diagnostic Sheets

Checking procedure of the high oil


pressure in the crankcase
Excessive gas pressure inside the breather pipe can be
caused by a sealing defect on the turbocharger or the
piston rings.
– Remove the turbo oil return pipe (A) and direct it too a
container.
– Start the engine, at maximum no-load speed.
– Check that supercharging pressure expels oil into the
drain pipe.
If yes. —> Turbo sealing problem.
If no. —> Gas pressure on the level of the breather pipe,
and therefore, check piston ring/liner sealing
A
Checking the turbocharger oil sealing
– Checkthat the oil return pipe (A) is neither twisted nor 251hsm23 Fig. 176
cracked. Replace it if necessary.
– Check there is no obstruction in the air filter, hoses,
and connecting tube.
– Check there is no obstruction in the exhaust system,
also check the proper position of the exhaust orifice.

101hsm09 Fig. 177

A2.78 Ares 806 – 09.2004 – GB


Diagnostic Sheets

"Engine oil pressure too low" sheet


Before applying this procedure, check the level and quality of oil, the oil filter, and the operation of the oil pressure switch.

221hsm17 Fig. 178

Ares 806 – 09.2004 – GB A2.79


Diagnostic Sheets

"Coolant temperature too high" sheet


Before applying this procedure, check the quality and quantity of coolant. Check there are no leaks in the engine outside
system.

221hsm18 Fig. 179

A2.80 Ares 806 – 09.2004 – GB


Diagnostic Sheets

"Coolant temperature too low" sheet


Faulty thermostat
Control: Heat water in a container, and check the
thermostat triggering temperatures. Stir while water is
heating.

Caution when heating the water, keep the


thermostat or thermometer away from the
edge or bottom of the container. This
could result in overheating and breaking.

Take the thermostat out of the water and check that it


closes as it cools down. At ambient temperature, the
thermostat must close slowly and gradually until it is
completely closed (as soon as its temperature reaches
80°C). If not, change it.
251hsm24 Fig. 180

Reminder of the triggering values


Nominal opening value 82°C.
Initial opening 80-84°C.
Full opening (nominal) 94°C.

Ares 806 – 09.2004 – GB A2.81


Diagnostic Sheets

Failure searching procedure of – Discoloration or presence of soot caused by a


combustion gas leak.
cylinder head seal – Leak on the radiators (oil and water), the tank,
overflow, or pipe hoses.
– Coolant leaking at the water pump bleed hole.

Combustion gas sealing


C Symptoms
– Gas exhausting through the cylinder head seal.
D – Air bubbles in the water radiator or the overflow tank.
D
– Coolant discharged through the overflow hose.
– Engine overheating.
– Loss of power.
– Irregular engine running.
– White smoke at the exhaust pipe.
B
– Loss of heating in driver's cab.
– Sealing unseating or absent (ejection).
A
– Coolant in a cylinder.
– Coolant in the crankcase oil.
221hsm10 Fig. 181
– Insufficient coolant level.
Possible causes
Parts list
– Insufficient liner protrusion.
A Combustion gas sealing surface.
B Oil sealing surfaces. – Excessive protrusion difference of the liners between
C Coolant sealing surfaces. cylinders.
– Insufficient tightening torque.
Three types of seal failures can occur – Roughness, damaged surface on the liner rim.
– Combustion gas faulty sealing. – Cracks, distortion on the gasket.
– Cooling system faulty sealing. – Distorted, damaged, or irregular cylinder head surface.
– Lubrication system faulty sealing. – Fire ring section of the seal missing or displaced.
Visual inspection to be carried out before – Engine block cracked in the liner support area.
intervention on the cylinder head gasket – Excessive fuel supply.
– Injection pump timing too advanced.
– Presence of oil or coolant on the seal face or adjacent
surfaces. – Hydraulic or pneumatic disturbance of the combustion
seal.
– Seal displaced in respect of its normal position.
N.B.: In case of cracked cylinder head or liner,
combustion gas might also flow into the coolant.

A2.82 Ares 806 – 09.2004 – GB


Diagnostic Sheets

Coolant sealing Oil circuit sealing


Symptoms
Symptoms
– Coolant leaking through the cylinder head gasket.
– Oil leaking through the cylinder head gasket.
– Coolant in the oil pan.
– Oil in the coolant.
– Insufficient level in the tank.
– Insufficient oil level in the crankcase.
– High oil level.
– Insufficient rocker lubrication (abnormal noises).
– Coolant leaking through the crankcase breather.
Possible causes
Possible causes
– Excessive liner protrusion.
– Excessive liner protrusion.
– Excessive difference in liner protrusion between the
– Excessive difference in liner protrusion between the
cylinders.
cylinders.
– Insufficient tightening torque.
– Insufficient tightening torque.
– Deformed, damaged, or irregular engine block surface.
– Deformed, damaged, or irregular engine block surface.
– Deformed, damaged or irregular cylinder head surface.
– Deformed, damaged or irregular cylinder head surface.
– Oil or coolant temperature too high.
– Oil or coolant temperature too high.
– Cylinder head gasket surface deformed or cracked.
– Cylinder head gasket surface deformed or cracked.
– Elastomer parts of cylinder head gasket damaged or
– Elastomer parts of cylinder head gasket damaged or
cracked.
cracked.
– O-rings damaged in the oil passages to the rockers.
Important: Oil may be found in the coolant as a result
of a poor oil cooler seal.

Ares 806 – 09.2004 – GB A2.83


Notes

A2.84 Ares 806 – 09.2004 – GB


TOOLS
Engine tools

Ares 806 – 09.2004 – GB


Engine tools

60 05 005 501 60 05 005 503

Flywheel turning tool Pencil injector extractor

60 05 005 504 60 05 005 507

Liner disassembly/assembly tool Ring groove wear gauge

60 05 005 509 60 05 005 510

Rear bearing seal extractor Rear bearing bush seal fitting tool

A2.86 Ares 806 – 09.2004 – GB


Engine tools

60 05 005 511 60 05 005 513

Shimming tool Installation tool of injection seal

60 05 005 514 60 05 005 515

Injection pump extractor Fuel pipe

60 05 005 516 60 05 005 517

Cleaning tool for the threads on the cylinder block "bolt-cylinder


Pencil-type injector adapter for compression gauge No. 8122
head"

Ares 806 – 09.2004 – GB A2.87


Engine tools

60 05 005 519 60 05 005 520

Bore cleaning tool "pencil injectors" Set of camshaft bush extraction tools

60 05 005 521 60 05 005 528

Pressure control kit: Fuel supply system. Supercharging system


Flywheel turning tool
(pressure gauge from 0 to 2 000 mbars)

60 05 005 530

Time Trac kit spare parts:


– 1 measuring device n° 60 05 005 564.
– 1 magnetic TDC probe n° 60 05 005 562.
– 1 injector in-line probe n° 60 05 005 561.

Time Trac Kit – Dynamic adjustment check

A2.88 Ares 806 – 09.2004 – GB


Engine tools

60 05 005 531 60 05 005 532

Set of extraction tools for camshaft bushes, to be used with tool


Set of tools for disassembly/assembly of the
No. 60 05 005 520: 1 taper end stud. (M8 x 1,25) 3 flat end studs
tapered end connecting rod bush
(M8 x 1,25)

60 05 005 533 60 05 005 534

Wear bush disassembly/assembly tool Crankshaft front bearing and pinion fitting tool

60 05 005 573 60 05 005 575

Oil pressure valve extractor Injection pump timing axis DE 10

Ares 806 – 09.2004 – GB A2.89


Engine tools

60 05 005 576 60 05 005 578

Adjustment pin Injection pump timing axis VP 44

60 05 005 579 60 05 005 585

Viscous fan coupling locking tabs


Injector extractor
(in progress)

77 01 388 003 77 01 388 031

0,20 to 7 daN.m torque wrench Depth gauge

A2.90 Ares 806 – 09.2004 – GB


Engine tools

77 01 388 047 77 01 388 080

Bore checking apparatus Setting torque wrench (0 to 20 daN.m)

77 01 388 084 77 01 388 110

Extractor hook Piston ring disassembly/assembly pliers

77 01 388 111 77 01 388 127

Piston assembly ring collar (Ø 55 to 110) with


Liner smear removing apparatus (Flex hone)
tightening wrench

Ares 806 – 09.2004 – GB A2.91


Engine tools

77 01 388 180 77 01 388 204

Liner or piston protrusion checking tool Engine oil pressure checking kit (0 to 10 bar)

A2.92 Ares 806 – 09.2004 – GB


B1 – GBA 10 GEARBOX

Ares 806 – 09.2004 – GB


General specifications

Meaning of transmission system designations


Designation of gearboxes

GBA xx

E.g.: GBA 10

G = GIMA

B = Gearbox

A = Agricultural

10 = Type of gearbox

Designation of rear axles

GPA zz

E.g.: GPA 41

G = GIMA

P = Rear axle

A = Agricultural

40 = Type of rear axle

1 = Type of axle tubes

Designation of the transmission system


The full transmission system is a combination of the gearbox and
the axle.

GTA xx zz

E.g.: GTA 10 41

G = GIMA

T = Transmission

A = Agricultural

See plates on transmission system.

B1.2 Ares 806 – 09.2004 – GB


General specifications

Introduction to the GBA 10

II I III
4
3
2
1 II IV

1 2 3 4 5 6

322hsm04 Fig. 1

Hub (1) – Wet clutch (2) – REVERSHIFT (3)

Type GBA 10

Hub Spring shock absorber


Wet clutch Multidisc
Number of discs 6/7/8
Disc diameter (in mm) 230
Type of lining Organic
Pressurising Hydraulic
Control Electrical
Driver interface Pedal, reverser lever and switch

Quadrishift (4)

Type GBA 10

Control Electrical
Pressurising Hydraulic
Clutches 2 wet multidisc
Operating diagram 2 epicyclic gear sets
Number of gears 4

Gears (5) – Ranges (6)

Type GBA 10

Number of gears 4 synchronised gears


Number of ranges 2 synchronised ranges
Optional Crawler (1 epicyclic gear set)

Ares 806 – 09.2004 – GB B1.3


General specifications

Transmission kinematics
General diagram

N E F
B
31
38 41
33 C D
94 26
24 18 94
21 15
48 18
42 58 58

54
24
I
17
18 39
A M
O
15
29
21
27
H
33
46 G
2 1 4 3 H L

J K
L

25 14 54

322hsm01 Fig-. 2

Parts list
A Engine. F 1000 rpm PTO. K Proportional power take-off (option)*.
B Damper. G Direct drive. L Principal brake.
C Power take-off clutch. H Crawler (option). M Forward gear clutch.
D Economy power take-off (option). I Handbrake. N Reverse gear clutch.
E 540 rpm PTO. J 4 WD clutch. O Quadrishift.

* The economy PTO and the proportional PTO are not fitted together.

B1.4 Ares 806 – 09.2004 – GB


General specifications

GTA 1041 Overdrive

E F
B
37
40 63
35 C 28
D 36

94 29
24 24
18 94
21 20
48 18
42 58 58

68
24
49/45* I
23
22 43
A
8
25
27
24
30
H 45/49*
37/35*
36
66 G
2 1 4 3 H L
72
79
37/38* 84

J K
L

25 14
64

322hsm05 Fig. 3

* Depending on assembly.

Ares 806 – 09.2004 – GB B1.5


General specifications

GTA 1042 and 42+ Overdrive

E F
B
36
40 63
35 C 28
D 36

94 29
24 24
18 94
21 20
48 18
42 58 58

68
24
49/45* I
23
22 44
A
9
25
28
24
30
H 45/49*
37/35*
36
66 G
2 1 4 3 H L
72
79
37/38* 84

J K
L

29 14
73

322hsm06 Fig. 4

* Depending on assembly.

B1.6 Ares 806 – 09.2004 – GB


General specifications

GTA 1044 Overdrive

E F
B
36
40 63
35 C 28
D 36

94 29
24 24
18 94
21 20
48 18
42 58 58

68
24
49/45* I
23
22 44
A
9
25
28
24
30
H 45/49*
37/35*
36
66 G
2 1 4 3 H L
72
79
37/38* 84

J K
L

29 14
73

322hsm07 Fig. 5

* Depending on assembly.

Ares 806 – 09.2004 – GB B1.7


General specifications

GTA 1044 non-Overdrive

E F
B
36
40 43
35 C 28
D 36

94 30
24 24
18 94
21 20
48 18
42 58 58

68
24
49/45* I
23
22 44
A
17
29
24
30
H 45/49*
37/35*
35
66 G
2 1 4 3 H L
72
79
37/38* 84

J K
L

29 14
73

322hsm08 Fig. 6

* Depending on assembly.

B1.8 Ares 806 – 09.2004 – GB


General specifications

GBA 10 removal/refitting procedure


Stage 1: Front clutch

322hsm09 Fig. 7

Stage 2: Rear clutch

322hsm10 Fig. 8

Stage 3: Quadrishift unit

322hsm08 Fig. 9

Ares 806 – 09.2004 – GB B1.9


General specifications
Stage 4: Output shaft

322hsm12 Fig. 10

Stage 5: Input shaft

322hsm13 Fig. 11

Stage 6: Countershaft

322hsm14 Fig. 12

B1.10 Ares 806 – 09.2004 – GB


Tightening torques
Engine/gearbox coupling

1,27 ± 0,03 daN.m

5 ± 0,4 daN.m

Frenetanch (242)

10,5 ± 0,5 daN.m 26 ± 1 daN.m


Frenetanch (242) Frenetanch (242) 3 ± 0,5 daN.m 4,1 ± 0,5 daN.m

13 ± 0,5 daN.m 50 daN.m


Frenetanch (242) Frenetanch (242) 3,3 ± 0,4 daN.m 5,2 ± 0,5 daN.m

20 ± 0,5 daN.m
Frenetanch (242)

322hsm15 Fig. 13

Ares 806 – 09.2004 – GB B1.11


Tightening torques
Gearbox/rear axle coupling

28 ± 1 daN.m
Frenetanch (242)

25 ± 1 daN.m
Frenetanch (242)

322hsm16 Fig. 14

B1.12 Ares 806 – 09.2004 – GB


Tightening torque

A 4,1 ± 0,5 daN.m 4,1 ± 0,5 daN.m 5,2 ± 0,5 daN.m 1,4 ± 0,2 daN.m 3,3 ± 0,2 daN.m 1,4 ± 0,1 daN.m 1,4 ± 0,2 daN.m 3,3 ± 0,4 daN.m 0,6 ± 0,1 daN.m 3,3 ± 0,4 daN.m
Frenetanch (242) Frenetanch (242) Frenetanch (242) Frenetanch (242) Frenetanch (242) Frenetanch (242) Rectijoint (242) Frenetanch (242)

Rectijoint (518)

5 ± 2 daN.m
Frenboc (270)

12,5 ± 1,5 daN.m 6,2 ± 0,5 daN.m


Frenbloc (270)

3 ± 0,5 daN.m

E
12 ± 1,8 daN.m
Frenbloc (270)

1,27 ± 0,03 daN.m


13 bar Formajoint (510)

5 ± 0,4 daN.m
1,5 bar
C D Scelbloc (648)

E
4,1 ± 0,5 daN.m Rectijoint (518) 5,8 ± 1 daN.m 15 ± 2 daN.m 10,5 ± 1,5 daN.m 5,8 ± 1 daN.m 4,4 ± 0,4 daN.m
Frenbloc (270)

C
D

1,2 ± 0,2 daN.m


B 3,3 ± 0,4 daN.m 3,3 ± 0,4 daN.m Frenetanch (242)

322hsm17 Fig. 15

Ares 806 – 09.2004 – GB B1.13


Main adjustments

P = 0,05 ± 0,05 mm J1 = 0,16 ± 0,14 mm

0,06 ± 0,09 mm

A B

P2 = 0,03 ± 0,02 mm

P1 = 0,15 ± 0,05 mm X > 0,8 mm

A B

J = 0,70 ± 0,10 mm

J = 0,10 ± 0,10 mm J = 0,60 ± 0,10 mm

322hsm18 Fig. 16

B1.14 Ares 806 – 09.2004 – GB


REVERSHIFT

Clutch function

322hsm19 Fig. 17

The REVERSHIFT shuttle reverser is made up of 2 wet The clutch is engaged by the pressure supplied by the
multidisc clutches (front and rear clutch) which control proportional solenoid valves mounted on the hydraulic
forward and reverse movement. These two clutches also unit (see chapter "B2").
act as the main clutch.

Ares 806 – 09.2004 – GB B1.15


REVERSHIFT

Shuttle reverser operation


Forward movement - Front clutch
pressurised
Direct torque transmission with no change to direction of
rotation (Fig. 18).

Reverse movement - Rear clutch


pressurised
Direct torque transmission by the epicyclic gear set with
change to direction of rotation (Fig. 19).

Neutral
Both clutches are free. No torque transmission (Fig. 20).

322hsm20 Fig. 18

322hsm21 Fig. 19

322hsm22 Fig. 20

B1.16 Ares 806 – 09.2004 – GB


Front clutch

Exploded view

14

13
12
11
10
32
9
8
7
6
5
4
20
3
19
2
1
18

17
16
15

27
26
25
24
23
22
21

31
30
28 29

322hsm23 Fig. 21

Parts list
1 Circlip. 12 Seal. 23 Ring.
2 Bearing. 13 Piston. 24 O-ring.
3 Shims. 14 Belleville washer. 25 Ring.
4 Lubrication pump cover. 15 Circlip. 26 Circlip.
5 Lubrication pump. 16 Bearing. 27 Bush.
6 Lubrication pump housing. 17 Front clutch hub. 28 Clutch shaft.
7 Bush. 18 Front clutch housing. 29 Circlip.
8 Bearing. 19 Circlip. 30 Backplate.
9 Rings. 20 Bearing. 31 Disc.
10 Cover. 21 Circlip. 32 Spacer.
11 Seal. 22 Sleeve.

Ares 806 – 09.2004 – GB B1.17


Front clutch

6
18

33 34
28

21 6

34

322hsm24 Fig. 22

Removal/refitting (stage 1 page B1.9)


Uncouple the tractor between the engine and the gearbox 28 22
as follows: 34
– Drain the transmission system.
– Remove the reservoir and disconnect the pipes, hoses 18
and wiring harnesses interfering with the uncoupling
operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.

322hsm25 Fig. 23

B1.18 Ares 806 – 09.2004 – GB


Front clutch
– Remove the cover (33).
23 80
– Remove the lubrication tubes (34).
ø8
– Remove the lubrication pump (6), front clutch (18) and
shaft (28) assembly with the locally made tool (A),
(Fig. 24).
– Assemble the components in reverse order to removal,
making sure that they are the right way round. 100
– Refit the bearings using a press and an appropriate jig.
165
– Lubricate the new seals before fitting.
– Fit the lip seal in the cover (33) using a press.
28 6 18
– Fit the splined sleeve (22) onto the lip seal smeared
with grease.
– Place 2 guide rods on the housing and assemble all A
parts, paying attention to the O-rings fitted to the shaft.
– Fit the circlip (21).

322hsm26 Fig. 24

Ares 806 – 09.2004 – GB B1.19


Front clutch

Removal
22 27 1 6 10 18
Pump
– Remove the circlips (1), (21) and the sleeve (22).
– Extract the pump body (6).
Disassemble the pump and carry out any necessary
repairs (rings, seals, valve, etc.).

Clutch
– Separate the housing (18) from the cover (10) by
means of the screws (35).
– Take out the discs and backplates.
– Position the clutch vertically on the locally made
support (Fig. 26).
– Compress the Belleville washers (14) with the tool.
– Remove the circlip (26) and the bush (27). 21 26 35 37 36
– Gradually decompress the Belleville washers. 322hsm27 Fig. 25

– Remove the cover (10) with the piston (13), the


Belleville washers (14) and the spacer (32).
– To separate the hub (17) from the shaft (28), extract
the circlip (15). 28
– If necessary, remove the retainer (36) and the sun
gear (37). 26
– Clean and check the parts.
10 A
– Carry out the ecessary repairs (piston seal, bearings,
ø8
Belleville washers, discs, etc.).

13 180

32 14

15
60

X 17
ø 36
X
124
248

X–X

60

322hsm28 Fig. 26

B1.20 Ares 806 – 09.2004 – GB


Front clutch

Refitting
13 18
Clutch
– Refit the assembly in reverse order to removal, making 10
sure that the parts are the right way round.
28 A
– Refit the bearings using a press and an appropriate jig.
– Lubricate the new seals before fitting.
– Refit the piston (13), aligning it with the cover (10) by 17
means of a pin of appropriate diameter in the indexed
holes (A). Tap gradually and alternately around the
edge with a mallet. Check that there are no fragments 3 ± 0,4 daN.m
of seal after assembling. Frenbloc (270)
– Fit the bearing (16) using an appropriate jig, with the 16
sealed side against the shoulder of the shaft.
32
– Assemble the shaft (28), retainers, spacer (32),
Belleville washers and cover (10) with the locally made
Frenbloc (270)
tool. 322hsm30 Fig. 27
– Assemble the body (18) and cover (10), inserting the
backplates and discs (first backplate against the
6 Scelbloc (648)
piston).
– Check the rotation of the hub (17) by hand.
Important: New discs must be soaked in a bath of
transmission fluid for approximately one hour. 10
Pump
– Refit the rings (9) with miscible grease.
– Check that the pin (38) is fitted (hydraulic calibration).
– Refit the bush (7) inside the pump body (6), positioning
the chamfer so as to ensure easier fitting on the rings. 38
– Check that the hydraulic ports are not blocked by the
product and lubricate the bush.
– Refit the 1,5 bar valve.
– Oil and reassemble the pump on the cover (10),
9 7
positioning the flat sections of the rotor appropriately.
322hsm29 Fig. 28

5 ± 0,3 daN.m 4,1 ± 0,5 daN.m

3 ± 0,4 daN.m
Frenbloc (270)
322hsm31 Fig. 29

Ares 806 – 09.2004 – GB B1.21


Front clutch

Adjustment
This operation consists of obtaining 0,7 ± 0,1 mm axial
clearance between the pump cover (4) and the
cover (33).

Preparing for adjustment


– Remove the PTO shaft (39) to eliminate the thrust from
B
the spring mounted to the rear of the shaft and to free
the clutch. 39
– Fit the clutch and the pump with the locally made
tool (Fig. 24).
– Do not fit the hydraulic tubes.
– Preadjust at (B) to limit the measured clearance.
– Fit the cover (33) according to the procedure described
in "Removal/refitting".
– Make sure that the front clutch assembly is flush up
against the rear clutch cover.

Adjustment
– Place a dial gauge at the end of the shaft (28) and
measure the play while pulling the shaft towards you. 28
– Remove the cover (33) and clutch assembly in order to
refit the PTO shaft. 33 4
– Depending on the value measured, add or remove
shims to obtain a clearance of 0,7 ± 0,1 mm.
– Smear the shims with grease and reassemble
according to the procedure described in the "refitting"
section.

0,7 ± 0,1 mm
322hsm32 Fig. 30

28

322hsm33 Fig. 31

B1.22 Ares 806 – 09.2004 – GB


Rear clutch

Exploded view

32
16
15
14
13
12
5
10
7
8
7
5
4
3
2
1
24
6 23
22
11 31
21
11
20
19

19
19

30
29
28

27
26
25

322hsm34 Fig. 32

Parts list
1 Cover. 12 Circlip. 23 Plungers.
2 Circlip. 13 Circlip. 24 Spring.
3 Sun gear. 14 Bearing. 25 Seal.
4 Circlip. 15 Guide pin. 26 Seal.
5 Washer. 16 Planet carrier. 27 Seal.
6 Pins. 17 Coupling. 28 Pins.
7 Needles. 18 Bearing. 29 Discs.
8 Spacer. 19 Rear clutch cover. 30 Spring.
9 Planet gear. 20 Piston. 31 Backing plate.
10 Pinions. 21 Sun gear. 32 Greasing ring.
11 Circlip. 22 Pressure plate.

Ares 806 – 09.2004 – GB B1.23


Rear clutch

Removal/refitting (stage 2 page B1.9)


• Uncouple the tractor between the engine and the
gearbox as follows:
– Drain the transmission system.
– Remove the reservoir and disconnect the pipes, hoses
and wiring harnesses interfering with the uncoupling
operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.
• Remove the front clutch and the pump (cf. removal/
refitting stage 1).
• Remove the solenoid valve block (34) in order to
remove the tubes (35).
• Disconnect and remove the gradual engagement
sensor (36).
• Remove the gearshift cover (37) and take out the 322hsm35 Fig. 33
screw (38) from the Quadrishift unit. Do not slacken the
2 screws (39) holding the rear clutch cover (Fig. 39).
• Remove the PTO shaft. 36
• Use the locally made tool to extract the Quadrishift unit
(Fig. 36 and 37).
• Refit the Quadrishift unit using the locally made tool
and 2 guide rods measuring 10 x 150 by 250 mm long.
• Refit the assembly in reverse order to removal.
• Set the sensor (36) to ½-¾ of a turn before contact.

37 34 35
322hsm36 Fig. 34

38

322hsm37 Fig. 35

B1.24 Ares 806 – 09.2004 – GB


Rear clutch

Quadrishift removal tool

ø 8,5

– 0,5

– 0,2
–0
ø 60

–0
ø 32,5

ø 43

ø 31

ø 30

ø 25
40 15

131 43 363 200

176 156

20 20

ø 15 ø 44 ø 15

322hsm2g Fig. 36

ø 14 x 150

45

322hsm2h Fig. 37

Ares 806 – 09.2004 – GB B1.25


Rear clutch

19 22 12 3 2 14 1 20

322hsm38 Fig. 38

Removal
• Position the unit vertically (rear clutch facing upwards). 39 17
• Mark the cover (19) in relation to the unit.
• Unscrew the 2 screws (39) and remove the cover (19).
• Take the cover (19) and remove:
– the plate (22) and replace the seal;
– the piston (20) and replace the seals;
– the 13 bar valve (17) if necessary.
• Retrieve the pins (28), plungers (23) and springs (24)
and (30).
• Prevent planet carrier rotation.
• Unscrew the 6 screws (40) and remove the cover (1).
• Remove the discs and the backplates.
19
• Extract the circlip (2) and the sun gear (3).
• Remove the circlip (12) and take out the planet carrier
322hsm39 Fig. 39
and bearing (14).
• If necessary, remove the bearing (14) and the planet
gears with their needles, spacers and pins.
23 22
• Clean and check the parts.
• Carry out the necessary repairs (piston seal, bearings,
40
discs, etc.).

30 28 24

322hsm40 Fig. 40

B1.26 Ares 806 – 09.2004 – GB


Rear clutch

Refitting the epicyclic gear set


– Refit the planet gears with their pins, spacers and
needles coated with grease.
Important: Check that the ducts lubricating the pins
and planet carrier are not blocked. On fitting the pins,
position the ducts opposite one another. Remember
to fit the washers (5) to ensure correct pin assembly.
– Refit the planet carrier in reverse order to removal,
making sure that the parts are the right way round
(check that the circlip (4) is fitted).
– Position the locators (A) of each double planet gear so
that they pass along a line concurrent with "O".
– For easier planet gear positioning, use tool
n° 60 05 005 511.
4
– Slide the sun gear (3) correctly, checking that the
locators (A) have remained in position. 322hsm41 Fig. 41

322hsm42 Fig. 42

“0”

322hsm43 Fig. 43

Ares 806 – 09.2004 – GB B1.27


Rear clutch

22 28 20 42 19 41 23

322hsm44 Fig. 44

Refitting the assembly


– Refit the assembly in reverse order to removal, making 23
sure that the parts are the right way round and that
installation instructions are observed.
– Refit the bearings using a press and an appropriate jig.
– Lubricate the new seals before fitting.
– Refit the piston (20), aligning it with the cover (19),
then refit the plate (22), aligning its holes with those in
the cover. Tap gradually and alternately around the 30
edges of the piston and plate with a mallet.
– Check that there are no fragments of seal after
assembling.
Important: New discs must be soaked in a bath of
transmission fluid for approximately one hour. Check 24 24
28
that the rivets (41) are present on the cover (19).
– Refit the cover (19); pay attention to the locations of 322hsm45 Fig. 45
the pins (28), plungers (23) and springs (24) and (30)
(align the marks made on removal).
– Before and while tightening, check the sliding action of
42
the plungers (23) with a screwdriver through the
tapped holes (42).
– The 13 bar valve (17) must be fitted with new seals.

17

322hsm46 Fig. 46

B1.28 Ares 806 – 09.2004 – GB


Quadrishift unit

General 1 2

The Quadrishift assembly is mounted to the rear of the


Revershift. This is a hydraulically controlled gear change
system providing 4 input ratios to the gearbox. P
This function is provided by 2 epicyclic gear sets
combined with 2 hydraulic clutches.
The Quadrishift is designed to enable the 4 gears to be
selected, without declutching, by means of 2 +/-
pushbuttons placed on the gearshift lever and on the right-
hand pillar of the cab.
The Quadrishift is controlled by 2 solenoid valves
mounted on the low-pressure hydraulic circuit.
The 2 solenoid valves are themselves controlled by the
tractor's "Drivetronic" system.
P
P
1 2
Operating diagram 322hsm47 Fig. 47

The Quadrishift unit is made up of 2 epicyclic gear sets.


The planet carrier on the second epicyclic gear set is
linked to the sun gear on the first, which means that the
second gear set determines the rotation speed of the sun
gear on the first gear set. The 4 gears are obtained by the
operation of 2 clutches (Fig. 47).

Parts list

Movement in by the crown wheel on the first


epicyclic gear set.

Movement out by the planet carrier of the first


epicyclic gear set.

Stationary parts, kept in place relative to the


housing by hydraulic pressure.

Intermediate movements by the planet gears


and sun gear on the first epicyclic gear set.

Action of pressure to immobilise certain parts.

Ares 806 – 09.2004 – GB B1.29


Quadrishift unit
Speed 1 (Fig. 48)
The 2 clutches are disengaged by pressure.
The sun gear and the crown wheel on the second P
epicyclic gear set are immobilised. P

Only the former operates.


Output speed = 0,617 x Input speed.

Speed 2 (Fig. 49)


Only the first clutch is disengaged by pressure and
the 2 epicyclic gear sets are operating; the second gear
set determines the rotation speed of the sun gear on the
first, and this speed is equal to the output speed.

Output speed = 0,722 x Input speed.


P
P

322hsm48 Fig. 48

322hsm49 Fig. 49

B1.30 Ares 806 – 09.2004 – GB


Quadrishift unit
Speed 3 (Fig. 50)
Only the second clutch is disengaged by pressure
and the 2 epicyclic gear sets are operating; the second P
determines the rotation speed of the sun gear on the first.

Output speed = 0,854 x Input speed.

Speed 4 (Fig. 51)


The 2 clutches are engaged as there is no pressure; the
whole Quadrishift unit is therefore locked into a single
block and everything is running at the same speed.

Output speed = Input speed.

322hsm50 Fig. 50

322hsm51 Fig. 51

Ares 806 – 09.2004 – GB B1.31


B1.32
322hsm03
13
33
12
19
11
31
10
30
6
29
4
Exploded view

28
5
27
3
1

9 26
8 23
32
7 22 55
21
20
38
19 40
18 39
11 38
54
17 37
11
16 53 67
14 52

Ares 806 – 09.2004 – GB


43
51
Quadrishift unit

38
50
40 63
49
39
48 61
38
47
37
44
45 66
15
46 65
44 64
45 62
44 60
42 59
41 56
36 58
35 56
34 57
56

Fig. 52
Quadrishift unit
Parts list
1 Greasing ring. 23 Screw. 46 Spacer.
2 Screw. 24 Spring washer. 47 Secondary planet carrier.
3 Front cover. 25 Ball bearing. 48 Secondary sun gear.
4 Spring. 26 Primary ring gear. 49 Retaining ring.
5 Bearing. 27 Primary shaft. 50 Shims.
6 Screw. 28 Retaining ring. 51 Rear clutch splined hub.
7 Needle bearing. 29 Thrust bearing. 52 Rear brake thrust plate.
8 Washer. 30 Secondary ring gear. 53 Rear clutch housing.
9 Friction washer. 31 Retaining ring. 54 Rear clutch disc.
10 Front clutch housing. 32 Screw. 55 Rear clutch backplate.
11 Front brake disc. 33 Rear brake piston. 56 Rear brake disc.
12 Front clutch Belleville washer. 34 Tab washer. 57 Rear brake backplate.
13 Front clutch and brake thrust plate. 35 Shims. 58 Rear clutch and brake thrust plate.
14 Front clutch disc. 36 Primary ring gear carrier. 59 Belleville washers.
15 Front clutch backplate. 37 Planet gear pin. 60 Cover.
16 Front clutch splined hub. 38 Washer. 61 Screw.
17 Front brake backplate. 39 Needle bearing. 62 Friction washer.
18 Front brake piston. 40 Planet gear. 63 Washer.
19 O-ring. 41 Deflector. 64 Spring.
20 Centre housing. 42 Primary sun gear. 65 Rear cover.
21 Guide pin. 43 Needle. 66 Screw.
22 Secondary ring gear carrier. 44 Retaining ring. 67 Secondary shaft.
45 Bearing.

Ares 806 – 09.2004 – GB B1.33


Quadrishift unit

Removal/refitting (stage 3 page B1.9)


– Proceed with removing the Quadrishift unit in the same
way as the "Rear clutch removal/refitting" procedure.
– Position the unit vertically (rear clutch facing upwards).
– Remove the rear clutch according to the procedure.
– Refit in reverse order to removal, referring to the rear
clutch refitting instructions.

29
Removing the front brake and clutch 20

– Mark the housing (20) in relation to the rear cover (65). 65


– Remove the screws (66).
66
– With the aid of 2 locally made rings (Fig. 53), remove
the central housing, cover, primary shaft, clutch and
front brake.
322hsm52 Fig. 53
– Retrieve the thrust bearing (29) and the centring pins.
– Turn the assembly over on a bench with a hole to feed
the shaft through or on blocks.
– Remove the piston from the rear brake (33).
– Prevent the shaft from rotating using the following
locally made tool: Weld a 30 x 5 flat metal bar,
approximately 300 mm long, to thrust bearing
n° 60 05 018 806 (Fig. 54).
32 30 23 22 28 24 26 33 20
– Remove the secondary ring gear (30) by extracting the
screws (32).
– Compress the primary ring gear manually to remove
the retaining ring (28).
– Remove the primary ring gear complete with bearing
and the spring washer (24).
– Again hold the shaft in rotation to remove the
screws (23) and the ring gear carrier (22).

60 05 018 806

322hsm53 Fig. 54

B1.34 Ares 806 – 09.2004 – GB


Quadrishift unit

18 16

20

4 6 10 27 12

322hsm54 Fig. 55

– Mark the housing (20) in relation to the front cover (3).


– Extract the 3 screws (2) ro remove the centre housing.
– Remove the front brake piston (18).
– Remove the front brake and clutch discs and
backplates, hub (16), springs (4), bearing plate and the
final brake disc.
– Remove the Belleville washer (12), the housing (10),
the 2 washers and the shaft (27).
– Separate the cover (3) from the bearing (5) by
removing the 3 screws (6), then screwing 2 screws (6)
into the holes (68) to provide leverage. 2

322hsm55 Fig. 56

68

5 3

322hsm56 Fig. 57

Ares 806 – 09.2004 – GB B1.35


Quadrishift unit

31

322hsm57 Fig. 58 322hsm58 Fig. 59

48 31
Removing the planet carrier assembly
42
– Compress the planet carrier assembly slightly using
tool n° 60 05 006 133 (Fig. 58). 50
– Remove the retaining ring (31), washers and shims.
– Remove the compression tool and the planet carrier
assembly.
– Retrieve the shims (50).
– Remove the secondary sun gear (48), its bearing and
the spacer.
– Extract the secondary planet carrier and primary sun
gear and remove the bearing from the primary sun
gear (42).
– Separate the primary sun gear from the secondary
planet carrier by tapping lightly on a wooden block to
retrieve the needles (43). 322hsm59 Fig. 60

43

322hsm60 Fig. 61

B1.36 Ares 806 – 09.2004 – GB


Quadrishift unit

38
40
39
38
37
44
43
38 50
40 49
39 48
38 47
37
35 45
34 46
45
42
41
36
322hsm61 Fig. 62

Assembling the planet carriers


– Clean and inspect all parts, replace all faulty parts. 40
– Make sure that the lubrication holes of the planet gear
shafts are not blocked.
– Check manually for the presence of axial play and the 38
rotation of each planet gear (40).
– If necessary, take out the shaft (37) and replace the 37
washers (38) and the bearing (39).
39
– Mount the primary sun gear (42) fitted with the ring (44)
and deflector (41) on the secondary planet carrier. 42
49
– Slide the 3 needles (43) right into each inner hole in the 41
primary sun gear.
– Fit the primary sun gear bearing (45) and the ring (44). 44
– Assemble the secondary planet carrier (47) and the
primary sun gear (42) with the primary planet
carrier (36).
– Fit the spacer (46), bearing (45) and final ring (44).
– Fit the ring (49) and the secondary sun gear (48).
– Check manually for the presence of a gap between the
planet gear teeth.
46

44
47

43

48

36

322hsm62 Fig. 63

Ares 806 – 09.2004 – GB B1.37


Quadrishift unit

52 53 51 57

52

72 60 69
322hsm63 Fig. 64 322hsm64 Fig. 65

Removing the rear brake and clutch 53

– Remove the rear brake bearing plate (52), springs,


discs and backplate (57).
– Remove the rear clutch housing (53) with the rear
clutch and brake bearing plate (57).
– Retrieve the final disc and the friction washers.
– Remove the cover (60) and extract the Belleville 57
washers, thrust washer, discs and backplates.
– Remove the hub (51).

Removing the secondary shaft


– Remove the screws (69) and housing (70).
– Retrieve the centring pin (71). 322hsm65 Fig. 66

– Remove the secondary shaft (67).


– If necessary, replace the bearings with appropriate jigs. 73 71 67

Beware of the deflector (72) and adjustment shims


behind the bearing cup (73). 70

322hsm66 Fig. 67

B1.38 Ares 806 – 09.2004 – GB


Quadrishift unit

Refitting and adjusting the secondary


shaft 69 72

70
– Check that the secondary shaft lubrication holes are
not blocked. 73
– Lubricate the bearing cones and cups prior to
assembly with a press and an appropriate jig. 65
– Reposition the secondary shaft in the rear cover (65).
– Do not fit shims (74) behind the cup (73) to obtain a
provisional clearance.
– Refit the cover (70) with the screws (69) tightened
to 3,3 ± 0,4 daN.m.
– Do not fit the deflector (72) on measuring.
– Measure the play on the shaft with a dial gauge by
seating the upper bearing then the lower bearing.
– Remove the cover (70), take out the cup (73) and fit a
shim (74) corresponding in thickness to the play 322hsm67 Fig. 68

measured plus a preload of 0,10 ± 0.05 mm.


– If possible, adjust towards the maximum end of the
tolerance scale.
69
For example, if the play measured is 0,84 mm
0,84 + 0,05 = 0,89
0,84 + 0,15 = 0,99
The thickness of the shims to be inserted must be 70
between 0,89 and 0,99 (and as close to 0,99 as possible).

– Check that the centring pin is present.


– Refit the cover (70) with the screws (69) tightened
to 3,3 ± 0,4 daN.m and coat them lightly with
Frenetanch (242).
– Check shaft rotation by hand.
– Refit the deflector (72) and the roller bearing flush
against the housing (70).
322hsm68 Fig. 69

73
74

70

322hsm69 Fig. 70

Ares 806 – 09.2004 – GB B1.39


Quadrishift unit

51 53
60

58

61

322hsm70 Fig. 71 322hsm71 Fig. 72

Refitting the rear brake and clutch


– Position the planet carrier assembly on the primary. 51 56 52
– Fit the rear clutch housing (53) and the splined
hub (51) with the inner splines facing down.
– Fit the discs, backplates, thrust washer (58) and
Belleville washers in reverse order to removal.
– Position the cover (60).
– Centre the planet carrier assembly and clutch housing
with tool n° 60 05 006 137. 63 65
– Coat the screws (61) lightly with Frenetanch (242) and
tighten to 1,4 ± 0,2 daN.m.
– Position the friction washer, smeared with grease, on
the cover (60).
– Stick the washer (63) with Scelbloc (648) in the rear
cover (65).
322hsm72 Fig. 73
– Remember to fit the disc (56).
– Fit the housing with its friction washer on the shaft (67).
– Fit the hub (51) with its inner splines facing up. 67
– Position the 2 discs, backplate, springs and rear brake
bearing plate (52).
The planet carrier assembly will be fitted after adjustment
(see following pages).

56

322hsm73 Fig. 74

B1.40 Ares 806 – 09.2004 – GB


Quadrishift unit

Refitting the front brake and clutch


18 10 13
– Place the cover (3) on a table and check that the
rivets (75) are present.
– Fit the bearing (5) and roller bearing, aligning the
ducts.
– Tighten the screws (6), lightly coated with
Frenetanch (242), to a torque of 1,4 ± 0,2 daN.m for
the M6 screws and 2,4 ± 0,4 daN.m for the M8 screws.
– Stick the washer (8) to the bearing (5) with
Scelbloc (648).
– Place the cover (3) on 2 blocks to fit the shaft (Fig. 76).
– Fit the housing (10) with its friction washer precoated
with grease.
– Position the Belleville washer and a disc before the
bearing plate (13). 6 5 8 3
– Fit the discs, backplates and springs (4). 322hsm74 Fig. 75

Important: Lift the shaft from underneath to ensure


that the final disc is in the correct position on the
hub (16).
– Lubricate the new seals before fitting. 20
– Refit the piston (18) by tapping gradually and 13
alternately around the edge with a mallet.
Important: New discs must be soaked in a bath of
transmission fluid for approximately one hour. Check
that the rivets (75) are present on the centre 75
housing (20).
– Position the housing (20) by aligning the marks made
on removal [lubrication duct aligned with the cover (3)].
– Tighten the 3 screws underneath to 3,3 ± 0,4 daN.m.

Piston tightness test


– Connect a pressure gauge equipped with a sealed
valve and an appropriate locally sourced jig to the front 322hsm75 Fig. 76
piston supply port.
– Supply fluid to the circuit at a pressure of 0,3 bar. Close
the valve and check that no pressure is lost during the
following minute. 16

4
322hsm76 Fig. 77

Ares 806 – 09.2004 – GB B1.41


Quadrishift unit

32 26 25 33 22

23 24

60 05 018 806

322hsm77 Fig. 78

– Fit the bearing (25) on the ring gear (26).


– Fit the secondary ring gear carrier (22) with its ring
gear, the spring washer (24) and the primary ring
gear (26).
– Align the holes in the 2 ring gears with those in the
housing.
23
– Prvent the shaft (27) from rotating using the locally
made tool.
– Fit and tighten the screws (23), coated with
Frenetanch (242), to 3,3 ± 0,2 daN.m.
– Tighten the screws (32), coated with Frenetanch (242),
to 1,4 ± 0,1 daN.m. 26
– Lubricate the new seals before fitting. 32
– Refit the piston (33) by tapping gradually and
alternately around the edge with a mallet.
– Check that there are no fragments of seal after
assembling.
322hsm78 Fig. 79
– Hold the piston using an appropriate jig.
– Check piston tightness as explained on the previous
page.
– Press the ring gears and fit the retaining ring (28). 29
– Fit the thrust bearing (29) as shown.

28

322hsm79 Fig. 80

B1.42 Ares 806 – 09.2004 – GB


Quadrishift unit

Adjusting the planet carrier


65
Adjustment J1 (Fig. 81)
Measuring JA
– Position the cover (65) with the rear clutch fitted on a
table.
– Remove the springs and the rear brake bearing plate.
– Position tool n° 60 05 006 146 (tool height 60 mm)
flush against the hub (51).
– Measure "X" to determine JA [JA corresponds to the
offset between the hub (51) and the face (53) of the
housing].
JA = 60 – X

Measuring JB
J2 = 0,1 ± 0,1 mm J1 = 0,6 ± 0,1 mm
– Position the planet carrier assembly on the primary
planet carrier. 322hsm80 Fig. 81

– Position tool n° 60 05 006 147 (tool height 10 mm)


flush against the secondary sun gear (48).
– Measure "Y" to determine JB [JB corresponds to the
offset between the sun gear (48) and the shaft (67)].

X
JB = Y – 10

Shim thickness E1
Determine E1 according to JA, JB and the play value - 53
J1 = 0,6 ± 0,1 mm. 6 0 05 0 0 6 14 6
E1 = JA + JB + J1

For example, if X = 60,8 and Y = 11,5


JA = 60 – 60,8 = – 0,8
JB = 11,5 – 10 = 1,5
65
E1 (minimum) = – 0,8 + 1,5 + 0,5 = 1,2 51
E1 (maximum) = – 0,8 + 1,5 + 0,7 = 1,4
322hsm81 Fig. 82

In the example, the shim should be 1,2 to 1,4 mm thick.


Y

60 05 006 147

67 48

322hsm82 Fig. 83

Ares 806 – 09.2004 – GB B1.43


Quadrishift unit

Adjustment J2 (Fig. 81)


– Position the sun gear (48) and the planet carrier 31 34
assembly on the housing (53) with shims (50) to a
thickness E1.
Do not fit the springs or the rear brake bearing plate.
48
– Fit the tab washer (34) and the retaining ring (31)
without shims to measure the play. 50
– Place a dial gauge probe on the primary planet
carrier (36).
– Measure the value JC.
– Determine E2 according to JC an the play 53
value J2 = 0,1 ± 0,1 mm.
E2 = JC – J2

For example, if JC = 1,18


E2 (maximum) = 1,18 – 0 = 1,18
322hsm83 Fig. 84
E2 (minimum) = 1,18 – 0,2 = 0,98

In the example, the shim should be 0,98 to 1,18 mm thick.


JC
– Remove the planet carrier assembly.
– Fit the springs (64) and the bearing plate (52), aligning
it with the notches in the cover (65).
– Check that the shims (50) of thickness (E1) are fitted.
– Refit the sun gear and the planet carrier assembly and
compress by means of the locally made tool (see
removal in Fig. 58).
– Fit the shims (35) of thickness (E2), the tab
washer (34) and the retaining ring (31).
– Remove the locally made tool.

36

322hsm84 Fig. 85

31 35

50

64

52 65

322hsm85 Fig. 86

B1.44 Ares 806 – 09.2004 – GB


Quadrishift unit
Refitting the Quadrishift unit
• Check that the centring pin and the oil restrictor are 66
present on the cover (65).
• Check that the thrust bearing (29) is present.
• Refit the cover (65) on the centre housing (20), aligning
the marks made on removal.
• Rotate the shaft to engage the planet gears in the ring 65
gears.
• Tighten the screws (66), coated with Frenetanch (242),
to 3,3 ± 0,4 daN.m.
• Check shaft rotation.
• Refit the greasing ring (1), lightly coated with
Scelbloc (648), taking care not to block the lubrication 20
holes.
• Refit the parts according to the component refitting
methods covered in this chapter.
– Refit the Quadrishift unit. 322hsm86 Fig. 87

– Refit the rear clutch.


– Refit the front clutch.
– Refit the pump.
66 29
– Couple up the tractor.

322hsm87 Fig. 88

Ares 806 – 09.2004 – GB B1.45


Gearshift cover

General
– The gearshift cover is mounted on the right-hand side of the gearbox.
– The lever mounted on the cover controls the shift between the 4 gears. A hydraulic device provides the field/road
functions.

5
4

13
12
14
11
10
9
8
7
6

15

17
18
3
16
2
1

29

28 19
20
27 21
24 23
26

25 22

322hsm88 Fig. 89

Parts list
1 Lip seal. 11 Guide pin. 21 Field/road range solenoid valve.
2 Guide bush. 12 Screw. 22 O-rings.
3 Return orifice and coupling. 13 Control shaft. 23 Gearshift cover.
4 Field/road range piston. 14 Bearing. 24 Return port.
5 Guide bearing. 15 Guide pin. 25 Screw.
6 Retaining ring. 16 Screw. 26 Temperature sensor.
7 Washer. 17 Gate. 27 Return coupling.
8 Spring. 18 Ball. 28 Neutral position switch.
9 Washer. 19 Earthing lug. 29 Seal.
10 Rocker. 20 Solenoid valve fastener.

B1.46 Ares 806 – 09.2004 – GB


Gearshift cover

Removing/refitting the cover


Removal
– Chock the tractor.
– Remove the right-hand rear wheel. 23
– Make safe with a stand placed under the axle tube. 34
– Drain the gearbox.
– Disconnect the pipes, hoses and wiring harnesses
interfering with the removal of the cover.
– Disconnect the 2 remote gear control cables (34). 34
– Remove the screws (25) and mark the various lugs (on
the crawler speed option, remove the remote control
cable support).
– Detach and remove the gearshift cover (23). 25

Refitting 30
– Clean the mating surfaces of the gearbox and cover. 322hsm89 Fig. 90

– Put the field/road range piston in the road position.


– Put the range fork (35) in the road position and the 36
gear fork (36) in the neutral position.
– Coat the housing mating surface lightly with
Formajoint (510).
– Make sure that the selectors are in the correct position
in relation to the forks (Fig. 92).
– Refit the lugs and tighten the screws (25)
to 3,7 ± 0,3 daN.m.
– Refit and adjust the remote control cables.
– Refit the pipes, hoses, wiring harnesses and the rear
wheel.
– Fill the transmission system with fluid and check the
level.
– Adjust the remote gear control cables with the
35
nuts (30), check that the gears change correctly and
finely adjust the setting.
322hsm90 Fig. 91

322hsm91 Fig. 92

Ares 806 – 09.2004 – GB B1.47


Gearshift cover

Replacing the range piston seals


– Remove the cover.
– Remove the retaining ring (31) and take out the 5
piston (4) and guide bearing (5).
– Discard the O-rings and check that the piston and bear 4
slide properly.
31
– Lubricate the seals and refit the assembly.
Important: Replacing the piston and bearing implies
adjusting the range selector.

Removing and refitting the gear


selector
– Remove the cover.
– Remove the external control system. 322hsm92 Fig. 93

– Remove the switches, probes and couplings fitted to


the cover.
– Turn over the cover.
– Remove the retaining ring (6), washers (7) and (9),
spring (8) and rocker (10) and retrieve the ball.
– Remove the shaft (13) and take out the guide bush (2).
– Refit in reverse order to removal.
– Check that the centring pins are present for the
bearing (14).
– Coat the bush (2) lightly with Scelbloc (648) and fit it
flush to the cover.
– Tighten the screws (16), lightly coated with
Frenetanch (242), to 3,3 ± 0,4 daN.m.
– Position the rocker (10) in the correct direction.
– Tighten the screws (11), lightly coated with
Frenetanch (242), to 3 ± 0,5 daN.m.
– Using an appropriate jig, fit the seal (1) smeared with 322hsm93 Fig. 94

grease on its inner lip and lightly coated with


Frenetanch (542) on its outer edge.
– Refit all controls and check that it all works smoothly. 11
10
– Check that the neutral position switch (28) works 9
smoothly and check its continuity with the aid of a 8
multimeter. 7
– Tighten the switch fitted with an O-ring 6 13
to 2 ± 0,5 daN.m. 2
1
14

16

28

322hsm94 Fig. 95

B1.48 Ares 806 – 09.2004 – GB


Gearshift cover

Adjusting the field/road range


23
On the cover (Fig. 96)
– Place the piston (4) at the bottom of the chamber (road
position).
– Position tool n° 60 05 006 143 as shown on the
cover (23).
– Hold the piston down while tightening the screw (A) on A
the tool. 4

On the gearbox (Fig. 97)


– Place the same tool on the housing as shown.
– Bring the guide rod to the maximum point of its road
position (the fork pads must be bearing on the slide).
– Coat the screws (32) with Frenetanch (242) and tighten
them to 3 ± 0,5 daN.m; adjust such that face (F) of the
selector (33) is at least 0,2 mm from the face of the
322hsm95 Fig. 96
tool.
– Refit the cover (23) temporarily.
– With compressed air at a minimum pressure of 3 bar,
move the piston (4) to the tortoise position. 32
– Check the 1 mm maximum play on the fork in the slide
through the opening under the gearbox.

33

0,2 mm

322hsm96 Fig. 97

Ares 806 – 09.2004 – GB B1.49


Guide rods

General
The gearshift guide rods are located on the right-hand Each guide rod is equipped with a fork and an adjustable
side of the gearbox behind the gearshift cover. The guide selector. They are supported at the 2 ends by a front
rods are as follows: bearing fastened to the rear of the Quadrishift unit, and by
– First and second gear. the rear gearbox housing. A 2-lock system fastened to the
– Field and road range. rear of the gearbox prevents shifting to first or second
gear with the shift to third or fourth gear.
– Third and fourth gear.

Exploded view

1
2
3
4
5
6
7
8
20
10
9
10

19
18
17
16

13
14 12
11

322hsm97 Fig. 98

Parts list
1 Short first and second gear lock. 11 Field and road range guide rod.
2 Rear bearing. 12 Third and fourth gear guide rod.
3 Indexing with long spacer. 13 Third and fourth gear fork/selector.
4 First and second gear guide rod. 14 Gearshift cover.
5 First and second gear selector. 15 Needle screw.
6 First and second gear fork. 16 Field and road range selector.
7 Screw. 17 Field and road range fork.
8 Front bearing. 18 Pin.
9 Guide pin. 19 Indexing with short spacer.
10 Quadrishift rear bearing. 20 Long third and fourth gear lock.

B1.50 Ares 806 – 09.2004 – GB


Guide rods

Removing the guide rods


• Uncouple the tractor between the gearbox and rear 5 15 6
axle as follows::
– Refer to Chapter "H" for partial cab removal.
Operations 1 to 7.
– Drain the transmission system.
– Remove the reservoir(s) and disconnect the pipes,
hoses and wiring harnesses interfering with the
uncoupling operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.
– Uncouple the tractor.
18
• Remove the right-hand gearshift cover.
• Remove the screws (15) from the selector (5), fork (6) 13
and fork/selector (13). 11
• Remove the upper (3) and lower (19) side indexing 322hsm98 Fig. 99
pins.
• Push the guide rods (4) and (12) forwards to extract 4 1 3
the locks (1) and (20).
• Drive the pin (18) from the field/road range fork and
remove the guide rod (11) through the rear of the
housing.
• Remove the third and fourth gear and field/road range
forks.
N.B.: The first and second gear fork can only be
removed with its synchroniser.

12 20 19
322hsm99 Fig. 100

Ares 806 – 09.2004 – GB B1.51


Guide rods

Refitting the guide rods


3
1
• Refit in reverse order to removal while observing the
following instructions.
– The pin must be replaced in the field/road fork.
– The short first and second gear lock (1) is fitted at the
top.
– The long third and fourth gear lock (20) is fitted at the
bottom.
– The indexing with a long spacer (3) is fitted at the top
with the screw lightly coated in Frenetanch (242) and
tightened to 6 ± 1 daN.m.
– The indexing with a short spacer (19) is fitted at the
bottom with the screw lightly coated in
Frenetanch (242) and tightened to 6 ± 1 daN.m.
– Adjust the forks. 20 19
• Refit the assembly in reverse order to removal, 322hsm1a Fig. 101
observing the instructions mentioned in the parts
concerned.

B1.52 Ares 806 – 09.2004 – GB


Guide rods

Adjusting the forks


The positioning of the forks is adjusted by the difference 15 A 15
between the centre-distance (A) of the screws (15) and
the centre-distance (B) of the recesses.
– Tighten one screw and slacken the other to shift the
fork to the left or right.
– Coat the screws (15) lightly with Frenetanch (242).
– Adjust such that when the gear is engaged, the fork
pads do not touch the face of the slide used to engage
that gear.
– Tighten the screws to a torque of 3,5 daN.m without
altering the setting.
– Adjust the hare/tortoise selector as described in the
section on "Adjusting the field/road range".
B

322hsm1b Fig. 102

Ares 806 – 09.2004 – GB B1.53


Output shaft

General
The output shaft transmits the movement provided by the shaft and the second in the rear bearing. It supports the
various gears to the rear axle. It is mounted on the bottom double-cone field and road range synchroniser. The
line to the rear of the gearbox. It is supported by 2 tapered bearings are preloaded by means of shims placed behind
roller bearings, the first of which is mounted in the input the bearing cup (15).

Parts list
1 Bearing cup. 8 Field and road range double-cone 14 Adjustment shims.
2 Bearing cone. synchroniser. 15 Rear bearing (setup without crawler
3 Sealing ring. 9 Field range pinion (66 tooth). speed).
4 Lubrication bush. 10 Output shaft. 16 Rear bearing (setup with crawler
5 Bearing cone. 11 Retaining ring (if crawler speed fitted). speed).
6 Bearing cup. 12 Bearing cone. 17 Screw.
7 Road range third gear pinion (30 tooth). 13 Bearing cup.

B1.54 Ares 806 – 09.2004 – GB


Output shaft

Exploded view

16

18
17

14
13
12
11
10

5
6
7
8

6
5
4
3
2
1

322hsm1c Fig. 103

Ares 806 – 09.2004 – GB B1.55


Output shaft

15

10

19

322hsm1d Fig. 104

Removing the shaft (stage 4


page B1.10)
It is not necessary to remove the gearbox to work on the
output shaft only.
• Uncouple the tractor between the gearbox and rear
axle as follows:.
– Refer to Chapter "H" for partial cab removal.
Operations 1 to 7.
– Drain the transmission system.
– Remove the reservoir(s) and disconnect the pipes,
hoses and wiring harnesses interfering with the
uncoupling operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.
– Remove the right-hand gearshift cover. 10
– Remove the bottom plate (19) under the gearbox. 322hsm00 Fig. 105

– Remove the rod guides and the forks.


– If the tractor is fitted with the crawler speed option,
remove the step-down gear unit.
– Remove the rear bearing (15) (or (16) if crawler speed
fitted).
– Pull the shaft (10) to remove.
– By opening the right-hand gearshift cover, remove the
synchroniser (8), pinion (9), pinion (7) with its bearings,
lubrication bush (4) and bearing (2).

B1.56 Ares 806 – 09.2004 – GB


Output shaft

20 4
B

21

A 9

322hsm1e Fig. 106 322hsm1f Fig. 107

9
Refitting the shaft
– Replace the faulty parts.
– Fit the bearings using appropriate jigs.
– Refit the assembly in reverse order to removal while
observing the following instructions:
– Fit the bush (4), with its sealing ring lightly smeared
with grease, into the input shaft (20). 22
– Position the bush (4) such that the flat section is facing
upwards.
– Smear the synchroniser bushes and cones lightly with
grease.
– Fit the pinion assembly and secure it
with 2 screws (21) flush with pinion (9).
– If the gearbox has been removed, position it vertically
Fig. 108
and secure pinion (9) with 2 overturned threaded 322hsm1g

rods (22) (Fig. 108), then fit the rest of the pinions.
Important: Position the pinion locator (A) and the A
synchroniser lubrication duct (B) to the rear of the
gearbox.
– Engage the shaft, positioning the flat section
uppermost (aligned with the previously fitted bush (4)).
– Refit the assembly in reverse order to removal,
observing the instructions mentioned in the parts
concerned.

B
7

322hsm1h Fig. 109

Ares 806 – 09.2004 – GB B1.57


Output shaft

Adjusting the shaft


– Place the cup (13) in the bearing without shims.
– Fit the bearing with the centring pin and tighten the 17
screws (17) to the following torque:
13
– Bearing (15) without crawler option: 6,2 ± 0,5 daN.m.
– Bearing (16) with crawler option: 4,4 ± 0,4 daN.m.
– Place a dial gauge probe at the end of the shaft (10).
– To seat the bearings correctly, push hard on the
protected shaft and rotate it with pliers.
– Repeat this operation while pulling hard on the shaft
and take the measurement.
– Remove the bearing, take out the cup (13) and fit a
shim corresponding in thickness to the play measured
plus a preload of 0,03 ± 0,02 mm.
– If possible, adjust towards the maximum end of the
tolerance scale. 322hsm1i Fig. 110

For example, if the play measured is 0,86 mm


0,86 + 0,01 = 0,87
0,86 + 0,05 = 0,91

– The thickness of the shims to be inserted must be


between 0,87 and 0,91 (and as close to 0,91 as 10
possible).
– Refit the bearing and tighten the screws to the
aforementioned torque.
– Refit the various components in reverse order to
removal while observing the fitting instructions. 17
– Assemble in reverse order using guiding studs to align
the gearbox and the rear axle more easily.

322hsm1j Fig. 111

B1.58 Ares 806 – 09.2004 – GB


Input shaft

General
The input shaft supports the double-cone gear bearings mounted in the lower bearings of the gearbox
synchronisers. It is mounted on the bottom line, in front of housing. The bearings are preloaded by means of shims
the output shaft. It is supported by 2 tapered roller placed behind the bearing cup (5).

Ares 806 – 09.2004 – GB B1.59


Input shaft

Exploded view

20
19

18
17

16
15
14
13
12

11

10

9
8

7
6
5
4
3
2
1

322hsm1k Fig. 112

B1.60 Ares 806 – 09.2004 – GB


Input shaft
Parts list
1 Nut. 9 Second gear driving pinion. 16 Spring.
2 Washer. 10 First and second gear synchroniser. 17 Input shaft.
3 Input pinion. 11 First gear driving pinion. 18 Fourth gear pinion.
4 Bearing cone. 12 Bearing cup. 19 Third and fourth gear synchroniser.
5 Bearing cup. 13 Bearing cone. 20 Retaining ring.
6 Adjustment shims. 14 Lubrication tube.
7 Washer. 15 Circlip.
8 Sleeve.

Ares 806 – 09.2004 – GB B1.61


Input shaft

Removing the shaft (stage 5


page B1.10)
23 22
• For this operation, the gearbox needs to be removed
as follows.
– Refer to Chapter "H" for complete cab removal.
Operations 1 to 21.
– Drain the transmission system.
– Remove the reservoir(s) and disconnect the pipes,
hoses and wiring harnesses interfering with the
uncoupling operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.
– Uncouple between the engine and gearbox.
– Make the gearbox safe on a trolley and the rear axle on
stands.
– Uncouple the gearbox from the rear axle.
• Remove the front cover and clutch, the rear clutch and
the Quadrishift unit as described in the sections
concerned.
• Remove the output shaft as described in the previous
section. 20
• Remove the retaining ring (22) and push back the
intermediate shaft pinion (23). 19
• Remove the retainer (20) and remove the
synchroniser (19), noting its position and the assembly
of its components.
• Remove the pinion (18).
• Block the rotation of pinion (3) and release and 18
unscrew the nut using socket n° 60 05 006 140.
• Remove the washer and input pinion (3).

322hsm1l Fig. 113

322hsm1m Fig. 114

B1.62 Ares 806 – 09.2004 – GB


Input shaft

Removing the shaft


– Remove the sleeve (8) with the bearing cone (4). 11
– Remove the shaft rearwards with the bearing cone
while holding the pinion and synchroniser assembly. 8
– The fork of synchroniser (10) can only be removed with 15
the synchroniser - mark its position.
– Remove the pinion and synchroniser assembly,
marking their position, through the opening in the
gearshift cover.
– If necessary, remove the bearing cones and cups and 14
pair them up; retrieve the shims (11).
4
– Remove the lubrication tube (14), paying attention to
the retainer (15) and spring.

9 10
Refitting the shaft 322hsm1n Fig. 115

– Check the lubrication ducts.


– Refit the lubrication tube (14).
– Fit the bearing cups and cone using a press and an
appropriate jig.
– If the synchroniser components need to be refitted,
mark them on removal to ensure that they are put back
into their initial position.
Important: Assemble pinion (9) on a table with the
synchroniser (10) and its correctly positioned fork. 9
– Fit the assembly, add the first gear pinion and insert the
shaft (17) from the rear.
– Adjust the shaft - see below.
– Fit the input pinion (3). 17
– Degrease the shaft and nut threads, coat the nut with
Frenbloc (270), then fit the nut and tighten
to 15 ± 2 daN.m.
322hsm1o Fig. 116
– Lock the nut, which is always replaced, by striking the
flange.
– Refit the pinion (18), synchroniser (19) and stop ring.
– Refit the assembly in reverse order to removal,
observing the instructions mentioned in the parts
concerned.

19 18 10 3
322hsm1p Fig. 117

Ares 806 – 09.2004 – GB B1.63


Input shaft

Adjusting the shaft


Important: Loosen the nut on the intermediate shaft in
order to lift it and enable the input shaft to be adjusted
without stress.
– Place the cup (5) inside the bearing with the washer (7)
and no shims.
7
– Fit the bearing cone, pinion, washer and nut and
tighten to 15 ± 2 daN.m.
– Place a dial gauge probe at the rear end of the 5
shaft (17).
– To seat the bearings correctly, pull hard on the shaft
from the front and rotate it.
– Repeat this operation while pushing hard on the shaft
and take the measurement.
– Take out the cup (5) and fit a shim corresponding in
thickness to the play measured plus a preload 322hsm1q Fig. 118
of 0,15 ± 0,05 mm.
– If possible, adjust towards the maximum end of the
tolerance scale.

For example, if the play measured is 1,23 mm


1,23 + 0,10 = 1,33
1,23 + 0,20 = 1,43

– The thickness of the shims to be inserted must be


17
between 1,23 and 1,43 (and as close to 1,43 as
possible).
– Place the shims between the washer (7) and the
bearing cup (5).
– Refit the assembly, coat the nut with Frenbloc (270),
then fit the nut and tighten to 15 ± 2 daN.m.
– Continue the fitting procedure described in the
previous section.
322hsm1r Fig. 119

B1.64 Ares 806 – 09.2004 – GB


Countershaft

General
The intermediate shaft supports the driven gear pinions. It is mounted on the top line of the gearbox. It is supported
by 2 tapered roller bearings mounted in the rear housing and a roller bearing mounted in the Quadrishift rear bearing. The
bearings are adjusted by means of a shim inserted between the 2 bearing cones (2).

Exploded view

1
2
3
4
3
2

8
9

10
11

12
13
14

15
16
17
322hsm1s Fig. 120

Parts list
1 Nut. 7 Retaining ring. 13 Spacer.
2 Bearing cone. 8 Third gear driven pinion. 14 Adjustment shims.
3 Bearing cup. 9 Spacer. 15 Second gear driven pinion.
4 Shim. 10 Fourth gear driven pinion. 16 Washer.
5 Countershaft. 11 Spacer. 17 Retaining ring.
6 Needle bearing. 12 First gear driven pinion.

Ares 806 – 09.2004 – GB B1.65


Countershaft

Removing the shaft


(stage 6 page B1.10) 17 3
• For this operation, the gearbox needs to be removed
as follows. 6 4
– Refer to Chapter "H" for complete cab removal.
Operations 1 to 21.
– Drain the transmission system. 5 2
– Remove the reservoir(s) and disconnect the pipes,
hoses and wiring harnesses interfering with the
uncoupling operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.
– Uncouple between the engine and gearbox.
– Make the gearbox safe on a trolley and the rear axle on
stands.
– Uncouple the gearbox from the rear axle. 322hsm1t Fig. 121

• Remove the front cover and clutch, the rear clutch and
the Quadrishift unit as described in the sections
concerned.
• Release and loosen the nut (1) beforehand, holding the
gearbox firmly, to break the adhesive seal.
• Remove the output and input shafts as described in the
previous sections.
• Loosen the nut completely using socket 1
n° 60 05 006 142.
• Pair up the bearing cones (2) and cups (3).
• Retrieve the shim (4).
• Remove the shaft (5) and its pinions from the front.
• Remove the ring (17) followed by the washer, pinions
and spacers.
• If necessary, remove the needle bearing (6).

322hsm1u Fig. 122

B1.66 Ares 806 – 09.2004 – GB


Countershaft

Adjusting the shaft


16 6
– Clean the parts and refit them in reverse order to
removal. 15 17
– Fit without the shims (14). 14
– Turn over the stack on the table and place a dial gauge
probe on the pinion (8).
– Press the pinion to make sure of stack contact.
– Pull the pinion and take the measurement at 3 points
and calculate the average of the 3.
– Remove the ring (17), washer (16) and pinion (15). Fit
a shim corresponding in thickness to the play
measured plus a preload of 0,16 ± 0,14 mm.
8
If possible, adjust towards the minimum end of the
7
tolerance range.

For example, if the play measured is 1,23 mm 322hsm1v Fig. 123

1,23 – 0,02 = 1,21


1,23 – 0,30 = 0,93

The thickness of the shims to be inserted must be


between 0,93 and 1,21 (and as close to 1,21 as possible).

Refitting the shaft


– Fit the shims and remove the ring (7) and pinion (8)
before fitting the shaft in order to fit the other shafts
more easily.
– Fit the needle bearing (6) using a press and an
appropriate jig.
– Fit the bearing cups (3) with the aid of an appropriate
jig.
Important: The largest bearing cup (3+) must be fitted
in the gearbox rear bore. 322hsm1w Fig. 124

– Refit the shaft into the gearbox housing with the first
cone (2).
3 3+

5 2 4

322hsm1x Fig. 125

Ares 806 – 09.2004 – GB B1.67


Countershaft

Adjusting the bearings


– 0,06 ± 0,09 mm
• Fit the largest shim (4): 4,46 mm.
• Fit the final bearing cone.
• Degrease the shaft and nut threads, tighten the nut
(which is always replaced) to 5 daN.m, rotate the shaft
to seat the bearings and finally tighten to
12,5 ± 2,5 daN.m.
• Place a dial gauge probe at the end of the shaft
• To seat the bearings correctly, pull hard on the shaft (5)
from the front and rotate it.
• Repeat this operation while pushing hard on the shaft 5
and take the measurement.
– If the play measured is in the 0,06 ± 0,09 mm tolerance 1
range. The 4,46 mm shim corresponds to the
recommended adjustment. 4
– If the play measured is higher than 0,15 mm. Fit a 322hsm1y Fig. 126
thinner shim and repeat the adjustment procedure.
• Measure the play and repeat the procedure until it is
within the 0,06 ± 0,09 mm tolerance range.
• Five shim thicknesses are available: 4,46 ; 4,40 ;
4,34 ; 4,28 and 4,22.
• Finish the refitting procedure.
• Refit the cone, coat the nut (1) (always replaced) with
Frenetanch (242) and tighten to the torque
recommended above.
• Lock the nut by deforming its flange.
• Refit the input and output shafts.
• Refit the assembly in reverse order to removal,
observing the instructions mentioned in the parts
concerned.

B1.68 Ares 806 – 09.2004 – GB


Crawler speeds

General
It is made up of a step-down gear and a dog control is mounted on the rear axle and activates the engagement
function. The step-down gear is made up of an epicyclic dog of the step-down gear via the fork. The dog can only
gear set comprising a planet carrier and ring gear be engaged at a standstill. The reduction ratio of the step-
assembly housed at the rear of the gearbox. The control down gear is 0,25.

Ares 806 – 09.2004 – GB B1.69


Crawler speeds

Exploded view

16

15
2
14
3
13 7
12

17
4
18
5
6
10 8
11 9

19

20
21
22

23

24

31
32
22

33
34
30
11
25
26
27
28
29

35

322hsm1z Fig. 127

B1.70 Ares 806 – 09.2004 – GB


Crawler speeds
Parts list
1 Control cable. 13 Nut. 25 Spacer.
2 Control cable support. 14 Lock. 26 Friction plate.
3 Control link. 15 Spring. 27 Planet gear.
4 Screw. 16 Screw. 28 Friction plate.
5 O-ring. 17 Gearbox housing. 29 Pins.
6 Spindle. 18 Toothed output shaft bearing. 30 Needles.
7 Pin. 19 Output shaft. 31 Retaining ring.
8 Adjustment shims. 20 Screw. 32 Clutching gear.
9 Lever. 21 Retaining ring. 33 Unit.
10 Fork. 22 Friction washers. 34 Screw.
11 Sliding sleeve. 23 Ring gear. 35 Retaining ring.
12 Guide rod. 24 Planet carrier.

Ares 806 – 09.2004 – GB B1.71


Crawler speeds

Removing/refitting the housing


• Uncouple the tractor between the gearbox and rear 34
axle as follows:.
– Refer to Chapter "H" for partial cab removal.
Operations 1 to 7.
35
– Drain the transmission system.
– Remove the reservoir(s) and disconnect the pipes,
hoses and wiring harnesses interfering with the
uncoupling operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.
– Uncouple the tractor. 33
• Remove the ring (35) and screws (34).
• Remove the step-down gear assembly.
• Remove the retainer (21) and the friction washer (22).
• Drive out the pins (29), paying attention to the needles, 322hsm2a Fig. 128

in order to remove each planet gear (27).


• The clutching gear (32) is pressed onto the planet
carrier (24) and the retainer (31) ensures that the
assembly is held correctly. 21
22
• Refit the assembly in reverse order to removal while 23
observing the following instructions. 24
31
– Equip each planet gear with 2 rows of needles coated
with grease and separated by a spacer. 32
– Centre the friction plates (26) and (28).
– Position the shafts (29) correctly in order to be able to
fit the retainer (21).
– Smear the faces of the step-down gear lightly with 26
grease and fit the friction washers (22), positioning 27
their tabs correctly. 28
– Fit the ring gear (23) with the clearance on the bearing 29
34
side.
– Position the cutout part of housing (33) to the bottom. 322hsm2b Fig. 129

– Tighten the screws (34) coated with Frenetanch (242)


to 1,2 ± 0,2 daN.m.

• Refit the assembly in reverse order to removal,


observing the instructions mentioned in the parts
concerned.

B1.72 Ares 806 – 09.2004 – GB


Crawler speeds

Removing, adjusting and refitting the


control system
16
Removal
– Disconnect the control cable.
– Remove the PTO clutch (see chapter C).
– Remove the lock (14) and nut (13) (discard the nut) to
extract the guide rod (12).
– Remove the fork and dog assembly from the front.
– Remove the control link (3) and pin (7) to extract the
shaft (6).
– Retrieve the shims (8). 13

Adjusting and refitting


– To limit the axial play on the spindle (6), insert
shims (8) to obtain 0,3 ± 0,2 mm of play at the end of 10 12 7 9 8 6 4 3
the spindle. 322hsm2c Fig. 130

– Position the dog correctly and fit the fork and guide rod
complete with a new nut (13).
– Fit the lock (14) and spring and tighten the screw (16)
to 6 ± 1 daN.
– Put the dog (11) in the "Crawler" position with its rear
face flush against the retainer (36).
– Degrease the thread of the guide rod (12) and nut (13).
Precoat the nut with Frenetanch (242).
– Hold the nut (13) against the sunken face of the
housing and turn the guide rod (12) simultaneously to
the right or left (as required) with a screwdriver to
obtain an approximately equal gap between the
dog (11) and the bearing faces of the fork (10).
– Lock the nut (13) by deforming its flange.
N.B.: When the tractor is coupled up, translational
movement of the guide rod (12) will be prevented by 13 14 16 10 12
the contact of the nut (13) with the rear face of the
322hsm2d Fig. 131
gearbox.
– Couple up the tractor.
– Refit the rocker bar (3) with the screw (4) lightly coated
with Frenetanch (242).
– Check manually with the aid of the rocker bar that the
dog locks correctly in each "direct drive" and "crawl"
position.

11 36

322hsm2e Fig. 132

Ares 806 – 09.2004 – GB B1.73


Crawler speeds

Setting the controls


– Put the rocker bar (3) in the "crawler" position.
– Put the range lever (40) in the cab in the "crawler"
position.
– Screw the yoke (36) onto the control cable (1) and 40
tighten the check nut.
– Mount the yoke (36) on the cab range lever.
– Mount the yoke (37) in the same way on the rocker
bar (3).
– Adjust the sheath stops with the nuts (38) and (39)
while checking that the cable (1) is not strained.
– Check operation and locking in the 2 positions.
– Finely adjust the setting with nuts (38) and (39) if 36
necessary.

38

39

37

3
322hsm2f Fig. 133

B1.74 Ares 806 – 09.2004 – GB


B2
GTA 1040 AND GPA 30 LOW-
PRESSURE HYDRAULIC CIRCUIT

Ares 806 – 09.2004 – GB


LS 100 l/min low-pressure circuit on GTA 1040

Circuit layout on beam

2
4
5
6
1

T
P
25
8
27
12
17
3

15

18
19
20
21
13
10

23
24
29
7

28
26
16
9
11

14

392hsm08 Fig. 1

B2.2 Ares 806 – 09.2004 – GB


LS 100 l/min low-pressure circuit on GTA 1040

Hydraulic system
Parts list (Fig. 1, 2, 3 and 4)
1 Pump, 19 cm³ per rev. 13 Lubrication valve, 2,1 bar, in feeder 23 Control circuit accumulator.
2 High-pressure filter, 15 µ, with bypass tank. 24 Field/road range solenoid valve.
valve and clogging indicator. 14 RH axle tube lubrication. 25 Braking booster circuit accumulator.
3 Steering unit. 15 LH axle tube lubrication. 26 Rear power take-off brake solenoid
4 Control pressure switch. 16 Low-pressure filter, 60 µ. valve.
5 Control pressure limiter, 17 bar. 17 Automatic handbrake solenoid valve. 27 Rear power take-off clutch solenoid
6 Lubrication circuit safety valve, 8,5 bar. 18 Reverse gear clutch solenoid valve. valve.
7 Cooler. 19 Forward gear clutch solenoid valve. 28 Differential locking solenoid valve.
8 Gearbox lubrication . 20 Quadrishift front brake solenoid valve. 29 Four-wheel-drive solenoid valve.
9 4-wheel-drive clutch lubrication. 21 Quadrishift rear brake solenoid valve. A Intake from tank.
10 Handbrake disc lubrication. 22 Front power take-off clutch solenoid B Return from high-pressure pumps
11 Power take-off shaft lubrication . valve. (recirculation).
12 Power take-off clutch lubrication. C To braking booster.

Ares 806 – 09.2004 – GB B2.3


LS 100 l/min low-pressure circuit on GTA 1040

20 18

22

23

21 19
25
C

17
26
3
27

24 28
60 µ

16 29

3,5 bar
B

B 15 > 200 8
2,4 bar
7
9

10
2
1 11 12
A 17 bar 8,5 bar 13
2,1 bar
14 15
4 5 6
392hsm09 Fig. 2

B2.4 Ares 806 – 09.2004 – GB


LS 100 l/min low-pressure circuit on GTA 1040

Gearbox and rear axle lubrication

8
12

7
7
Frenbloc (270)

12

9
9
13

10
11

11

392hsm10 Fig. 3

Ares 806 – 09.2004 – GB B2.5


LS 100 l/min low-pressure circuit on GTA 1040

Axle tube lubrication


ND

15
13
14
HD – HDE

392hsm11 Fig. 4

B2.6 Ares 806 – 09.2004 – GB


LS 110 l/min low-pressure circuit on GTA 1040

Circuit layout on beam

1
2
3
9
20
28
21
12

30 32
31 33
22
16

23
11

24
14

25
8

26
10
7 18
19
27
5
4
6
17
13

15

391hsm35 Fig. 5

Ares 806 – 09.2004 – GB B2.7


LS 110 l/min low-pressure circuit on GTA 1040

Hydraulic system
Parts list (Fig. 5, 6, 7 and 8)
1 Tank/rear axle. 14 Lubrication valve, 2,1 bar, in feeder 27Control pressure switch, 9 bar.
2 Suction strainer, 150 µ. tank. 28Field/road range solenoid valve.
3 Booster pump, 60 cm³ per rev. 15 RH axle tube lubrication. 29Front PTO clutch solenoid valve.
4 High-pressure filter, 15 µ, with bypass 16 LH axle tube lubrication. 30Reverse gear clutch solenoid valve.
valve and clogging indicator. 17 Control pressure priority valve, 17 bar. 31Forward gear clutch solenoid valve.
5 Variable-displacement pump, 45 cm³ 18 Low-pressure filter, 60 µ. 32Quadrishift front brake solenoid valve.
per rev. 19 Control pressure limiter, 22 bar. 33Quadrishift rear brake solenoid valve.
6 Lubrication/boost pressure 20 Control circuit accumulator. ATo priority unit.
switch, 3 bar. 21 Braking booster circuit accumulator. BHigh pressure from steering/braking
7 Boost pressure limiter, 5 bar. 22 Automatic handbrake solenoid valve. priority valve.
8 Oil cooler. 23 Rear power take-off clutch solenoid C High pressure to auxiliary spool valves.
9 Gearbox lubrication . valve. D To braking booster.
10 4-wheel-drive clutch lubrication. 24 Rear power take-off brake solenoid
11 Handbrake disc lubrication. valve.
12 Power take-off clutch lubrication. 25 Rear differential locking solenoid valve.
13 Power take-off shaft lubrication . 26 Four-wheel-drive solenoid valve.

B2.8 Ares 806 – 09.2004 – GB


391hsm36
17 bar
B C

17
20 21

18 60 µ

22 bar
19 D

23

A 24

8 6 5 25
76/65 22
9 3 bar 26
27

Ares 806 – 09.2004 – GB


10 29
9 bar
5 bar

11 2,4 bar
7
B 15 > 200 3,5 bar
12 4
13
28
15
14
2,1 bar 30 31
3
LS 110 l/min low-pressure circuit on GTA 1040

76/61
16
2 33
150 µ 32
1

B2.9
Fig. 6
LS 110 l/min low-pressure circuit on GTA 1040

Gearbox and rear axle lubrication

8
9
12 Frenbloc (270)

12

8
8

10
4
14

14
11
13

13

391hsm37 Fig. 7

B2.10 Ares 806 – 09.2004 – GB


LS 110 l/min low-pressure circuit on GTA 1040

Axle tube lubrication


ND

16
14
15
HD – HDE

391hsm38 Fig. 8

Ares 806 – 09.2004 – GB B2.11


LS 110 l/min low-pressure circuit on GPA 30

Circuit layout on beam

20
19
18
3
2
9
13

17
11

15
23
21
8
16
22
7
5
6
4
14
10

12

393hsm19 Fig. 9

B2.12 Ares 806 – 09.2004 – GB


LS 110 l/min low-pressure circuit on GPA 30

Hydraulic system
Parts list (Fig. 9, 10, 11 and 12)
1 Tank/rear axle. 11 Lubrication valve, 2,8 bar, in feeder 21Four-wheel-drive solenoid valve.
2 Suction strainer, 150 µ. tank. 22Control pressure switch, 9 bar.
3 Booster pump, 60 cm³ per rev. 12 RH axle tube lubrication. 23"Park Lock" solenoid valve.
4 High-pressure filter, 15 µ, with bypass 13 LH axle tube lubrication. 24Front PTO clutch solenoid valve.
valve and clogging indicator. 14 Control pressure priority valve, 17 bar. ATo priority unit.
5 Variable-displacement pump, 45 cm³ 15 Check valve. BHigh pressure from steering/braking
per rev. 16 Control pressure limiter, 22 bar. priority valve.
6 Lubrication/boost pressure 17 Braking booster circuit accumulator. C High pressure to auxiliary spool valves.
switch, 3 bar. 18 Rear power take-off clutch solenoid D To braking booster.
7 Boost pressure limiter, 5 bar. valve.
8 4-wheel-drive clutch lubrication. 19 Rear power take-off brake solenoid
9 Power take-off shaft lubrication . valve.
10 Power take-off clutch lubrication. 20 Rear differential locking solenoid valve.

Ares 806 – 09.2004 – GB B2.13


B2.14
393hsm20
17 bar
B C

14
15 17

22 bar

16 D

18

19
A
23
20
6 5
76/65 21
3 bar

Ares 806 – 09.2004 – GB


24
9 bar
8
5 bar 22

2,4 bar
7
B 15 > 200 3,5 bar
4
9 10
LS 110 l/min low-pressure circuit on GPA 30

12 2,8 bar 11
3 76/61
13
2
150 µ
1

Fig. 10
LS 110 l/min low-pressure circuit on GPA 30

Rear axle lubrication

8
9

8
9
11
11
10

10

393hsm21 Fig. 11

Ares 806 – 09.2004 – GB B2.15


LS 110 l/min low-pressure circuit on GPA 30

Axle tube lubrication

13
11
12

393hsm22 Fig. 12

B2.16 Ares 806 – 09.2004 – GB


Low-pressure hydraulic components

LS 100 l/min distribution valve


2
1
Geographical situation
8
– The valve is integrated into the left cover of the rear
axle on the transmission side. 4
To remove/refit the left-hand cover, refer to chapter "E". 3
5
Parts list
1 Pump outlet to steering filter.
6
2 Return from the LS signal circuit selector.
3 Return from the steering unit.
4 Supply to the 17 bar elements.
5 Outlet to cooler.
6 Return from high-pressure pumps (recirculation).
7 Lubrication circuit safety valve, 8,5 bar.
8 17 bar pressure switch.
9 Pressure limiter, 17 bar.
10 Valve body.
392hsm12 Fig. 13

10

9 7

392hsm13 Fig. 14

Ares 806 – 09.2004 – GB B2.17


Low-pressure hydraulic components

LS 110 l/min distribution valve


Geographical situation
The 5 bar boost (lubrication) pressure limiter and
the 17 bar control pressure priority valve are built into
2
the right-hand cover of the rear axle. To remove/refit the 1
right-hand cover, refer to chapter "E".
Parts list
1 RH cover . 5
2 Steering, braking and control priority unit.
3 Boost (lubrication) pressure limiter, 5 bar.
4 Low pressure to lubrication circuit.
5 Control pressure priority valve, 17 bar. 6 3 Frenetanch (242)
6 Low pressure to control circuit. 4 2 daN.m
7 High pressure to auxiliary spool valves.
8 Steering and braking priority valve.

391hsm39 Fig. 15

6 7
391hsm40 Fig. 16

B2.18 Ares 806 – 09.2004 – GB


Low-pressure hydraulic components

Revershift and Quadrishift control Accumulator


Make: HYDAC.
General Capacity: 1 l.
The system control assembly consists of the Gas: Nitrogen.
following 3 main parts: Inflation pressure: 9 ± 1 bar.
The distribution unit (4) (hydraulic unit) mounted on the Service pressure: 17 bar.
right-hand side of the transmission. It consists of 2 distinct
Maximum pressure: 30 bar.
parts which control the Revershift and Quadrishift clutch
assembly. N.B.: The accumulator maintains a pressure of 17 bar
The accumulator, mounted on the supply tube connected for a while after switching off the engine. If immediate
to the hydraulic unit, can be used to step up the oil flow to action on the circuit is necessary, proceed with
fill the clutch piston chambers when necessary. As a caution.
result, the pistons react more quickly.

Parts list (Fig. 17, 18 and 19)


1 Low-pressure filter, 60 µ. 10 Revershift reverse gear clutch proportional solenoid valve.
2 Field/road range solenoid valve. 10’ Revershift reverse gear clutch pressure coupling.
3 Accumulator. 11 Quadrishift front brake piston solenoid valve.
4 Distribution unit. 11’ Quadrishift front brake piston pressure coupling.
5 Revershift reverse gear clutch supply. 12 Quadrishift rear brake piston solenoid valve.
6 Revershift forward gear clutch supply. 12’ Quadrishift rear brake piston pressure coupling.
7 Quadrishift rear brake piston supply. 13 Distribution unit supply, 17 bar.
8 Quadrishift front brake piston supply. 13’ Supply pressure coupling, 17 bar.
9 Revershift forward gear clutch proportional solenoid valve.
9’ Revershift forward gear clutch pressure coupling.

Ares 806 – 09.2004 – GB B2.19


Low-pressure hydraulic components

Distribution unit

6
Frenetanch (242)
4,4 ± 0,2 daN.m
5
4
3

8
7
Frenbloc (270)
Formajoint (510)
4
2
1

391hsm41 Fig. 17

B2.20 Ares 806 – 09.2004 – GB


Low-pressure hydraulic components

The solenoid valves screwed into the hydrulic unit are allocated as follows.
– Two proportional solenoid valves (9) and (10) controlling the front and rear clutches of the Revershift assembly.
– Two solenoid valves (11) and (12) for Quadrishift control:
(11 : 4-port, 2-position solenoid valves (controlling the Quadrishift front brake piston);
(12 : 3-port, 2-position solenoid valves (controlling the Quadrishift rear brake piston).
Oil from the solenoid valves is returned directly into the housing via the upper port of the priority unit.

5 7 8

13’ 9 10 11’ 11 6
391hsm42 Fig. 18

9’ 13’

10’

12

8 12’ 13 6
391hsm43 Fig. 19

Ares 806 – 09.2004 – GB B2.21


Low-pressure hydraulic components

Operation
Speed 1 (Fig. 20)
Solenoid valve (11) is powered, thereby enabling the 2
pressurised fluid to reach line (A). This duct directs the oil 1
to the front brake piston and to solenoid valve (12). As this
solenoid valve is in neutral, the oil can flow through the
slide valve to the rear brake piston chamber.
The 2 pistons are therefore under pressure. 5
Speed 2 (Fig. 21) 9 10
The gear change from 1 to 2 is obtained when the 2 12 11
solenoid valves are powered. The fluid flow to the rear 6 3 Frenetanch (242)
piston is therefore interrupted. The rear piston is pushed A4 2 daN.m

back by the springs which return the fluid to line (B). 391hsm44 Fig. 20
This line communicates with the housing via solenoid
valve (11).
Speed 3 (Fig. 22)
The gear change from 2 to 3 is obtained by switching off
electrical power to solenoid valve (11), while maintaining
power to solenoid valve (12). Line (A) is no longer under
pressure but is linked to the casing. The front piston can
therefore return to neutral. Line (B) is under pressure.
Fluid flows to the rear piston via solenoid valve (12).
9 10
Speed 4 (Fig. 23)
Speed 4 is obtained by switching off the electrical supply 12 11
to (12). The 2 brake pistons are linked to the housing via
B
duct (A).
391hsm45 Fig. 21

9 10

12 11
A B
391hsm46 Fig. 22

9 10

12 11
A
391hsm47 Fig. 23

B2.22 Ares 806 – 09.2004 – GB


Low-pressure hydraulic components

Independent lubrication on GBA 10


Hydraulic system

5
3

1 6 7

391hsm48 Fig. 24

Parts list (Fig. 24 and 25)


1 Suction piping with 500 µ strainer located in the rear axle (replacement every 1 000 hours).
2 Lobe pump (30 l/min at 2 200 rpm). The pressure varies from 0,4 to 3 bar depending on the position of the clutch piston.
The pressure can be measured at connector (4).
3 1,5 bar valve. When the piston releases the engaged clutch discs, this shuts off the lubrication line causing the valve to open to divert
the oil while declutching. This causes head losses involving pressures in excess of 1,5 bar and which can reach approximately 3 bar.
4 Lubrication pressure test connector.
5 Revershift front and rear clutch lubrication.
6 Revershift front clutch supply.
7 Revershift rear clutch supply.

Ares 806 – 09.2004 – GB B2.23


Low-pressure hydraulic components

Layout in the GBA 10 housing

5 ± 0,4 daN.m
3 2

5 5

4
6

Frenetanch (242)

391hsm49 Fig. 25

B2.24 Ares 806 – 09.2004 – GB


Solenoid valve measurement and checking points

Electrical tests on the solenoids


– If the pressure is incorrect on a clutch, check the power supply and resistance of the solenoid valve.

Proportional solenoid valve


– With the solenoid valve live, connect clamp-on ammeter n° 60 05 006 707 with multimeter n° 60 05 006 744 (ammeter
function) to the solenoid valve supply cable.
– Put into gear - the current should be 0,8 to 1,2 A.
– With the power off, connect a multimeter (ohmmeter function) between the two solenoid valve terminals.
– The resistance should be 10 ohms.

324hsm33 Fig. 14

Ares 806 – 09.2004 – GB B2.25


Solenoid valve measurement and checking points

On/off solenoid valve


– With the solenoid valve live, connect cable n° 60 05 005 734 to the solenoid valve electrical circuit and multimeter
n° 60 05 006 744 (voltmeter function).
– Put in gear - the voltage should be 12 V.
– With the power off, connect cable n° 60 05 005 734 only to the solenoid valve and to a multimeter (ohmmeter function).
– The resistance should be 10 ohms.
– Using Ohm's Law, the current can be checked with clamp-on ammeter n° 60 05 006 707 and the multimeter (ammeter
function) on the solenoid valve supply cable.
– Put into gear - the current should be 1,2 A.


60 05 005 734

391hsm50 Fig. 15

B2.26 Ares 806 – 09.2004 – GB


GBA 10 distribution unit measurement and checking points

Test conditions.
– Engine at nominal speed.
– Oil temperature at 60°C.

Distribution unit supply pressure check


– Connect tester n° 60 05 705 076 to the distribution unit pressure coupling (13’)).
– The pressure should be 17 bar.

13’

391hsm51 Fig. 16

Revershift supply pressure check


– Connect tester n° 60 05 705 076 to pressure coupling (9’) for the forward gear clutch and (10’) for the reverse gear
clutch.
– Put into forward or reverse gear.
– The pressure should be 17 bar.

10’ 9’

391hsm52 Fig. 17

Ares 806 – 09.2004 – GB B2.27


GBA 10 distribution unit measurement and checking points

Test conditions.
– Engine at nominal speed.
– Oil temperature at 60°C.

Quadrishift supply pressure check


– Connect tester n° 60 05 705 076 to pressure coupling (11’) for the front brake piston and (12’) for the rear brake piston.
– Engage the 4 speeds in turn.
– The pressure should be 17 bar on the corresponding solenoid valve.

12’ 11’

391hsm53 Fig. 18

Front brake piston Rear brake piston


Test conditions
Transmission oil temperature: 60°C
Pressure in Pressure in
Engine running at 2 000 rpm Solenoid valve supply Solenoid valve supply
bar bar

First speed 17 12 17 0
Second speed 17 12 0 12
Third speed 0 0 17 12
Fourth speed 0 0 0 0

B2.28 Ares 806 – 09.2004 – GB


"Hydraulic inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If it is to be sent to CLAAS after-
sales department, it is essential to complete:

Tractor type: ...........................................................................................................................................................................

Serial n°: ................................................................................................................................................................................

Total operating hours: ............................................................................................................................................................

Date of operation: ..................................................................................................................................................................

Distribution unit supply pressure check

Test conditions
Pressure in bar Measured value
Oil temperature at 60°C

Engine running at 2 000 rpm 17

Revershift supply pressure check

Test conditions
Clutch solenoid valve current Solenoid resistance
Transmission oil temperature: 60°C Pressure in bar
(Amps) (Ohm)
Engine running at 2 000 rpm

Forward gear engaged 17 0,8 to 1,2 10


Reverse gear engaged 17 0,8 to 1,2 10

Recorded values

Test conditions
Clutch solenoid valve current Solenoid resistance
Transmission oil temperature: 60°C Pressure in bar
(Amps) (Ohm)
Engine running at 2 000 rpm

Forward gear engaged


Reverse gear engaged

Quadrishift supply pressure check

Recorded values

Front brake piston Rear brake piston


Test conditions
Transmission oil temperature: 60°C
Pressure in Pressure in
Engine running at 2 000 rpm Solenoid valve supply Solenoid valve supply
bar bar

First speed
Second speed
Third speed
Fourth speed

Ares 806 – 09.2004 – GB B2.29


GBA 10 lubrication measurement and checking points

Test conditions.
– Engine at nominal speed.
– Oil temperature at 60°C.

Independent lubrication check


– Connect tester n° 60 05 705 076 to pressure coupling (4) on the right-hand side of the gearbox.
– The pressure should be:
• Forward or reverse gear engaged: 0,7 to 1,2 bar (0,25 to 0,4 bar at 1 000 rpm).
• Forward or reverse gear in neutral: 2 to 3 bar (1,5 to 2 bar at 1 000 rpm).

391hsm54 Fig. 19

B2.30 Ares 806 – 09.2004 – GB


"Hydraulic inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If it is to be sent to CLAAS after-
sales department, it is essential to complete:

Tractor type: ...........................................................................................................................................................................

Serial n°: ................................................................................................................................................................................

Total operating hours: ............................................................................................................................................................

Date of operation: ..................................................................................................................................................................

Independent lubrication check

Engine running at 1 000 rpm Engine running at 2 000 rpm


Test conditions
Oil temperature at 60°C Pressure in bar Measured value Pressure in bar Measured value

Forward or reverse gear engaged 0,25 to 0,4 0,7 to 1,2


Forward or reverse gear in neutral 1,5 to 2 2 to 3

Ares 806 – 09.2004 – GB B2.31


LS 110 l/min measurement and checking points

Test conditions.
– Engine at nominal speed.
– Oil temperature at 60°C.

Lubrication pressure check


– Connect tester n° 60 05 705 076 to pressure coupling (A) on the right-hand cover.
– The pressure should be 6,3 ± 1 bar (5,2 ± 1 bar at 1 000 rpm).

391hsm55 Fig. 20

GBA 10 lubrication pressure check


– Connect tester n° 60 05 705 076 to the cooler return circuit.
– The pressure should be 3,7 bar (3,4 bar at 1 000 rpm).

391hsm56 Fig. 21

B2.32 Ares 806 – 09.2004 – GB


LS 110 l/min measurement and checking points

Test conditions.
– Engine at nominal speed.
– Oil temperature at 60°C.

Checking the control pressure


– Connect tester n° 60 05 705 076 to pressure coupling (B) on the right-hand cover.
– The pressure should be 17 bar.

391hsm57 Fig. 22

Lubricating oil flow rate through the cooler at 60°C


– Connect tester n° 60 05 005 736 to the cooler return circuit.
– The flow should be 15 ± 1 l/min.

391hsm79 Fig. 23

Ares 806 – 09.2004 – GB B2.33


"Hydraulic inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If it is to be sent to CLAAS after-
sales department, it is essential to complete:

Tractor type: ...........................................................................................................................................................................

Serial n°: ................................................................................................................................................................................

Total operating hours: ............................................................................................................................................................

Date of operation: ..................................................................................................................................................................

Lubrication pressure check

Test conditions
Pressure in bar Measured value
Oil temperature at 60°C

Engine running at 1 000 rpm 5,2 ± 1


Engine running at 2 000 rpm 6,3 ± 1

GBA 10 lubrication pressure check

Test conditions
Pressure in bar Measured value
Oil temperature at 60°C
Engine running at 1 000 rpm 3,4
Engine running at 2 000 rpm 3,7

Checking the control pressure

Test conditions
Pressure in bar Measured value
Oil temperature at 60°C

Engine running at 2 000 rpm 17

Lubricating oil flow rate through the cooler at 60°C

Test conditions
Flow in l/min Measured value
Oil temperature at 60°C

Engine running at 2 000 rpm 15 ± 1

B2.34 Ares 806 – 09.2004 – GB


LS 100 l/min measurement and checking points

Test conditions.
– Engine at nominal speed.
– Oil temperature at 60°C.

Checking the flow coming from the steering box


– Connect tester n° 60 05 005 736 upstream of the distribution valve.
– Check the flow rate which should be 56 ± 5 l/min.

392hsm14 Fig. 24

Checking the control pressure


– Connect tester n° 60 05 705 076 onto the transmission hydraulic unit or instead and in place of the flowmeter above.
– The pressure should be 17 bar.

392hsm15 Fig. 25

Ares 806 – 09.2004 – GB B2.35


LS 100 l/min measurement and checking points

Test conditions.
– Engine at nominal speed.
– Oil temperature at 60°C.

Cooler inlet pressure check


– Disconnect the oil cooler feed hose.
– Connect tester n° 60 05 705 076 in a bypass on the hose.
– The pressure should be approximately 7 bar.

392hsm16 Fig. 26

Lubrication pressure check


– Connect tester n° 60 05 705 076 in a bypass on the lubrication circuit (cooler return hose).
– The pressure should be approximately 5,5 ± 1 bar.

392hsm17 Fig. 27

B2.36 Ares 806 – 09.2004 – GB


"Hydraulic inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If it is to be sent to CLAAS after-
sales department, it is essential to complete:

Tractor type: ...........................................................................................................................................................................

Serial n°: ................................................................................................................................................................................

Total operating hours: ............................................................................................................................................................

Date of operation: ..................................................................................................................................................................

Checking the flow coming from the steering box

Test conditions
Flow in l/min Measured value
Oil temperature at 60°C

Engine running at 2 000 rpm 56 ± 5

Checking the control pressure

Test conditions
Pressure in bar Measured value
Oil temperature at 60°C

Engine running at 2 000 rpm 17

Cooler inlet pressure check

Test conditions
Pressure in bar Measured value
Oil temperature at 60°C

Engine running at 2 000 rpm 7

Lubrication pressure check

Test conditions
Pressure in bar Measured value
Oil temperature at 60°C

Engine running at 2 000 rpm 5,5 ± 1

Ares 806 – 09.2004 – GB B2.37


Notes

B2.38 Ares 806 – 09.2004 – GB


B3
GBA 31 FULL POWERSHIFT GEARBOX

Ares 806 – 09.2004 – GB


General

Under no circumstances attempt to


operate directly in the gearbox.
WARNING: Dismantling of the gearbox
without special tooling may result in severe
damage. In the event of a fault requiring the
gearbox to be opened, either replace it with a
standard exchange unit or have the gearbox
repaired by a workshop approved by CLAAS for
gearbox repairs.

GBA 31 Full Powershift gearboxes have a front and rear


housing with 7 shafts and 9 clutches. Six gear clutches
and 3 range clutches. Three clutches must be engaged
hydraulically to transmit engine power. The transmission
systems have their own Gerotor hydraulic pump,
filter, pressure control valve, lubrication controller
and 9 proportional solenoid valves that engage the
clutches. They use an oil reservoir shared by the tractor 324hsm01 Fig. 1
gearbox/rear axle assembly. The gearbox is coupled to
the engine by means of a splined coupling shaft located in
the transmission and a vibration damper in the flywheel.

Characteristics
– 18 forward gears.
– 8 reverse gears.
– Constant mesh, helical gears.
– Ball and roller bearings to prevent any vibration.
– Common oil reservoir for the gearbox / rear axle
assembly.
– Hydraulically-actuated multidisc clutches.
– Electro-hydraulic gear change control.
– 100 % modulated gear changing.
– Adaptation to the displacement speed.
– Direction reversal by a lever under the steering wheel.
– Compact design in a 2-piece housing.
– The housing also acts as the tractor chassis between
the engine and the rear axle assembly.
– Pressure lubrication of all the clutches.
– Autonomous hydraulic pump.
– Vibration damper in the flywheel.
– Electronic protection.

B3.2 Ares 806 – 09.2004 – GB


General

Description of the Transmission System


Parts list (Fig. 2 and 3)
1 Clutch 1 proportional solenoid valve. 4th Shaft 4 location.
1’ Pressure connection : 1 Clutch. 5th Shaft 5 location.
2 Clutch 2 proportional solenoid valve. 6th Shaft 6 location.
2’ Pressure connection : 2 Clutch. 7th Shaft 7 location.
3 Front transmission housing. A, B, C Intermediate clutches and solenoid valves.
4 Rear transmission housing. A’, B’, C’ Clutch A, B, C pressure take-off point.
L, M, H Range clutches and solenoid valves.
1st Shaft 1 location. L’, M’, H’ Clutch L, M, H pressure take-off point.
2nd Shaft 2 location. R Reverse drive input clutch and proportional solenoid valve.
3rd Shaft 3 location. R’ Pressure connection : R Clutch.

Parts list (Fig. 4)


5 Pressure control valve (18 bar). 12 Gerotor pump pressure outlet orifice.
6 Pump pressure switch (9 bar). 13 Pump pressure inlet orifice to the front housing.
7 Engine speed sensor. 14 Pump pressure test orifices - 7/8" plugs.
8 Displacement speed sensor. 15 Oil outlet orifice to the cooler and the lubrication discharge
9 Calibration sensor. valve.
10 Temperature sensor. 16 Oil return orifice from the cooler.
11 Pump inlet orifice from the reservoir. 17 Lubrication pressure test orifices - 9/16" plugs.
18 Return line to the housing orifice.

Ares 806 – 09.2004 – GB B3.3


General

Gearbox arrangement diagram

74 L 40 5th

70
C 71
1 62 4th

42 70
B 71
R 62 3rd

42
A 71
2 48 2nd

32 1st

48
H 72 6th

65
M 40 7th

324hsm02 Fig. 2

B3.4 Ares 806 – 09.2004 – GB


General
Clutch solenoid valves and pressure take-up points

3 M’ H’ L’

Z Y

W
1 R B C A 2

3rd

M 2nd 4th
1st

7th
Y 6th Z

Grolleau le technicien
12345x
Teddy

5th

3 L 4 X 4 H M 3

2 C

A’ 1

2’ B’ R’ 3 R B 1’ C’
324hsm03 Fig. 3

Ares 806 – 09.2004 – GB B3.5


General
Hydraulic circuit orifices and sensors

3 17 14

Z Y

W
10 9 13 7 12 11

3rd

2nd 4th
1st

7th
Y 6th Z

Grolleau le technicien
12345x
Teddy

5th

3 16 15 5 4 X 4 18 8 3

3 6 14 17
324hsm04 Fig. 4

B3.6 Ares 806 – 09.2004 – GB


Notes

Ares 806 – 09.2004 – GB B3.7


General

Operation and Power Transmission


Engine power is transmitted to shaft 1 which drives clutch (1, 2 or R) and leave via another (A, B or C) and,
shafts 2, 3 and 4. Shaft 1 also drives the Gerotor therefore, another shaft. Thanks to this configuration, the
hydraulic pump and acts as the power take-off input shaft. various clutches provide the transmission system
Shafts 2 and 4 act as the forward drive and shaft 3 acts as with 6 forward gear ratios and 3 reverse gear ratios.
the reverse drive. When clutch 1, 2 or R is engaged, it The output of the clutches (A, B or C) directs the power
blocks the clutch housing on the corresponding shaft. towards the selected range clutch (L, M or H), thereby
Each clutch housing is fitted with a pinion which meshes offering 18 forward gear and 8 reverse gear ratios..
with the other gear shafts, enabling power to enter via one

Speed Clutches Ratio Power transmission path

F1* 1-A-L 10,241 A-C-E-F-G-I-H-J-K-L-M-P*


F2 2-A-L 7,929 A-B-I-H-J-K-L-M-P
F3 1-B-L 6,145 A-C-E-F-J-K-L-M-P
F4 1-A-M 5,397 A-C-E-F-I-O-Q-P
F5 2-B-L 4,757 A-B-G-F-J-K-L-M-P
F6 2-A-M 4,179 A-B-I-O-Q-P
F7 1-C-L 3,687 A-C-K-L-M-P
F8 1-B-M 3,238 A-C-E-F-H-I-O-Q-P
F9 2-C-L 2,854 A-B-G-F-E-K-L-M-P
F10 2-B-M 2,507 A-B-G-F-H-I-O-Q-P
F11 1-A-H 2,214 A-C-E-F-G-I-O-N
F12 1-C-M 1,943 A-C-K-J-H-I-O-Q-P
F13 2-A-H 1,714 A-B-I-O-N
F14 2-C-M 1,504 A-B-G-F-E-K-J-H-I-O-Q-P
F15 1-B-H 1,329 A-C-E-F-H-I-O-N
F16 2-B-H 1,029 A-B-G-F-H-I-O-N
F17 1-C-H 0,797 A-C-K-J-H-I-O-N
F18 2-C-H 0,617 A-B-G-F-E-K-J-H-I-O-N
R1 R-A-L 10,241 A-D-F-G-I-H-J-K-L-M-P
R2 R-B-L 6,145 A-D-J-K-L-M-P
R3 R-A-M 5,397 A-D-F-G-I-O-Q-P
R4 R-C-L 3,687 A-D-F-E-K-L-M-P*
R5 R-B-M 3,238 A-D-H-I-O-Q-P
R6 R-A-H 2,214 A-D-F-G-I-O-N
R7* R-C-M 1,934 A-D-F-E-K-J-H-I-O-Q-P*
R8 R-B-H 1,329 A-D-H-I-O-N
* See figures 6 and 7.

B3.8 Ares 806 – 09.2004 – GB


General

Power transmission path

L L M 5th

K
C E
1 C 4th

J H
B F
R D 3rd

I
A G
2 B 2nd

A 1st

N
H P 6th

O
M Q 7th

324hsm05 Fig. 5

Ares 806 – 09.2004 – GB B3.9


General
Power transmission path in gear F1 (1st forward gear)

L L M 5th

K
C E
1 C 4th

J H
B F
R D 3rd

I
A G
2 B 2nd

A 1st

N
H P 6th

O
M Q 7th

324hsm06 Fig. 6

B3.10 Ares 806 – 09.2004 – GB


General
Power transmission path in gear R7 (7th reverse gear)

L L M 5th

K
C E
1 C 4th

J H
B F
R D 3rd

I
A G
2 B 2nd

A 1st

N
H P 6th

O
M Q 7th

324hsm07 Fig. 7

Ares 806 – 09.2004 – GB B3.11


General
Engine/Gearbox Coupling

10 9 8 5 2 4 7

1 3 6
324hsm08 Fig. 8

Parts list
1. Flywheel. 5. Spring. 9. Bearing.
2. Damper. 6. Gearbox input shaft seal. 10. Circlips.
3. Drive hub. 7. First stage shaft.
4. Coupling shaft. 8. Collar screw, M 10 x 150 – 45.

B3.12 Ares 806 – 09.2004 – GB


Repair

Replacing the input shaft seal


6
Replacing the seal only without removing
the gearbox
Separate the tractor between the engine and gearbox as
follows:
– Disconnect the pipes, hoses and wiring harnesses
interfering with the uncoupling operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.
– Beware of the spring (5) and coupling shaft (4) on
disconnecting.
N.B.: Never attempt to separate the tractor between
the front and rear gearbox housings as this will cause
serious damage.
– Remove the input shaft seal (6) from the front of the
324hsm00 Fig. 9
gearbox housing with a suitable extractor.
– Observing the seal diameter, use a drift to fit a new
seal.
– Make sure that the new seal is straight otherwise it will
leak. Lubricate the lip of the seal with miscible grease.
– Reassemble in reverse order, using locating pins to
align the gearbox with the engine more easily.

Removing the gearbox completely


– Refer to Chapter "H" for complete cab removal. Operations 1 to 21.
– Drain the transmission system.
– Remove the reservoir and disconnect the pipes, hoses and wiring harnesses interfering with the uncoupling operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.
– Uncouple between the engine and gearbox.
– Beware of the spring (5) and coupling shaft (4) on disconnecting.
– Make the gearbox safe on a trolley and the rear axle on stands.
– Uncouple the gearbox from the rear axle.
– Reassemble in reverse order to removal, using locating pins and observing the instructions on the following pages.

Ares 806 – 09.2004 – GB B3.13


Repair

Tightening torques
Gearbox/engine link

B A B

C C

D D

G G

D D

A A

E F E

327hsm00 Fig. 10

Ref Screw Quantity Tightening torque in daN.m.


A M 16 x 200-60 4 23 ± 4
B M 16 x 200-70 2 23 ± 4
C M 18 x 250-80 4 28 ± 5
D M 12 x 175-70 4 8,5 ± 1,5
E M 22 x 250-100 4 56 ± 10
F M 22 x 250-120 2 56 ± 10
G Centring studs, 9,5 x 30 2 —

B3.14 Ares 806 – 09.2004 – GB


Repair
Gearbox/rear axle intermediate housing link

28 ± 4 daN.m Formajoint (510)

324hsm10 Fig. 11

Damper hub / engine flywheel link

Frenbloc (270)

8 ± 1 daN.m

Frenbloc (270)

324hsm09 Fig. 12

Ares 806 – 09.2004 – GB B3.15


Notes

B3.16 Ares 806 – 09.2004 – GB


1

B4
FULL POWERSHIFT LOW PRESSURE
HYDRAULIC CIRCUIT

Ares 806 – 09.2004 – GB


General

Operation
Clutch pressure circuit Proportional solenoid valves
GBA 31 Full Powershift transmission systems are Each clutch is monitored by a proportional solenoid valve
equipped with their own "Gerotor" toothed rotor hydraulic which sends a pressure in correlation to the electric signal
pump mounted to the rear of the gearbox. The pump is emitted by the Tracto Control (TC) transmission ECU.
driven at engine speed by the first-stage shaft. When the Each solenoid valve is linked to the free return. When the
engine is running, the pump provides the pressure and TC cuts off the supply to the solenoid valve, the oil
flow rate required to actuate the clutches and lubricate the contained in the engaged clutch returns to the reservoir.
transmission. The oil is drawn in through a strainer in the
intermediate housing. The pump delivers the oil through Lubrication system
the gearbox filter and feeds the clutch solenoid valves and After feeding the clutches, the oil delivered by the pump is
the pressure control valve as a priority. Once sufficient conveyed through the cooler or it is diverted by the
flow rate and pressure is obtained to feed the clutches, the thermostatic valve and used to lubricate the clutches.
pressure control valve opens and maintains the working Chilled lube oil is therefore supplied to the gearbox to
pressure of the clutches. The remaining flow is channelled lubricate the shafts, clutches and bearings. All oil supplied
towards lubrication via the thermostatic valve. 3 solenoids to the bearings is metered by gauged orifices.
are then activated simultaneously to engage 3 clutches
and transmit engine power to the transmission system.

Characteristics
Hydraulic characteristics at 2 200 rpm and 60°C
– Clutch pressure control valve ........................................................................................................................ 17,2 – 19 bar
– Lubricating pressure control valve .................................................................................................................. 6,2 – 9,3 bar
– Filter bypass valve - Differential pressure....................................................................................................... 3,1 – 3,7 bar
– Cooler thermostatic valve opens at ............................................................................................................................. 71°C
– Cooler thermostatic valve is fully open at .................................................................................................................... 85°C
– Gerotor pump flow rate ........................................................................................................................................ 94,5 l/min
– Gearbox oil filter................................................................................................................................................. 15 microns
– Oil capacity of transmission system GTA 3130 .................................................................................................... 155 litres

B4.2 Ares 806 – 09.2004 – GB


Description

Transmission hydraulic circuit

4 3

3,4 bar
250 µ 2

15 > 200 µ

18 bar 7
6 bar
11

8
2,4 bar ˚C

10
9 bar
6

9 1
324hsm11 Fig. 1

Key to figures 1, 2 and 3


1. Tank. 6. Control pressure switch.
2. Suction strainer (250 µ) (replace every 1 000 hours). 7. Gearbox control circuit pressure relief valve (18 bar).
3. "Gerotor" pump. 8. Thermostatic valve (located under the RH step).
4. Filter (15 µ) with 3, 4 bar bypass valve (replace every 9. Oil cooler.
500 hours). 10. Control pressure test orifice.
5. Gearbox proportional solenoid valves. 11. Lubrication circuit discharge valve.

Key to figures 2 and 3


A. Inlet orifice and tube. D. Rear transmission housing.
B. Front transmission housing. E. Control circuit orifice and tube.
C. Intermediate housing. F. Lubrication circuit orifice and tube.

Ares 806 – 09.2004 – GB B4.3


Description

Transmission circuit layout


Right side

3
B

1 2

324hsm12 Fig. 2

B4.4 Ares 806 – 09.2004 – GB


Description
Left side

10 B D C

11 7 F E 4

324hsm13 Fig. 3

Ares 806 – 09.2004 – GB B4.5


Description

Oil filter
Oil penetrates the head of the filter from the Gerotor
pump. It flows into the filter from the outside to the inside
of the element. Filtered oil from the centre of the element
emerges from the head of the filter to feed the
transmission. If the filter is blocked, a bypass valve opens
and diverts the unfiltered oil to the lubrication circuit. The
bypass valve is based on a pressure differential between
the filtered and unfiltered oil. The pressure differential is
monitored by the bypass valve spring set to between 3,1
and 3,7 bar.

Thermostatic valve
When the transmission oil temperature drops below 71°C,
the thermostatic valve closes to prevent the oil from
flowing to the cooler. When the oil temperature 324hsm14 Fig. 4
reaches 85°C, the thermostatic valve opens fully to
allow the oil to flow to the cooler. The thermostatic valve A
is located under the RH step.
(A) Thermostatic valve closed.
(B) Thermostatic valve open.

324hsm15 Fig. 5

324hsm34 Fig. 6

B4.6 Ares 806 – 09.2004 – GB


Description

Parts list (Fig. 7)


7. Gearbox pressure control valve.
11. Return orifice to the reservoir. 14 15 18 14
12. Oil pressure return - Outlet to lubrication.
13. Pump pressure inlet.
14. Plug.
15. O-ring.
16. Shims.
17. Washer.
18. Regulating slide valve.

Parts list (Fig. 8) 15 7 16 11 12 17 13 15


5. Proportional solenoid valve.
19. Solenoid: Resistance 100 ohm (supply voltage 6,6 V).
20. O-ring.
21. Clutch oil return orifice.
22. Control pressure outlet to clutch.
23. Control pressure inlet.

324hsm16 Fig. 7

0,23± 0,05 daN.m

19

20

21
20

22
20

23

324hsm17 Fig. 8

Ares 806 – 09.2004 – GB B4.7


Repair

IN
D OUT
C

327hsm01 Fig. 9 324hsm18 Fig. 10

Pump ("Gerotor" type)


Removing the pump without dismantling the
gearbox
Separate the tractor between the rear transmission
24
housing (D) and the intermediate housing (C) as follows:
– Refer to Chapter "H" for partial cab removal.
Operations 1 to 7;
– Drain the transmission system;
– Remove the reservoir and disconnect the pipes, hoses
and wiring harnesses interfering with the uncoupling
operation by around 500 mm;
– Make the tractor safe with stands and trolleys;
– Chock the tilt between the front axle and the cradle;
– Uncouple leaving the top shaft and its sleeve on the
intermediate housing (C); 324hsm22 Fig. 11

– Remove the pump (3);


The pump inlet and outlet orifices are on the rear
transmission housing and are sealed by O-rings. The 27
suction (RH side) and delivery (LH side) lines are cast into
the housing. 28
– Remove the screws (24) holding the pump body (25)
and cover (26) to release the rotor (27) and stator (28).

25 26
324hsm19 Fig. 12

B4.8 Ares 806 – 09.2004 – GB


Repair
Measuring wear on pump parts
Maintain the position of the parts in relation to each other A
to avoid obtaining a new wear zone due to shifting.
A - Maximum acceptable wear between the outer
circumference of the stator (28) and the body (25): 28 25
0,51 mm.
B - Maximum acceptable wear between the tip of the
rotor (27) and the inside of the stator (28): 0,18 mm.
C - Lateral clearance of the 2 components in relation to
the body: 0,1 mm. B
Examine the flatness of the surface of the body and cover.
If pump wear is higher than the above values, replace it
completely.
28 27
Reassembling the pump
– Reassemble the pump cover and body with the
screws (24) (unless a new pump is fitted).
Fig. 13
– Lubricate the pump with transmission oil. 324hsm20

– Clean the pump mating surface on the rear


transmission housing. C
– Mount 2 studs on the housing (to guide the pump and
aid assembly), (see Fig. 16).
– Smear the 2 O-rings with grease and position them on
the pump cover.
– Mount the pump, aligning the rotor splines with the
ones in the top shaft.

324hsm21 Fig. 14

2,4 daN.m

324hsm23 Fig. 15

Ares 806 – 09.2004 – GB B4.9


Repair
– Tighten the 6 assembly screws (Fig. 16).
– Clean the mating surfaces of the rear transmission
housing and the intermediate housing and apply
Formajoint (510).
– Recouple and refit in reverse order to removal.
– Fill the transmission system with oil and check the
level.

Pressure control valve


The pressure control valve is a repairable cartridge and 2,4 daN.m
must be inspected for any signs of deposits, scratches
and friction points. The control pressure can be adjusted
by adding or removing shims (16).
Important: Replace the O-rings on the cartridge
whenever it is removed from the transmission.
324hsm24 Fig. 16

Proportional solenoid valve


The hydraulic slide valves of the proportional solenoid
valves cannot be repaired, apart from the O-rings and the
solenoid (19). The solenoid is attached to the slide valve 16
by an aluminium nut (29) which must be tightened
to 0,23 ± 0,05 daN.m.

324hsm25 Fig. 17

29 19

324hsm26 Fig. 18

B4.10 Ares 806 – 09.2004 – GB


Repair

Discharge valve
The lubrication discharge valve (11) is located at the
bottom of the threaded orifice designed for the
thermostatic valve. It can be replaced by tapping the
inside of the valve and removing with a slide hammer
puller.
11

324hsm27 Fig. 19

Ares 806 – 09.2004 – GB B4.11


Measurement and checking points

Test conditions:
– Engine at nominal speed.
– Oil temperature at 80°C.

Checking the control pressure


Pressure control valve operation
– Fit pressure coupling n° 60 05 005 909 in place of the plug (14) and connect tester n° 60 05 705 076.
– The pressure must be 18 ± 1 bar (and at 1 000 tr/min).

14

14

324hsm29 Fig. 20

B4.12 Ares 806 – 09.2004 – GB


Measurement and checking points

Test conditions:
– Engine at nominal speed.
– Oil temperature at 80°C.

Lubrication pressure check


Discharge valve operation
– Fit pressure coupling n° 60 05 005 911 in place of the plug (17), connect quick-release coupling n° 60 05 005 731, the
adapter (¼ – 18 NPTF – BSPP ¼), hose n° 60 05 005 703 and 0 to 2 bar tester n° 60 05 005 521.
– The pressure must be 1,8 ± 0,2 bar (at 1 000 rpm, it must be 0,6 ± 0,2 bar).

17
60 05 005 911

60 05 005731

¼ – 18 NPTF

BSPP ¼

60 05 005 521

60 05 005 703

17

324hsm30 Fig. 21

Ares 806 – 09.2004 – GB B4.13


Measurement and checking points

Test conditions:
– Engine at nominal speed.
– Oil temperature at 80°C.
– Tractor in motion.

Checking the clutch feed pressures


– Check the corresponding clutch pressures according to the selected gear in the table.

Clutches Clutches Clutches


Gears selected Gears selected Gears selected
engaged engaged engaged

F1 1–A–L F10 2–B–M R1 R–A–L

F2 2–A–L F11 1–A–H R2 R–B–L

F3 1–B–L F12 1–C–M R3 R–A–M

F4 1–A–M F13 2–A–H R4 R–C–L

F5 2–B–L F14 2–C–M R5 R–B–M

F6 2–A–M F15 1–B–H R6 R–A–H


F7 1–C–L F16 2–B–H R7 R–C–M
F8 1–B–M F17 1–C–H R8 R–B–H
F9 2–C–L F18 2–C–H

– Fit 3 pressure couplings n° 60 05 005 910 at the points concerned and connect tester n° 60 05 705 076.
– Put into gear and drive the tractor (beware: reading in the cab).
– The pressure on the 3 clutches concerned must be 18 ± 1 bar and remain constant when the clutches are fully engaged.

X
W
M’ H’ L’

A C

2 1

A’ 2’ B’ R’ R B 1’ C’

324hsm32 Fig. 22

B4.14 Ares 806 – 09.2004 – GB


Measurement and checking points

Electrical check on the solenoids


If the pressure is incorrect on a clutch, check the power – Put into gear - the current should be 0,66 A*.
supply and resistance of the solenoid valve: – With the power off, connect a multimeter (ohmmeter
– With the solenoid valve live, connect clamp-on function) between the 2 solenoid valve terminals.
ammeter n° 60 05 006 707 with multimeter – The resistance should be 10 ohms.
n° 60 05 006 744 (ammeter function) to the solenoid – If the solenoid power and resistance values are correct,
valve supply cable. replace the solenoid valve (mechanical failure).

324hsm33 Fig. 23

* Important: Even in neutral, the solenoid valve receives a current of 0,10 A.

Ares 806 – 09.2004 – GB B4.15


"Inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:

Tractor type.............................................................................................................................................................................
The serial number...................................................................................................................................................................
Total operating hours..............................................................................................................................................................
Date of operation ....................................................................................................................................................................
The gearbox model.................................................................................................................................................................
The gearbox serial n°..............................................................................................................................................................

Description of the incident (error codes)


................................................................................................................................................................................................
................................................................................................................................................................................................
................................................................................................................................................................................................

Checking the control pressure

Test conditions
Pressure in bar Measured value
Oil temperature at 80°C

Engine running 2 200 and 1 000 rpm 18 ± 1

Lubrication pressure check

Test conditions
Pressure in bar Measured value
Oil temperature at 80°C

Engine running 2 200 rpm 1,8 ± 0,2


Engine running 1 000 rpm 0,6 ± 0,2

Checking the clutch feed pressures

Clutch solenoid valve current


Gear selected Clutch used Clutch pressure (bar) Solenoid resistance (Ohm)
(Amps)

1 17 0,66 10
Example: 1st forward A 17 0,66 10
L 17 0,66 10

B4.16 Ares 806 – 09.2004 – GB


TOOLS

Low-pressure hydraulics and gearbox tools

Ares 806 – 09.2004 – GB


Low-pressure hydraulics and gearbox tools

60 05 005 511 60 05 005 521

Shimming tool Pressure gauge kit (0 to 20 bar)

60 05 005 736 60 05 005 703

Hydraulics test set Pressure hose

60 05 005 731 60 05 005 734

Quick-release coupling Solenoid valve test harness

B4.18 Ares 806 – 09.2004 – GB


Low-pressure hydraulics and gearbox tools

60 05 006 142 60 05 006 143

Pin socket Field/road selector setting gauge

60 05 006 146 60 05 006 147

Measuring sleeve Measuring bush

60 05 006 707 60 05 006 744

Ammeter pliers Multimeter

B4.20 Ares 806 – 09.2004 – GB


Low-pressure hydraulics and gearbox tools

60 05 705 076

MANO ∆ pressure check kit

Ares 806 – 09.2004 – GB B4.21


Notes

B4.22 Ares 806 – 09.2004 – GB


C1 – GPA 40 REAR AXLE

Ares 806 – 09.2004 – GB


Notes

C1.2 Ares 806 – 09.2004 – GB


Tightening torques and principal adjustments

Gearbox/rear axle coupling

Formajoint (510)

28 ± 1 daN.m
Frenetanch (242)
25 ± 1 daN.m
Frenetanch (242)

341hsm71 Fig. 1

Ares 806 – 09.2004 – GB C1.3


Tightening torques and principal adjustments

Rear axle/PTO housing coupling

Formajoint (510)

28 ± 4 daN.m
Frenetanch (242)

341hsm72 Fig. 2

C1.4 Ares 806 – 09.2004 – GB


Tightening torques and principal adjustments

General cross-section
± 0,2 ±1 ±4 ± 0,05 ±4
12 ± 1 daN.m 2,6 daN.m ± 0,03 12 daN.m 20 daN.m 0,05 mm 28 daN.m
0,11 mm Formajoint (510)
Frenbloc (270) Frenetanch (242) Frenbloc (270) Frenetanch (242)

±1
13 daN.m
Frenbloc (270)

± 0,2
3,2 daN.m
Frenetanch (242)

23 ± 2 daN.m
Frenbloc (270)

± 0,05
0,05 mm
Formajoint (510)

13 ± 1 daN.m
Frenetanch (242)

± 0,05
0,05 mm
± 0,2
± 0,05 ±1 ± 0,05 2,6 daN.m ± 0,05
0,05 mm 8 daN.m 1,25 mm Formajoint (510) 0,10 mm
Frenbloc (270)

341hsm74 Fig. 3

Ares 806 – 09.2004 – GB C1.5


Tightening torques and principal adjustments

5" differential ND axle tubes


± 1,5
0,10
± 0,05
mm
11,5 daN.m 0,35 ± 0,10 mm 11,5 ± 1,5 daN.m
Frenbloc (270)

26 ± 4 daN.m 45 ± 5 daN.m
0,07 ± 0,05 mm
Frenetanch (242) Frenbloc (270)

341hsm76 Fig. 5

HD and HD+ axle tubes


±7
± 0,05 85 daN.m
Scelbloc (648) 0,07 mm
Frenbloc (270)

±4
26 daN.m
Frenetanch (242)

341hsm77 Fig. 6

HDE axle tubes


±7
± 0,05 85 daN.m
Scelbloc (648) 0,07 mm
Frenbloc (270)

11,5 ± 1,5 daN.m ±4


26 daN.m
Scelbloc (648)
Frenbloc (270) Frenetanch (242)

341hsm75 Fig. 4 341hsm78 Fig. 7

C1.6 Ares 806 – 09.2004 – GB


GPA 40 drive pinion

General
The helical drive pinion is supported by 2 tapered supporting the four-wheel drive driving gear is located in
bearings mounted opposite each other. The bearing the rear axle housing. Its position is adjusted by means of
cone (2) is press-fitted onto the drive pinion and the cup one or more shims (4) located between the handbrake
(12) is also press-fitted into the cover (7). The cup (3) is casing and the housing. The bearings are preloaded by
mounted freely in the handbrake casing. The bearing means of one or more shims (11) fitted between the
cone (13), free on the drive pinion, enables the shims (11) bearing cone (13) and the thrust washer (10).
to be fitted for packing purposes. The drive pinion

Parts list
1 Drive pinion. 6 Screw. 11 Shims.
2 Bearing cone. 7 Handbrake cover. 12 Bearing cup.
3 Bearing cup. 8 Centring pin. 13 Bearing cone.
4 Shims. 9 Screw. 14 Nut.
5 Handbrake casing. 10 Thrust washer.

Exploded view

2
3
4
5
7
10
11
12
13
14

6
8
9

341hsm26 Fig. 8

Ares 806 – 09.2004 – GB C1.7


GPA 40 drive pinion

Removal/refitting
Uncouple the tractor between the gearbox and rear axle
as follows:
– Refer to Chapter "H" for partial cab removal. 15 18
Operations 1 to 7.
– Drain the transmission system.
– Remove the reservoir(s) and disconnect the pipes,
hoses and wiring harnesses interfering with the
uncoupling operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.
– Release the transmission lock.
– Remove the RH and LH hydraulic covers.
– Remove the PTO clutch (15) (see paragraph
concerned).
– Remove the four-wheel drive shaft and clutch (16) (see
chapter "D").
– Remove the crawler speed system if fitted (see
chapter "B").
17
– Remove the retaining ring (17), washer and shims.
– Remove the driving gear (18) from the 4WD casing.
– Remove the pivot screw (19) from the handbrake
compensator.
– Free and secure the nut (14) with spanner
n° 60 05 006 310. Fit special socket n° 60 05 006 311
at the end of the drive pinion (Fig. 10) and turn
clockwise.
– Only release the nut.
– Remove the eight screws (9) and two screws (6).

16

341hsm27 Fig. 9

19

60 05 14
006 3
10
6

9
60 05 006 311

341hsm28 Fig. 10

C1.8 Ares 806 – 09.2004 – GB


GPA 40 drive pinion

– Extract the handbrake casing using an extension and


socket n° 60 05 006 311.
– Recover the protrusion distance adjustment shims (4).
– Position the casing vertically on the drive pinion.
60 05 006 311
– Finish unscrewing the nut (14) and discard it.
– Remove the bearing cone (13), shims (11) and thrust
washer (10).
– Remove the cover (7) and handbrake device (see
paragraph concerned).
– Separate the drive pinion from the handbrake casing.
– Extract the cone (2) and cup (3) if necessary.
N.B.: If the drive pinion, tapered bearings, casing,
cover, thrust washer or rear axle housing need to be
replaced, it is essential to adjust the drive pinion
protrusion distance and then shim the tapered
bearings.
– Clean and inspect all parts, replace all faulty parts. If 341hsm29 Fig. 11
removed, fit the bearing cone (2) fully onto the drive
pinion using an appropriate jig and a press and bring
the cup (3) into contact inside the casing (5). 14
– Refit the assembly in reverse order to removal.
– The shims (11) must be fitted between the thrust 13
washer (10) and the bearing cone.
– Lubricate the bearing cones. 11
– Screw on the new nut (14); it will be tightened up once
the casing has been refitted inside the rear axle
housing.
– Fit the measured shims (4) between the casing and the 10
7
housing. 3
5
2
4

341hsm30 Fig. 12

Ares 806 – 09.2004 – GB C1.9


GPA 40 drive pinion

– Refit the casing in the housing in reverse order to


removal. 20
– Fit the handbrake compensator (20) at the same time.
– Coat the screws with Frenetanch (242).
60 05 006 311
– Tighten the screws progressively to fit the casing
correctly.
– Finish tightening to 12 ± 1 daN.m. .
– Adjust the braking device (see paragraph concerned).
– Remove and coat the nut (14) lightly with
Frenbloc (270), and hold it with spanner
n° 60 05 006 310.
– Turn the drive pinion anticlockwise with tool
n° 60 05 006 311 to tighten to 23 ± 2 daN.m.
– Lock the nut in the 3 grooves.
– Fit the driving gear (18) of the 4 drive wheels.
– Position the shims between the thrust washer and the
gear to obtain 0,05 ± 0,05 mm play.
– Refit the equipment in reverse order to removal and 341hsm31 Fig. 13

couple up the tractor.

14

0
006 31
6 0 05

006 3
11
0 05

341hsm32 Fig. 14

18

± 0,05
0,05 mm

341hsm33 Fig. 15

C1.10 Ares 806 – 09.2004 – GB


GPA 40 drive pinion

Setting and adjusting the protrusion


distance of the drive pinion
N.B.: Shim thicknesses "E1" and "E2" must be 14
produced with no more than 3 shims. The drive pinion
and the ring gear are paired by a number and a letter
engraved on each component.

Setting the drive pinion bearings


The brake casing must be free of the braking device.
– Assemble the cover with two screws (9). Setting will be
carried out on the press.
– Fit the prelubricated tapered bearings with an 9
appropriate jig.
– Make a set-up with the thrust washer and a greater
thickness of shims.
– Tighten a new nut (14) provisionally to 23 ± 2 daN.m.
341hsm34 Fig. 16

Measuring "X"
On a press equipped with a pressure gauge.
– Position the casing vertically with the pinion bearing on
the base (Fig. 17).
– Exert 200 daN axial pressure on the cover with an
appropriate jig.
– Rotate the casing a few times to seat the bearings.
– Measure the value "X".
X
Measuring "Y"
On a press equipped with a pressure gauge. X
– Position the casing vertically on the base (Fig. 18).
– Exert 200 daN axial pressure at the end of the drive
pinion shaft.
– Rotate the casing a few times to seat the bearings.
– Measure the value "Y".

341hsm35 Fig. 17

341hsm36 Fig. 18

Ares 806 – 09.2004 – GB C1.11


GPA 40 drive pinion

Calculating J1
"J1" corresponds to the measured play.
11
J1 = X – Y

Thickness "E1" of shims (11)


Determine thickness "E1" corresponding to the higher
number of shims minus "J1" minus a preload "P1"
of 0,11 ± 0,03 mm.
E1 = J1 + P1
The maximum number of shims will be 3.

For example, if X = 9,60, Y = 8,20 and the higher shim


thickness is 4
J1 = 9,60 – 8,20 = 1,40 mm

"E1" (minimum) = 4 – 1,40 – 0,14 = 2,46


14 13
"E1" (maximum) = 4 – 1,40 – 0,08 = 2,52
341hsm37 Fig. 19
According to the example, shims with a thickness of
between 2,46 and 2,52 mm should be inserted.
– Remove the nut (14) and bearing cone (13) and insert
the measured thickness of shims "E1".
– Refit the cone and tighten the nut to 23 ± 2 daN.m.
N.B.: The drag torque must now be checked.
– Place the casing in a vice. Use a torque wrench and
socket n° 60 05 006 311.
– Complete a few regular turns to measure the drag
torque. This value should be between 0,15
and 0,4 daN.m.
– Adjust the setting by removing or adding shims in an 60 0
5 00
effort to get as close as possible to the 0,4 daN.m 6 31
1
tolerance.

341hsm38 Fig. 20

C1.12 Ares 806 – 09.2004 – GB


GPA 40 drive pinion

Setting the drive pinion protrusion distance


Measuring "A"
Measure "A" with a depth gauge (Fig. 21). Distance A
between the end of the drive pinion and the bearing
surface of the casing.

Thickness "E2" of shims (4)


Determine "E2" according to "A" and – 100,23 mm.
Given that – 100,23 mm corresponds to the result of the
nominal housing and differential torque dimensions.
E2 = – 100,23 + A

For example, if A = 100,85


E2 = – 100,23 + 100,85 = 0,62
According to the example, shims with a thickness
of 0,60 mm must be inserted.
– Proceed with refitting the braking device. 341hsm39 Fig. 21

– Refit the handbrake casing and drive pinion assembly


according to the procedure described on the previous
pages.

Ares 806 – 09.2004 – GB C1.13


5" differential

General
The ring gear is riveted to the differential case. The The piston chamber housed in the cover (19)
differential assembly rotates on 2 tapered bearings held communicates with a duct in the bearing (36), enabling
by 2 side supports (2) and (36) screwed onto the housing. low pressure (17 bar) to act on the piston. The duct is
The differential assembly consists of 2 half-cases sealed by 2 piston rings (34).
containing 4 planet gears and 2 sun gears. The differential
assembly is preloaded by means of shims (32) placed Clutched position
between the cone (31) and the left-hand bearing (36). When the differential locking solenoid valve is activated,
The backlash between the drive pinion and the ring gear oil flows into the piston chamber. The piston compresses
is obtained by means of shims (7) inserted between the the intermediate plates (24) and the discs (23) connected
cup (6) and the differential half-case (10). to the hub (25) and case (21) respectively. In this clutched
position, the input sun gear of the RH and LH axle tubes
Differential lock rotate at the same speed.
The multidisc locking device located on the left-hand side
of the half-case (19) comprises. Declutched position
– A unit (21) containing the discs (23) and the When power is turned off, the piston withdraws and the
backplates (24). discs and intermediate plates are decompressed,
– A hub (25) connected by splines to the sun gear of the enabling the sun gears and planets gears to fulfil their
LH axle tube. differential function.
– An assembled cover (29) for the piston (27) supported
by a tapered bearing.

Parts list
1 Screw. 15 Friction washer. 29 Differential locking cover.
2 RH bearing. 16 Planet gear. 30 Bearing cup.
3 O-ring. 17 Spider shaft. 31 Bearing cone.
4 Centring pin. 18 Friction ring. 32 Shims.
5 Bearing cone. 19 Differential half-case. 33 O-ring.
6 Bearing cup. 20 Screw. 34 Sealing piston ring.
7 Shims. 21 Differential locking case. 35 Centring pin.
8 Deflector. 22 Screw. 36 LH bearing.
9 Rivets. 23 Differential locking disc. 37 Screw.
10 Differential half-case. 24 Differential locking backplate. 38 O-ring.
11 Friction ring. 25 Differential locking hub. 39 Supply tube.
12 Ring gear. 26 O-ring. 40 Seal.
13 Drive pinion. 27 Piston. 41 Coupling.
14 Sun gear. 28 O-ring.

C1.14 Ares 806 – 09.2004 – GB


5" differential

Exploded view

17
15
14
12
10
8
6 19
18
5 14
3
16
2
13

11
9
7 25
4
1

24

23

22
21 41

20 38
36 40
33
32 39
31
30
29
28
27 37
26
35

34

342hsm28 Fig. 22

Ares 806 – 09.2004 – GB C1.15


5" differential

42

39

41

342hsm29 Fig. 23 342hsm30 Fig. 24

Removing/refitting the bearings


29 32
LH bearing
N.B.: The bearing (36) and sealing rings (34) of the 37
differential lock can be worked on by removing just
the left-hand axle tube. 36
– Remove the left-hand axle tube (see paragraph
concerned).
– Unscrew the coupling (41) and remove the transfer 31
tube (39).
– Remove the brake piston (see chapter "C3").
– Remove the forward motion sensor (42) from the
housing.
– Remove the screws (37) from the bearing (36), fit 2
diametrically opposed locating studs "A" into the
housing and tighten them firmly up against the 34
differential locking cover (29) (Fig. 26). 342hsm31 Fig. 25
– Extract the bearing with the aid of the tapped holes and
two screws (B) and recover the cone (31) and
shims (32) (Fig. 26).
N.B.: The locating studs (A) hold and centre the
differential assembly in the housing. Do not loosen
the studs or the assembly may become skewed and
section the sealing rings (34) on refitting the bearing.

29 B

36 A

342hsm32 Fig. 26

C1.16 Ares 806 – 09.2004 – GB


5" differential

33 38 35 31

37

34 32
342hsm33 Fig. 27

N.B.: If the bearing block or roller bearing has to be


replaced, always adjust the differential roller bearings
(see following pages). 35
– Check that the centring pin (35), shims (32) and
bearing cone (31) are present.
– Check that the sealing rings (34) are not damaged and
rotate normally in their groove. After checking, remove
the rings and coat them with miscible grease so that
they remain seated in the groove while the support is
refitted.
– Fit new O-rings (33) and (38).
– Slide the bearing (36) onto the locating studs (A) and
tighten 4 screws (37) evenly and alternately
to 11,5 ± 1,5 daN.m (Fig. 28 and 29).
A
– Remove the locating studs. Fit and tighten the other
screws to the same torque.
– Position the supply tube and coupling.
– Refit the brake piston (see chapter "C3"). 342hsm34 Fig. 28

– Check that the seal (33) is correctly positioned.


– Refit the left-hand axle tube (see paragraph
concerned).

RH bearing
The removal/refitting procedure for the right-hand bearing
is similar to the one for the left-hand bearing. Except that
the RH bearing is not equipped with hydraulic ducts and
seals (34).
A

36

37

342hsm35 Fig. 29

Ares 806 – 09.2004 – GB C1.17


5" differential

Removing/refitting the differential


case
– Drain the transmission system.
– Disconnect the PTO control cables and pipes.
– Remove the linkage and lift accessories obstructing the
uncoupling of the PTO housing.
– Remove the PTO speed sensor from the rear axle to
avoid damaging it.
– Remove the PTO housing with a chain and hoist.
– Remove the countershaft connected to the clutch.
– Remove the axle tubes (see paragraph concerned).
– Position rear differential stand n° 60 05 006 319 in
support. (This stand requires base n° 60 05 006 314).
With the aid of the stand, keep the differential assembly 32 5
in line with the RH and LH bearings ((2) and (36)
respectively). 2
– Remove the RH and LH bearings according to the
procedure described above.
– Recover the cones (31) and (5) and shims (32) from 31 7
the LH bearing.
36 6
– Remove the differential case from the rear axle
housing (Fig. 31).
N.B.: As space is restricted around the differential
case, it is essential to fit the hydraulic tubes in the
rear axle housing before refitting the case.
In order to avoid damaging the sealing rings (34), it is
necessary to align the differential assembly correctly with
the housing axis before fitting the bearings (2) and (36).
With the aid of the tool, insert the differential assembly into
the central housing and hold it in line with the axle tubes.
– Fit the measured thickness of shims (7) behind the
cup (6).
– Fit the bearing (2) according to the procedure
described above. 342hsm36 Fig. 30

60 05 006 319
342hsm0r Fig. 31

C1.18 Ares 806 – 09.2004 – GB


5" differential

Prepare to fit the bearing (36) as follows:


– Slide the bearing cone onto setting tool
n° 60 05 006 309 adapted to the differential case.
Using the tool, centre the differential assembly in the
housing while turning the central screw clockwise as
far as it will go.
– Fit 2 diametrically opposed locating studs (A) into the
housing and tighten them firmly. This method keeps
the differential assembly centred after removing tool
n° 60 05 006 309.
– Remove the tool and recover the bearing cone.
– Check the presence of the centring pin (35) and shims.
– Fit a new O-ring (33).
– Check that the sealing rings (34) are not damaged and
rotate normally in their groove.
– Fit the bearing (36) according to the procedure 60 05 006 309
described above. After fitting the bearings, check the
rotation of the differential assembly by hand. 342hsm38 Fig. 32
– Refit the brake pistons (see chapter "C3").
– Refit the axle tubes (see paragraph concerned). If 34
removed, refit the PTO housing.
– Couple up the tractor between the intermediate
housing and the rear axle housing.
– Check the operation of all controls (mechanical,
hydraulic and electronic). Road test. 35 36
– Check the mating surfaces and hydraulic couplings for
leaks.

33
342hsm39 Fig. 33

Ares 806 – 09.2004 – GB C1.19


5" differential

Removing/refitting the differential


lock 27

– Remove the differential case as described in the


29
procedure above.
30
– Position the differential case with the cover (29) facing 25
up.
– Remove the screws (20). 23
– Remove the cover (29), discs (23), backplates (24) and
24
hub (25).
– Remove the screws (22) and case (21). 21
– Tap the cover (29) lightly on a wooden block to remove
the piston (27). 22
– Replace the O-rings. Drive out the cup (30) if
necessary.
N.B.: If the case (21), cover (29) and bearing (36) need 20
to be replaced, the differential case must be shimmed 342hsm40 Fig. 34
and the backlash between the drive pinion and the
ring gear checked (see following pages).
– Check that the hydraulic duct in the cover is not
blocked.
– Lubricate the new seals before fitting.
– Refit the piston (27) by tapping gradually and
alternately around the edge with a mallet.
– Check that there are no seal fragments after fitting.
– Coat the screws (22) lightly with Frenbloc (270) and
tighten to 11,5 ± 1,5 daN.m. .
– Fit the hub, backplates and discs.
– Position the assembled cover (29) of the piston (27).
– Fit and tighten the screws (20) coated with
Frenbloc (270) to 11 ± 1 daN.m.
– Check manually that the discs and backplates are not
stressed.
– Refit the differential case as described in the procedure
above.

C1.20 Ares 806 – 09.2004 – GB


5" differential

Removing/refitting the planet gears,


sun gears and ring gear 19 16 12

– Remove the differential locking system.


– Separate the half-cases (10) and (19).
N.B.: These parts have the same number. They must 9
imperatively be coupled.
22 10
– Remove the sun gears (14) fitted with friction rings (11)
and (18), planet gears (16), washers and spider (17). 18 11
If necessary, drive out the bearing cup on half-
casing (10) and recover the shims.
– Extract and discard the deflector. The drive pinion must
17
be replaced if the ring gear is replaced.
N.B.: These parts have the same number. They must
imperatively be coupled.
14
The ring gear and case are originally riveted together. For 342hsm41 Fig. 35
repair, the rivets are replaced by screws and nuts
referenced in the spare parts catalogue.
– Punch (on the ring gear teeth side) the centre of each
rivet (9). Using a 5 mm dia. bit, drill the rivets to a depth
of 12 mm (Fig. 36). 10
– Drill again to an identical depth with a 12 mm bit. 12
– Drive the rivets hard with a suitable drift punch
(Fig. 37).
– Clean the bearing surfaces of the new ring gear (12)
and half-case (10), as well as the screws and nuts.
– Coat the initial threads of the screws with
Frenbloc (270) and position them in the ring gear and
case.
– Tighten the nuts to 18 ± 2 daN.m.
– Refit the deflector, shims and cup.
– Refit the planet gears and sun gears in reverse order to
removal.
– Tighten the screws (22) coated with Frenbloc (270)
342hsm42 Fig. 36
to 11,5 ± 1,5 daN.m.

342hsm43 Fig. 37

Ares 806 – 09.2004 – GB C1.21


5" differential

Adjusting the backlash


N.B.: The backlash to be obtained between the ring
gear and drive pinion ensures that the final drive is
reliable and that the assembly operates correctly.
6
This backlash must be checked following:
– Adjustment of the protrusion distance. 7
– Shimming of the differential case.
With the aid of a suitable extractor, remove the cup (6) 8
and discard the deflector (8). 10
– Position shims (7) with a thickness of 0,20 mm on the
differential half-case (10). 2
– Fit the cup (6) up against the shims without the
deflector (8).
– Refit the differential case (see corresponding
paragraph) with only the RH bearing (2). On the LH
side, fit tool n° 60 05 006 309 with the roller
bearing (31). . 342hsm44 Fig. 38

– Tighten the tool's centre screw to 1 daN.m (Fig. 39).


– Turn the differential to seat the bearings.
– Check once again that the tool screw is tight.
– Couple and fasten the intermediate housing
temporarily with the rear axle housing by tightening the
screws to 61 ± 7 daN.m. With the PTO housing
removed, place the plunger of a dial gauge at half- 31
length on a tooth of the ring gear (Fig. 40).
– Check that the backlash is 0,35 ± 0,10 mm.
– Carry out this operation at 3 points of the ring gear. If
the presetting is incorrect, the principle consists of
removing or adding shims (7) until the backlash is
within the aforementioned tolerance.
– Insert the selected shims (7).
– Partly insert a new deflector (8). The deflector will be
fitted completely with the cup (6).
– Check that the cup is bearing properly on the shims
and is in contact with the deflector. 342hsm45 Fig. 39

– The next essential step is to shim the differential case


roller bearings.

342hsm46 Fig. 40

C1.22 Ares 806 – 09.2004 – GB


5" differential

Shimming the differential case roller


bearings 31

N.B.: If the rear axle housing, ring gear, tapered roller


bearings and bearing blocks need to be replaced, the
differential case must be shimmed. Check
beforehand that the backlash is correct.
– Fit the differential (see paragraph concerned).
– Fit the RH bearing with the measured number of shims.
On the LH side, fit tool n° 60 05 006 309 with the roller
bearing (31). Using two bolts, mount the tool on the
housing (Fig. 41).
– Tighten the centre bolt to 1 daN.m.
N.B.: Turn the ring gear a few times to seat the cones
correctly in the cups. Check the centre bolt torque
again.
342hsm47 Fig. 41
Measuring "Y"
– Determine "Y" according to "A" and "B".
– Measure "A", the distance between the top of the
bearing and the contact surface of the shims, with tool
n° 60 05 006 309 (Fig. 42 and 43).
– Measure "B", the distance between the top of the
bearing and the contact surface of the bearing on the A
housing, with tool n° 60 05 006 309 (Fig. 42).
B
Y=B–A Y

342hsm48 Fig. 42

60
05
00
6
30
9

342hsm49 Fig. 43

Ares 806 – 09.2004 – GB C1.23


5" differential

Measuring "X"
Using a suitable depth gauge, measure "C" and determine
dimension "X" between the bearing cone (31) and the
contact surface of the bearing on the housing (Fig. 45):
X = C – 10
(10 mm is the thickness of measuring tool
n° 60 05 006 309).
C

Thickness "E" of shims (32)


Determine "E" according to "X" and "Y" plus a preload
P1 = 0,10 ± 0,05 mm.
E = X – Y + P1

For example, if A = 39,65, B = 103,45 and C = 74,5


Y = 103,45 – 39,65 = 63,8
X = 74,5 – 10 = 64,5
E (minimum) = 64,5 – 63,8 + 0,05 = 0,75
342hsm50 Fig. 44
E (maximum) = 64,5 – 63,8 + 0,15 = 0,85
According to the example, the shim thickness must be
between 0,75 and 0,85 mm.
– Remove the tool and the bearing cone (31). Place
shims (32) to a thickness "E" on the bearing (36).
– Fit the RH bearing (36) (see paragraph concerned). 31
– Refit the assembly as described in the procedures on
the pages concerned. X

342hsm51 Fig. 45

32

31
36

342hsm52 Fig. 46

C1.24 Ares 806 – 09.2004 – GB


Notes

Ares 806 – 09.2004 – GB C1.25


ND axle tubes

General
ND axle tubes are only equipped with plate wheel shafts. gear of the reduction gear unit is press-fitted into the axle
The wheel shaft is supported by 2 tapered roller bearings. tube and ensures that the brake backing plate is centred.
It is preloaded by shims placed at the end of the shaft. It The sun gear is connected to the differential by splines
is sealed on the outside by a 3-lip seal and by a single-lip and supports the brake disc. The oil in the brake housing
seal on the inside. The planet carrier with its 3 planet is renewed via a hydraulic port.
gears is connected by splines to the wheel shaft. The ring

Parts list
42 Plate wheel shaft. 52 Pins. 62 Lockwasher.
43 Wheel studs. 53 Ring gear. 63 Screw.
44 3-lip seal. 54 Tab washer. 64 Sun gear.
45 Seal housing. 55 Screw. 65 Backing plate.
46 Bearing cone. 56 Spacer. 66 Brake disc.
47 Bearing cup. 57 Circlip. 67 Guide pin.
48 Greasing plug. 58 Planet gear pin. 68 Brake piston.
49 Axle tube body. 59 Planet gear. 69 O-rings.
50 Guide pin. 60 Planet carrier. 70 Screw.
51 Single-lip seal. 61 Shims.

C1.26 Ares 806 – 09.2004 – GB


ND axle tubes

Exploded view

13
12
5
6
10
1 9

11

8
7
6
5
4
3
28
19
27
15
26
14
25
24

23
22
21 1
20
29

18

17
16

341hsm00 Fig. 47

Ares 806 – 09.2004 – GB C1.27


ND axle tubes

Removal
– Immobilise the tractor. Apply the handbrake. Chock the
tilt between the front axle and the cradle.
– Disconnect the battery.
– Using a trolley jack, lift the concerned side of the tractor
and position a jack stand.
– Unscrew and remove the cab damper support on the
axle tube side by lifting the cab slightly (Fig. 48).
– Make the cab safe.
– Remove the draft sensor and accessories.
– Position under the axle tube an appropriate support on
a trolley jack or using a hoist.
– Separate the axle tube from the rear axle housing.
– Remove:
• The brake disc (25).
• The sun gear (23). 341hsm01 Fig. 48
• The centring stud (26).
– Remove the backing plate (24).

26

25

23

24

341hsm02 Fig. 49

C1.28 Ares 806 – 09.2004 – GB


ND axle tubes

Refitting
– Clean the housing and axle tube gasket faces with a
non-greasy solvent.
– Apply a bead of hydrocarbon-resistant silicone in the
inside angle of the housing (Fig. 50).
N.B.: Do not obstruct the oil return hole on the
housing.

341hsm03 Fig. 50

Ares 806 – 09.2004 – GB C1.29


ND axle tubes

– Check that the disc (25) slides freely on the sun – Clean the screws (29) and coat them with Loctite
gear (23) (Fig. 51). Frenetanch (242).
– Refit the sun gear and disc (25) on the rear axle (23). – Refit the screws (29) and tighten to 26 ± 4 daN.m.
– Screw two opposite guide studs on the casing of the – Refit the draft sensor and lift arms.
rear axle.
N.B.: Coat the sensor lightly with grease.
– Install the backing plate (24) in the axle tube.
– Reassemble the cab securing screws with nuts and
N.B.: To hold the plate, apply 3 spots of grease to the locknuts to:
face of the ring gear (12). Couple the axle tube to the
rear axle housing. • Nut 3,1 ± 0,4 daN.m.
• Locknut 1,7 ± 0,3 daN.m and coat with
N.B.: Rotate the shaft (1) to help the sun gear (23) lock
Frenbloc (270).
into the planet gears (18).
– Reassemble the wheel. Torque to 45 daN.m.
– Lifting test and braking circuit test.

23 25 24 18

12 29 1

341hsm04 Fig. 51

C1.30 Ares 806 – 09.2004 – GB


ND axle tubes

Removing the planet carrier


14 15 19 20 21 22
– Remove screw (22).
– Remove the retaining washer (21) and shim(s) (20)
(Fig. 52).
– Remove the planet carrier (19).
– Remove the screw (14) and the spacer (15).
– Open the circlip (16) (Fig. 53). 33
– Tap the 3 pins (17) lightly with a soft-face
hammer (Fig. 53).
– Remove the 3 planet gears (18), needles (32),
spacers (33) and friction washers (31).

Refitting the planet carrier


13 16 17 31 18 32 31
– Clean and check the parts.
– Coat the needles (32) with grease. Position two rows of 341hsm05 Fig. 52

needles separated by a spacer (33) in each planet


gear (18).
– Fit the planet gears (18) and the friction washers (31).
– Insert the 3 pins (17) with the circlip (16) (Fig. 53).
– Position one end of the circlip in contact with a pin (17) 16
(Fig. 54).
– Position the spacer (15). Fit the screw (14) with Loctite
Frenbloc (271). Tighten to 4,2 ± 0,8 daN.m.
– Make sure the washer (13) is present.
– Refit the planet carrier.
– Shim as described in the procedure below.

18
17

341hsm06 Fig. 53

17 16
15
14

341hsm07 Fig. 54

Ares 806 – 09.2004 – GB C1.31


ND axle tubes

Removing the roller bearings and


9 mm
seals
– Remove the axle tube from the rear axle housing.
5
– Remove the planet carrier (19).
– Remove: 19
• The tab washer (13).
• The cone (5) on the planet carrier side (free on the
shaft).
– Extract the shaft (1) from the axle tube.
– Extract the wheel-side cone (5).
– Drive out the 3-lip seal (3) and its housing (4).
– Use an extractor to remove the bearing cups.
– Push out the seal (10).
1 10 8 mm 13
Refitting the roller bearings and seals 341hsm08 Fig. 55

– Clean the seal bearing faces. The seal bearing faces, 1 mm


the cups and cones should be free from burrs and
impacts.
– Coat the outside diameter of the seal (10) with Loctite
Frenetanch (542).
N.B.: Fit the seals the right way round.

Without replacing the shaft (1)


Important: To prevent the lip of the seal from bearing
at the same point on the shaft, fit the seal 9 mm from
the shoulder of the cup (Fig. 55).

When replacing the shaft (1)


– Position the seal 8 mm from the shoulder of the cup
(Fig. 55).
3 4 7 5
– Lubricate and fit the bearing cups.
– Fit the seal housing (4) 1 mm from the face of the axle 341hsm09 Fig. 56

tube.
– Fit the 3-lip seal (3) with a suitable jig.
– Lubricate the shaft (1) and fit the wheel-side cone (5).
– Grease the cone and lips of the seal moderately.
– Protect the splines of the shaft (1) and insert it in the
axle tube.
– Shim as described in the procedure below.
– Grease via the plug (7).
– Refit the axle tube.

C1.32 Ares 806 – 09.2004 – GB


ND axle tubes

Shimming the wheel shaft


bearings 22 21

– Position the axle tube vertically.


– Remove the screw (22), and the washer (21).
– Add a higher thickness of shims (20) to obtain play.
– Fit the bolt (21) and the washer (22). Tighten
to 45 ± 5 daN.m.
– Seat the cones in their cups by rotating the axle tube
on its pin. 19
– Place a dial gauge probe on the planet carrier (19) and 18
apply leverage (Fig. 58). Measure at 3 points and take
the average.
– Remove the screw (22), and the washer (21).
Fit shims (20) with a thickness corresponding to the
higher number of shims minus the measured play 1
minus a preload of 0,07 ± 0,05 mm.
341hsm10 Fig. 57

For example, if the measured play is 0,90 mm and the


higher number of shims is 2 mm
2 – 0,90 = 1,10 mm of shims with zero play and preload.
1,10 – 0,02 = 1,08 mm. 19
1,10 – 0,12 = 0,98 mm.
The shims to be fitted should have a thickness of 0,98
to 1,08 mm.
– Refit the washer (21).
– Tighten the screw (22) coated with Frenbloc (270)
to 45 ± 5 daN.m. .

Replacing the wheel stud


– Extract the faulty stud using a bronze drift and a
hammer.
– Clean the striation marks left by the stud on the shaft
341hsm11 Fig. 58
flange.
– Bond the striations of the new stud with Frenbloc (270).
– Position the new stud on the striation marks left by the
old stud.
– After having made sure that the splines are properly
fitted, bring the stud head against the inside flange of
the wheel shaft with a bronze mass.

Ares 806 – 09.2004 – GB C1.33


HD et HD+ axle tubes

General
HD and HD+ axle tubes can be equipped with plate wheel inside. The planet carrier with its 3 planet gears is
shafts or smooth wheel shafts. The design of the HD+ connected by splines to the wheel shaft. The ring gear of
axle tube is identical to that of the HD axle tube. It has a the reduction gear unit is placed between the axle tube
larger wheel shaft diameter and is reinforced at the and the brake backing plate. The sun gear is connected to
epicyclic gear set and housing. The wheel shaft is the differential by splines and supports the brake disc. The
supported by 2 tapered roller bearings. It is preloaded by oil in the brake housing is renewed via a hydraulic port in
shims placed at the end of the shaft. It is sealed on the the backing plate.
outside by a 3-lip seal and by a single-lip seal on the

Parts list
1 Plate or smooth wheel shaft. 11 Ring gear. 21 Screw.
2 Wheel studs. 12 Tab washer. 22 Sun gear.
3 3-lip seal. 13 Screw. 23 Backing plate.
4 Seal housing. 14 Spacer. 24 Brake disc.
5 Bearing cone. 15 Circlip. 25 Guide pin.
6 Bearing cup. 16 Planet gear pin. 26 Brake piston.
7 Greasing plug. 17 Planet gear. 27 O-rings.
8 Axle tube body. 18 Planet carrier. 28 Nut.
9 Single-lip seal. 19 Shims. 29 Screw.
10 Pins. 20 Lockwasher. 30 Screw.

C1.34 Ares 806 – 09.2004 – GB


HD et HD+ axle tubes

Exploded view

12
11
10
6
1 9
8
2

7
6 27
5 26
4 24
3

23
22
21
20
19 25
18
14
13

28
1

17
30
16 29
15

8
341hsm12 Fig. 59

Ares 806 – 09.2004 – GB C1.35


HD et HD+ axle tubes

Removal
– Immobilise the tractor. Apply the handbrake. Chock the
tilt between the front axle and the cradle.
– Disconnect the battery.
– Using a trolley jack, lift the concerned side of the tractor
and position a jack stand.
– Unscrew and remove the cab damper support on the
axle tube side by lifting the cab slightly (Fig. 60).
– Make the cab safe.
– Remove the draft sensor and accessories.
– Position under the axle tube an appropriate support on
a trolley jack or using a hoist.
– Separate the axle tube from the rear axle housing
without removing screw (30) (Fig. 59).
– Remove.
• The brake disc (24).
341hsm01 Fig. 60
• The sun gear (22).
• The centring stud.
– Remove the brake backing plate (23) and the ring gear
(11 by removing screw (30) (Fig. 61).
N.B.: Remove the brake backing plate and the ring
gear whenever the axle tube is uncoupled in order to
renew the seals and avoid leaks.

24

22

23

341hsm13 Fig. 61

C1.36 Ares 806 – 09.2004 – GB


HD et HD+ axle tubes

Refitting
– Clean the gasket faces with a non-greasy solvent.
– Apply a bead of hydrocarbon-resistant silicone in the
inside angles of the housing, backing plate, ring gear
and axle tube (Fig. 62).
N.B.: Do not obstruct the oil return hole on the
housing.
If the studs need to be replaced, coat them with
Frenbloc (270).

341hsm03 Fig. 62

Ares 806 – 09.2004 – GB C1.37


HD et HD+ axle tubes

– Check that the disc (24) slides freely on the sun – Refit the screws and nuts and tighten them
gear (22) (Fig. 63). to 26 ± 4 daN.m.
– Refit the sun gear (22) and disc (24) to the rear axle. – Refit the draft sensor and the lift arm.
– Refit the ring gear (11) and the backing plate (23) to N.B.: Coat the sensor lightly with grease.
the axle tube and torque screw (30) to 12 ± 1 daN.m.
– Couple the axle tube to the rear axle housing. – Reassemble the cab securing screws with nuts and
locknuts to:
N.B.: Rotate the shaft (1) to help the sun gear (22) lock
• Nut: 3,1 ± 0,4 daN.m. .
into the planet gears (17).
• Locknut: 1,7 ± 0,3 daN.m and coat
– Clean the screws (29) and nuts (28) and coat them with with Frenbloc (270).
Loctite Frenetanch (242).
– Reassemble the wheel. Torque to 45 daN.m.
– Lifting test and braking circuit test.

24 23 30 11 22 28

17 29 1

341hsm14 Fig. 63

C1.38 Ares 806 – 09.2004 – GB


HD et HD+ axle tubes

Removing the planet carrier


13 14 18 19 20 21
– Remove screw (21).
– Remove the retaining washer (20) and shim(s) (19)
(Fig. 64).
– Remove the planet carrier (18).
– Remove the screw (13) and the spacer (14).
– Open the circlip (15) (Fig. 65). 33
– Tap the 3 pins (16) lightly with a soft-face
hammer (Fig. 65).
– Remove the 3 planet gears (17), needles (32),
spacers (33) and friction washers (31).

Refitting the planet carrier


12 15 16 31 17 32 31
– Clean and check the parts.
– Coat the needles (32) with grease. Position two rows of 341hsm15 Fig. 64

needles separated by a spacer (33) in each planet


gear (17).
– Fit the planet gears (17) and the friction washers (31).
– Insert the 3 pins (16) with the circlip (15) (Fig. 65).
– Position one end of the circlip in contact with a pin (16) 15
(Fig. 66).
– Position the spacer (14). Fit the screw (13) with Loctite
Frenbloc (271). Tighten to 4,2 ± 0,8 daN.m.
– Make sure the washer (12) is present.
– Refit the planet carrier.
– Shim as described in the procedure below.

17
16

341hsm16 Fig. 65

16 15
14
13

341hsm17 Fig. 66

Ares 806 – 09.2004 – GB C1.39


HD et HD+ axle tubes

Removing the roller bearings and


9 mm
seals
– Remove the axle tube from the rear axle housing.
5
– Remove the planet carrier (18).
– Remove: 18
• The tab washer (12).
• The cone (5) on the planet carrier side (free on the
shaft).
– Extract the shaft (1) from the axle tube.
– Extract the wheel-side cone (5).
– Drive out the 3-lip seal (3) and its housing (4).
– Use an extractor to remove the bearing cups.
– Push out the seal (9).
1 9 8 mm 12
Refitting the roller bearings and seals 341hsm18 Fig. 67

– Clean the seal bearing faces. The seal bearing faces, 3 20 mm 4 5


the cups and cones should be free from burrs and
impacts.
– Coat the outside diameter of the seal (9) with Loctite
Frenetanch (542).
N.B.: Fit the seals the right way round.

Without replacing the shaft (1)


Important: To prevent the lip of the seal from bearing
at the same point on the shaft, fit the seal 9 mm from
the shoulder of the cup (Fig. 67).

When replacing the shaft (1)


– Position the seal 8 mm from the shoulder of the cup
(Fig. 67).
34 7
– Lubricate and fit the bearing cups.
– Fit the seal housing (6) 20 mm from the face of the axle 341hsm19 Fig. 68

tube (Fig. 68).


– Fit the bush (34) coated with Scelbloc (648).
– Lubricate the shaft (1) and fit the wheel-side cone (5).
– Grease the cone and lips of the seal moderately.
– Protect the splines of the shaft (1) and insert it in the
axle tube.
– Fit the three-lip seal (3) with a suitable jig fully onto the
bearing cone (5).
– Shim as described in the procedure below.
– Grease via the plug (7).
– Refit the axle tube.

C1.40 Ares 806 – 09.2004 – GB


HD et HD+ axle tubes

Shimming the wheel shaft


bearings 21 20

– Position the axle tube vertically.


– Remove the screw (21), and the washer (20).
– Determine a higher thickness of shims (19) to obtain
play.
– Fit the bolt (20) and the washer (21). Tighten
to 85 ± 7 daN.m.
– Seat the cones in their cups by rotating the axle tube 19
on its pin. 18
– Place a dial gauge probe on the planet carrier (18) and
apply leverage (Fig. 70). Measure at 3 points and take
the average.
– Remove the screw (21), and the washer (20).
Fit shims (19) with a thickness corresponding to the 1
higher number of shims minus the measured play
Fig. 69
minus a preload of 0,07 ± 0,05 mm. 341hsm20

For example, if the measured play is 0,90 mm and the


higher number of shims is 2 mm
2 – 0,90 = 1,10 mm of shims with zero play and preload. 18
1,10 – 0,02 = 1,08 mm.
1,10 – 0,12 = 0,98 mm.
The shims to be fitted should have a thickness of 0,98
to 1,08 mm.
– Refit the washer (20).
– Tighten the screw (21) coated with Frenbloc (270)
to 85 ± 7 daN.m.

Replacing the wheel stud


– Extract the faulty stud using a bronze drift and a
hammer.
341hsm21 Fig. 70
– Clean the striation marks left by the stud on the shaft
flange.
– Bond the striations of the new stud with Frenbloc (270).
– Position the new stud on the striation marks left by the
old stud.
– After having made sure that the splines are properly
fitted, bring the stud head against the inside flange of
the wheel shaft with a bronze mass.

Ares 806 – 09.2004 – GB C1.41


HDE axle tubes

General
HDE axle tubes can be equipped with plate wheel shafts inside. The planet carrier with its 3 planet gears is
or smooth wheel shafts. These are sealed partition axle connected by splines to the wheel shaft. The ring gear of
tubes in which the reduction gear has undergone special the reduction gear unit is placed between the axle tube
treatment. The sealed compartment is set to atmospheric and the brake backing plate. The sun gear is connected to
pressure by means of a breather. The wheel shaft is the differential by splines and supports the brake disc via
supported by 2 tapered roller bearings. It is preloaded by a splined pinion. The oil in the brake housing is renewed
shims placed at the end of the shaft. It is sealed on the via a hydraulic port in the backing plate.
outside by a 3-lip seal and by 3 single-lip seals on the

Parts list
1 Plate or smooth wheel shaft. 12 Tab washer. 23 Backing plate.
2 3-lip seal. 13 Screw. 24 Single-lip seal.
3 Seal housing. 14 Spacer. 25 Single-lip seal.
4 Bearing cone. 15 Circlip. 26 Splined pinion.
5 Bearing cup. 16 Planet gear pin. 27 Circlip.
6 Greasing plug. 17 Planet gear. 28 Brake disc.
7 Axle tube body. 18 Planet carrier. 29 Brake piston.
8 Breather tube. 19 Shims. 30 O-rings.
9 Single-lip seal. 20 Lockwasher. 31 Nut.
10 Pins. 21 Screw. 32 Screw.
11 Ring gear. 22 Sun gear. 33 Screw.

C1.42 Ares 806 – 09.2004 – GB


HDE axle tubes

Exploded view

10
8

12
11
4
5
9

30
29
7
28
6
27
5
26
4
25
3
24
2
23
22
21
20
19
18
14
13

31
33

17
16
15
32
1
7

341hsm22 Fig. 71

Ares 806 – 09.2004 – GB C1.43


HDE axle tubes

Removal
– Immobilise the tractor. Apply the handbrake. Chock the
tilt between the front axle and the cradle.
– Disconnect the battery.
– Using a trolley jack, lift the concerned side of the tractor
and position a jack stand.
– Unscrew and remove the cab damper support on the
axle tube side by lifting the cab slightly (Fig. 72).
– Make the cab safe.
– Remove the draft sensor and accessories.
– Position under the axle tube an appropriate support on
a trolley jack or using a hoist.
– Separate the axle tube from the rear axle housing
without removing screw (33) (Fig. 71).
– Remove:
• The brake disc (28).
341hsm01 Fig. 72
• The circlip (27) and the splined pinion (26).
• The backing plate (23) with its seals (24) and (25) by
removing screw (33) ;
• The sun gear (22).
– Remove the ring gear.
N.B.: Remove the brake backing plate and the ring
gear whenever the axle tube is uncoupled in order to
renew the seals and avoid leaks.

28

26

27

22

24
25

23

341hsm23 Fig. 73

C1.44 Ares 806 – 09.2004 – GB


HDE axle tubes

Refitting
– Clean the gasket faces with a non-greasy solvent.
– Apply a bead of hydrocarbon-resistant silicone in the
inside angles of the housing, backing plate, ring gear
and axle tube (Fig. 74).
N.B.: Do not obstruct the oil return hole on the
housing.
– Coat the outside diameters of seals (24) and (25)
with Frenetanch (542).
– Using a suitable tool on the press, fit seals (24)
and (25) back to back against shoulder (A).
– If the studs need to be replaced, coat them with
Frenbloc (270).

341hsm03 Fig. 74

A
25

24

341hsm24 Fig. 75

Ares 806 – 09.2004 – GB C1.45


HDE axle tubes

– Check that the disc (28) slides freely on the splined – Clean the screws (32) and nuts (31) and coat them with
pinion (26) (Fig. 76). Loctite Frenetanch (242).
– Refit the sun gear (22) and protect its splines. – Refit the screws and nuts and tighten them
– Refit the ring gear (11) and the backing plate (23) onto to 26 ± 4 daN.m.
the axle tube. – Refit the draft sensor and the lift arm.
– Tighten screw (33) to 12 ± 1 daN.m. N.B.: Coat the sensor lightly with grease.
– Fit the splined pinion (26) and the circlip (27) with the
locally made tool (Fig. 77). – Reassemble the cab securing screws with nuts and
locknuts to:
– Slide the disc onto the splined pinion.
– Couple the axle tube to the rear axle housing. • Nut: 3,1 ± 0,4 daN.m. .
• Locknut: 1,7 ± 0,3 daN.m and coat
N.B.: Rotate the shaft (1) to help the sun gear (22) lock
with Frenbloc (270).
into the differential.
– Reassemble the wheel. Torque to 45 daN.m.
– Lifting test and braking circuit test.

28 27 26 23 33 22 31

24 25 11 32 1

341hsm25 Fig. 76

342hsm05 Fig. 77

C1.46 Ares 806 – 09.2004 – GB


HDE axle tubes

Removing the planet carrier


13 14 18 19 20 21
– Remove screw (21).
– Remove the retaining washer (20) and shim(s) (19)
(Fig. 78).
– Remove the planet carrier (18).
– Remove the screw (13) and the spacer (14).
– Open the circlip (15) (Fig. 79). 33
– Tap the 3 pins (16) lightly with a soft-face hammer
(Fig. 79).
– Remove the 3 planet gears (17), needles (32),
spacers (33) and friction washers (31).

Refitting the planet carrier


12 15 16 31 17 32 31
– Clean and check the parts.
– Coat the needles (32) with grease. Position two rows of 341hsm15 Fig. 78

needles separated by a spacer (33) in each planet


gear (17).
– Fit the planet gears (17) and the friction washers (31).
– Insert the 3 pins (16) with the circlip (15) (Fig. 79).
– Position one end of the circlip in contact with a pin (16) 15
(Fig. 80).
– Position the spacer (14). Fit the screw (13) with Loctite
Frenbloc (271). Tighten to 4,2 ± 0,8 daN.m.
– Make sure the washer (12) is present.
– Refit the planet carrier.
– Shim as described in the procedure below.

17
16

341hsm16 Fig. 79

16 15
14
13

341hsm17 Fig. 80

Ares 806 – 09.2004 – GB C1.47


HDE axle tubes

Removing the roller bearings and


9 mm
seals
– Remove the axle tube from the rear axle housing.
5
– Remove the planet carrier (18).
– Remove: 18
• The tab washer (12).
• The cone (5) on the planet carrier side (free on the
shaft).
– Extract the shaft (1) from the axle tube.
– Extract the wheel-side cone (5).
– Drive out the 3-lip seal (3) and its housing (4).
– Use an extractor to remove the bearing cups.
– Push out the seal (9).
1 9 8 mm 12
Refitting the roller bearings and seals 341hsm18 Fig. 81

– Clean the seal bearing faces. The seal bearing faces, 3 20 mm 4 5


the cups and cones should be free from burrs and
impacts.
– Coat the outside diameter of the seal (9) with Loctite
Frenetanch (542).
N.B.: Fit the seals the right way round.

Without replacing the shaft (1)


Important: To prevent the lip of the seal from bearing
at the same point on the shaft, fit the seal 9 mm from
the shoulder of the cup (Fig. 81).

When replacing the shaft (1)


– Position the seal 8 mm from the shoulder of the cup
(Fig. 81).
34 7
– Lubricate and fit the bearing cups.
– Fit the seal housing (6) 20 mm from the face of the axle 341hsm19 Fig. 82

tube (Fig. 82).


– Fit the bush (34) coated with Scelbloc (648).
– Lubricate the shaft (1) and fit the wheel-side cone (5).
– Grease the cone and lips of the seal moderately.
– Protect the splines of the shaft (1) and insert it in the
axle tube.
– Fit the three-lip seal (3) with a suitable jig fully onto the
bearing cone (5).
– Shim as described in the procedure below.
– Grease via the plug (7).
– Refit the axle tube.

C1.48 Ares 806 – 09.2004 – GB


HDE axle tubes

Shimming the wheel shaft


bearings 21 20

– Position the axle tube vertically.


– Remove the screw (21), and the washer (20).
– Determine a higher thickness of shims (19) to obtain
play.
– Fit the bolt (20) and the washer (21). Tighten
to 85 ± 7 daN.m.
– Seat the cones in their cups by rotating the axle tube 19
on its pin. 18
– Place a dial gauge probe on the planet carrier (18) and
apply leverage (Fig. 84). Measure at 3 points and take
the average.
– Remove the screw (21), and the washer (20).
Fit shims (19) with a thickness corresponding to the 1
higher number of shims minus the measured play
Fig. 83
minus a preload of 0,07 ± 0,05 mm. 341hsm20

For example, if the measured play is 0,90 mm and the


higher number of shims is 2 mm
2 – 0,90 = 1,10 mm of shims with zero play and preload. 18
1,10 – 0,02 = 1,08 mm.
1,10 – 0,12 = 0,98 mm.
The shims to be fitted should have a thickness of 0,98
to 1,08 mm.
– Refit the washer (20).
– Tighten the screw (21) coated with Frenbloc (270)
to 85 ± 7 daN.m.

Replacing the wheel stud


– Extract the faulty stud using a bronze drift and a
hammer.
341hsm21 Fig. 84
– Clean the striation marks left by the stud on the shaft
flange.
– Bond the striations of the new stud with Frenbloc (270).
– Position the new stud on the striation marks left by the
old stud.
– After having made sure that the splines are properly
fitted, bring the stud head against the inside flange of
the wheel shaft with a bronze mass.

Ares 806 – 09.2004 – GB C1.49


GPA 40 power take-off clutch

General
The clutch is mounted at the front of the rear axle housing. – A hub supports the discs.
It is driven by a countershaft traversing the gearbox. This – A cover accommodates the backplates.
shaft also drives the hydraulic pump gear via the clutch The clutch is supplied by a proportional solenoid valve on
housing. The clutch assembly consists of: the 17 bar low-pressure circuit. The oil reaches the piston
– A housing supported by 2 ball bearings mounted in a chamber through the shaft ducts. In the clutched position,
holder. the PTO brake piston located in the rear PTO housing is
– A shaft centred by a bearing, supporting the drive hub idle and allows the driven gears to rotate freely. When the
and the piston. It has a duct for the piston supply. clutch is engaged, the discs are cooled by the oil from the
shaft ducts. When the supply is interrupted, the spring and
Belleville washer release the discs. The 17 bar supply
displaces the brake piston, stopping the driven gears. The
PTO brake is described in the section on the output shaft.

Parts list
1 Drive shaft. 13 Hydraulic pump driving gear. 24 Retaining ring.
2 Bearing. 14 Clutch housing. 25 Ball bearing.
3 Screw. 15 Shaft. 26 Chamfered washer.
4 Guide pin. 16 O-ring. 27 Screw.
5 Clutch support. 17 O-ring. 28 Drive hub.
6 Bush. 18 Piston. 29 Retaining ring.
7 Sealing ring. 19 O-ring. 30 Shaft.
8 Retaining ring. 20 Belleville washer. 31 Discs.
9 Shims. 21 Spring holder. 32 Backplates
10 Sealing ring. 22 Spring. 33 Cover.
11 Bearing. 23 Spring seat.
12 Screw.

C1.50 Ares 806 – 09.2004 – GB


GPA 40 power take-off clutch

Exploded view

1 3
2 4
5

6
8
10
11
13
14
7
9

12

15
16
17
18
19
20
21
22
23
24
25
26
27

28
29
30
32
31

33
30

341hsm40 Fig. 85

Ares 806 – 09.2004 – GB C1.51


GPA 40 power take-off clutch

Removal/refitting
Uncouple the tractor between the gearbox and rear axle
as follows:
– Refer to Chapter "H" for partial cab removal.
Operations 1 to 7.
– Drain the transmission system.
– Remove the reservoir(s) and disconnect the pipes,
hoses and wiring harnesses interfering with the
uncoupling operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.
– Remove the RH hydraulic cover (see chapter "E").
– Recover the hydraulic connection tube between the 34
cover and the clutch.
– Remove the lubrication tube mounted on the housing
above the clutch.
– Remove the PTO clutch speed sensor (34). 341hsm41 Fig. 86

– Remove the screws (3) from the clutch support.


– Remove the clutch/support assembly with the aid of
the PTO shaft and a suitable hoist (Fig. 88).
– Remove the sealing ring (6).
– Separate the support from the clutch by removing the
retaining ring (8) and the shims (9).
Refit the assembly in reverse order to removal while
observing the following instructions: 3 3
– Check the state of the bush surface.
– If replacement is necessary, fit and position the
bush 0,50 mm from the bearing contact surface.
– Check that the rings rotate correctly in their groove.
– Coat the rings with grease and fit permanently.
– Position the shims and retaining ring and check that
there is functional play.
– Tighten the screws (3) to 12 ± 1 daN.m.
– Coat the sensor lightly with Frenetanch (242) and 341hsm42 Fig. 87
tighten by 1/2 to 3/4 of a turn before contact.

9 0,50 mm

341hsm43 Fig. 88

C1.52 Ares 806 – 09.2004 – GB


GPA 40 power take-off clutch

Removing the clutch


– Remove the clutch/support assembly (see previous

10

6
page).
– Remove the sealing rings (10).
– Remove the pump driving gear by removing 21 151,5
± 0,2
screws (12). ø8
– If necessary, remove the ball bearings.
– Remove the cover (33), discs and backplates.

25
170
– Clamp the housing (14) in a vice equipped with grips.

= =
– With the aid of a locally made tool (Fig. 89), compress
the spring via the hub (28). + 0,5
ø 58,5
– Remove the screw (27) and the washer (26). 0
ø 92
– Remove the tool.
64
– Remove the drive hub (28), the spring seat (23), the 6
spring, the spring holder and the Belleville washer.
– If necessary, remove the retaining ring (24) and the
bearing (25). 341hsm44 Fig. 89

– With a jet of compressed air, extract the piston (18) and


remove the O-rings. 28 26 27

14

341hsm45 Fig. 90

26 28

27

25

24

23

22

18 14

341hsm46 Fig. 91

Ares 806 – 09.2004 – GB C1.53


GPA 40 power take-off clutch

Refitting the clutch


27 26
N.B.: The valve (35) is crimped onto the housing (14).
33
– Clean and check the parts. Replace any defective
parts.
– Replace and lubricate the O-rings.
– Fit shaft (15), lightly coated with Scelbloc (648), on the 28
25
press.
– Fit piston (18) by tapping gradually and alternately 24
around its edge with a soft-faced hammer.
– If removed, fit bearing (25) into hub (28) with a suitable
jig.
– Fit the retaining ring (24).
– Refit Belleville washer (20), as illustrated in the general
arrangement, and the spring holder, spring, spring seat 20
and drive hub.
– Compress the spring with a locally made tool (see 18
removal procedure).
15
– Fit washer (26) and tighten screw (27) coated with
Frenbloc (270) to 2,6 ± 0,2 daN.m.
– Fit the discs and backing plates by placing tabs (A)
between screw holes (B).
14
Important: New discs must be soaked in a bath of
transmission fluid for approximately one hour.
– Position cover (33) and driving gear (13). 35
– Tighten screws (12) lightly coated with
Frenetanch (242) to 3,2 ± 0,2 daN.m. 11
– Assemble the clutch and its support as described in the
procedures above.
– The bearing (11) is fitted with its sealed side against 13
the housing (14).
12

341hsm47 Fig. 92

28 A

14 B

341hsm48 Fig. 93

C1.54 Ares 806 – 09.2004 – GB


GPA 40 power take-off upper shaft

General
The upper shaft line is linked to the clutch via a – one 540/1 000 rpm dog or 2 dogs
countershaft. It consists of: (540/1 000 and 750 rpm).
– a shaft supported by 2 tapered roller bearings. The shaft is adjusted by means of shims placed between
– a 1 000 rpm gear. the shaft and the cover. The lube oil flows to the rear PTO
– a 540 rpm gear. housing and is conveyed through a calibrated orifice
– a 750 rpm (540 rpm economy) gear or a bushing (1 mm approx. dia.) to the gears.
depending on the equipment.

Ares 806 – 09.2004 – GB C1.55


GPA 40 power take-off upper shaft

Exploded view of 540/1 000 rpm version

22
1 23
2 24
3
4 25
5 26
6
14 7
15 8
16
18

9
12
10 19
13
11 20
17
21

341hsm49 Fig. 94

Parts list
1 Countershaft. 13 Control shaft. 25 Bearing cup.
2 Retaining ring. 14 Locking screw. 26 Bearing cone.
3 Shims. 15 Locknut. 27 750 rpm sliding gear hub.
4 Bearing cup. 16 Blocking pin. 28 750 rpm sliding gear.
5 Bearing cone. 17 O-ring. 29 750 rpm fork.
6 Spacer (without 750 rpm). 18 540/1 000 rpm control. 30 750 rpm guide rod.
7 Washer. 19 O-ring. 31 Prevention system.
8 540 rpm drive gear. 20 Bushing with calibrated orifice. 32 750 rpm control.
9 540/1 000 rpm sliding gear. 21 Shaft (540/1 000 rpm version). 33 750 rpm drive gear.
10 540/1 000 rpm fork. 22 Sealing ring. 34 Shouldered bushing.
11 Needle screw. 23 1 000 rpm drive gear. 35 O-ring.
12 540/1 000 rpm guide rod. 24 Deflector. 36 Shaft (540/1 000 and 750 rpm version).

C1.56 Ares 806 – 09.2004 – GB


GPA 40 power take-off upper shaft

Exploded view of 540/1 000 and 750 rpm version

17
13
16 32
15
14
30
31

29

11
1
2
3
4
33
5
34
27
8
28
9

19
20
35
36
31
12
14
15
16

10
13
22
11
23
17
24
18
25
26

341hsm50 Fig. 95

Ares 806 – 09.2004 – GB C1.57


GPA 40 power take-off upper shaft

Prevention system
The 540/1 000 and 750 rpm version comprises a locking
system (31) (Fig. 96) preventing 540/1 000 rpm switching 17 16 13 11
operations at the same time as the 750 rpm.

Removing/refitting the prevention system


– Drain the transmission system.
– Disconnect the PTO control cables and pipes.
– Remove the linkage and lift accessories obstructing the
uncoupling of the PTO housing.
– Remove the PTO speed sensor from the rear axle to
avoid damaging it.
– Remove the PTO housing with a chain and hoist. 15 14 31 37 31
– Remove the countershaft connected to the clutch.
– Extract the blocking pin (16) with a screw.
– Free the control shafts (13) from the guide rods.
– Remove the guide rods after removing the locking
screw (14), shorten the prevention locks (31) and
unscrew the needle screw (11) from the fork.
Refit in reverse order to removal while observing the
following instructions:
– Tighten the needle screw (11) of the fork coated with
Frenetanch (242) to 3 ± 0,5 daN.m.
– Fit the control shaft O-ring (17) from outside the
housing to avoid damaging it.
– Proceed with system adjustment.

Adjustment
– Place one guide rod in neutral and the other with a
gear engaged.
– Adjust the sleeve (37) to leave 0,1 mm functional play
between the prevention locks and the guide rods.
– Check by attempting to engage 2 opposite speeds at
the same time.
341hsm51 Fig. 96
– Tighten screw (14) slightly to compress the ball, then
loosen by 1/4 of a turn.
– Tighten locknut (15) coated with Frenetanch (242)
to 1,8 ± 0,2 daN.m.

C1.58 Ares 806 – 09.2004 – GB


GPA 40 power take-off upper shaft

Removal/refitting
– Uncouple the PTO housing (see previous page).
– Remove the locking and prevention systems (see 38
previous page).
39
– Remove the tube (38).
– Remove the cover (39).
– Remove the guide rods.

40 40

341hsm52 Fig. 97

Ares 806 – 09.2004 – GB C1.59


GPA 40 power take-off upper shaft

38

39

540/1 000 – 750

540/1 000

341hsm53 Fig. 98

– Remove the complete upper shaft (gear, sliding gear, Removal/refitting


fork and bearing cone) from the housing.
N.B.: The driven gears need to be removed before the – Proceed with removing the entire upper shaft (see
upper shaft can be extracted. paragraph concerned).
– If necessary, drive out the bearing cups and recover
Refit in reverse order to removal while observing the
the shims and oil deflector.
following instructions:
– Check that shims (3) are present between the cover
and the cup (4).
– Tighten cover screws (40) to 8 ± 1 daN.m.
– Fit tube (38) with new O-rings.

C1.60 Ares 806 – 09.2004 – GB


GPA 40 power take-off upper shaft

– Remove the forks from the sliding gear(s).


– Remove sealing ring (22).
– Extract the bearing cone (26).
– Remove drive gear (23) and sliding gear (9). 35 27 28 33 34 26 22
– If necessary, drive out bushing (20) and discard the O-
ring.
– Extract the bearing cone (5).
– Retrieve O-ring (35) (depending on the assembly).
– Depending on the assembly, remove:
• Sliding gear (28) with hub (27), and drive gear (33)
with bushing (34).
• Spacer (6) and washer (7).
– Remove the pinion (8)
– Check that the shaft lubrication orifices are not
blocked. 5 20 8 9 23
– Fit a lubricated seal to bushing (20) with an
unobstructed, calibrated orifice. 341hsm54 Fig. 99

N.B.: The bushing will be mounted up against the


internal shoulder of the shaft with the calibrated 20 9 26 22
orifice facing the large chamber.
Stack the assembly in reverse order to removal while
observing the following instructions:
– Washer (7) will be fitted with the large diameter facing
the gear (depending on assembly).
– Fit the bearings fully onto the shaft by means of a
suitable jig on the press.
– Check the correct overlap of the sliding gear(s).
– Check gear rotation.
– Refit deflector (24) (Fig. 101).
– Refit the measured shims (see following page).
– Refit the 2 cups fully with a suitable jig.
– Put the assembly back into the PTO housing.
– Refit the components by consulting the sections 5 6 7 8 23
concerned.
341hsm55 Fig. 100

24

341hsm56 Fig. 101

Ares 806 – 09.2004 – GB C1.61


GPA 40 power take-off upper shaft

Adjustment
– Shim with cover (39) only.
– Do not mount the lower shaft with the driven gears,
guide rods and lubrication line.
– Fit shims to the thickness measured on removal
minus 0,15 mm.
– Lubricate the bearings.
– Fit the cover.
– Tighten screws (40) in opposition to 8 ± 1 daN.m.
3
Thickness "E1" of shims (3)
– Push the shaft firmly and turn it to seat the bearings.
– Place a dial gauge probe at the end of the shaft.
– Pull hard on the shaft and rotate it to seat the bearings.
– Add to the shims positioned on measuring, shims of a
thickness corresponding to the measured play minus
the preload value 0,05 ± 0,05 mm.
– If possible, adjust towards the minimum end of the
tolerance range.
For example, if the measured play is 0,35 mm and the
shim thickness is 1,50 mm:
"E1" (minimum) = 1,50 + 0,35 – 0,10 = 1,75 mm
39
"E1" (maximum) = 1,50 + 0,35 – 0 = 1,85 mm
According to the example, the thickness of the shims to be 40
positioned should be as close to 1,85 mm as possible.
Refit the assembly, consulting the sections concerned.

Adjusting the controls


– Fit the remote cables (41) on the control side in the cab
and on the lever side to the housing.
– Set the control to the required speed and set lever (18)
or (32) to the same speed. 341hsm57 Fig. 102
– Tighten the remote cable with nuts (42) while checking
that the cable is not stressed.
– Check the operation and locking function in each
position.
– Adjust nuts (42) if necessary. 18

32

42

41
42

341hsm58 Fig. 103

C1.62 Ares 806 – 09.2004 – GB


Notes

Ares 806 – 09.2004 – GB C1.63


GPA 40 power take-off lower shaft

General
– The driven gears are mounted on the lower shaft of the – A nut assembles the bearing cone and gears together
rear PTO housing. on the shaft.
– These gears are constantly engaged with the drive – A sensor is mounted to the right of the PTO housing to
gears entrained by the upper shaft line. measure the speed of the lower shaft via the 540 rpm
– The lower shaft is supported at the front by a tapered gear.
bearing mounted in the rear axle housing and at the – The lube oil flows to the rear PTO housing and is
rear by a tapered bearing mounted in the rear PTO conveyed by a tube to the holes in the lower shaft.
housing. – The cover-side bearing is splash-lubricated.
– The gears are connected to the shaft by splines.
– The 750 rpm gear is fastened to the 540 rpm gear Power take-off brake
when fitted. – It consists of a piston located in the PTO housing.
– When one of the drive gears transfers movement to the – When the supply to the clutch is interrupted, the low
lower shaft, the other drive gear is passive and rotates pressure is directed to the brake which gradually
freely around its shaft. blocks the lower shaft via the 1 000 rpm gear.
– The rear bearing is fitted with a lip seal.
– The tapered bearings are adjusted by shims placed
between the cover and the bearing cup at the shaft
end.

Parts list
1 Screw. 8 1 000 rpm driven gear. 15 Shaft.
2 Cover. 9 Bearing cup. 16 Guide pin.
3 Nut. 10 Bearing cone. 17 Interchangeable sleeve.
4 Shims. 11 Lip seal. 18 Screw.
5 Bearing cup. 12 Lubrication tube. 19 750 rpm driven gear (depending on
6 Bearing cone. 13 Screw. assembly).
7 540 rpm driven gear. 14 O-ring. 20 Screw (depending on assembly).

C1.64 Ares 806 – 09.2004 – GB


GPA 40 power take-off lower shaft

Exploded view of 540/1 000 rpm version

2
3
4
5
6
7
1

14
9
10
11

16
17
12
13
14
15
18
341hsm59 Fig. 104

Exploded view of 540/1 000 and 750 rpm version

2
3
4 19
5 7
6 20

8
9
10
11

14
16

12
13
14
14
17
18
341hsm60 Fig. 105

Ares 806 – 09.2004 – GB C1.65


GPA 40 power take-off lower shaft

Power take-off brake


Remove or refit the brake in accordance with the following
instructions:
– Remove the PTO housing (21) and the lower shaft (see 23
paragraph concerned).
– Mount the chamfer of piston (22) facing the chamber in 22
the PTO housing.
– The striated face (23) is positioned on the 1 000 rpm 8 21
gear (8) side.
– Always fit a new O-ring (24) and lightly coated with
24
grease.

Removing/refitting the lower shaft


– Drain the transmission system.
– Disconnect the PTO control cables and pipes. 341hsm61 Fig. 106

– Remove the linkage and lift accessories obstructing the


uncoupling of the PTO housing.
– Remove the PTO speed sensor from the rear axle to
avoid damaging it.
– Remove the PTO housing with a chain and hoist.
– Remove the output speed sensor mounted to the right
of the housing.
– Remove the speed selection device (see previous 20
page).
5
– Remove the cover (2).
– Prevent the lower shaft (15) from rotating with ø16 mm 2
screw held in the sleeve-side locking hole.
– Free and loosen nut (3). 3
– Extract the bearing cone (6) and remove the driven
gears. 6

N.B.: For the version including 750 rpm, remove the 15


upper shaft at the same time. 10
– Use the splined shaft (15) and its locking system to
unscrew the screws (20) and uncouple the 750
and 540 rpm gears (depending on assembly).
– Drive out the shaft with a suitable soft-face hammer.
– Retrieve the cone (10) and remove the cup (9) if
necessary.

11

341hsm62 Fig. 107

C1.66 Ares 806 – 09.2004 – GB


GPA 40 power take-off lower shaft

– Remove the cup (5) and recover the shims if


necessary.
– Drive out the seal (11) and discard it. 11

Refit in reverse order to removal while observing the 15


following instructions:
– Coat the outside diameter of the new seal (11) lightly
with Frenetanch (542). 17
– Fit a new seal with the locally made tool (Fig. 109). 20
– Check that the seal is fitted 2,40 mm from the face of
the housing (Fig. 108). 5
– Slide the shaft (15) with the seal bearing surface 3
lubricated.
– Fit the bearing cones with a suitable jig.
18
– Assemble the 750 and 540 rpm gear and tighten the
screws (20), lightly coated with Frenbloc (270), 2,40 mm
to 13 ± 1 daN.m (depending on assembly).
– Determine the number of shims to be inserted behind
341hsm63 Fig. 108
the cup (5) (see following page).
– Immobilise the shaft according to the locking method
described in the removal section.
– Tighten the nut (3), lightly coated with Frenbloc (270),
ø 105
to 20 ± 4 daN.m.
ø 90
– Lock the nut by deforming its flange.
ø 70
– Reposition the cover and fit the PTO speed selection
ø 20
device.
– Tighten the cover screws to 8 ± 1 daN.m. ø 66

– Coat the sensors lightly with Frenetanch (242) and


tighten to 1/2 to 3/4 of a turn prior to contact.
– Couple the PTO housing (21) to the rear axle.
2 mm
– Immobilise the lower shaft according to the locking
18 mm
method and fit the interchangeable sleeve (17).
– Check that the centring pin is present. 10 mm

– Tighten the screws (18) to 13 ± 1 daN.m. 2,40 mm

004fl
004fl Fig. 109

3 21

341hsm64 Fig. 110

Ares 806 – 09.2004 – GB C1.67


GPA 40 power take-off lower shaft

Adjustment
– Shim with the cover only.
– Do not mount the upper shaft with the drive gears and
guide rods.
– Assemble the upper shaft.
– Tighten nut (3) provisionally to 20 ± 4 daN.m.
– Fit shims (4) to the thickness measured on removal
minus 0,15 mm. 4
– Lubricate the bearings.
– Fit the cover (2). 3
– Tighten screws (1) in opposition to 8 ± 1 daN.m.
– Check that the end of the interchangeable sleeve (17)
is a smooth, flat surface. 0,05
± 0,05
mm

Thickness "E2" of shims (4) 2


– Push the shaft firmly and turn it to seat the bearings.
– Place a dial gauge probe at the end of the sleeve.
– Pull hard on the shaft and rotate it to seat the bearings.
– Add to the shims positioned on measuring, shims of a
thickness corresponding to the measured play plus the 17
preload value 0,05 ± 0,05 mm.
– If possible, adjust towards the maximum end of the
tolerance scale.
3
For example, if the measured play is 0,10 mm and the
shim thickness is 1,50 mm: 4
"E2" (maximum) = 1,50 + 0,10 + 0,10 = 1,70 mm
"E2" (minimum) = 1,50 + 0,10 + 0 = 1,60 mm
According to the example, the thickness of the shims to be
positioned should be as close to 1,70 mm as possible.
Refit the assembly, consulting the sections concerned. 1

341hsm65 Fig. 111

C1.68 Ares 806 – 09.2004 – GB


Notes

Ares 806 – 09.2004 – GB C1.69


Proportional power take-off

General
– Power take-off proportional to forward motion is an – The 4 wheel drive unit (see section "D") drives a
optional feature. Movement comes from the drive countershaft. This is connected by splines to a sleeve.
pinion via the 4 wheel drive gear. A coupler drives the lower shaft via a pair of gears.
– The PTO speed is therefore proportional to the speed – The drive gear is fastened to the 540 rpm gear in place
of wheel rotation. of the 750 rpm gear (if fitted).
– The coupler control is located on the right-hand lower
part of the PTO housing.

Parts list
1 Circlip. 11 Hub. 21 Needle screw.
2 Sleeve. 12 Bearing cone. 22 Guide rod.
3 Countershaft. 13 Bearing cup. 23 Locking screw.
4 Retaining ring. 14 Shims. 24 Nut.
5 Sleeve. 15 Cover. 25 Control shaft.
6 Screw. 16 Bearing cone. 26 O-ring.
7 Washer. 17 Bearing cup. 27 Retaining ring.
8 Bearing. 18 Proportional PTO drive gear. 28 Control lever .
9 Nut. 19 Proportional PTO driven gear. 29 Needle screw.
10 Sliding gear. 20 Fork.

C1.70 Ares 806 – 09.2004 – GB


Proportional power take-off

Exploded view

9
8
7
6
5
4

2
1

19

15

18
17
16

14
13
12
25 11
26 10
27
29
21

28 22
23
24 20

341hsm66 Fig. 112

Ares 806 – 09.2004 – GB C1.71


Proportional power take-off

Removing/refitting the
selection system 25

– Drain the transmission system. 26


– Disconnect the PTO control cables and pipes.
– Remove the linkage and lift accessories obstructing the 28
uncoupling of the PTO housing.
– Remove the PTO speed sensor from the rear axle to
avoid damaging it.
– Remove the PTO housing with a chain and hoist.
– Remove the control lever (28). 27
– Remove the retaining ring (27).
– Push the control shaft (25), then rotate and withdraw it 23
to recover the O-ring (26).
– Finish remove the shaft by pushing it completely
towards the inside of the housing.
– Unscrew locking screw (23) and screw (21). 341hsm67 Fig. 113
– Recover the guide rod and fork.
– Refit the assembly in reverse order to removal while
observing the following instructions: 21 20
– Tighten screw (21), lightly coated with
Frenetanch (242), to 3 ± 0,5 daN.m.
– The lubricated O-ring (26) must be refitted from the
outside of the housing and after refitting the control
shaft.
– Reposition the control shaft finger correctly in the slot
in the guide rod.

22

341hsm68 Fig. 114

C1.72 Ares 806 – 09.2004 – GB


Proportional power take-off

Removing/refitting the gears


– Remove the rear PTO housing (see previous page).
– If necessary, recover the countershaft and sleeve on 6
the 4 wheel drive casing side.
5
– Remove the selection system (see previous page).
– Unscrew screw (6) and recover the sleeve (5). 9
– Remove the bearing (8) if necessary.
– Free the nut (9). 11
– Use the locking of the lower shaft to release the nut 8 10
(see lower shaft removal).
– Remove the cover (15) and finish unscrewing the 30 15
nut (9).
– Remove the hub (11), sliding gear (10), bearing cones
and cups, shims (14) and gear (18).
– If necessary, remove the gear (19) fastened to
the 540 rpm gear (see lower shaft removal). 14
Refit the assembly in reverse order to removal while
18
observing the following instructions:
19
– Refit the countershaft in the same position from which
it was removed.
N.B.: The free-cut end of the shaft must be facing the
4 wheel drive casing.
– Press-fit the bearing (8) using a suitable jig.
– Shim the tapered bearings (see following page).
– Refit the cover (15) and tighten screws (30)
to 8 ± 1 daN.m.
– Tighten the nut coated with Frenbloc (270)
to 20 ± 4 daN.m while immobilising the shaft
according to the removal procedure.
– Lock the nut by deforming its flange.
– Tighten screw (6), lightly coated with Frenbloc (270),
to 2,6 ± 0,2 daN.m.
– Refit the selection system.
Fig. 115
– Couple the housing to the rear axle. 341hsm69

Ares 806 – 09.2004 – GB C1.73


Proportional power take-off

Adjusting the bearings


– Put the cover (15) in a vice equipped with grips.
– Assemble the gear (18) and the lubricated tapered
bearings.
– Separate the bearings by a higher thickness of
shims (14) to obtain play.
– Refit the hub (11).
– Tighten nut (9) provisionally to 20 ± 4 daN.m.

Thickness "E3" of shims (14) 15


– Push the gear (18) hard and rotate it to seat the
bearings.
– Place a dial gauge probe at the end of the shaft (18).
– Pull the gear *1 hard and rotate it to seat the bearings.
– Subtract from the thickness of the shims positioned on
measuring, the thickness of shims corresponding to the
measured play and the preload value 0,10 ± 0,05 mm.
If possible, adjust towards the maximum end of the 14
tolerance scale.

For example, if the measured play is 0,10 mm and the


shim thickness is 12,4 mm 18
"E3" (minimum) = 12,4 – 0,10 – 0,15 = 12,15 mm
"E3" (maximum) = 12,4 – 0,10 – 0,05 = 12,25 mm
According to the example, the thickness of the shims to be
positioned should be as close to 12,15 mm as possible.
– Refit the nut and check that the gear rotates correctly.
– Refit the assembly, consulting the sections concerned.

9
± 0,05
0,10 mm
11
341hsm70 Fig. 116

C1.74 Ares 806 – 09.2004 – GB


C2 – GPA 30 REAR AXLE
(The HD+ and HDE axle tubes fitted to GPA 30 rear axles are described
in chapter "C1").

Ares 806 – 09.2004 – GB


Tightening torques and main adjustments

Gearbox/intermediate housing coupling

Formajoint (510)

28 ± 4 daN.m
Frenetanch (242)

342hsm0k Fig. 1

C2.2 Ares 806 – 09.2004 – GB


Tightening torques and main adjustments

Intermediate housing/rear axle coupling

Formajoint (510)

28 ± 4 daN.m
Frenetanch (242)

342hsm0l Fig. 2

Ares 806 – 09.2004 – GB C2.3


Tightening torques and main adjustments

Rear axle/PTO housing coupling

Formajoint (510)

52 ± 4 daN.m
Frenetanch (242)

342hsm0m Fig. 3

C2.4 Ares 806 – 09.2004 – GB


Tightening torques and main adjustments

General cross-section

±2 ±1 ± 0,2 ± 0,05
5
±1
daN.m 23 daN.m 12 daN.m 2,6 daN.m 0,05 mm 6
±1
daN.m
Formajoint (510)
Frenbloc (270) Frenbloc (270) Frenbloc (270)

3,2 ± 0,2 daN.m


Frenetanch (242)

13 ± 1 daN.m
Frenetanch (242)

±1
8,6 daN.m

0,05
± 0,05
mm 8 ± 1 daN.m 0,07
± 0,03
mm Formajoint (510) Formajoint (510) ±4
52 daN.m 0,10
± 0,05
mm
Frenetanch (242)

342hsm0n Fig. 4

Ares 806 – 09.2004 – GB C2.5


Tightening torques and main adjustments

5" differential HD+ axle tubes


± 1,5 ±7
85 daN.m
0,10
± 0,05
mm
11,5 daN.m 0,35 ± 0,10 mm 11,5 ± 1,5 daN.m Scelbloc (648) 0,07
± 0,05
mm
Frenbloc (270) Frenbloc (270)

26 ± 4 daN.m
Frenetanch (242)

341hsm77 Fig. 6

HDE axle tubes


±7
85 daN.m
Scelbloc (648) 0,07 ± 0,05 mm
Frenbloc (270)

±4
26 daN.m
Frenetanch (242)

341hsm78 Fig. 7

11,5 ± 1,5 daN.m


Scelbloc (648)
Frenbloc (270)

341hsm75 Fig. 5

C2.6 Ares 806 – 09.2004 – GB


GPA 30 drive pinion

General
The helical drive pinion is supported by 2 tapered supporting the 4-wheel drive driving gear is located in the
bearings mounted opposite each other. The bearing intermediate housing. Its position is adjusted by means of
cone (2) is press-fitted onto the drive pinion and the one or more shims (6) placed between the bearing (5) and
cups (3) and (9) are also press-fitted into the intermediate the housing. The bearings are preloaded by means of one
housing and the bearing (5) respectively. The bearing or more shims (8) fitted between the bearing cone (10)
cone (10), free on the drive pinion, enables the shims (8) and the thrust washer (7).
to be fitted for packing purposes. The drive pinion

Parts list
1 Drive pinion. 5 Bearing. 9 Bearing cup.
2 Bearing cone. 6 Shims. 10 Bearing cone.
3 Bearing cup. 7 Thrust washer. 11 Nut.
4 Screw. 8 Shims.

Exploded view

7
8
9
10
11

3
4
5

6
342hsm16 Fig. 8

Ares 806 – 09.2004 – GB C2.7


GPA 30 drive pinion

Removal/refitting
Uncouple the tractor between the gearbox and the
intermediate housing (12) as follows:
– Refer to Chapter "H" for partial cab removal.
Operations 1 to 7.
– Drain the transmission system.
12
– Remove the reservoir(s) and disconnect the pipes,
hoses and wiring harnesses interfering with the
uncoupling operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.
– Release the ratchet of the "Park Lock" transmission
lock.
– Mark the position and extract the sleeve between the
drive pinion and the lower shaft.
– Remove the bearing/hydraulic pump driving gear
assembly. 342hsm17 Fig. 9

– Disconnect the handbrake mechanism control shaft.


– Free and secure the nut (11) with spanner
n° 60 05 006 310. 11
– Fit special socket n° 60 05 006 311 to the end of the
drive gear (Fig. 10) and turn in a clockwise direction.
– Remove the bearing cone (10), shims (8) and thrust
washer (7).

60 05 006 311

60 05 006 310

342hsm18 Fig. 10

10

11

342hsm19 Fig. 11

C2.8 Ares 806 – 09.2004 – GB


GPA 30 drive pinion

13

13

6
342hsm20 Fig. 12

– Uncouple the intermediate housing (12) from the rear


axle.
– Remove 2 diametrically opposite screws (13) from the 5
bearing (5).
– Screw 2 locating studs in replacement (Fig. 13).
– Finish removing the other screws.
– Extract the bearing (5) with the aid of 2 screws inserted
into the tapped holes.
– Remove the shims (6).
– Remove the handbrake casing and the 4-wheel drive
gear (17).
– Make a visual note of the position of the parts.
– Remove the retaining ring (14).
– Remove the screws (15).
– Separate the handbrake casing from the bearing (5).
– Remove the discs, the intermediate plates and the
handbrake mechanism.
If necessary, extract the bearing cups and the cone from 342hsm21 Fig. 13

the drive pinion.

17 14 5 15

342hsm22 Fig. 14

Ares 806 – 09.2004 – GB C2.9


GPA 30 drive pinion

7 5

13

10

2
11
6
8

342hsm23 Fig. 15

N.B.: If the drive pinion, tapered roller bearings, – Fit and adjust the brake control.
bearing block, thrust washer or intermediate housing – Refit the bearing/hydraulic pump driving gear
need to be replaced, it is essential to adjust the drive assembly.
pinion protrusion distance and then shim the tapered – Refit the ratchet and sleeve of the "Park Lock"
bearings. transmission lock.
– Clean and inspect all parts, replace all faulty parts. If – Couple up the tractor.
removed, fit the bearing cone (2) fully onto the drive N.B.: If the ring gear and drive pinion have needed to
pinion using an appropriate jig and a press and bring be replaced, check the backlash (see paragraph
the cup (3) into contact with the bearing block (5). concerned).
– Lubricate the roller bearing with transmission oil.
Check the operation of all controls. Road test.
– Refit the handbrake mechanism, the intermediate
plates and the discs. Check the gasket faces for leaks.
– Assemble the handbrake casing and the bearing. Check the hydraulic couplings for leaks.
– Slide the drive pinion, handbrake and bearing (5)
assembly with the aid of locating studs and with the
measured number of shims (6).
– Drive the screws (13) gradually and alternately to fit the
bearing correctly.
– Coat the screws (13) lightly with Frenbloc (270) and
tighten to 12 ± 1 daN.m.
– The thrust washer (7) must be placed in contact with
the shoulder in the drive pinion.
– Slide on the shims (8).
– Lubricate the bearing cone (10) with transmission oil
and mount it on the drive pinion in contact with the
shims.
– Degrease the nut (11) and the drive pinion threads.
– Coat the nut thread lightly with Frenbloc (270) and
immobilise it with spanner n° 60 05 006 310. Using
socket n° 60 05 006 311, turn the drive pinion
anticlockwise to a torque of 23 ± 2 daN.m.
Important: Check drive pinion rotation manually.
Lock the nut by deforming its flange, without breaking
it, using a suitable tool.

C2.10 Ares 806 – 09.2004 – GB


GPA 30 drive pinion

Drive pinion protrusion distance and shimming


Reminder: It is essential to adjust the pinion – Fit the bearing (9) and (10) and the thrust washer
protrusion before shimming the tapered roller without shims.
bearings. Do not alter the adjustment without
N.B.: The thrust washer (7) will be fitted while the
reviewing the shimming of the drive pinion bearings.
distance between the bearing ocone and the nut is
being measured.
Setting the drive pinion
protrusion distance – Tighten the nut (11) to 4 ± 1 daN.m with tools
n° 60 05 006 310 and n° 60 05 006 311.
Without the handbrake casing and the 4-wheel drive gear.
– Turn the drive pinion 8 times to seat the bearings
– Fit the bearing (5) with its bearing cup (3) and without
properly.
shims, tighten screws (13) to 12 ± 1 daN.m.
– Check the nut torque once again.
– Slide the drive gear (1) with the bearing cone (2).

7 9 5 1

11 10 2 13

342hsm24 Fig. 16

Ares 806 – 09.2004 – GB C2.11


GPA 30 drive pinion

Z
X
Y

342hsm25 Fig. 17

Measuring "X"
Measure "X" with a depth gauge (Fig. 18).
1 5
Thickness "E1" of shims (6)
Determine "E1" from "X", "Y" and "Z".
Given that:
– "Z" corresponds to the nominal dimension determined
between the rear face of the intermediate housing and
the differential axis = 241 ± 0,05 mm.
N.B.: This dimension is marked inside the housing
along the horizontal axis of the differential case. X

– "Y" corresponds to the nominal positioning dimension


of the drive pinion in relation to the differential
axis = 139 ± 0,05 mm.
E1 = Z – (X + Y)

For example, if X = 101,35 and Z = 241


342hsm26 Fig. 18
"E1" (minimum) = 241 (101,35 + 138,95) = 0,7
"E1" (maximum) = 241 (101,35 + 139,05) = 0,6
According to the example, shims with a thickness of
between 0,6 and 0,7 mm should be inserted.
N.B.: Thickness "E1" should be achieved with no
more than 3 shims. The drive pinion and the ring gear
are paired by a number and a letter engraved on each
component.

C2.12 Ares 806 – 09.2004 – GB


GPA 30 drive pinion

11 8 7 6 5

0,07 ± 0,03 mm
10 9 3 13
342hsm27 Fig. 19

Setting the drive pinion bearings Measuring "W"


N.B.: Always proceed with shimming the roller – Position a dial gauge probe on the end of the drive
bearings after adjusting the drive pinion protrusion pinion (Fig. 19).
distance. – Apply an axial tensile force of 45 ± 5 daN and turn the
drive pinion at least 8 times to seats the bearings
Without the handbrake casing and the 4-wheel drive gear. correctly. .
– Mount the bearing (5) with its bearing cup (3) and – Set the dial gauge to zero.
shims (6) (thickness "E1") and tighten the screws (13) – Apply an axial thrust force of 45 ± 5 daN and turn the
to 12 ± 1 daN.m. drive pinion at least 8 times to seats the bearings
N.B.: The thrust washer (7) must be placed in contact correctly. .
with the shoulder in the drive pinion (Fig. 19). – Measure the value "W".
– Determine a higher thickness of shims (8) to obtain Thickness "E2" of shims (8)
play.
– Determine thickness "E2" corresponding to the higher
– Lubricate the bearing cup (9). number of shims minus the measured play minus a
– Mount the taper (10). Using spanner n° 60 05 006 310 preload of 0,07 ± 0,03 mm.
and socket n° 60 05 006 311, tighten the nut (11)
to 23 ± 2 daN.m.

Ares 806 – 09.2004 – GB C2.13


GPA 30 drive pinion

11 8 7 6 5

0,07 ± 0,03 mm
10 9 3 13
342hsm27 Fig. 20

For example, if the measured play is 0,15 mm and – Loosen and remove the nut (11). Slide on shims (8) to
the higher number of shims equates to a thickness the measured thickness "E2" between the thrust
of 1 mm washer (7) and the bearing cone (10).
1 0,15 = 0,85 mm of shims with zero play and preload. – Lubricate the two tapered bearings. Using spanner
"E2" (minimum) = 0,85 – 0,1 = 0,75 n° 60 05 006 310 and socket n° 60 05 006 311,
tighten the nut (11) to 23 ± 2 daN.m.
"E2" (maximum) = 0,85 – 0,04 = 0,81
– Turn the drive pinion at least 8 times to seat the
According to the example, the shim thickness should be
bearings correctly.
between 0,75 and 0,81 mm.
– Check that the drive pinion drag torque
is 0,23 ± 0,12 daN.m.
– Loosen and remove the nut (11).
– Refit the handbrake casing and the 4-wheel drive gear
according to the drive pinion refitting procedure.

C2.14 Ares 806 – 09.2004 – GB


Notes

Ares 806 – 09.2004 – GB C2.15


5" differential

General
The ring gear is riveted to the differential case. The The piston chamber housed in the cover (19)
differential assembly rotates on two tapered bearings held communicates with a duct in the bearing (36), enabling
by 2 side supports (2) and (36) screwed onto the housing. low pressure (17 bar) to act on the piston. The duct is
The differential assembly consists of 2 half-cases sealed by 2 piston rings (34).
containing 4 planet gears and 2 sun gears. The differential
assembly is preloaded by means of shims (32) placed Clutched position
between the cone (31) and the left-hand bearing (36). The When the differential locking solenoid valve is activated,
backlash between the drive pinion and the ring gear is oil flows into the piston chamber. The piston compresses
obtained by means of shims (7) inserted between the the intermediate plates (24) and the discs (23) connected
cup (6) and the differential half-case (10). to the hub (25) and case (21) respectively. In this clutched
position, the input sun gear of the RH and LH axle tubes
Differential lock rotate at the same speed.
The multidisc locking device located on the left-hand side
of the half-case (19) comprises. Declutched position
– A unit (21) containing the discs (23) and the When power is turned off, the piston withdraws and the
backplates (24). discs and intermediate plates are decompressed,
– A hub (25) connected by splines to the sun gear of the enabling the sun gears and planets gears to fulfil their
LH axle tube. differential function.
– An assembled cover (29) for the piston (27) supported
by a tapered bearing.

Parts list
1 Screw. 15 Friction washer. 29 Differential locking cover.
2 RH bearing. 16 Planet gear. 30 Bearing cup.
3 O-ring. 17 Spider shaft. 31 Bearing cone.
4 Centring pin. 18 Friction ring. 32 Shims.
5 Bearing cone. 19 Differential half-case. 33 O-ring.
6 Bearing cup. 20 Screw. 34 Sealing piston ring.
7 Shims. 21 Differential locking case. 35 Centring pin.
8 Deflector. 22 Screw. 36 LH bearing.
9 Rivets. 23 Differential locking disc. 37 Screw.
10 Differential half-case. 24 Differential locking backplate. 38 O-ring.
11 Friction ring. 25 Differential locking hub. 39 Supply tube.
12 Ring gear. 26 O-ring. 40 Seal.
13 Drive pinion. 27 Piston. 41 Coupling.
14 Sun gear. 28 O-ring.

C2.16 Ares 806 – 09.2004 – GB


5" differential

Exploded view

17
15
14
12
10
8
6 19
18
5 14
3
16
2
13

11
9
7 25
4
1

24

23

22
21 41

20 38
36 40
33
32 39
31
30
29
28
27 37
26
35

34

342hsm28 Fig. 21

Ares 806 – 09.2004 – GB C2.17


5" differential

42

39

41

342hsm29 Fig. 22 342hsm30 Fig. 23

Removing/refitting the bearings


29 32
LH bearing
N.B.: The bearing (36) and sealing rings (34) of the 37
differential lock can be worked on by removing just
the left-hand axle tube. 36
– Remove the left-hand axle tube (see paragraph
concerned).
– Unscrew the coupling (41) and remove the transfer 31
tube (39).
– Remove the brake piston (see chapter "C3").
– Remove the forward motion sensor (42) from the
housing.
– Remove the screws (37) from the bearing (36), fit two
diametrically opposite locating studs "A into the
housing and tighten them firmly up against the 34
differential locking cover (29) (Fig. 25). 342hsm31 Fig. 24
– Extract the bearing with the aid of the tapped holes and
two screws (B) and recover the cone 25 and
shims (31).
N.B.: The locating studs (A) hold and centre the
differential assembly in the housing. Do not loosen
the studs or the assembly may become skewed and
section the sealing rings (34) on refitting the bearing.

29 B

36 A

342hsm32 Fig. 25

C2.18 Ares 806 – 09.2004 – GB


5" differential

33 38 35 31

37

34 32
342hsm33 Fig. 26

N.B.: If the bearing block or roller bearing has to be


replaced, always adjust the differential roller bearings
(cf. following pages). 35
– Check that the centring pin (35), shims (32) and
bearing cone (31) are present.
– Check that the sealing rings (34) are not damaged and
rotate normally in their groove. After checking, remove
the rings and coat them with miscible grease so that
they remain seated in the groove while the support is
refitted.
– Fit new O-rings (33) and (38).
– Slide the bearing (36) onto the locating studs (A)
and tighten 28 screws 4 evenly and alternately
to (37) daN.m.
A
– Remove the locating studs. Fit and tighten the other
screws to the same torque.
– Position the supply tube and coupling.
– Refit the brake piston (see chapter "C3"). 342hsm34 Fig. 27

– Check that the seal (33) is correctly positioned.


– Refit the left-hand axle tube (see paragraph
concerned).

RH bearing
The removal/refitting procedure for the right-hand bearing
is similar to the one for the left-hand bearing. Except that
the RH bearing is not equipped with hydraulic ducts and
seals (34).
A

36

37

342hsm35 Fig. 28

Ares 806 – 09.2004 – GB C2.19


5" differential

Removing/refitting the differential


case
Uncouple the tractor between the intermediate housing
and the rear axle housing as follows:
– Refer to Chapter "H" for partial cab removal.
Operations 1 to 7.
– Drain the transmission system.
– Remove the reservoir(s) and disconnect the pipes,
hoses and wiring harnesses interfering with the
uncoupling operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.
– Release the ratchet of the "Park Lock" transmission
lock. 32 5
If necessary, remove the PTO housing.
2
– Remove the axle tubes (see paragraph concerned).
– Position rear differential stand n° 60 05 006 314 in
support. With the aid of the stand, keep the differential
31 7
assembly in line with the RH and LH bearings ((2)
and (36) respectively). 36 6
– Remove the RH and LH bearings according to the
procedure described above.
– Recover the cones (31) and (5) and shims (32) from
the LH bearing.
– Remove the differential case from the rear axle
housing (Fig. 30).
N.B.: As space is restricted around the differential
case, it is essential to fit the hydraulic tubes in the
rear axle housing before refitting the case.
In order to avoid damaging the sealing rings (34), it is
necessary to align the differential assembly correctly with
the housing axis before fitting the bearings (2) and (36).
With the aid of the tool, insert the differential assembly into
the central housing and hold it in line with the axle tubes. 342hsm36 Fig. 29

– Fit the measured thickness of shims (7) behind the


cup (6).
– Fit the bearing (2) according to the procedure
described above.

342hsm37 Fig. 30

C2.20 Ares 806 – 09.2004 – GB


5" differential

Prepare to fit the bearing (36) as follows:


– Slide the bearing cone onto setting tool
n° 60 05 006 309 adapted to the differential case.
Using the tool, centre the differential assembly in the
housing while turning the central screw clockwise as
far as it will go.
– Fit 2 diametrically opposed locating studs (A) into the
housing and tighten them firmly. This method keeps the
differential assembly centred after removing tool
n° 60 05 006 309.
– Remove the tool and recover the bearing cone.
– Check the presence of the centring pin (35) and shims.
– Fit a new O-ring (33).
– Check that the sealing rings (34) are not damaged and
rotate normally in their groove.
– Fit the bearing (36) according to the procedure 60 05 006 309
described above. After fitting the bearings, check the
rotation of the differential assembly by hand. 342hsm38 Fig. 31
– Refit the brake pistons (see chapter "C3").
– Refit the axle tubes (see paragraph concerned). If 34
removed, refit the PTO housing.
– Couple up the tractor between the intermediate
housing and the rear axle housing.
– Check the operation of all controls (mechanical,
hydraulic and electronic). Road test. 35 36
– Check the mating surfaces and hydraulic couplings for
leaks.

33
342hsm39 Fig. 32

Ares 806 – 09.2004 – GB C2.21


5" differential

Removing/refitting the differential


lock 27

– Remove the differential case as described in the


29
procedure above.
30
– Position the differential case with the cover (29) facing 25
up.
– Remove the screws (20). 23
– Remove the cover (29), discs (23), backplates (24) and
24
hub (25).
– Remove the screws (22) and case (21). 21
– Tap the cover (29) lightly on a wooden block to remove
the piston (27). 22
– Replace the O-rings. Drive out the cup (30) if
necessary.
N.B.: If the case (21), cover (29) and bearing (36) need 20
to be replaced, the differential case must be shimmed 342hsm40 Fig. 33
and the backlash between the drive pinion and the
ring gear checked (see following pages).
– Check that the hydraulic duct in the cover is not
blocked.
– Lubricate the new seals before fitting.
– Refit the piston (27) by tapping gradually and
alternately around the edge with a mallet.
– Check that there are no seal fragments after fitting.
– Coat the screws (22) lightly with Frenbloc (270) and
tighten to 11,5 ± 1,5 daN.m.
– Fit the hub, backplates and discs.
– Position the assembled cover (29) of the piston (27).
– Fit and tighten the screws (20) coated with
Frenbloc (270) to 11 ± 1 daN.m.
– Check manually that the discs and backplates are not
stressed.
– Refit the differential case as described in the procedure
above.

C2.22 Ares 806 – 09.2004 – GB


5" differential

Removing/refitting the planet gears,


sun gears and ring gear 19 16 12

– Remove the differential locking system.


– Separate the half-cases (10) and (19).
N.B.: These parts have the same number. They must 9
imperatively be coupled.
22 10
– Remove the sun gears (14) fitted with friction rings (11)
and (18), planet gears (16), washers and spider (17). 18 11
If necessary, drive out the bearing cup on half-
casing (10) and recover the shims.
– Extract and discard the deflector. The drive pinion must
17
be replaced if the ring gear is replaced.
N.B.: These parts have the same number. They must
imperatively be coupled.
14
The ring gear and case are originally riveted together. For 342hsm41 Fig. 34
repair, the rivets are replaced by screws and nuts
referenced in the spare parts catalogue.
– Punch (on the ring gear teeth side) the centre of each
rivet (9). Using a 5 mm dia. bit, drill the rivets to a depth
of 12 mm (Fig. 35). 10
– Drill again to an identical depth with a 12 mm bit. 12
– Drive the rivets hard with a suitable drift punch
(Fig. 36).
– Clean the bearing surfaces of the new ring gear (12)
and half-case (10), as well as the screws and nuts.
– Coat the initial threads of the screws with
Frenbloc (270) and position them in the ring gear and
case.
– Tighten the nuts to 18 ± 2 daN.m.
– Refit the deflector, shims and cup.
– Refit the planet gears and sun gears in reverse order to
removal.
– Tighten the screws (22) coated with Frenbloc (270)
342hsm42 Fig. 35
to 11,5 ± 1,5 daN.m.

342hsm43 Fig. 36

Ares 806 – 09.2004 – GB C2.23


5" differential

Adjusting the backlash


N.B.: The backlash to be obtained between the ring
gear and drive pinion ensures that the final drive is
reliable and that the assembly operates correctly.
6
This backlash must be checked following:
– Adjustment of the protrusion distance. 7
– Shimming of the differential case.
With the aid of a suitable extractor, remove the cup (6) 8
and discard the deflector (8). 10
– Position shims (7) with a thickness of 0,20 mm on the
differential half-case (10). 2
– Fit the cup (6) up against the shims without the
deflector (8).
– Refit the differential case (see corresponding
paragraph) with only the RH bearing (2). On the
LH side, fit tool n° 60 05 006 309 with the roller
bearing (31) (Fig. 38). 342hsm44 Fig. 37

– Tighten the tool's centre screw to 1 daN.m.


– Turn the differential to seat the bearings.
– Check once again that the tool screw is tight.
– Couple and fasten the intermediate housing
temporarily with the rear axle housing by tightening the
screws to 61 ± 7 daN.m. With the PTO housing
removed, place the plunger of a dial gauge at half- 31
length on a tooth of the ring gear (Fig. 39).
– Check that the backlash is 0,35 ± 0,10 mm.
– Carry out this operation at 3 points of the ring gear. If
the presetting is incorrect, the principle consists of
removing or adding shims (7) until the backlash is
within the aforementioned tolerance.
– Insert the selected shims (7).
– Partly insert a new deflector (8). The deflector will be
fitted completely with the cup (6).
– Check that the cup is bearing properly on the shims
and is in contact with the deflector. 342hsm45 Fig. 38

– The next essential step is to shim the differential case


roller bearings.

342hsm46 Fig. 39

C2.24 Ares 806 – 09.2004 – GB


5" differential

Shimming the differential case roller


bearings 31

N.B.: If the rear axle housing, ring gear, tapered roller


bearings and bearing blocks need to be replaced, the
differential case must be shimmed. Check
beforehand that the backlash is correct.
– Fit the differential (see paragraph concerned).
– Fit the RH bearing with the measured number of shims.
On the LH side, fit tool n° 60 05 006 309 with the roller
bearing (31). Fasten the tool to the housing with 2
screws (Fig. 40).
– Tighten the centre bolt to 1 daN.m.
N.B.: Turn the ring gear a few times to seat the cones
correctly in the cups. Check the centre bolt torque
again.
342hsm47 Fig. 40
Measuring "Y"
– Determine "Y" according to "A" and "B".
– Measure "A", the distance between the top of the
bearing and the contact surface of the shims, with tool
n° 60 05 006 309 (Fig. 41 and 42).
– Measure "B", the distance between the top of the
bearing and the contact surface of the bearing on the A
housing, with tool n° 60 05 006 309 (Fig. 42).
B
Y=B–A Y

342hsm48 Fig. 41

60
05
00
6
30
9

342hsm49 Fig. 42

Ares 806 – 09.2004 – GB C2.25


5" differential

Measuring "X"
Using a suitable depth gauge, measure "C" and determine
dimension "X" between the bearing cone (31) and the
contact surface of the bearing on the housing:
X = C – 10 mm
(10 mm is the thickness of measuring tool n°
60 05 006 309).
C

Thickness "E" of shims (32)


Determine "E" according to "X" and "Y" plus a preload
P1 = 0,10 ± 0,05 mm.
E = X – Y + P1

For example, if A = 39,65, B = 103,45 and C = 74,5


Y = 103,45 – 39,65 = 63,8
X = 74,5 – 10 = 64,5
E (minimum) = 64,5 – 63,8 + 0,05 = 0,75
342hsm50 Fig. 43
E (maximum) = 64,5 – 63,8 + 0,15 = 0,85
According to the example, the shim thickness must be
between 0,75 and 0,85 mm.
– Remove the tool and the bearing cone (31). Place
shims (32) to a thickness "E" on the bearing (36).
– Fit the RH bearing (36) (see paragraph concerned). 31
– Refit the assembly as described in the procedures on
the pages concerned. X

342hsm51 Fig. 44

32

31
36

342hsm52 Fig. 45

C2.26 Ares 806 – 09.2004 – GB


Notes

Ares 806 – 09.2004 – GB C2.27


GPA 30 power take-off clutch

General
The clutch is mounted on the rear PTO housing. It is The clutch is supplied by a proportional solenoid valve on
driven by a countershaft traversing the transmission the 17 bar low-pressure circuit. The oil reaches the piston
system. This shaft also drives the hydraulic pump gear. chamber through the shaft ducts. In the clutched position,
The clutch assembly consists of: the PTO brake piston located in the rear axle housing is
– A casing supported by 2 tapered roller bearings. idle and releases the clutch casing. When the clutch is
– A shaft centred by a bushing in the rear housing and by engaged, the discs are cooled by the oil from the shaft
a ball bearing in the clutch. It comprises 2 ducts: ducts.
• A central duct to lubricate the bearings. Power take-off brake
• An axial duct to feed the piston. When the supply is interrupted, the spring and Belleville
– A hub supports the discs. washer release the discs. The 17 bar supply displaces the
– A cover accommodates the backplates. brake piston, stopping the casing. A duct communicating
with the brake piston chamber lubricates around the
casing during the braking phase.

Parts list
1 Retaining ring. 15 O-ring. 29 Cover.
2 Sealing ring. 16 Belleville washer. 30 Retaining ring.
3 Screw. 17 Spring holder. 31 Retaining ring.
4 Unit. 18 Spring. 32 Ball bearing.
5 Brake piston. 19 Spring seat. 33 Bearing.
6 Brake cylinder. 20 Retaining ring. 34 Thrust bearing.
7 Screw. 21 Ball bearing. 35 Screw.
8 Valve. 22 Chamfered washer. 36 Sleeve.
9 Plug. 23 Screw. 37 Hydraulic pump driving gear.
10 Pin/hydraulic throttle. 24 Drive hub. 38 Screw.
11 Shaft. 25 Retaining ring. 39 Retaining ring.
12 O-ring. 26 Shaft. 40 Shaft.
13 O-ring. 27 Backplates.
14 Piston. 28 Discs.

C2.28 Ares 806 – 09.2004 – GB


GPA 30 power take-off clutch

Exploded view

1
2
4
9
3 10
7 11
12
13
14
8 15
5 16
6 17
18
19
24 20
25
26

27
28 21
22
23

26
30 29
31
32
33
32
36
37
39
40

34
35

38
342hsm53 Fig. 46

Ares 806 – 09.2004 – GB C2.29


GPA 30 power take-off clutch

26 47 41

42 43 44 46 45

342hsm54 Fig. 47

Removal/refitting
– Drain the transmission system. – Pull the lower shaft then remove the gears (44)
– Disconnect the PTO control cables and pipes. and (45).
– Remove the linkage and lift accessories obstructing the – Recover the friction washers and the dog (46).
uncoupling of the PTO housing (41). – Remove screws (47).
– Remove the rear PTO housing with a chain and hoist. – Remove the clutch and upper shaft assembly.
– Leave the shaft (26) in the rear axle. – Remove the sealing rings (2). Using a press and a
– Remove the sensor located on the right-hand upper suitable jig, compress the Belleville washer (50)
side of the PTO housing. moderately (Fig. 48).
– Recover the friction washers from the lower shaft. – Remove the circlip (48), the washer (49) - noting which
– Remove the circlip (42) and washer (43) from the lower way round it is fitted - and the Belleville washer (50)
shaft and maintain the driven gears. (Fig. 48).

C2.30 Ares 806 – 09.2004 – GB


GPA 30 power take-off clutch

2 47 50

51 52 49 48

342hsm55 Fig. 48

– Separate the clutch assembly from the drive gears.


When the screws (47) have been removed, separate
48 49 50
the half-cases (51) and (52).
– If necessary, replace the tapered bearings with the aid
of a suitable jig.
– Check the state of the bushing (53), the alignement
iand the cleanliness of the duct (Fig. 50).
N.B.: If removed, postion the bushing (53) with the aid
of a suitable drift. Observe the 16 ± 0,1 mm distance
measured between the contact surface of the casing
(52) and the end of the bushing (53) (Fig. 50). Place
the outer groove of the bushing in a line with the PTO
housing duct.
– Always fit a new circlip, increasing its diameter to the
minimum.
– Place the sealing rings in their groove and attach their
ends.
Fig. 49
– Check that they rotate freely. 342hsm56

– Refit the clutch and upper shaft assembly.


– Tighten the screws (47) to 6 ± 1 daN.m. 53
– Refit the driven gears with the friction washers slightly
coated with miscible grease.
– Insert the lower shaft in the rear bearing and the driven
gears.
– Refit the circlip.
– Mount and adjust the sensor, coated with
Frenetanch (542), to 3/4 of a turn prior to contact.

16 ± 0,1 mm

342hsm57 Fig. 50

Ares 806 – 09.2004 – GB C2.31


GPA 30 power take-off clutch

24 22 23

6
5

± 0,2
21 146,25
ø8
25
170

4
= =

+ 0,5
ø 58 0
ø 92
64
6

342hsm59 Fig. 51 342hsm60 Fig. 52

Removing the clutch


19 24 20 21 23 22 27 28 29
– Remove and separate the clutch from drive gears (see
above).
– Clamp the housing (4) in a vice equipped with grips.
– Remove screws (3).
– Separate the cover (29) from the casing.
– Remove the discs (28) and the backplates (27). With
the aid of a locally made tool (Fig. 51), compress the
spring via the hub (24).
– Remove the screw (23) and the washer (22).
– Remove the tool.
– Remove the drive hub (24), the spring seat (19), the
spring, the spring holder and the Belleville washer.
– If necessary, remove the retaining ring (20) and the
bearing (21).
– With a jet of compressed air, extract the piston (14) and
remove the O-rings.

3 14 4

342hsm61 Fig. 53

C2.32 Ares 806 – 09.2004 – GB


GPA 30 power take-off clutch

Refitting the clutch


29 22 23 24 21 20
N.B.: The valve (8) is crimped onto the casing (4). The
throttle (10) is placed in the shaft (11). The shaft (11),
coated with scelbloc (648), is press-fitted. If removal
is necessary, check after refitting that the hydraulic
ducts are not blocked by sealant. The threaded
plug (9) is lightly coated with Frenetanch (542).
– Clean and check the parts. Replace any defective
parts.
– Replace and lubricate the O-rings.
– Lubricate the shaft (11) and the piston (14) and fit the
piston in the casing (4) by tapping gradually and
alternately around its edge with a soft-faced hammer.
– If removed, fit the bearing (21) in the hub (24) with a
suitable jig.
– Fit the retaining ring (20).
– Refit the Belleville washer, as illustrated in the general
arrangement, and the spring holder, spring, spring seat
and drive hub (24).
– Compress the spring with a locally made tool (see
removal procedure).
– Fit washer (22) and tighten screw (23) coated with
Frenbloc (270) to 2,6 ± 0,2 daN.m. 8 4
– Fit the discs and backing plates by placing tabs (A)
between screw holes (B). 14
Important: New discs must be soaked in a bath of
transmission fluid for approximately one hour. 3

– Position the cover (29). 10


– Tighten the screws (3), lightly coated with
Frenetanch (242), to 3,2 ± 0,2 daN.m. 11
– Check hub rotation by hand. 9
– Assemble the clutch in the housing as described in the
refitting procedure above.
342hsm62 Fig. 54

24 A

4 B

342hsm63 Fig. 55

Ares 806 – 09.2004 – GB C2.33


GPA 30 power take-off upper shaft

26 30 32 33 32 36

34

342hsm64 Fig. 56

Removal/refitting
27 53
– Remove the drive gears as described in the clutch
removal procedure.
N.B.: To remove the shaft (26), the left-hand cover
must be removed in order to access the retaining
ring (30) as it cannot be passed through the hole in
the intermediate housing partition. Before removing
the shaft, make a visual note of the clearance for the
ring gear passage. To refit the ball bearings (32),
bearing block (33) and hub (36), remove the thrust
bearing (34) and uncouple between the gearbox and
the intermediate housing.
If necessary, refit the correctly positioned
countershaft (26) and the retaining ring (30).
– Refit the left-hand cover. If required, refit the bearings 51 52
cups in the cover and casing respectively.
342hsm65 Fig. 57
– Refit the drive gears, the half-cases (51) and (52) and
the measured shims (53).
– Tighten the screws (27), coated with Frenetanch (242),
to 6 ± 1 daN.m.

C2.34 Ares 806 – 09.2004 – GB


GPA 30 power take-off upper shaft

Adjustment
– Assemble the clutch with the gears and half-cases.
– Assemble the half-cases (51) and (52), without shims, 54
with 4 bolts (54) (Fig. 58).
– Fit the Belleville washer (50), the washer (49) and the 50
retaining ring (48).
– Keep the drive gear assembly in a vice equipped with 49
grips (Fig. 59).
– Place a dial gauge probe at the end of the shaft (11)
(Fig. 59).
– To seat the bearings properly, pull hard on the shaft 48
and rotate it.
– repeat this operation by pushing hard on the shaft and 52
measuring the distance.
– Fit shims with a thickness corresponding to the 51
measured play minus 0,05 ± 0,05 mm.
342hsm66 Fig. 58
For example, if the measured play is 0,86 mm
0,86 – 0 = 0,86
0,86 – 0,1 = 0,76 11 54
According to the example, shims with a thickness of
between 0,76 and 0,86 mm should be inserted.
– Refit the assembly observing the instructions
mentioned in the sections concerned.

52 51

342hsm67 Fig. 59

Ares 806 – 09.2004 – GB C2.35


GPA 30 power take-off lower shaft

General
The driven gears are mounted on the lower shaft of the (540 or 1 000 rpm) via the external control located on the
rear PTO housing. These gears are constantly engaged right-hand side of the housing. The rear bearing is fitted
with the drive gears entrained by the upper shaft line. The with a lip seal and an O-ring. The tapered bearings are
lower shaft is supported at the front by a roller bearing adjusted by shims placed between the rear PTO housing
fitted in the rear axle housing and at the rear by 2 tapered and the bearing block. A notched washer transmits the
bearings mounted in the PTO rear housing bearing. The information required for sensor operation and also acts as
dog hub is connected to the lower shaft by splines. The a spacer for the tapered bearing cones. Lubrication is
gears drive the shaft when the dog (10) is displaced either provided by the transmission oil. The oil kept in the
forward (540 rpm) or rearward (1 000 rpm). When one of deflector lubricates the roller bearing and the tapered
the drive gears transfers movement to the lower shaft, the bearings via the shaft containing an axial duct and radial
other gear is passive and rotates freely around its shaft. A holes.
fork enables the required speed to be selected

Parts list
1 Deflector. 12 Needle screw. 23 Bearing cup.
2 Roller bearing. 13 Control shaft. 24 Bearing cone.
3 Retaining ring. 14 Control link. 25 Notched washer.
4 Splined washer. 15 Bush. 26 Lip seal.
5 540 rpm gear. 16 Screw. 27 Shims.
6 Retaining ring. 17 Spring. 28 O-ring.
7 Hub. 18 Lock. 29 Bearing.
8 Sliding sleeve. 19 Retaining ring. 30 Screw.
9 O-ring. 20 1 000 rpm gear. 31 Shaft.
10 Pads. 21 Rear PTO housing. 32 Guide pin.
11 Fork. 22 Retaining ring.

C2.36 Ares 806 – 09.2004 – GB


GPA 30 power take-off lower shaft

Exploded view

1 14
2 9
3 13
5
4 12
9
6
21
15
18 16
11 17
10

7
8
19
20

22
23
24
25
24
23
22
26
27
28
29
30
31
32

342hsm68 Fig. 60

Ares 806 – 09.2004 – GB C2.37


GPA 30 power take-off lower shaft

Removal
1 2 8 5 24 23 24 26 27 29
N.B.: The rear power take-off housing must be
removed for all work on the lower shaft line.
– Drain the transmission system.
– Disconnect the PTO control cables and pipes.
– Remove the linkage and lift accessories obstructing the
uncoupling of the PTO housing.
– Remove the rear PTO housing with a chain and hoist.
– Remove the retaining ring (3) and the splined
washer (4).
– Remove the clutch/upper shaft assembly and the
gear (5).
– Remove the needle screw (12). Remove the shaft (13),
link (14) and fork (11) fitted with its pads.
– Remove retaining ring (6), hub (7) and dog (8),
retaining ring (19) and driven gear (20).
– Remove and discard the O-rings (9) from the 22
shaft (13). If necessary, mark the position of the
bearing (2) and extract it from the rear axle housing.
– Remove the deflector (1).
– Remove the speed sensor from the lower shaft located 3 4 6 7 19 20 25 22 28 30
on the right-hand side of the housing.
– Remove the screws (30), pull the interchangeable PTO 12 13 14
end fitting and extract the bearing assembly (29)
composed of:
• the lip seal (26).
• The O-ring (28).
• The shims (27).
• The bearing cups (23).
• The bearing cones (24).
• The notched washer (25).
9 11 9
– Remove the cup (23) from the rear PTO housing.
– Remove the retaining ring (22). 342hsm69 Fig. 61
– Remove the cones (24), the notched washer (25), the
bearing cup (23) and the retaining ring (22).
– Separate the bearing (29) from the shaft.
– Extract the seal (26) and O-ring (28). If necessary,
remove the interchangeable end fitting.

C2.38 Ares 806 – 09.2004 – GB


GPA 30 power take-off lower shaft

Refitting
25 28 26 29 33
– Clean and inspect all parts, replace all faulty parts.
– Check that the shaft ducts are not blocked. With a
press and a suitable jig, fit the lip seal (26) into the
bearing (29) with the spring facing the roller bearings
and the outside diameter lightly coated with
Frenetanch (542).
– Observe the 10,1 ± 0,05 mm distance (Fig. 62).
– Lubricate the inside lip of the seal (26) with
transmission oil.
– Fit the shaft into the bearing seal.
– Position the retaining ring (22) and refit the bearing
cups and cones with a suitable jig.
– Insert the notched washer (25) between the two roller
bearings.
22 10 ± 0,5 mm 30 34
– Fit the retaining ring.
– Refit the shaft assembled with the bearing, roller 342hsm70 Fig. 62

bearings and O-ring (28) in the bore in the PTO


housing.
– Tighten the screws (30) to 8,6 ± 1 daN.m. 1 2 12
– Position the deflector (1) in the bore in the PTO
housing (Fig. 63). Using a suitable drift, mount the
bearing (2) with the rounded housing in contact with
the deflector.

10

342hsm71 Fig. 63

Ares 806 – 09.2004 – GB C2.39


GPA 30 power take-off lower shaft

Refit the driven gears and the fork in reverse order to


removal, observing the following instructions: 25 28 26 29 33
– Lubricate the gear bushings (35) before fitting.
– Grese the fork pads (10) before fitting.
– Tighten the needle screw (12) coated with
Frenetanch (242).
– Mount the clutch and the upper shaft with the 540 rpm
gear.
– Fit the control link. Using the external control, check
that the coupler meshes correctly on the driven gears.
– Apply Formajoint (510) and couple the PTO housing.
– Mount and adjust the sensor, coated with
Frenetanch (542), to 3/4 of a turn prior to contact.
N.B.: If the interchangeable end fitting (33) needed to
be removed, check that the centring stud (34) is
present. Tighten the screws, lightly coated with 10 ± 0,5 mm
22 30 34
Frenetanch (242), to 13 ± 1 daN.m.
342hsm70 Fig. 64
N.B.: Should the bushings (35) become deteriorated,
replace the driven gears (Fig. 66). The bushings are
bored after fitting. 1 2 12

10

342hsm71 Fig. 65

35

342hsm72 Fig. 66

C2.40 Ares 806 – 09.2004 – GB


GPA 30 power take-off lower shaft

Adjusting the bearings


N.B.: If the PTO housing, bearing block, roller
bearings or splined washer needed to be replaced, B
always shim the roller bearings.
N.B.: Shim the roller bearings without seal (26) fitted.
25
Measuring A
Using a depth gauge, measure A on the PTO housing
(distance between the bearing cup contact face and the 22
bearing block contact face).
29
Measuring B
Fit the bearing (29), the retaining ring (22), the first cup
with its cone, the notched washer (25), the second cone
and the retaining ring on the shaft: .
– Position the shaft and bearing assembly on an
appropriate support (Fig. 67).
– Exert continuous, diametrically opposite pressure on
the perimeter of the second cup according to the
arrows (Fig. 67). A
– rotate the shaft alternately from right to left to seat the
bearings correctly. With a depth gauge, measure B at 3
points and take the average.

Shim thickness E
Determine E on the basis of A, B and the play value
J1 = 0,10 ± 0,05 mm.
E = (B – A) + J1

For example, if A = 81,5 and B = 82,8


E = 82,8 – 81,5 = 1,3 mm of shims with zero play and
preload.
E (minimum) = 1,3 + 0,05 = 1,35
E (maximum) = 1,3 + 0,15 = 1,45
According to the example, the shim thickness must be 342hsm73 Fig. 67

between 1,35 and 1,45 mm.

J1 = 0,10 ± 0,05 mm

26
342hsm58 Fig. 68

Ares 806 – 09.2004 – GB C2.41


GPA 30 crawler gears

General
It is made up of a step-down gear and a dog control mounted on the rear axle and activates the engagement
function. The step-down gear consists of an epicyclic gear dog of the step-down gear via the fork. The dog can only
set comprising a planet carrier and ring gear assembly be engaged at a standstill. The reduction ratio of the step-
located at the front of the rear axle housing. The control is down gear is 0,25.

Parts list
1 Screw. 17 Retaining ring. 33 Ring gear.
2 Control cable support. 18 Park lock sleeve. 34 Friction washer.
3 Screw. 19 Secondary shaft. 35 Retaining ring.
4 Control link. 20 Needle bearing. 36 Pinion.
5 O-ring. 21 Retaining ring. 37 Retaining ring.
6 Spindle. 22 Sliding sleeve. 38 Crawler gear support.
7 Pin. 23 Clutching gear. 39 Screw.
8 Adjustment shims. 24 Retaining ring. 40 Bearing.
9 Lever. 25 Screw. 41 Retaining ring.
10 Nut. 26 Unit. 42 Retaining ring.
11 Guide rod. 27 Planet carrier. 43 Pin.
12 Fork. 28 Pins. 44 Gearbox shaft.
13 Lock. 29 Needles. 45 Sleeve.
14 Spring. 30 Planet gear. 46 Retaining ring.
15 Screw. 31 Friction plate.
16 Intermediate housing. 32 Spacer.

C2.42 Ares 806 – 09.2004 – GB


GPA 30 crawler gears

Exploded view

4
3

5
1
7 6
2
8
10
11 9

13 12
14
15
24
23
22
21 16
20
19
18
17

39
38
37
36
35
34
33
27
26
25

32
31
30
29
28

46
45
44
42
41
43
40
342hsm0d Fig. 69

Ares 806 – 09.2004 – GB C2.43


GPA 30 crawler gears

Removing/refitting the housing


Uncouple the tractor between the gearbox and the
intermediate housing as follows:
– Refer to Chapter "H" for partial cab removal. 25
Operations 1 to 7.
– Drain the transmission system.
– Remove the reservoir(s) and disconnect the pipes,
hoses and wiring harnesses interfering with the
uncoupling operation.
– Make the tractor safe with stands and trolleys.
– Chock the tilt between the front axle and the cradle.
– Uncouple the tractor. 26
– withdraw the gearbox shaft.
– Remove the crawler gear support located in the
intermediate housing.
– Remove screws (25).
Fig. 70
– Remove the step-down gear assembly. 342hsm0e

– Remove the retainer (35) and the friction washer (34).


– Drive out the pins (28), paying attention to the needles,
in order to remove each planet gear (30).
– The clutching gear (23) is pressed onto the planet 35
carrier (27) and the retainer (24) ensures that the 34
assembly is held correctly. 33
27
24
Refit the assembly in reverse order to removal while
observing the following instructions: 23
– Equip each planet gear with 2 rows of needles coated
with grease and separated by a spacer.
– Centre the friction plates (31).
– Position the shafts (28) correctly in order to be able to 31
fit the retainer (35). 30
– Smear the faces of the step-down gear lightly with 31
grease and fit the friction washers (34), positioning 28
25
their tabs correctly.
– Fit the ring gear (33) with the clearance on the bearing 342hsm0f Fig. 71

side.
– Position the cutout part of housing (26) to the bottom.
– Tighten the screws (25), coated with Frenetanch (242),
to 1,2 ± 0,2 daN.m.
– Refit the assembly in reverse order to removal,
observing the instructions mentioned in the parts
concerned.

C2.44 Ares 806 – 09.2004 – GB


GPA 30 crawler gears

Removing, adjusting and refitting the


control system
12
Removal
– After removing the casing.
– Disconnect the control cable.
– Remove the lock (13) and nut (10) (discard the nut) to 15
extract the guide rod (11). 22
10
– Remove the fork and dog assembly from the front.
– Remove the control link (4) and pin (7) to extract the 8
shaft (6).
11 4
– Retrieve the shims (8).

Adjusting and refitting


7 6 3
– To limit the axial play on the shaft (6), position
shims (8) to obtain 0,3 ± 0,2 mm of play at the end of
the shaft. 342hsm0g Fig. 72

– Position the dog correctly and fit the fork and guide rod
complete with a new nut (10). 15
– Fit the lock (13) and spring and tighten the screws (15)
to 6 ± 1 daN.m. 14
– Put the dog (22) into the "crawl" position with the rear 13
face resting on the circlip (47).
– Degrease the thread of the guide rod (11) and nut (10). 11
Coat the nut beforehand with Frenetanch (242).
– Hold the nut (10) against the sunken face of the
housing and turn the guide rod (11) simultaneously to
the right or left (as required) with a screwdriver to
obtain an approximately equal gap between the
dog (22) and the bearing faces of the fork (12). 10 12
– Lock the nut (10) by deforming its flange.
N.B.: When the tractor is coupled up, translational
movement of the guide rod (11) will be prevented by
the contact of the nut (10) with the rear face of the
342hsm0h Fig. 73
gearbox.
– Couple up the tractor.
– Refit the link (4) with the screw (3) lightly coated with
Frenetanch (242).
– Check manually with the aid of the rocker bar that the
47
dog locks correctly in each "direct drive" and "crawl"
position.

22

342hsm0i Fig. 74

Ares 806 – 09.2004 – GB C2.45


GPA 30 crawler gears

Setting the controls


– Put the rocker bar (4) in the "crawler" position.
– Put the range lever (52) in the cab in the "crawler"
position.
– Screw the yoke (51) onto the control cable (50) and
tighten the check nut.
– Mount the yoke (51) on the cab range lever.
52
– Mount the yoke (47) in the same way on the rocker
bar (4).
– Adjust the sheath stops with the nuts (48) and (50)
while checking that the cable (49) is not strained.
– Check operation and locking in both positions.
– Finely adjust the setting with nuts (48) and (50) if
necessary.

51

50

49

2
48 4
47

342hsm0j Fig. 75

C2.46 Ares 806 – 09.2004 – GB


C3 – SERVICE BRAKES

Ares 806 – 09.2004 – GB


Technical specifications

Foot brake

GTA 32-30

Type Oil-immersed
Number of disks per wheel 2
Diameter of outside discs (friction) 343 mm
Diameter of inside discs (friction) 275 mm
Thickness of discs (friction) 4,9 mm
Type of slave Tubular piston (in the axle tube)
Type of control Hydrostatic with servo
Brake control fluid Brake fluid type (LHM) or equivalent
Position of brake fluid reservoir In engine compartment on right-hand front side of cab.
Circuit capacity 1l
Capacity between maximum and minimum 300 cm³
Level detection Indication in cab

C3.2 Ares 806 – 09.2004 – GB


Brake pistons and seals

Draining the service brake


circuit
N.B.: It is important to dry the drain plugs properly in
order to eliminate all traces of humidity.

Draining the circuit


– Open the drain holes (1), on the central housing of the
rear axle, 2 drain screws M12, as well as the drain
screw of the trailer braking valve. 1
– Place a recipient under the drain screws and connect a
flexible translucent hose attached to a recipient onto
the brake valve drain.
– With coupled pedals, slowly depress and release 3
times over the complete stroke of the pedal assembly
and repeat the operation around ten times to enable
the fluid (LHM) to flow.
– Open the right and left-hand slave bleed screws and 362hsm00 Fig. 1

allow the fluid (LHM) remaining in the braking circuit


flow out. The drain holes should be left open for at
least 10 minutes.

Rinsing the circuit


To rinse the circuit:
– Close the bleed screws of the right and left-hand
slaves and fill the reservoir with new fluid (LHM). To
enable the brake fluid to flow when rinsing, couple
pedals, depress and release slowly about ten times,
covering the entire stroke of the pedal assembly, and
repeat the operation if required.
– Open the right and left-hand bleed screws of the slaves
and braking valve and allow the fluid (LHM) remaining
in the brake circuit to flow out for at least 10 minutes.
– Tighten the right and left-hand slave drain screws
under the central housing as well as the braking valve
bleed screw.
– Fill up and bleed the circuit.

Ares 806 – 09.2004 – GB C3.3


Brake pistons and seals

General
5
The brake pistons are located in the 2 side cavities of the
rear axle housing, concentric to the contact surface of
each axle tube. They have a shoulder section and are
guided by 3 centring studs (fit tight on the housing). For
sealing purposes, 2 O-rings are fitted in the grooves of the
rear axle housing. Each piston is controlled by a master 4
cylinder assisted by a hydraulic booster. Each piston acts
on a friction disc, with a hub, on the axle tube input sun
gear and a backing plate centred by studs and bearing on
the ring gear of the reduction gear unit. When the brake is
released, there is a minimum clearance between the
piston and discs. The brakes are self-adjusting and a
constant clearance is maintained at the pedal. The discs
are constantly lubricated by the rear axle oil and the
auxiliary spool valve return. The oil film is kept on the
braking surfaces when they are not used, in order to cool
362hsm11 Fig. 2
the brakes on use.

Removal
1. Remove the axle tube (see chapter "C1").
2. Disconnect the brake supply hose. Remove the
piston (4) from the housing by blasting compressed air
through the coupling (5) (Fig. 2).
3. Remove the O-rings (7), (8) on the piston and discard
them (Fig. 3).

7 8

362msm04 Fig. 3

C3.4 Ares 806 – 09.2004 – GB


Brake pistons and seals

450
10 410
40

Ø 16
= =
= =
001fl

001fl Fig. 4

Refitting
– Clean and inspect all parts, replace all faulty parts.
– Fit the piston (4) without seals in the casing (2).
N.B.: Check that the piston slides freely in the casing
bore and it enters without tight points on the centring
studs (3) (Fig. 5).
– Fit new O-rings (7), (8) (Fig. 5).
N.B.: Smear the seals with a moderate amount of
grease to keep them correctly at the bottom of the
groove.
– Position the piston along the axis of the centring studs,
then fit it with the aid of the locally made tool (Fig. 4).

7 8 2 3

362hsm12 Fig. 5

Ares 806 – 09.2004 – GB C3.5


Brake pistons and seals

Sealing test
Important: When intervening on the brake piston and 5
O-rings, it is highly recommended to check the
sealing.
– Keep the piston in place with the locally made tool
(Fig. 4 and 6).
– Make the illustrated jig locally to carry out the leak test
(Fig. 7): Fit an air inflation nozzle (C) to a "Jic"
(1/2-100) coupling (A) to be screwed onto the bend (5).
Connect this assembly to a conventional inflation
handle equipped with its pressure gauge. Then place a
relief regulator upstream.
– Supply the circuit with compressed air at
approximately 5 bar to ensure correct piston operation.
– Reduce the pressure to 0,3 bar.
– Close the pressure regulator valve. After 1 minute, no
pressure drop should be observed at the pressure 362msm07 Fig. 6

gauge.
– Remove the pressure gauge. Remove the restraining
tool.
– Connect the brake hose.
Parts list (Fig. 7) 5 A B
A Coupling 1/2-100.
B Inflation handle.
C Pneumatic valve.
D Pressure gauge.

Refitting the axle tubes


– Clean the gasket face with a non-greasy solvent.
C D
N.B.: Apply a bead of hydrocarbon-resistant silicone
in the inside angles of the housing and axle tube. The
coat the contact surfaces of the housing and axle
tube with Formajoint (510).
– Check that the discs slide freely on the sun gear.
– Refit the axle tubes (see chapter "C1"). 362msm08 Fig. 7

C3.6 Ares 806 – 09.2004 – GB


Boosters and master cylinders

Description of the master cylinders/boosters

1 2 3 4

11 7 8

362msm26 Fig. 8

Parts list
1 Brake valve control. 7 Return .
2 Brake fluid reservoir supply. 8 Supply, 17 bar.
3 Brake supply. 9 Connector bleed screw (braking valve).
4 Brake balancer pipe. 10 Brake fluid reservoir.
5 Braking valve control pipe. 11 Master cylinder.
6 Master cylinder mounting nut. Tightening torque 2 daN.m.

Important: The assembly of this type of master


cylinder/booster does not require any adjustment.

4 3 10

9
11

8 7 6 5

362hsm15 Fig. 9

Ares 806 – 09.2004 – GB C3.7


Replacing the master cylinders

– Drain and remove the brake fluid reservoir (10).


– Remove the braking valve control pipe (5), the two
brake supply pipes (3) and the balancer pipe (4).
– Remove the defective master cylinder(s) (11) by
unscrewing the nuts (6).
– Fit the new master cylinder(s) (nuts (6) torqued 4 3 10
to 2 daN.m) and refit all previously removed
components.

Adjusting the brake pedals 11

Adjustment procedure
– Measure the length of the pedal high end stops (A).
6 5
– Adjust the end stops (A) respecting the dimension
indicated.
– Tighten the locknut (B).
– Check that the lock coupling the pedals together slides 362hsm04 Fig. 10

freely when the pedals are in high position.


– Adjust the length of fork joint (D) so that rod (C) comes
in contact with the master cylinder piston.
– Press the brake pedal gently by hand until you clearly
feel a hard point. When bearing on this point, there B A
should be 3 mm of play between the end stop (A) and
the pedal (Fig. 11). If not, screw or unscrew the push
rod (C) in the fork joint (D). IRUNA mm
44

m
3m
C

362hsm14 Fig. 11

C3.8 Ares 806 – 09.2004 – GB


Bleeding the brake circuit

Bleeding the circuit manually


– Start the engine.
– Top up the reservoir with brake fluid (LHM).
– Connect 3 flexible transparent hoses (ID 6 mm), one to
4
each of the right and left-hand bleed screws (D)
and (G) plus one to the hydraulic or pneumatic braking
valve (I), and immerse them in a 1-litre receptacle (J)
containing 0,5 litres of fluid (LHM) (Fig 13, 14 or 15).
Open the bleed screws. 9
– With the pedals coupled, pump about 10 times over the
entire stroke of the master cylinders in order to fill the
entire circuit (the oil must flow towards the receptacle).
Now close the bleed screws (D), (G), (I) (Fig 13, 14
or 15). Top up the reservoir with (LHM).
– Unscrew the bleed screw on the master cylinder (9) to
evacuate the air by pressing very lightly on the brake
pedals. Carry out the same operation for the balancer 362hsm05 Fig. 12
pipe (4).
N.B.: On bleeding, all of the transparent hoses must
be immersed in the fluid (LHM).
The rest of the operation requires 2 operators (engine
running).
– Disengage the pedals.
– Press the right-hand pedal 1/3 of the way down and
hold it there.
– Pump with the left-hand pedal.
– Keep pressed down and open the left-hand bleed
screw (G) (Fig 13, 14 or 15).
– Allow the fluid to flow out then close the bleed screw.
– Repeat these "pump, press and hold" operations until
there are no more air bubbles.
– Proceed in the same way to bleed the right-hand
side (D) and for the braking valve (I) (Fig 13, 14 or 15).

Ares 806 – 09.2004 – GB C3.9


Bleeding the brake circuit

Closed-centre hydraulic circuit (LS 110 l/min) on GTA 3130

362hsm06 Fig. 13

C3.10 Ares 806 – 09.2004 – GB


Bleeding the brake circuit

Closed-centre hydraulic circuit (LS 110 l/min) on GTA 1040

362hsm10 Fig. 14

Ares 806 – 09.2004 – GB C3.11


Bleeding the brake circuit

Closed-centre hydraulic circuit (LS 100 l/min) on GTA 1040

362hsm09 Fig. 15

C3.12 Ares 806 – 09.2004 – GB


Bleeding the brake circuit

Bleeding the brake circuit with a


pressurising device
– Use a brake circuit pressurising device and connect it
to the brake fluid reservoir (10).
– Start the engine. 10
– Pressurise the brake fluid (LHM) reservoir
(0,5 to 1,5 bar maximum). If bleeding completely and
flushing the circuit, it is preferable to have a device with
9
a minimum capacity of 5 litres of fluid (LHM).
– Connect a flexible transparent pipe to each bleed
screw and immerse them in a receptacle.
– Prepare 2 collecting receptacles (one at the start of the
bleeding operation for the spent fluid and the second
for the fluid which will be recovered). 6
– Allow the fluid (LHM) to flow copiously during the
bleeding operation (at least 2 litres). This liquid will be
collected. 362hsm16 Fig. 16

Filling the brake circuit


– Loosen the bleed screw on the master cylinders (9)
and allow the fluid (LHM) to flow out through a
transparent pipe until there are no more air bubbles.
Tighten up the screw again.
– Loosen the bleed screw (G) on the left-hand brake and
allow the fluid (LHM) to flow out through a transparent
pipe until there are no more air bubbles (Fig 13, 14
or 15). Then tighten up the screw again.
– Loosen the bleed screw (D) on the right-hand brake
and allow the fluid (LHM) to flow out through a
transparent pipe until there are no more air bubbles
(Fig 13, 14 or 15). Leave the bleed screw open then
carry out the bleeding operation.

Bleeding the right and left-hand brakes


1. Press the RH brake pedal a third of the way down. Hold
it there.
2. Gradually press the left brake pedal as far as it will go.
3. Release both brake pedals.
4. Repeat operations (1), (2) and (3) 10 times in
succession to bleed the balancing pipe.
5. Tighten the bleed screw (D) (Fig 13, 14 or 15).

Ares 806 – 09.2004 – GB C3.13


Bleeding the brake circuit

Bleeding the braking valve


• Loosen the bleed screw (I) on the hydraulic or B
pneumatic braking valve and allow the fluid (LHM) to
flow out for at least 3 minutes through a transparent
pipe until the air bubbles have disappeared.
• Leave the bleed screw open, then.
– Press the right-hand brake pedal down a third of the
way and hold it there for one-and-a-half minutes.
– Release the right-hand pedal.
– Press the left-hand brake pedal down a third of the way
and hold it there for one-and-a-half minutes.
– Release the brake pedal.
– Tighten up the bleed screw.

362hsm13 Fig. 17

C3.14 Ares 806 – 09.2004 – GB


Bleeding the brake circuit

Checking the effectiveness of the


100 l/min and 110 l/min circuit air
bleed (Bosch valve)
– Connect the pressure gauge 0-200 bar to the trailer
braking socket (engine idling).
– Gradually press the coupled brake pedals. The
pressure must be between 120 and 150 bar.
N.B.: For tractors equipped with a 100 l/min
closed-centre circuit(Bosch valve), the pointer rises
in stages up to a maximum pressure of 150 bar.

Checking the SNR valve (100 l/min


circuit)
362hsm17 Fig. 18
– Connect the input of hydraulic tester n° 60 05 005 736
to the outside trailer brake socket.
– Connect the tester output to the return circuit of the
spool valves (B).
– Open the tester valve.
– Start the engine and leave it running at 1 000 rpm.
The second operator must keep the brake pedals pressed
down.
– Close the tester valve until a minimum flow rate
of 20 l/min is obtained at a pressure of 130 bar.
– Release the pressure on the brake pedals.

362hsm18 Fig. 19

Ares 806 – 09.2004 – GB C3.15


Notes

C3.16 Ares 806 – 09.2004 – GB


C4 – AUTOMATIC BRAKE, PARK
LOCK AND HANDBRAKE

Ares 806 – 09.2004 – GB


Automatic brake

Operating principles
The mechanical handbrake assembly (secondary brake)
is mounted at the front of the rear axle on the drive pinion
shaft. It consists of a plate mechanisms inserted
between 6 lined discs connected to the shaft and 4
intermediate backplates immobilised by lugs on the
casing. The mechanism consists of 2 cast iron plates
which can expand by means of balls housed in raceways.
The mechanism is activated by an adjustable rod
equipped with a relay assembly, itself controlled by a
pushrod displaced by a cylinder and Belleville
washer. 17 bar of hydraulic pressure is required to
compress the Belleville washers and release the brake.
The hydraulic circuit is assisted by an electronic
management system comprising sensors and solenoid
valves. The hydraulic circuit is drained via a line into the
Belleville washer chamber which discharges into the
housing. The casing is lubricated by a perforated pipe in
the drive pinion. The brake can be activated by a manual
control, placed right next to the control unit, in the event of
a problem. This is controlled by the handbrake lever in the
cab. A release screw located above the hitch yoke can be
used to free the brake in case of a hydraulics problem.

363hsm00 Fig. 1

C4.2 Ares 806 – 09.2004 – GB


Automatic brake

When the tractor is at a standstill with the engine switched


off, braking is provided by the load exerted by the
Belleville washers. When the engine is running, the brake
S1
is released by a single action on the electric shuttle
reverser control (forward or reverse gear) or by pressing
S2
the automatic handbrake control. The low hydraulic
pressure compresses the Belleville washers and E2
therefore releases the load on the pushrod. The hydraulic
control is equipped with electronic management. See
chapter "G7". When the tractor engine is switched off, the E1
solenoid valve "E2" is activated for a few seconds to drain
the compression chamber and thereby activate the brake.
In the event of a hydraulics problem, the brake can be
17 bar
freed by action on the release screw.
– To release the brake: Turn clockwise to locking point.
– To apply the brake: Turn anticlockwise to locking point.

Truth table
363hsm18 Fig. 2

E1 E2 S1 S2 Function

0 0 0/1 0/1 Memory


0 1 0 0 Parking
1 0 1 0 Road
0 1 0 1 Parking (but stroke too long)

363hsm01 Fig. 3

Ares 806 – 09.2004 – GB C4.3


Automatic brake

Exploded view of control unit

11

E1

E2
6

8
5

10
S1

12
3

S2
14

13

15

16

17

18

19

23

22

20
21

363hsm02 Fig. 4

C4.4 Ares 806 – 09.2004 – GB


Automatic brake

Parts list
1 Control unit housing. 13 Lever. 26 Backplate.
2 Piston. 14 Split pin. 27 Plate mechanism.
3 Belleville washer (x8). 15 Spring cover. 28 Closing cover.
4 Upper housing. 16 Bush. 29 Compensation bar.
5 Cover. 17 Spring. 30 Adjustment nut.
6 Stop pin. 18 Spacer. 31 Bush.
7 Release rod. 19 O-ring. 32 Screw and washer.
8 Wedge. 20 Cam. 33 Pushrod.
9 Thrust bolt. 21 Sheath stop. E1 Solenoid valve, 3/2, flange-fitting.
10 O-ring. 22 Washer. E2 Solenoid valve, 2/2, screw-fitting.
11 Flange. 23 Circlip. S1 Position sensor.
12 Pressure chamber O-rings. 24 Mechanism housing. S2 Wear sensor and pushrod.
25 Disc (x6).

Exploded view of brake mechanism

28 32 33
29
30

31

27

25

24

26

363hsm03 Fig. 5

Ares 806 – 09.2004 – GB C4.5


Automatic brake

Removing/refitting the automatic


brake assembly 13

The cab does not need to be removed for this operation.


– Remove the left rear wheel.
– Disconnect the two solenoid valves (E1), (E2) and the 21 A 1
two sensors (S1), (S2).
– Disconnect the hydraulic supply line.
E1
– Disconnect the handbrake cabler from the lever (13)
and sheath stop (21).
– Screw the release rod (7) clockwise as far as it will go
(Fig. 4).
– Disconnect the release bolt (9) (Fig. 4).
– Unscrew and remove the 3 screws and the nut (A) A
– Remove the unit (1). S1
S2 E2
Beware that the pushrod (33) does not fall into the
rear axle. 363hsm04 Fig. 6

Refit in reverse order to removal while taking the following


precautions: Check the O-rings (10) (if necessary, replace
them and make sure that they are fitted properly: hole for
13
return to tray and on the shoulder of the control unit (1))
(Fig. 8). The screws must be coated with
Frenetanch (242) threadlocker before screwing in.

21
S1

S2

363hsm05 Fig. 7

33

10

363hsm06 Fig. 8

C4.6 Ares 806 – 09.2004 – GB


Automatic brake

Removing/refitting the unit


2 6 4
– Remove the cover (5) (Fig. 4).
– Unscrew the release bolt to remove the pin (6) (circlip).
– Unscrew the two screws (B) while holding the upper
housing (4) with a press. B B
– Remove the upper housing (4) by gently releasing the
press.
– Remove the Belleville washers (3).
– Remove the piston (2) with a press.
– Remove the solenoid valves and sensors (E1), (E2),
(S1) and (S2).
– Check all parts and replace the O-rings and metal-
plastic seals.

Ref Electrical components Characteristics

S1 High position sensor Normally closed 363hsm07 Fig. 9

S2 Wear sensor Normally closed

Solenoid valve, 3/2, flange-


E1 Resistance: 10 W 1 3
fitting
Solenoid valve, 2/2, screw-
E2 Resistance: 10 W
fitting

2
4

363hsm08 Fig. 10

12

363hsm09 Fig. 11

Ares 806 – 09.2004 – GB C4.7


Automatic brake

Refit in reverse order to removal while taking the following


precautions:

Fitting the Belleville washers


Eight Belleville washers fitted from top to bottom as
follows:
1. Concave side.
2. Convex side.
3. Concave side. 3
4. Convex side.
5. Concave side.
6. Convex side.
7. Concave side.
8. Convex side.

363hsm10 Fig. 12

2
3

4
5

6
7

363hsm44 Fig. 13

C4.8 Ares 806 – 09.2004 – GB


Automatic brake

Removing/refitting the parking


brake
25 26 24
To remove the assembly in the rear axle (see
chapter "C1").
– Remove the 8 screws (hex head).
– Separate the cover (28) from the handbrake casing.
– Note the pin position.
– Make a visual note of the components of the
handbrake system.
– Remove the discs (25), backplates (26) and
mechanism (27).
– Remove the screws (32), washer, compensation
bar (29) and bush (31).
– Clean and check the parts: If the casing (24) and
cover (28) present anomalies such as discolouring due 27 28
to overheating or friction surface wear, a new assembly
363hsm11 Fig. 14
will need to be fitted.
– Refit in reverse order to removal.
The screw (32) is to be torqued to 24 ± 1 daN.m and fitted
with threadlocker (Frenbloc (270)) (Fig. 15).
Note: The pin (31) of the compensation bar is to be fit
tight on the housing.

32 29

363hsm12 Fig. 15

28

25
26 24
27

363hsm13 Fig. 16

Ares 806 – 09.2004 – GB C4.9


Automatic brake

– Note the angular position of the lever (13) on the


splined pin (20) of the cam.
– Remove the pin (14) and remove the lever (13) with the 13
spring (17).
20
– Remove the circlip, spacer and washer.
– Pull the cam (20) down to release it from the housing.
– Replace the seals.
– Clean and check the parts. Replace any defective
parts.
– Coat the pin and cam lightly with grease (Molycote).
– Proceed with refitting the assembly in reverse order to
removal.
– Check the mobility of the assembly.

363hsm14 Fig. 17

C4.10 Ares 806 – 09.2004 – GB


Automatic brake

Basic parking brake adjustment


Before adjusting the mechanism, it is essential that the 30
force exerted on it be neutralised. To do this, screw the
release rod (7) clockwise to the locking point. 32
– Remove the cap (D) to access the adjustment nut (30).
– Move the cam (20) momentarily away from the 29
compensation bar (29).
– Using shims, adjust the mechanism by turning the
nut (30) to obtain a clearance "X" of 1,25 ± 0,05 mm
between the discs (25) and the intermediate
backplates. 24
– Check the mobility of the discs and backplates after
28
operating the control several times at rest.
Note: When the tractor has not been separated
between the gearbox and the rear axle and the
clearance needs to be adjusted, remove the right-
hand hydraulic cover from the rear axle. 363hsm15 Fig. 18

20

29 30

363hsm16 Fig. 19

Ares 806 – 09.2004 – GB C4.11


Automatic brake

Adjusting the parking brake lever: Adjust while changing the position of the lever (13)
in relation to the cam (20).
control – Refit the remote control cable and adjust it to obtain a
The remote control cable must be disassembled. The length "Y" of 206 ± 5 mm between the sheath stop (21)
purpose of this adjustment is to obtain a length "Y" and the cable hooking point on the lever (13): Adjust by
of 179 ± 9 mm with a load of 10 daN on the end of the altering the sheath nuts. This setting corresponds to 7
notches on the handbrake lever in the cab.

10 daN
13
Y

20

21

363hsm17 Fig. 20

C4.12 Ares 806 – 09.2004 – GB


Notes

Ares 806 – 09.2004 – GB C4.13


Park Lock

General
The Park lock device, mounted in the intermediate housing, consists of a ratchet (17) and a toothed sleeve (15), splined to
the drive pinion and lower shaft linked to the gearbox. A box (3) mounted on the right-hand side of the housing and a spring-
loaded control rod activate this device. The Park lock is mounted only on transmissions with a Full Powershift gearbox.

Remark
The special bolt (6) is used to release the system if there is a fault on the hydraulic or electrical circuit (Fig. 21). Remove
the nut (9). Turn the screw clockwise until resistance is felt; in this position, the rear face of the piston (1) is in contact with
the shoulder of the housing. In normal use, this screw must be loosened completely and held in place with lock nut (9)
(Fig. 21).

C4.14 Ares 806 – 09.2004 – GB


Park Lock

Overall view

6 9 7 8 10 11 12 13 14 15 16 17 18 19

2
20

4 7

393hsm39 Fig. 21

Parts list
1 Piston. 8 O-ring. 15 Notched sleeve.
2 O-ring. 9 Locknut. 16 Pin and split pin.
3 Control unit. 10 Spring. 17 Ratchet.
4 Screw. 11 Operating rod. 18 Seal.
5 O-ring. 12 Pin and split pin. 19 Switch.
6 Special bolt. 13 Link. 20 O-ring.
7 Solenoid valve. 14 Pin and split pin.

Ares 806 – 09.2004 – GB C4.15


Park Lock

Schematic diagram

12 V
2

+ APC
7
8
RCC
5
3

+ APC

TC
6

17 bar 9

11 12
10
363hsm43 Fig. 22

Parts list
1 Gearbox output speed sensor. 5 "RCC" unit. 9 Park Lock safety switch.
2 Displacement speed sensor. 6 "TC" unit. 10 Park Lock control solenoid valve.
3 Shuttle reverser lever. 7 Park Lock relay. 11 Engaged position.
4 Transmission display. 8 Park Lock switch. 12 Released position.

C4.16 Ares 806 – 09.2004 – GB


Park Lock

The Park lock is a parking brake which, for obvious safety reverser in neutral), the Park lock is effectively engaged
reasons, is applied automatically when the engine is and the "P" symbol on the display (4) stays lit.
switched off. The Park lock is only applied when the
N.B.: In normal operation, the speed for Park lock
shuttle reverser lever (3) is in neutral and the forward
engagement at 1,1 km/h is read by the gearbox output
speed is less than 1,1 km/h. As soon as the pulse speed sensor (1). If there is a problem on the "TC"
control (8) is pressed, the request to engage the Park lock unit, the froward speed will be read on the theoretical
is represented by the "P" symbol on the display (4). As speed sensor (2).
soon as the tractor speed drops to below 1 km/h (shuttle

Ares 806 – 09.2004 – GB C4.17


Park Lock

Operation
Engaged position

6 3 1 10 15 17 18

9 11 13 19
363hsm40 Fig. 23

The Park lock is automatically applied when the engine is switched off or on starting the engine and locks the transmission
mechanically. In the engaged position, the solenoid valve (7) is not powered and the system operates in a purely
mechanical manner (Fig. 21).
The spring (10) pushes the piston (1) back towards the box (3). The control rod (11) screwed into the piston drives the
links (13) which mesh the ratchet (17) onto the toothed sleeve (15), lockig the lower shaft line of the transmission.

C4.18 Ares 806 – 09.2004 – GB


Park Lock

Released position (hydraulic action)

3 10 13 15 17 11

6 1
363hsm41 Fig. 24

With the engine running, when the shuttle reverser control is shifted to forward or reverse gear, the Park lock switch
disengages the electronic system (TC), controls the solenoid valve (7) powering the control unit (3) and releases the Park
lock. The pressure within the chamber of the piston (1) presses on the front face of the piston, compressing the spring (10)
and releasing the ratchet (17) from the toothed sleeve (15). The electronic system (TC) is informed of the release by the
switch (19).

Ares 806 – 09.2004 – GB C4.19


Park Lock

Removing/refitting the safety


switch
11 19
Removal
– Partly drain the intermediate housing.
– Disconnect the harness from the switch (19) to be
replaced, and remove it as well as the nut (9) (Fig. 21).

Refitting
– After adjusting (see below), coat the thread of the new
switch with Frenetanch (242), refit and torque
to 2 daN.m.
– Connect the harness.
– Top up the oil level in the housing and check it on the 0,2 – 1,4 mm
transparent tube located on the LH side of the centre
housing.
N.B.: The intermediate housing drain plug has a 363hsm42 Fig. 25
different shape from the others. It has a cylindrical
portion which is absent on conventional plugs. It is
essential to fit this plug in the correct position during
reassembly.
Remark: Following a service operation, it is essential
that the special screw (6) is put back into its initial
position, i.e. unscrewed completely to a torque
of 4 - 5 daN.m to ensure correct Park lock operation
and to seal the unit (3) (Fig. 21).
Using spanners, hold the special screw in the above-
mentioned position and tighten the nut (9) against the
unit (3) to 8,5 – 11,5 daN.m.

C4.20 Ares 806 – 09.2004 – GB


Park Lock

Safety switch adjustment "A" (mm) between Thickness of seal (18)

– With the microswitch (19) removed, remove the nut (9) 39,9 – 38,7 No seal
(Fig. 21). Turn the special screw (6) clockwise until 38,6 – 38,2 1 mm
resistance is felt (rear face of piston (1) in contact with 38,1 – 37,7 1,5 mm
the shoulder of the housing) (Fig. 24). 37,6 – 37,2 2 x 1 mm seals
– Using a gauge of appropriate depth, measure the
distance "A" between the end of the rod (11) and the
face of the housing (Fig. 24). Depending on the
reading obtained, determine the appropriate assembly
(with or without a seal) (18) - refer to the table.
– Slide the seal(s) determined above onto the switch and
tighten to 2 daN.m.
– Remove the switch again and check that the ball
mounted at its end returns to its initial position after
pressing manually.
– Refit the switch permanently (see paragraph heading).
The values indicated in the table allow for an
approximate space of 0,2 to 1,4 mm between the end
of the rod (11) and the body of the switch (19), with the
Park Lock in the released position (Fig. 25).

Ares 806 – 09.2004 – GB C4.21


Park Lock

"Inspection results" sheet


This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:

Tractor type.............................................................................................................................................................................

The serial number...................................................................................................................................................................

Total operating hours..............................................................................................................................................................

Date of operation ....................................................................................................................................................................

The gearbox model.................................................................................................................................................................

The gearbox serial n°..............................................................................................................................................................

Checking the pressure upstream of the Park lock solenoid valve


– Connect tester n° 60 05 705 076 to socket (P1).
– The coil resistance should be 8,4 ohm.

60 05 705 076

P1

342hsm00 Fig. 26

Engine off Engine running


Test conditions
Transmission temperature: 60°C
Nominal value Measured value Nominal value Measured value

Pressure (P1) 0 bar 17 bar


Solenoid valve voltage 0V 12 V

C4.22 Ares 806 – 09.2004 – GB


Notes

Ares 806 – 09.2004 – GB C4.23


Handbrake

General
The mechanical handbrake control assembly is mounted cast iron plates held by springs (33) and separated by
on the drive pinion located on the intermediate housing. It balls housed in runners. It is actuated by a tie-rod (22)
consists of a mechanism (30) placed between 6 discs (21) mounted on a relay pin (15) whose cam (16) is in contact
connected to the drive pinion and 4 backing plates. The with the stem (1), itself bearing on a second cam (3),
mechanism is housed in a casing (25) fastened to the splined to a pin (7) controlled by the link (10).
drive pinion rear bearing support and is composed of 2

Operation
When the brake lever is pulled, the cable acts on the handbrake lever at rest, the link (10) is returned to its
link (10) splined to the pin (7). The pin (7) pivots and initial position by the spring (9). The mechanism
drives the cam (3) which pushes the stem (1) against a adjustment nut can be accessed via a screw cap on top of
relay cam (16), free of the pin (15), thereby causing the the intermediate housing. Sealing between the pin (7) and
mechanism (30) to spread via the tie-rod (22). With the the casing (4) is provided by seals (8) and (11).

Parts list
1 Spindle. 11 Seal. 21 Discs. 31 Plates.
2 Screw. 12 Plain washer. 22 Stud. 32 Ball.
3 Link. 13 Screw. 23 Pin. 33 Spring.
4 Support. 14 Needle bearings. 24 Spindle. 34 Screw.
5 Screw. 15 Spindle. 25 Unit. 35 Link.
6 Clevis or bush. 16 Link. 26 Screw. 36 Nut.
7 Spindle. 17 Spindle. 27 Support. 37 Clevis.
8 Seal. 18 Nut. 28 Pin. 38 Seal.
9 Spring. 19 Screw. 29 Screw. 39 Seal.
10 Link. 20 Backing plate. 30 Mechanism. 40 Bearing support.

C4.24 Ares 806 – 09.2004 – GB


Handbrake

Exploded view

31 30
33
32
34
35
31
36

19 40
Loctite (270)
14 ± 2 daN.m 20
21
22
18
37
17
16

23 30
21
25
24 29
38
26
28
14
13 15 27
14
12
11
10
9
8
1
7
2
39
6

3
4
5

361hsm03 Fig. 27

Ares 806 – 09.2004 – GB C4.25


Handbrake

Removing and refitting the handbrake


casing 15

For all operations on the handbrake casing composed of


discs, backing plates and the mechanism, it is necessary
to uncouple the tractor and remove the intermediate
housing and the drive pinion (see chapter "C1").
T
5
Removal (Fig. 28)
– Remove the circlip (5). 14
5
– Remove the screws (8). C
– Separate the casings (13) and (15). 6
– Remove the discs (14), the backing plates (6) and the 16
handbrake mechanism (16). 5
13
Refitting
8
N.B.: The assembly indicated in the general
361hsm00 Fig. 28
arrangement table must be complied with (Fig. 28).
After cleaning and checking the parts: Final operation
– Replace any defective parts (worn discs, plates with – Refit the drive pinion.
overheating marks, etc.). – Fit the pin (24) on the mechanism (16) so that it can be
– Depending on the options fitted, check that the drive released without interference.
pinion ducts are not blocked. – Fit the washer and a new retaining pin.
– Place the drive pinion in a vertical position with the – Adjust the control.
helical teeth facing down (Fig. 28). – Refit the bearing/hydraulic pump driving gear
– Place the housing (13), with the lubricated cup fitted, assembly, the ratchet and the correctly positioned Park
on the drive pinion bearing cone. lock sleeve.
– Mount the backing plates (6) by aligning the tabs "T", – Assemble the intermediate housing with the central
the discs (14) separated by the mechanism (16) and housing.
the correctly positioned control "C" (Fig. 28). – Couple up the tractor between the gearbox and the
– Assemble the handbrake casing (15) on the bearing intermediate housing.
casing (13). Fit and tighten the screws (8), lightly – Check the operation of all controls.
coated with Frenbloc (270), to 14 ± 2 daN.m. Fit the – Check handbrake operation and the dashboard
circlip (5). indicator. Road test.
– Check the gasket faces and the hydraulic couplings for
leaks.

C4.26 Ares 806 – 09.2004 – GB


Handbrake

Adjusting the handbrake


control 375-400

With the cam (3) in contact with the casing (4), adjust the
nut (18) to obtain 1,2 to 1,3 mm of functional play between 30-45
the discs/backplate and mechanism (Fig. 27).
N.B.: The right-hand hydraulic housing needs to be
removed for this operation. B 27
A
– Position the link (10) on the pin (7) so as to obtain a
distance of 375 to 400 mm between the cable axis and
the support (27) (position "A"), while verifying that the
cam (3) is always in contact with the casing (4)
(Fig. 29).
– Check that the link travel (10) is between 35
and 45 mm under a load of 20 ± 5 daN 7 10
(position "B") (Fig. 29).
– After adjusting, refit the handbrake cable and adjust the 361hsm01 Fig. 29
sheath nuts to give 7 notches on the handbrake lever in
the cab.
Note: If the 30 to 45 mm value is greatly exceeded on
the handbrake link on the intermediate housing, the
brake discs in the axle need to be adjusted or
changed.

Diagnosing brake disc wear


With the hydraulic housing removed.
– No striations on the discs.
– Overheating or burnishing marks on the backplates.
– Functional play in excess of 3,3 mm.

Ares 806 – 09.2004 – GB C4.27


Handbrake

Remark
On the casing (4) (Fig. 27).
16
– Fit the bush (6) with a drift.
– Fit the seal (11) in contact with the casing (4) using a
suitable jig. F
– Coat the screw (2) of the cam (3) lightly with
14
Frenetanch (242).
– Coat the contact surface of the casing (4) on the
intermediate housing with Formajoint (510).
– Tighten the screw (5) to 3 ± 0,5 daN.m and screw (13)
to 1,7 ± 0,3 daN.m.
N.B.: On fitting, remember the O-ring (11) which forms
the seal between the pin (7) and the link (10).
On the cam (16):
– Fit the needle bearings (14) flush with face "F"
(Fig. 30). 361hsm02 Fig. 30

– Coat the screw (29) with Frenetanch (242) and tighten


to 3 ± 0,5 daN.m.
On the cam (3):
– Coat the needle screw (2) with Frenetanch (242) and
tighten moderately.
On the mechanism (30):
– Fit the pin (24) so that it can be removed easily.
– Coat the short thread of the tie-rod (22) lightly with
Frenbloc (270) and screw into the clevis (37).

C4.28 Ares 806 – 09.2004 – GB


TOOLS

GPA 40 rear axle - GPA 30 rear axle - Service brakes -


Automatic brake, Park lock and Handbrake

Ares 806 – 09.2004 – GB C4.29


GPA 40 rear axle - GPA 30 rear axle - Service brakes - Automatic
brake, Park lock and Handbrake
60 05 705 076 60 05 006 309

Pressure gauge kit Shimming tool (dimension measurement)

60 05 006 310 60 05 006 311

Allen key Splined socket

60 05 006 314 60 05 006 319

Differential unit stand GPA 40 differential unit stand (requires tool n° 60 05 006 314)

C4.30 Ares 806 – 09.2004 – GB


GPA 40 rear axle - GPA 30 rear axle - Service brakes - Automatic
brake, Park lock and Handbrake
60 05 006 707 60 05 006 744

Clamp-on ammeter Multimeter

77 01 388 008 60 05 005 736

Dynamometer Flowmeter

Ares 806 – 09.2004 – GB C4.31


Notes

C4.32 Ares 806 – 09.2004 – GB


D1 – FRONT AXLE
20.29
20.29-3
20.43
20.43-2

Ares 806 – 09.2004 – GB


Description

General characteristics - rigid axle

Type of axle (a) 20.29 20.29-3 20.43 20.43-2

Reference (b) 136 673 147 869 141 331 147 870

Overall width (in mm) (c) 2 150 2 206

Width between plates (in mm) (d) 1 900 1 940

Pitch circle diameter of studs (in mm) (e) 335

Wheel disc centring diameter (in mm) (f) 280

Stud diameter (in mm) (g) M 20 x 1,5

Number of studs 10

Maximum inner steering angle (h) 55°

Roll angle (i) 10°

Dynamic load capability at less than 7 km/h (in daN.m) 7 500

Static load capability (in daN.m) 19 000

Oil type (j) See tractor user's manual.

Oil capacity of epicyclic gearbox (l) 1,5 l

Oil capacity of differential housing (k) 6l

Type of differential lock Electro-hydraulic

Number of differential discs 8

Number of crown wheel teeth 9/32 10/30 9/32 10/30

Number of epicyclic reduction gear teeth 13/31/77

Crown wheel reduction ratio 1/3,56 1/3 1/3,56 1/3

Epicyclic reduction ratio 1/6,92

Total reduction ratio of axle (m) 1/24,62 1/20,769 1/24,62 1/20,769

Power take-off (driving/driven) 49/45 45/49 49/45 45/49

Front/Rear inter-axle ratio See tractor user's manual.

Wheel alignment Toe-in (0/– 2)

D1.2 Ares 806 – 09.2004 – GB


Description

a m

b l

j k

451hsm00 Fig. 1

c
d
f

i
g
e

451hsm01 Fig. 2

Ares 806 – 09.2004 – GB D1.3


Description

Drive chain

13 77
31

9/32 (20.29, 20.43)


10/30 (20.29-3, 20.43-2)

31
13 77

49 (20.29, 20.43)
45 (20.29-3, 20.43-2)

45 (20.29, 20.43)
49 (20.29-3, 20.43-2)

451hsm02 Fig. 3

D1.4 Ares 806 – 09.2004 – GB


Removal/refitting

Tightening torques and sealants

7 daN.m
7 daN.m Frenbloc (270) 8 daN.m 1 daN.m 1,3 daN.m Frenbloc (270) 1,3 daN.m

Super Glue (401)

6 daN.m 23 daN.m Frenetanch (242) 19 daN.m 0,8 daN.m Formajoint (510)


2,5 daN.m

451hsm03 Fig. 4

Ares 806 – 09.2004 – GB D1.5


Removal/refitting

26 daN.m
Scelbloc (638) 0,4 daN.m 2,3 daN.m 0,3 daN.m

0,8 daN.m

0,8 daN.m 20daN.m Frenbloc (270) Formajoint (510) 17 daN.m Frenbloc (270) 20daN.m 0,8 daN.m

25 daN.m 30 daN.m

12 daN.m 6 daN.m 6 daN.m 22 daN.m 15 daN.m

451hsm04 Fig. 5

D1.6 Ares 806 – 09.2004 – GB


Removal/refitting

Adjusting the wheel alignment


Maximum toe-in: 4 mm
Wheel alignment is adjusted with the wheels fitted to the – Move the tractor forward until the wheels have
tractor and resting on the ground. The measurements completed a half-rotation (front axle disengaged) and
between the rims are taken at the horizontal axis of the measure A2 (between the same points X).
wheels, at the edge of the rims between the 2 points X. – Adjust the steering ball joint rods (M) so that A1 = A2
– Make a mark at these points. or A2 – 4 mm (forward angle closure).
– Measure A1 between points X. N.B.: Dimensions M must be equal.
– Tighten the rod locknuts to the recommended torque.

X
X X
A2

M M

A1
453hsm03 Fig. 6

Ares 806 – 09.2004 – GB D1.7


Disassembly prior to front axle operations

Preliminary operations

The front axle must be raised on stands


at the same time as the rear axle if the
A
current operation requires the engine to
be started up as the front axle remains engaged
when off. There is therefore a risk of the tractor
moving forward.

The tractor must be immobilised on flat, level ground.


– Apply the handbrake.
– Disconnect the battery.
Fig. 7
– Chock the rear wheels. 451hsm05

– Remove the housing and drive shaft.


– Remove the cover (A) from the angle sensor and
unplug the electrical connector.
– Drain the axle casing at (B) and the wheel hubs at (C).
– Chock the tractor under the crankcase with stands.
– Remove the front wheels.
– Disconnect the hose couplings from the steering
cylinder. To make the operation easier, take the weight
off the axle.
– Remove the supply hose coupling of the hydraulic
differential lock control (D).
– Using a hoist, lifting bar n° 77 01 388 906 and 2 slings, C E B D
lower the front axle then extract it after removing 451hsm06 Fig. 8
the 4 screws (E) holding the 2 bearings.
E

451hsm07 Fig. 9

453hsm06 Fig. 10

D1.8 Ares 806 – 09.2004 – GB


Removal/refitting

Steering cylinder
– Disconnect the steering tie-rods by unscrewing the
nuts (6).
– Remove the ball joint with the Stahlwille 12623-3 ball
joint puller.
– Remove the tie-rods (5).
Important: The length and position of the steering
stops must not be changed under any circumstances.
They must be measured before removal.
– Remove the 4 screws (1) from the steering cylinder.
– Open the cylinder.
– Refit the cylinder and the steering links and tighten to
the correct torque (Fig. 13).
– Refit the wheels.
– Carry out wheel alignment.
451hsm08 Fig. 11
Parts list
1 Cylinder attachment screw.
2 Angle sensor harness support.
3 Swivel end fitting.
4 Nut.
5 Steering tie-rod.
6 Nut.
7 Seals.
8 Piston seals.
9 O-ring.

451hsm09 Fig. 12

12 daN.m 30 daN.m 25 daN.m


1
5 4 3 2 5

6
22 daN.m
7 8 9 8 7

451hsm10 Fig. 13

Ares 806 – 09.2004 – GB D1.9


Removal/refitting

Removing the reduction gear and wheel hub

13
14
15
16
17
18
19
20
21
22
10
23
9
20.43
20.43-2

11
12
6
8
7
6 9
5
3
4
10
11
12
20.29
8
24 20.29-3
1
6
2
5
3
4
451hsm11 Fig. 14

Parts list
1 Filling, dipstick and drain plug. 9 Guide pin. 17 O-ring.
2 Bolts, M 8 x 20. 10 Screw. 18 Tapered roller bearing.
3 Planet gear pin. 11 Washer. 19 Circlip.
4 Socket. 12 Intermediate washer. 20 Ring gear carrier.
5 Washer. 13 Sealing ring. 21 Socket.
6 Needle. 14 Tapered roller bearing. 22 Screw.
7 Washer. 15 Wheel hub. 23 Ring gear.
8 31-tooth planet gear. 16 Wheel stud. 24 Planet carrier cover.

D1.10 Ares 806 – 09.2004 – GB


Removal/refitting

– Bring the reduction gear plug (1) to the bottom and


drain.
– Unscrew the 2 screws (2).
– Remove the cover (24).
– Remove the retaining ring (25) and washers (26)
and (27).
– Unscrew the 8 screws (22).
– Insert 2 of these screws (22) into the holes (A)
provided and use them as an extractor to remove the
ring gear carrier.
– Remove the hub (15).
– Extract the retainer (19) if necessary. 27 26 25
451hsm12 Fig. 15

Refitting the reduction gear and


wheel hub 22

– Check dimension "A" (Fig. 19).


– Use tool n° 60 05 006 535 to fit the new sealing
bush (13).

A
451hsm13 Fig. 16

15

19
451hsm14 Fig. 17

60 05 006 535
451hsm15 Fig. 18

Ares 806 – 09.2004 – GB D1.11


Removal/refitting

Important: No specific preload or clearance setting is


required to fit bearings (14) and (18). Check 14 18
dimensions A, B, C before fitting new parts.

• Front axles 20.29 and 20.29-3


A = 17,950 to 18,000 mm
C A C
B = 64,275 to 64,325 mm
C = 23,070 to 23,372 mm
B
• Front axles 20.43 and 20.43-2
A = 8,45 to 8,5 mm
B = 54,775 to 54,825 mm 451hsm16 Fig. 19

C = 23,070 to 23,072 mm

– Check the state of the planet gears (8).


N.B.: Pay attention to the positioning of the
intermediate washer (12) on refitting.
– Refit the hub and reduction gear in reverse order to
removal, tightening to the torques indicated below. 10
– Bolts, (10): 8 daN.m. 12
– Bolts, (22): 23 daN.m.
– Bolts, (2): 2,5 daN.m, Frenetanch (242). 8

451hsm17 Fig. 20

22

451hsm18 Fig. 21

451hsm19 Fig. 22

D1.12 Ares 806 – 09.2004 – GB


Removal/refitting

Removing the wheel pivot

31
50
32

33
29 40
47 48
30
34
49
46
39

38
35 45
44
28
36 43
37
42

41
451hsm20 Fig. 23

Parts list
28 O-ring. 36 Left-hand upper pivot pin. 43 Right-hand wheel pivot.
29 Left-hand wheel pivot. 37 Angle sensor pin retaining washer. 44 Bush.
30 Steering stop. 38 Spindle. 45 Lip seal.
31 Sensor cover screw. 39 Washer. 46 Grease nipple.
32 Angle sensor cover. 40 Sensor mounting screw. 47 Screw.
33 Washer. 41 Grease nipple. 48 Angular lower pivot pin.
34 Circlip. 42 Lower pivot pin. 49 Angle sensor.
35 Screw. 50 Angle sensor harness.

Ares 806 – 09.2004 – GB D1.13


Removal/refitting

18

451hsm45 Fig. 24 451hsm21 Fig. 25

– Remove the reduction gear and wheel hub


(see paragraph concerned).
– Extract the bearing inner ring (18) with an extractor.
– Remove the angle sensor (left-hand pivot only).
– Support the wheel pivot with a hoist.
– Remove the lower (42) and upper pins (36), (48)
(Fig. 23). 51
– Remove the Belleville washers (51) and (57).
– Extract the seal (45). 57
– Extract the bush (44).
– Fit the new bush (44) with tool n° 60 05 006 550.
451hsm22 Fig. 26
– Grease the lip of the new seal (45).
– Fit the seal with tool n° 60 05 006 549.

45

451hsm23 Fig. 27

44

451hsm24 Fig. 28

D1.14 Ares 806 – 09.2004 – GB


Removal/refitting

– Remove the universal shaft.


– Remove the seal (53) from the axle body. 44 52 53
– Change the bush (54) on the axle body.
N.B.: To remove the bush (52) from inside the axle, it
must be cut before it can be extracted.
– Extract the upper bush (52) and the lower ball joint (56)
from the pivot pin housings with an extractor.
– Unscrew the 2 screws from the angle sensor pin
retaining washer (10).
– Extract the ball joint (55) mounted on the pin.
45 55 56 54
Refitting the wheel pivot 451hsm25 Fig. 29

– Fit the new bush (54) to the axle body using tool
n° 60 05 006 538.
– Grease the chamber of the new seal (53) and coat
around the edge with Loctite Formajoint (510).
– Place the new seal inside the axle body with tool
n° 60 05 006 539.

53 52

451hsm26 Fig. 30

55
10

451hsm27 Fig. 31

60 05 006 538

60 05 006 539
451hsm28 Fig. 32

Ares 806 – 09.2004 – GB D1.15


Removal/refitting

– Position the sensor control pin retaining washer (10) in


the housing of the left-hand upper pivot pin.
– Tighten the 2 screws in the retaining washer (10). 56
N.B.: The lower and upper pivot pin bushes can be 10
inserted inside the axle body if they are chilled
beforehand.
– Fit the pivot pin inner bushes (52) and (56).
– Position the bushes (55) on the lower pivot pins with a
press.
– Grease the pivot pin housings.
– Position the Belleville washers (51) and (57).
– Insert the universal shaft into the axle body. 52
– Support the wheel pivot.
– Fit the pivot pins (36) or (48) and (42) and tighten the
screws to 19 daN.m.
N.B.: Make sure that the Belleville washers remain in
place. 451hsm29 Fig. 33

51

57

451hsm22 Fig. 34

451hsm30 Fig. 35

D1.16 Ares 806 – 09.2004 – GB


Removal/refitting

Refitting the angle sensor

c
Volts
5V d 13

ASE

0
e Ω
105˚ 122˚ 4 000

a b
451hsm31 Fig. 36

Parts list
a Electrical travel.
b Mechanical travel. 45˚
c Electricity supply (+12 V).
d Signal .
e Earth (0 V).

– Check all angle sensor components.


– Check its electrical characteristics (Fig. 36).
– The lower part of the rod (38) has 2 flat sections shown
by dotted lines (Fig. 37).
– Point these 2 flat sections long the same line as the
tractor. 38
– The upper part of the rod (38) also has a flat section to 45˚
be inclined to 45° in the direction of the tractor engine
(Fig. 37).
– Refit the angle sensor on the left-hand upper pivot.
N.B.: Use Métadiag for calibration.
– Refit the hub and reduction gear.

451hsm32 Fig. 37

Ares 806 – 09.2004 – GB D1.17


Removal/refitting

Removing the bevel gear and differential

8
7
6
5
4
3
2
1
9
10
11
12
13
14

25
24
18
5
17
16
15

27
28
26 29
23 30
22 31
21
20 32
19

33 39
42
34 40 34
35
43
41 57
44
40
45
39
46
38
47
37
48
36

56
55
54
53
52
51
50
49

451hsm33 Fig. 38

D1.18 Ares 806 – 09.2004 – GB


Removal/refitting

Parts list
1 Sealing ring. 20 Guide pin. 39 Sun gear.
2 Slotted nut. 21 Socket. 40 Tapered washer.
3 Washer. 22 Flange. 41 Spider.
4 Tapered roller bearing. 23 Screw. 42 Spindle.
5 Washer. 24 Adjustment shim. 43 Seal.
6 Socket. 25 Bevel gear. 44 Bush.
7 Bush. 26 Ring gear. 45 Seal.
8 Seal. 27 Disc. 46 Bush.
9 Bush. 28 Backplate. 47 Cover.
10 Bush. 29 Washer. 48 O-ring.
11 O-ring. 30 Half-shaft. 49 O-ring.
12 Bearing. 31 Planet gear. 50 Piston.
13 Screw. 32 Pin. 51 O-ring.
14 Grease nipple. 33 Differential housing. 52 Screw.
15 Cover attachment screw. 34 Screw. 53 Tapered roller bearing.
16 Cover. 35 Locking tab. 54 Washer.
17 Spacer. 36 Slotted nut. 55 O-ring.
18 Tapered roller bearing. 37 Bearing. 56 Slotted nut.
19 Drain plug. 38 Washer. 57 Locking tab.

N.B.: To remove the drive pinion and differential lock – Support then remove the cover (16) containing the
assembly, the universal shafts must be removed drive pinion and differential.
beforehand. – Remove the screws (34) and locking tabs (35)
and (57).
– Drain the differential by unscrewing the plug (19). – Mark the differential bearing flanges (22) in relation to
– Remove the bearing (12) by unscrewing the the cover (16) to avoid reversing them on refitting.
screw (13). – Unscrew the slotted nuts (36) with tool
– Extract the bushes (9), (10), (7). n° 60 05 006 534 and nut (56) with tool
– Remove the sealing bush (1). n° 60 05 006 581.
– Loosen the bevel pinion nut (2) using tool – Remove the screws (23).
n° 60 05 006 536.
Note: Do not reverse the bearings of the differential
bearing blocks if they are not replaced.

Ares 806 – 09.2004 – GB D1.19


Removal/refitting

5 C

18

17

451hsm36 Fig. 39 451hsm34 Fig. 40

– Put the cover fitted with the bevel pinion in a vice.


– Hold the drive pinion.
– Unscrew the nut (2) from the bevel pinion and 22
extract it.
– Extract the inner bush from the bearing with an
extractor.
– Extract the outer rings from the bevel pinion

D
bearings (4) and (18).

Disassembling the differential


N.B.: Mark the cover in relation to the front housing
before opening.
– Remove the ring gear (26). 16
– Open the housing.
– Remove all parts contained inside and check them. 451hsm35 Fig. 41

Adjusting the pinion protrusion


distance
mm
– Mount the bevel pinion bearings in the cover (16). 250

– Maintain the pressure on the inner rings of these


bearings with the aid of a screw and washers (Fig. 40).
The bearings should rotate when turned by hand. mm
90
– Mount a bearing half-flange (22) and measure the Ø = 15 mm
diameter "D" (Fig. 43).
– Place the locally made tool (X) at the bottom of the
Ø = 25 mm
bearing blocks (Fig. 42 and 43). Ø = 50 mm

451hsm37 Fig. 42

D1.20 Ares 806 – 09.2004 – GB


Removal/refitting

– Measure dimension "Y" with the end of the depth


gauge against the bearing inner ring.
– Deduct "B": B = Y – 50 + (D/2). X
– Add shims to the bevel pinion shaft to thickness "C":
C = B – V.
V Protrusion distance marked on the pinion head
(Fig. 43).
E N° of the pinion/ring gear pair.
50 : Diameter of the locally made tool.

D
50

B
Setting the bevel pinion preload

Y
N.B.: This adjustment is made on the bevel pinion
only, without the ring gear, after fitting the 2 tapered
bearings.
Note: All preloads must be measured without the
seal (1).
Important: Do not tighten the nut in one go. Tap the
ends of the pinion lightly with a hammer to seat the
bearings correctly. A new spacer (17) must be fitted.
V
– The nut must be tightened gradually, without
overtightening, using tool n° 60 05 006 536.
– Wind a cord around the splined part of the pinion
(Fig. 44).
– Using spring balance n° 77 01 388 008, measure the
107,00
force (P) required to rotate the pinion. It should be
between 9,2 and 13,7 daN.
00
– Bend down the nut collar.

451hsm38 Fig. 43

451hsm39 Fig. 44

Ares 806 – 09.2004 – GB D1.21


Removal/refitting

Adjusting the meshing backlash


– Refit the flanges (22).
N.B.: On the axle, change the O-ring (55) on the
differential lock aperture.
– Check the meshing backlash which should be
between 0,18 and 0,23 mm. 22
– Repeat several times by checking a number of teeth. If
the values differ, place the probe on the tooth where
the lowest value was recorded.
– Adjust the different bearing nuts with the same torque:
Use tools n° 60 05 006 534 and n° 60 05 006 581.
– Place the dial gauge probe at 90° with the surface of a
pinion tooth.
– Adjust the bearing nuts to move the ring gear away
from or closer to the bevel pinion, starting at the ring
gear side. 451hsm40 Fig. 45
– Tap the bearings lightly with a plastic hammer to seat
correctly.
– Adjust the bearing slotted nuts as follows:
• If the detected backlash is less than the indicated
tolerance range, tighten the nut on the opposite side
to the ring gear and loosen the other nut by the same
amount.
• If the detected backlash is greater than the indicated 56
tolerance range, tighten the ring gear nut and loosen 36
the other nut by the same amount.

Preloading the differential bearing


blocks
– Adjust the meshing backlash beforehand.
– Wind a cord around the splines in the bevel pinion
shaft. 451hsm41 Fig. 46

– Measure the rotation force "F" of the pinion-ring gear


assembly.
– Depending on the bevel pinion preload "P" measured
earlier, apply the formula:
F = P + 9,2 to 10,7 daN.
Example: If P = 11 daN, F = 20,2 to 21,7 daN.
– Adjust the bearing nuts while ensuring that the preset
backlash is maintained.
N.B.: Do not reverse the bearing nuts or the direction
in which the ring gear is fitted.

451hsm46 Fig. 47

D1.22 Ares 806 – 09.2004 – GB


Removal/refitting

Checking the settings


To check the contact print of the bevel gear teeth, stain
the ring gear with minium and detect the contact. The
contact print must always be examined on the teeth of the
ring gear and on 2 sides. Before checking, mount the ring
gear with Loctite Frenetanch (270) and tighten the screws
to 7 daN.m.

Contact correct (A)


If the bevel gear is set correctly, the contact of the teeth
surfaces will be regular.

Excessive contact at the tip of the tooth (B)


Move the pinion closer to the ring gear and then move the
ring gear away from the pinion to adjust the backlash.

Excessive contact at the base of the


451hsm42 Fig. 48
tooth (C)
Move the pinion away from the ring gear and then move
A B
the ring gear closer to the pinion to adjust the backlash.

Correction actions
D. Move the pinion to modify contact type (B).
E. Move the pinion to modify contact type (C).
If (D) and (E) are necessary, reset the preloads and the
meshing backlash.

C
Final reassembly
– Proceed in reverse order to the removal operations
and tighten to the specified torque.
– Coat the bearing faces of the differential housing with
Loctite Formajoint (510).
– Mount the combined joint (1) with tool 451hsm43 Fig. 49
n° 60 05 006 537.
– Refit the axle and tighten the 4 axle mounting screws
to a torque of 40 daN.m and the wheels to 45 daN.m.
– Check the condition of the breather.
Before putting the front axle back into operation,
remember to top up the oil levels: Axle and epicyclic
reduction gears.

451hsm44 Fig. 50

Ares 806 – 09.2004 – GB D1.23


Hydraulic measurement and checking points

Test conditions
– Transmission oil temperature: 60°C.
– Engine running at nominal speed.

Checking the differential lock circuit


pressure
In case of a front differential lock malfunction, check the
following items.
– The front differential control circuit pressure.
– Correct solenoid valve operation.
60 05 005 718
• Correct ECU operation by means of WIN METADIAG©.
If the ECU sends information but the solenoid valve is
not powered, check the continuity of the solenoid valve
supply circuit (see chapter F).
• Set up pressure gauge n° 60 05 705 076 and adapter
n° 60 05 005 718.
• Measure the pressure by activating the differential lock
button. The pressure should be 17 bar. If it is not equal
to 17 bar, check on the right-hand cover whether the
supply to the other 17 bar circuits is correct.
• If hydraulic oil leaks from the front differential locking
system it will flow directly into the differential housing.
A leak on the circuit can only be detected therefore by
checking that the differential housing level is not above 60 05 705 076
the maximum level.

453hsm68 Fig. 51

D1.24 Ares 806 – 09.2004 – GB


"Hydraulic inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If it is to be sent to CLAAS after-
sales department, it is essential to complete:

Tractor type: ...........................................................................................................................................................................

Serial n°: ................................................................................................................................................................................

Total operating hours: ............................................................................................................................................................

Date of operation: ..................................................................................................................................................................

Checking the differential lock circuit pressure

Test conditions
Nominal pressure Recorded pressure
Transmission oil temperature: 60°C

Engine at nominal speed 17 bar

Ares 806 – 09.2004 – GB D1.25


Notes

D1.26 Ares 806 – 09.2004 – GB


D2 – PROACTIV FRONT AXLE
20.43 SI
20.43 SI-2
20.43 SI-3

Ares 806 – 09.2004 – GB


Description

General characteristics - rigid axle

Type of axle (a) 20.43–3 SI 20.43–2 SI 20.43 SI

Reference (b) 149 928 147 217 142 120

Overall width (in mm) (c) 2 206

Width between plates (in mm) (d) 1 940

Pitch circle diameter of studs (in mm) (e) 335

Wheel disc centring diameter (in mm) (f) 280

Stud diameter (in mm) (g) M 20 x 1,5

Number of studs 10

Maximum inner steering angle (h) 50°

Roll angle (i) 8°

Dynamic load capability at less than 7 km/h 8 000

Static load capability 14 000

Oil type (j) See tractor user's manual.

Oil capacity of epicyclic gearbox (l) 1,5 l

Oil capacity of differential housing (k) 5,5 l

Type of differential lock Electro-hydraulic

Number of differential discs 7 or 8

Number of crown wheel teeth 10/30 9/32

Crown wheel reduction ratio 1/3 1/3,56

Number of epicyclic reduction gear teeth 13/31/77

Epicyclic reduction ratio 1/6,92

Total reduction ratio of axle (m) 1/20,769 1/24,62

Power take-off (driving/driven) 45/49 49/45

Front/Rear inter-axle ratio See tractor user's manual.

Wheel alignment Toe-in (0/–2)

Steering wheel turns between locks 4,25

D2.2 Ares 806 – 09.2004 – GB


Description

a m

b l

j k

451hsm00 Fig. 1

c
d
f

i
g

h
e

452hsm00 Fig. 2

Ares 806 – 09.2004 – GB D2.3


Description

Characteristics

13 77
31

9/32 (20.43-3)
10/30 (20.43, 20.43-2)

31
13 77

49 (20.43-3)
45 (20.43, 20.43-2)

45 (20.43-3)
49 (20.43, 20.43-2)

452hsm01 Fig. 3

D2.4 Ares 806 – 09.2004 – GB


Removal/refitting

Tightening torques and sealants

7 daN.m 13,5 daN.m


7,9 daN.m Frenbloc (270) 0,3 daN.m 1 daN.m 2,3 daN.m Frenetanch (242) 25 daN.m 30 daN.m 1 daN.m

6 daN.m 23 daN.m Frenetanch (242) 16,9 daN.m 25 daN.m 14 daN.m 7 daN.m 4,5 daN.m
2,5 daN.m

452hsm02 Fig. 4

Ares 806 – 09.2004 – GB D2.5


Removal/refitting

12 daN.m
1,3 daN.m
1,3 daN.m 0,4 daN.m Scelbloc (648)

7 daN.m 13,5 daN.m


22 daN.m

Frenetanch (242)

Frenbloc (270) 45 daN.m


6 daN.m Frenetanch (242) Frenetanch (242)
5 daN.m
20 daN.m 20 daN.m

26,6 daN.m 16,9 daN.m


Frenbloc (270)
Frenbloc (270)
Frenetanch (242)
9,5 daN.m 60 daN.m 7 daN.m
9,5 daN.m
Frenetanch (242)
7 daN.m
6 daN.m 1,3 daN.m

8 daN.m

3 daN.m

1,3 daN.m

Formajoint (510)

0,4 daN.m
3 daN.m

Super Glue (480)

1,3 daN.m Frenetanch (242)

16,9 daN.m

452hsm03 Fig. 5

D2.6 Ares 806 – 09.2004 – GB


Removal/refitting

Adjusting the wheel alignment


Maximum toe-in: 2 mm
Wheel alignment is adjusted with the wheels fitted to the – Move the tractor forward until the wheels have
tractor and resting on the ground. The measurements completed a half-rotation (front axle disengaged) and
between the rims are taken at the horizontal axis of the measure A2 (between the same points X).
wheels, at the edge of the rims between the 2 points X. – Adjust the steering ball joint rods (M) so that A1 = A2
– Make a mark at these points. or A2 – 2 mm (forward angle closure).
– Measure A1 between points X. N.B.: Dimensions M must be equal.
– Tighten the rod locknuts to the recommended torque.

X
X X
A2

M M

A1
453hsm03 Fig. 6

Ares 806 – 09.2004 – GB D2.7


Disassembly prior to front axle operations

Preliminary operations
A
The front axle must be raised on stands
at the same time as the rear axle if the
current operation requires the engine to
be started up as the front axle remains engaged
when off. There is therefore a risk of the tractor
moving forward.

The tractor must be immobilised on flat, level ground.


– Apply the handbrake.
– Disconnect the battery.
– Chock the rear wheels. 452hsm04 Fig. 7

– Remove the housing and drive shaft.


– Remove the cover (A) from the angle sensor and
unplug the electrical connector.
– Remove the covers from the suspension sensors (F)
and unplug the electrical connectors.
– Drain the axle casing at (B) and the wheel hubs at (C).
– Chock the tractor under the crankcase with stands.
– Remove the front wheels.
– Disconnect the hose couplings from the steering
cylinder. To make the operation easier, take the weight
off the axle.
– Remove the supply hose coupling of the hydraulic C E B D
differential lock control (D).
451hsm06 Fig. 8
– Using a hoist, lifting bar n° 77 01 388 906 and 2 slings,
lower the front axle then extract it after removing
the 4 screws (E) holding the 2 bearings.
F

451hsm07 Fig. 9

453hsm06 Fig. 10

D2.8 Ares 806 – 09.2004 – GB


Removal/refitting

Steering cylinder
– Disconnect the steering tie-rods by unscrewing the
nuts (6).
– Remove the ball joint with the Stahlwille 12623-3 ball
joint puller.
– Remove the tie-rods (5).
Important: The length and position of the steering
stops must not be changed under any circumstances.
They must be measured before removal.
– Remove the 4 screws (1) from the steering cylinder.
– Open the cylinder.
– Refit the cylinder and the steering links and tighten to
the correct torque (Fig. 13).
– Refit the wheels.
– Carry out wheel alignment.
451hsm08 Fig. 11
Parts list
1 Cylinder attachment screw.
2 Angle sensor harness support.
3 Swivel end fitting.
4 Nut.
5 Steering tie-rod.
6 Nut.
7 Seals.
8 Piston seals.
9 O-ring.

451hsm09 Fig. 12

12 daN.m 30 daN.m 25 daN.m


1
5 4 3 2 5

6
22 daN.m
7 8 9 8 7

451hsm10 Fig. 13

Ares 806 – 09.2004 – GB D2.9


Removal/refitting

Epicyclic reduction gear and wheel hub

13 7,9 daN.m
26
27
28
29
9
11
8
7
6
1 12
3

22
5
4 2,5 daN.m 25
2 24
23

15
14

19
20
18
17
16
21
10
452hsm06 Fig. 14

Parts list
1 Reduction gear cover. 11 Spacer. 21 Washer.
2 Filling, dipstick and drain plug. 12 Ring gear. 22 Stud.
3 Wheel nut. 13 Screw. 23 Half-hub.
4 Screw. 14 Screw (23 daN.m). 24 Tapered roller bearing.
5 Universal shaft. 15 Bush. 25 Seal.
6 Planet gear pins. 16 Washer. 26 Washer.
7 Washer. 17 Sprocket. 27 Guide pin.
8 Needles. 18 Circlip. 28 Washer.
9 Planet gear pinion. 19 O-ring. 29 Needles.
10 Circlip. 20 Tapered roller bearing.

D2.10 Ares 806 – 09.2004 – GB


Removal/refitting

Removing the epicyclic reduction


gear
14 10
– Unscrew the plug (2) in the top position to prevent
projection due to excessive pressure.
– Bring the hub to the bottom position to drain the oil.
– Unscrew the screws (4) and separate the cover (1)
from the wheel hub using the 2 notches at the edge.
– Check the condition of the O-ring (19) sealing the
reduction gear housing.
– Check the needles (8) and (29), the stop washer (7)
and the planet gear spacer (11). Replace them if
necessary.
– Check the pins (6) of the planet gears (9). If damaged,
16
replace the planet carrier and pins assembly (a single 21 5
reference).
– On refitting, ensure that the washer (28) is centred
Fig. 15
properly. 452hsm07

Removing the wheel hub


– Remove the circlip (10), extract the stop washer (21)
and the 2 washers (16) mounted on the universal
shaft (5), and change them if necessary.
– Unscrew the screws (14) to enable the wheel hub to be
removed from the steering swivel pin.
– To remove the sprocket (17) and ring gear (12)
assembly, insert 2 of the screws (14) into the threaded
holes in the sprocket (17) and use them as extractors.
– Remove all of the centring bushes (15) using a bearing
extractor.
– Replace the seal (25) every time. Grease it and use
tool n° 60 05 006 535 to refit.
– Extract the half-hub (23) and the bearings (20)
and (24).

Ares 806 – 09.2004 – GB D2.11


Removal/refitting

Wheel pivot and upper arm

34 25 daN.m 42 43

32 31
40
35
41
46
45
36 44

37
47 48
30 34
33 49
38
16,9 daN.m 50
37 51
39 53
54
55

52
63
64 72
59 56 65
73
57
58 60
56
58
63
64
65 71
61 70
54 69
55 68
57 67
59 66
452hsm08 Fig. 16

Parts list
30 Left-hand pivot. 45 Washer. 60 Fork.
31 Right-hand pivot. 46 Nut. 61 Lower pin.
32 Upper ball joint. 47 Upper arm. 62 Pin.
33 Lower ball joint. 48 Seal. 63 Washer.
34 Nut. 49 Spindle. 64 Bush.
35 Bush. 50 Washer. 65 Seal.
36 Belleville washer. 51 Bush. 66 Screw.
37 Nut. 52 Seal. 67 Seal.
38 Flange. 53 Upper pin. 68 Cover.
39 Screw. 54 Seal. 69 Washer.
40 Seal. 55 Bush. 70 Bush.
41 Bush. 56 Washer. 71 Bush.
42 Bush. 57 Centring bush. 72 Locking screw.
43 Plug. 58 Circlip. 73 Locknut.
44 Steering stop. 59 Grub screw.

D2.12 Ares 806 – 09.2004 – GB


Removal/refitting

Removing the angle sensor


– Remove the screws (74).
– Remove the "support and potentiometer"
assembly (75). 76
– Remove the plate (78).
– Remove the retainer (76). 77
– Retrieve the washer, control pin and O-ring (77).
N.B.: Angle sensor removal is only valid for the
left-hand side of the axle.

Removing the wheel pivots


– Remove the upper slotted nut (34) from the upper arm
using tool n° 60 05 006 553.
– Remove the lower slotted nut (37) from the lower arm
452hsm09 Fig. 17
using tool n° 60 05 006 554.

75

74
452hsm10 Fig. 18

76

78

452hsm11 Fig. 19

Ares 806 – 09.2004 – GB D2.13


Removal/refitting

– Loosen the locknut (79) and remove the locking


screw (80) from the fork shaft of the universal joint
protector.
– Remove the circlip (58). 80
At the opposite end to the circlip (58), there are 2 possible
assembly scenarios:

Case 1: Assembly with a grease nipple or


plug
– Remove the plug or grease nipple (81). 79
– Using a drift punch, push the shaft and the centring
bush (61) to remove them.

Case 2: No hole 452hsm12 Fig. 20

– Drill a hole (A) 6 mm in diameter (Fig. 22).


– Using a drift punch, push the shaft and the centring 47
bush (57) to remove them.
– Separate the upper arm (47) from the ball joint (32)
using a chisel.
– Keep the upper arm (47) in the air with a block.

61
57
58
81

452hsm13 Fig. 21

452hsm14 Fig. 22

32

47

452hsm15 Fig. 23

D2.14 Ares 806 – 09.2004 – GB


Removal/refitting

– Separate the lower arm from the ball joint.


– Support the hub carrier with a hoist or a factory crane.
– Remove the hub carrier pivot (30). 32
– Remove the lower nut from the upper ball joint (32) 60 05 006 554
using tool n° 60 05 006 554.
– Remove the upper ball joint (32).
– Extract the screws (39) from the lower flange (38) and
remove it.
– Remove the upper nut from the lower ball joint using
tool n° 60 05 006 554.
– Remove the lower ball joint.

452hsm16 Fig. 24

30

38

39

452hsm17 Fig. 25

Ares 806 – 09.2004 – GB D2.15


Removal/refitting

– Unscrew the nuts (82), then remove the sensor (83).


– With an indelible pen, mark the position of the ring
holder bush (84) so that the rubber ring (85) is
positioned correctly in relation to the housing on
refitting. 83 82
– Remove the ring holder bush (84) and the rubber
ring (85).

85

84

452hsm18 Fig. 26

82

83

452hsm19 Fig. 27

84

85

452hsm20 Fig. 28

D2.16 Ares 806 – 09.2004 – GB


Removal/refitting

Removing the upper arm


– Loosen the locknut (73) and remove the locking 73
screw (72) from the shaft (49).
72
– Remove the 3 attachment screws (66) from the
cover (68).
– Extract the shaft (49), O-ring and washer.
– Extract the bush (51).
Note: 2 notches are provided in the axle body to
remove the bush in case it is seized.
– Remove the upper arm (47).
68
66

452hsm21 Fig. 29

49

452hsm22 Fig. 30

47

51

452hsm23 Fig. 31

Ares 806 – 09.2004 – GB D2.17


Removal/refitting

Suspension cylinder and lower arm

125
126
127
128
124
130
129

87
88
89
90
91
92
94
100 112
99 111
86
98 110
92
93
114
113
109
108
95 107
106
96 105
104
97 103
102
101

123
122
121
110
120
111
119
113
118
114
115
116

117

452hsm24 Fig. 32

D2.18 Ares 806 – 09.2004 – GB


Removal/refitting

Parts list
86 Cylinder. 101 Seal. 116 Needle screw.
87 Circlip. 102 Bush. 117 Nut.
88 Washer. 103 Bush. 118 Torsion bar.
89 Seal. 104 Washer. 119 O-ring.
90 Washer. 105 Seal. 120 Spindle.
91 Grease nipple. 106 Nut. 121 Seal.
92 Washer. 107 Seal. 122 Washer.
93 Seal. 108 Front flange. 123 Bush.
94 Hydraulic coupling. 109 Screw. 124 Cylinder pin.
95 Lower arm. 110 Bush. 125 Screw.
96 Steering stop. 111 Screw. 126 Nut.
97 Screw. 112 Plug. 127 Screw.
98 Spindle. 113 Circlip. 128 Blanking plate.
99 Grease nipple. 114 Cover. 129 Nut.
100 Screw. 115 Rear flange. 130 Screw.

Wheel actuator
– In order to remove the suspension cylinder, it is – Use a 3-armed extractor to extract the cylinder from the
advisable to remove the upper arm first. upper part of the axle structure.
– To remove the suspension cylinder lower pin, release – On refitting, pay attention to the tightening and directon
the pressure on the torsion bars (118) by unscrewing of the coupling (94).
the adjustment screw (116) and the 3 attachment
screws (111).
N.B.: Use a flat body-panel chisel to free the pin (98)
when it is seized.

Removing the torsion bar


– Remove the caps (114).
– Mark the position of the torsion bar (118) in relation to
the front (108) and rear flanges (115).
– Mark the position of the flange (115) in relation to the 115
axle structure (Fig. 33).
– Loosen the 3 attachment screws (111) in the rear
flange (115) by a few turns.
– Loosen the locknut (117) and unscrew the screw (116)
slowly until the preload on the torsion bar (118) has
been eliminated.
– Remove the 2 circlips (113). 118
– Remove the 3 attachment screws (111) from the rear 113
flange (115) and extract it.
– To remove the front flange (108), screw one of the
attachment screws in the threaded hole provided.

452hsm25 Fig. 33

Ares 806 – 09.2004 – GB D2.19


Removal/refitting

Removing the lower arm


– Remove the lower cylinder pin: Use the 2 tapped holes 120
to extract it or a flat body-panel chisel if there are no 95
tapped holes.
– Unscrew and remove the nut (106) using tool
n° 60 05 006 551 and tool n° 60 05 006 552 (Fig. 32).
– Extract the pin (120) using tool n° 60 05 006 583
(Fig. 34).
– Support the lower arm (95).
– Extract the bushes using tool n° 60 05 006 583 and the
grooves (A) in the axle body (Fig. 35).
– Remove the lower arm (95).

Refitting the lower arm


– Insert the 2 wear bushes (103) on the lower arm using 452hsm26 Fig. 34

tool n° 60 05 006 559.


– Fit the 2 lip seals (101) inside the arm using tool A
n° 60 05 006 559 *.
– Fit the 2 stop bushes with the embossed part facing 102
out.
– Fit the 2 grease nipples.

452hsm27 Fig. 35

101

103

* Seal lip facing in. 452hsm28 Fig. 36

D2.20 Ares 806 – 09.2004 – GB


Removal/refitting

– If you change the lower arm.


– Retrieve and fit the steering stop (96); tightening torque
of the 3 stop screws: 6 daN.m.
N.B.: If you fit a new lower arm, also retrieve and fit the
axle identification plate from the old arm.

96

452hsm29 Fig. 37

452hsm30 Fig. 38

Ares 806 – 09.2004 – GB D2.21


Removal/refitting

100 105 119 106


98 106
107

119
105
120
102
121

107
119
452hsm33 Fig. 39 452hsm34 Fig. 40

– Drive the bush (121) onto the pin (120) with a mallet.
Mount the chamfered side first.
– Fit the O-rings (119) on the pin (120) and the
bush (105).
– Position the lower arm and fit the pin (120).
– Fit the bush (105) (chamfer facing in).
– Fit the second bush (107) over the first
(recess facing in).
– Tighten the slotted nut (106) with tool n° 60 05 006 551
and tool n° 60 05 006 552.
Tightening torque: 60 daN.m.
– Fit the lower cylinder pin (98) with the bushes. 106
– Tighten the screws (100) to a torque of 9,5 daN.m.
– Lubricate and fit the O-ring on the front flange (108).
– Position the front flange (108) in its housing.
– Apply Loctite (542) threadlocker to the screws and 452hsm31 Fig. 41
tighten to a torque of 7 daN.m.

452hsm32 Fig. 42

D2.22 Ares 806 – 09.2004 – GB


Removal/refitting

Refitting the torsion bar


– Using a jack, lift the lower arm as high as possible
(tractor in low position), (Fig. 43).
– Lubricate the splines of the front flange (108).
– Before refitting the torsion bar (118), check the stamp
on the end.
SX : Left-hand torsion bar.
DX : Right-hand torsion bar.
The arrow indicates the direction of torsion bar rotation on
preloading.
N.B.: The stamp should be located on the front flange
side (108).
– On the front flange side (108), introduce the torsion bar
fitted with the circlip so that it is fully inserted in the 108
flanges and flush up against the circlip.
Fig. 43
N.B.: Observe the marks made earlier. 452hsm35

– Position the rear flange (115) and insert the screws,


without tightening, so that they are at the base of the
slot on the left-hand side (looking at the flange
face-on).

118

452hsm36 Fig. 44

118

116

115 117
452hsm37 Fig. 45

Ares 806 – 09.2004 – GB D2.23


Removal/refitting

– Finish fitting the torsion bar (118) (the arm must be


raised to the cylinder limit).
117
N.B.: Observe the marks made earlier.
– Fit the circlip.
– Tighten the needle screw (116) by hand as far as it will 115
go. This approach point will be the zero position before
preloading the bar.
– Tighten the screw by 7,5 turns with a spanner.
– Tighten the locknut (117) to a torque of 4,5 daN.m.
– Tighten the screws in the rear flange (115) to a torque 116
of 16,9 daN.m.
– Position the front and rear flange covers.

Refitting the upper arm


– Screw on new grease nipples. 452hsm38 Fig. 46
– Smear the 2 pivots with grease.
– Fit the 2 wear bushes (71) and (51) and the 2 lip
seals (52) (lips on the inside and spring towards the
outside of the arm) using tool n° 60 05 006 559 and
tool n° 60 05 006 555.
– Fit the 2 brass washers (50) with the embossed side
facing the outside of the arms.
– Smear the 2 pivots with grease.

Universal shafts 50
51
N.B.: To remove the seals, the wheel pivot needs to be
removed first of all. 52

Universal shaft, wheel side 71


– The universal shaft can easily be extracted once the 69
wheel pivot has been removed.
452hsm39 Fig. 47
– Check the shafts and splines.
– Replace the spiders (131) if worn or damaged
(Fig. 49).

452hsm40 Fig. 48

D2.24 Ares 806 – 09.2004 – GB


Removal/refitting

Universal shaft, differential side


– The nut and grub screw securing the universal joint on – Pull out and extract the universal joint protector.
the 2 sides of the axle must be removed (Fig. 48). – On refitting, lubricate and insert the combined
– The pressure on the torsion bars must be released to joints (138) using tool n° 60 05 006 560 and tool
move the lower arm away freely and, in some cases, n° 60 05 006 561.
the torsion bar must be removed altogether.

134
132
131
133
132
131
5
16
21
135
10
154
132
153
132
152
131 151
150
149

142 132
145
136
146 137
138
148
139
140
141
143
144

147
452hsm41 Fig. 49

Parts list
5 Universal shaft. 137 Circlip. 146 Nut.
10 Circlip. 138 Seal. 147 Bearing.
16 Washers. 139 Bush. 148 Seal.
21 Washer. 140 Bearing. 149 Seal.
131 Spider. 141 Circlip. 150 O-ring.
132 Circlips. 142 Screw. 151 Bush.
133 Body. 143 Universal joint protector. 152 Bearing.
134 Countershaft. 144 Screw. 153 Circlip.
135 Differential shaft. 145 Needle screw. 154 Circlip.
136 Intermediate end fitting.

Ares 806 – 09.2004 – GB D2.25


Removal/refitting

– Drive out the pin (62).


– Remove the pin, bearing and bushes.
– Remove the fork. 62
– Check the parts and change any that are defective.
– Screw on new grease nipples.

452hsm42 Fig. 50

D2.26 Ares 806 – 09.2004 – GB


Removal/refitting

– Lubricate and fit O-rings on the upper pin (49) and the
bush (68).
– Position the upper arm and fit the pin (49).
Note: The upper pin is inserted from the front of the
axle. Position the slot in the pin facing the tapped
hole.
– Fit the spacer (70) on the non-machined arm side.
– Fit the bushing (68) with its O-ring.
– Insert the 3 screws (66).
– Screw in and tighten the needle screw (72) to a torque
of 13,5 daN.m.
– Tighten the locknut (73) to a torque of 7 daN.m.
– Tighten the 3 screws (66) to a torque of 5 daN.m.

452hsm43 Fig. 51

49

72

73

70

68

66

452hsm44 Fig. 52

Ares 806 – 09.2004 – GB D2.27


Removal/refitting

Refitting the wheel pivots


– Replace the lip seal.
– Fit the ball joint (the one with the hole).
– Fit the washer and screw on the lower slotted nut (37).
– Tighten to a torque of 25 daN.m using a 41 mm socket.
Use a vice if the ball joint rotates.
– Fit the lower ball joint (32).
37
– Screw on and tighten the upper nut (34) to a torque
of 14 daN.m. Use a jack if the ball joint rotates.
– Tilt the lower ball joint towards the reduction gear.
– Insert the protection tool n° 60 05 006 586 over the
universal shaft. 452hsm45 Fig. 53
– Tilt the hub carrier and insert it into the lower ball joint.
Beware of damaging the ball joint threads.
– In the same movement, insert the universal shaft (joint
protector fitted).
34
– Lower the upper arm and position it on the ball joint.
Insert it with a copper hammer.
– Refit the lower plate: Three screws (39) tightened to a
torque of 17 daN.m.
– Screw on and tighten the lower nut to a torque
of 25 daN.m.
– Position the fork pin and bearing in relation to the 33
needle screw hole (Fig. 56).
452hsm46 Fig. 54

39

452hsm47 Fig. 55

452hsm48 Fig. 56

D2.28 Ares 806 – 09.2004 – GB


Removal/refitting

– Insert the needle screw.


– Fit the circlip.
– Tighten the needle screw (145) to a torque
of 13,5 daN.m.
– Tighten the locknut (146) to a torque of 7 daN.m.
– Screw on the grease nipple and tighten to 0,8 daN.m. 145

Refitting the wheel hub


Important: Before refitting the new parts, check the
following dimensions.
A = 17,950 to 18,000 mm.
B = 64,275 to 64,325 mm. 146
C = 23,070 to 23,172 mm.
N.B.: The refitting of the wheel hub bearings does not
require any specific preload or clearance settings. 452hsm49 Fig. 57

– Use tool n° 60 05 006 535 to fit the seal (25) (Fig. 14).
– Tighten the screws (14) to a torque of 23 daN.m.

23
Refitting the epicyclic reduction gear 20 24

– Fit the new circlip (10) with the 2 splined washers.


N.B.: Force the universal shaft back out by levering
with a bar. A

C C
B
C C

452hsm50 Fig. 58

14 10

16
21 5

452hsm07 Fig. 59

Ares 806 – 09.2004 – GB D2.29


Removal/refitting

84

85

452hsm51 Fig. 60 452hsm20 Fig. 61

– Fit the O-ring. 82


– Refit the planet carrier (1).
– Insert and tighten the 2 screws (4) to 2,5 daN.m.
– Top up the reduction gear with oil and check the level.
– Connect the steering rod.
– Tighten the new nut to a torque of 25 daN.m.

Refitting the suspension position


sensor
– On refitting the bush, refer to the marks made earlier.
– Fit the ring (84) (Fig. 61).
83
N.B.: Make sure that the rubber ring (85) is positioned
correctly. Look for the side marked "Outside".
452hsm19 Fig. 62
– Insert the rubber ring into its housing while ensuring
that the protruding external part is seated in the bush
cavity.
– Refit and connect the sensor (83).
83 82

85

84

452hsm18 Fig. 63

D2.30 Ares 806 – 09.2004 – GB


Removal/refitting

Setting the suspension sensors


Check the setting of the Hall-effect sensor to identify the
optimum axle position.
– The measurement should be taken with the ignition
switched on.
– Unplug the connector between the sensor and the
suspension control unit.
– Make the test harness illustrated below (Fig. 66).
– Connect the multimeter (milliamp position) in series on
the sensor "Out" signal terminal.
N.B.: To identify the various sensor terminals, place it
in the direction in which the inscriptions are read.
Terminal 1 is the top one, 2 is the middle one and 3 is
the bottom one.
– Measure the electrical current which should
correspond to: 452hsm52 Fig. 64
Suspension in the low position: I = 7,8 mA.
Suspension in the high position: I = 15,9 mA.
– To set the current intensity, loosen the nuts and turn the
sensor gently by hand until the correct value is
obtained.
– Tighten the sensor mounting nuts to 0,4 daN.m.

Sensor Colours of ECU output


terminal sensor wire Allocation
identification output wires identification

1 Blue C Earth

2 Green/yellow A Ub (12 V)

3 Brown B Signal (Out)

452hsm53 Fig. 65

Ares 806 – 09.2004 – GB D2.31


Removal/refitting

Locally made test harness

A C
BC B
A

1 2 3 4

452hsm54 Fig. 66

Parts list
1 3-way AMP connector n° 77 03 297 036. 3 2 mm diameter conductors (length approximately 500 mm).
2 Sockets to connect multimeter n° 77 03 097 069. 4 3-way AMP connector n° 77 03 297 034.

D2.32 Ares 806 – 09.2004 – GB


Removal/refitting

Calibrating the suspension


This operation must only be performed in the following
cases. B
– Exchange of either or both of the 2 suspension position
sensors.
– Exchange of the suspension control unit. II
– Incessant flashing of the monitoring lamp
I
(once every second).
Calibration conditions:
– Engine idling. A
– Hold the mode switch (A) in position (II) (automatic)
for 10 seconds.
– The orange lamp on the switch begins to flash.
– Raise the axle to the maximum position with the
up/down switch (B).
– Lower to the maximum position.
452hsm55 Fig. 67
– Validate by pressing position (II) (automatic) on the
mode switch (A).
– The lamp lights up without flashing.
N.B.: If the lamp continues to flash, it means that the
system has rejected the calibration. The procedure
must therefore be repeated 2 or 3 times. If the
calibration cannot be validated after several attempts
and the sensors are properly set, switch off the
tractor and unplug the ECU connector or remove
fuses 7 and 21. This action will reset the system.
Attach the connector again and calibrate.

Ares 806 – 09.2004 – GB D2.33


Removal/refitting

76
76
77

452hsm09 Fig. 68 452hsm56 Fig. 69

Refitting the angle sensor


– Refit the control pin, O-ring and washer (77).
– Position the control pin and fit the circlip (76) (Fig. 69).
– Refit the sensor and support assembly (75).
N.B.: Refer to chapter "G" for the setting procedure. 75

Final steps
– Grease the axle.
– Refit the wheels and remove the stands.
– Connect the battery.
– Check all front axle oil levels and top up if necessary.
74
Test the tractor, especially the front axle suspension.
452hsm10 Fig. 70

452hsm04 Fig. 71

D2.34 Ares 806 – 09.2004 – GB


Removal/refitting

Bevel gear and differential


– Drain the axle via the plug hole (19); plug hole (63) is – On refitting, replace the washers (5) and especially the
used for filling and level checking. spacer (17).
– To remove the pinion set, the entire differential unit – Mark the flanges (22) before removing them to prevent
needs to be disassembled. However, it must be kept on inverting them on refitting.
until the bevel pinion nut has been loosened. – Extract the differential housing, taking care not to invert
– Remove the bearing (12) by unscrewing screw (13). the bearing outer rings.
– With an extractor, remove the bushes (7) and (10). – Whenever the housing is removed, change the
– Change the bushes (71), (69), (68) if necessary. screws (52), apply Loctite Frenetanch (242) and
– Remove the combined seal (1) and replace it on tighten them to a torque of 7 daN.m.
refitting. – Systematically change all the seals.
– Using tool n° 60 05 006 536, unscrew and remove the N.B.: The clearance between planet gear-pivot and
bevel pinion nut (2). pinion must be between 0,085 and 0,131.

Parts list
1 Sealing ring. 25 Bevel gear. 49 O-ring.
2 Slotted nut. 26 Ring gear. 50 Piston.
3 Washer. 27 Disc. 51 O-ring.
4 Tapered roller bearing. 28 Backplate. 52 Screw.
5 Washer. 29 Washer. 53 Tapered roller bearing.
6 Socket. 30 Half-shaft. 54 Washer.
7 Bush. 31 Planet gear. 55 O-ring.
8 Seal. 32 Pin. 56 Slotted nut.
9 Bush. 33 Differential housing. 57 Locking tab.
10 Bush. 34 Screw. 58 Screw.
11 O-ring. 35 Locking tab. 59 Nut.
12 Bearing. 36 Slotted nut. 60 Screw.
13 Screw. 37 Bearing. 61 Plug.
14 Grease nipple. 38 Washer. 62 Breather.
15 Cover attachment screw. 39 Sun gear. 63 Plug.
16 Cover. 40 Tapered washer. 64 Front bearing.
17 Spacer. 41 Spider. 65 Screw.
18 Tapered roller bearing. 42 Spindle. 66 Grease nipple.
19 Drain plug. 43 Seal. 67 O-ring.
20 Guide pin. 44 Bush. 68 Bush.
21 Socket. 45 Seal. 69 Bush.
22 Flange. 46 Bush. 70 Seal.
23 Screw. 47 Cover. 71 Bush.
24 Adjustment shim. 48 O-ring.

Ares 806 – 09.2004 – GB D2.35


Removal/refitting

Sectional view

34 22 63 33 38 39 31 30 32 42 29 27 52 49

50

47

35
51

53

46

43
36

39
37

44

41
54 55
30
48

16

26
24

25
18
5

17
9

3
4

10
2
1

452hsm57 Fig. 72

D2.36 Ares 806 – 09.2004 – GB


Removal/refitting

Exploded view

8
7
6
5
4
3
2
1
9
10
11
12
13
14 64
60 65
61
59 62 66
63

59 67
58 68
69
70
71
24
18
5
17
16
15
27
28
26 29
25 30
23 31
22
21 32
20
19 34
39
33 42 57
43
40
44
34
45
35 41
46
40
47
39
48
38 56
37 55
36 54
53
52
51
50
49

542hsm58 Fig. 73

Ares 806 – 09.2004 – GB D2.37


Removal/refitting

5 C

18

17

451hsm36 Fig. 74 451hsm34 Fig. 75

– Put the cover fitted with the bevel pinion in a vice.


– Hold the drive pinion.
– Unscrew the nut (2) from the bevel pinion and extract 22
it.
– Extract the pinion bearing inner ring with an extractor.
– Extract the outer rings from the bevel pinion
bearings (4) and (18).

D
Disassembling the differential
N.B.: Mark the cover in relation to the front housing
before opening.
– Remove the ring gear (26).
– Open the housing. 16
– Remove all parts contained inside and check them.
451hsm35 Fig. 76

Adjusting the pinion protrusion


distance
– Fit the bevel pinion bearings. mm
250
– Maintain the pressure on the inner rings of these
bearings with the aid of a screw and washers (Fig. 76).
The bearings should rotate when turned by hand.
– Mount a bearing half-flange (22) and measure the mm
90
diameter "D" (Fig. 76). Ø = 15 mm
– Place the locally made tool (X) at the bottom of the
bearing blocks (Fig. 77).
Ø = 25 mm
Ø = 50 mm

451hsm37 Fig. 77

D2.38 Ares 806 – 09.2004 – GB


Removal/refitting

– Measure dimension "Y" with the end of the depth


gauge against the bearing inner ring.
– Deduct "B": B = Y – 50 + (D/2). X
– Add shims to the bevel pinion shaft to thickness "C"
(Fig. 76): C = B – V.
V Protrusion distance marked on the pinion head.
E N° of the pinion/ring gear pair.
50 : Diameter of the locally made tool.

D
50
Setting the bevel pinion preload

B
Y
Note: All preloads must be measured without the
seal (1).
N.B.: This setting is performed on the bevel pinion
only, after fitting the 2 tapered bearings.
Important: Do not tighten the nut in one go. Tap the
ends of the pinion lightly with a hammer to seat the
bearings correctly. A new spacer (17) must be fitted.
– The nut must be tightened gradually, without
overtightening, using tool n° 60 05 006 536. V
– Wrap the cord around the splined part of the gear
(Fig. 79).
– Using spring balance n° 77 01 388 008, measure the
force (P) required to drive the bevel pinion. It should be
between 9,2 and 13,7 daN.
107,00
– Bend down the nut collar.
00

451hsm38 Fig. 78

451hsm39 Fig. 79

Ares 806 – 09.2004 – GB D2.39


Removal/refitting

Adjusting the meshing backlash


– Refit the flanges (22).
N.B.: On the axle, change the O-ring (55) on the
differential lock aperture.
– Check the meshing backlash which should be
between 0,18 and 0,23 mm. 22
– Repeat several times by checking a number of teeth. If
the values differ, place the probe on the tooth where
the lowest value was recorded.
– Adjust the different bearing nuts with the same torque:
Use tools n° 60 05 006 534 and n° 60 05 006 581.
– Place the dial gauge probe at 90° with the surface of a
pinion tooth.
– Adjust the bearing nuts to move the ring gear away
from or closer to the bevel pinion, starting at the ring
gear side. 451hsm40 Fig. 80
– Tap the bearings lightly with a plastic hammer to seat
correctly.
– Adjust the bearing slotted nuts as follows:
• If the detected backlash is less than the indicated
tolerance range, tighten the nut on the opposite side
to the ring gear and loosen the other nut by the same
amount.
• If the detected backlash is greater than the indicated 56
tolerance range, tighten the ring gear nut and loosen 36
the other nut by the same amount.

Preloading the differential bearing


blocks
– Adjust the meshing backlash beforehand.
– Wind a cord around the splines in the bevel pinion
shaft. 451hsm41 Fig. 81

– Measure the rotation force "F" of the pinion-ring gear


assembly.
– Depending on the bevel pinion preload "P" measured
earlier, apply the formula:
F = P + 9,2 to 10,7 daN.
Example: If P = 11 daN, F = 20,2 to 21,7 daN.
– Adjust the bearing nuts while ensuring that the preset
backlash is maintained.
N.B.: Do not reverse the bearing nuts or the direction
in which the ring gear is fitted.

451hsm46 Fig. 82

D2.40 Ares 806 – 09.2004 – GB


Removal/refitting

Checking the settings


To check the contact print of the bevel gear teeth, stain
the ring gear with minium and detect the contact. The
contact print must always be examined on the teeth of the
ring gear and on 2 sides. Before checking, fit the ring gear
with Loctite Frenetanch (270) and tighten the screws
to 7 daN.m.

Contact correct (A)


If the bevel gear is set correctly, the contact of the teeth
surfaces will be regular.

Excessive contact at the tip of the tooth (B)


Move the pinion closer to the ring gear and then move the
ring gear away from the pinion to adjust the backlash.

Excessive contact at the base of the


451hsm42 Fig. 83
tooth (C)
Move the pinion away from the ring gear and then move
A B
the ring gear closer to the pinion to adjust the backlash.

Correction actions
D Move the pinion to modify contact type (B).
E Move the pinion to modify contact type (C).
If (D) or (E) proves to be necessary, reset the preloads
and the meshing backlash

C
Final reassembly
– Proceed in reverse order to the removal operations
and tighten to the specified torque.
– Coat the bearing surfaces of the differential housing
with Loctite Formajoint (510).
– Mount the combined joint (1) with tool 451hsm43 Fig. 84
n° 60 05 006 537.
– Refit the axle and tighten the 4 axle mounting screws
to a torque of 40 daN.m and the wheels to 45 daN.m.
– Check the condition of the breather.
Before putting the front axle back into operation,
remember to top up the oil levels: Axle and epicyclic
reduction gears.

451hsm44 Fig. 85

Ares 806 – 09.2004 – GB D2.41


Removal/refitting

Suspension control unit


Suspension control unit - Hydraulic diagram
The suspension control unit is located under the cab, attached to the rear axle. The electronic unit (ECU) controlling front
axle operation is located on the upper part of the suspension control unit.

A1 A2

SVL SVR
AV
250 bar

WV

LS

P
T

452hsm59 Fig. 86

Parts list
SV-L LH cylinder solenoid valve. AV Valve. A1 LH cylinder supply.
SV-R RH cylinder solenoid valve. LS Load sensing signal. A2 RH cylinder supply.
W-V Control solenoid valve. T Return to reservoir. P Pressure.

D2.42 Ares 806 – 09.2004 – GB


Removal/refitting

Removal

SV-L
A1
AV SV-R
8 daN.m A2
WV

LS
P

5 daN.m

8 daN.m

452hsm63 Fig. 87

Before working on the suspension control unit, relieve the – Disconnect the solenoid valves (SV-L), (SV-R), (W-V).
internal pressure by putting the front axle in the Now unscrew the 4 electronic unit mounting screws
deactivated position. The suspension control unit and remove it from the block.
accumulators are discharged in a few seconds and the – Remove the block.
axle drops completely. – Remove the nuts from the solenoid valve coils.
– Open the valve (AV) to eliminate all residual pressure – Extract the solenoid valves and unscrew the valves
in the cylinders and accumulators by loosening the from the block.
locknut and unscrewing the screw by one turn (beware – Unscrew and remove the closing valve (AV).
of impurities). – Unscrew and remove the accumulators.

Ares 806 – 09.2004 – GB D2.43


Removal/refitting

100 L/min circuit – Quadrishift transmission

A1 A2

LS T P

452hsm60 Fig. 88

D2.44 Ares 806 – 09.2004 – GB


Removal/refitting

110 L/min circuit – Quadrishift transmission

A1 A2

LS T P

HP

BP

452hsm61 Fig. 89

Ares 806 – 09.2004 – GB D2.45


Removal/refitting

110 L/min circuit – Full Powershift transmission

A1 A2

LS T P

HP

BP

542hsm62 Fig. 90

D2.46 Ares 806 – 09.2004 – GB


Removal/refitting

Refitting

SV-L
A1
AV SV-R
8 daN.m A2
WV

LS
P

5 daN.m

8 daN.m

452hsm63 Fig. 91

If the couplings (LS), (T) and (P) have been replaced, N.B.: Check that the seal is fitted between the
screw all couplings back onto the valve block and tighten electronic unit and the valve block.
to the stated torques (Fig. 91).
– Install the electronic unit on the valve block and tighten
– Fit 2 new seals between the accumulators and the the mounting screws to a torque of 6 daN.m. Plug in
valve block. the solenoid valve connectors.
– Install and screw 2 new accumulators onto the valve
Important: The accumulators cannot be repaired.
block and tighten to 20 daN.m.
They must be replaced in case of failure. The inflation
– Lubricate the valves before refitting. Tighten them to a
pressure is 35 bar. The valves located inside the
torque of 2,5 daN.m.
suspension system hydraulic unit must not be
– Fasten the solenoid valves to the valves and tighten to removed under any circumstances.
a torque of 0,9 daN.m.

Ares 806 – 09.2004 – GB D2.47


Hydraulic measurement and checking points

Test conditions.
– Transmission oil temperature: 60°C.
– Engine running at nominal speed.
– Suspension disabled.

Suspension cylinder pressure check


N.B.: Check that the tractor's hydraulic functions are – The pressure at the start of the suspension rising
working properly before testing the axle hydraulic phase should be 130 bar for a tractor equipped with a
circuit. front lift .
To check the suspension cylinder pressure, connect – The pressure at the end of the rising phase should
pressure gauge n° 60 05 705 076 and adapter reach 150 bar (depending on the weight of the masses
n° 60 05 005 306 directly to the cylinder outlet. or the lift).
– The accumulators should take 20 seconds to inflate.
The suspension system should take 6 seconds to rise.

Nominal value Measured value Nominal value Measured value

Start pressure Pressure End pressure Pressure


130 bar 150

60 05 005 306

60 05 705 076

452hsm64 Fig. 92

D2.48 Ares 806 – 09.2004 – GB


Hydraulic measurement and checking points

Test conditions.
– Transmission oil temperature: 60°C.
– Engine running at nominal speed.

Checking the differential lock circuit


pressure
In case of a front differential lock malfunction, check the
following items.
– The front differential control circuit pressure.
– Correct solenoid valve operation.
60 05 005 718
• Correct ECU operation by means of WIN METADIAG©
(transmission). If the ECU sends information but the
solenoid valve is not powered, check the continuity of
the solenoid valve supply circuit (see chapter "F").
• Set up pressure gauge n° 60 05 705 076 and adapter
n° 60 05 005 718.
• Measure the pressure by activating the differential lock
button. The pressure should be 17 bar. If it is not equal
to 17 bar, check on the right-hand cover whether the
supply to the other 17 bar circuits is correct.
• If hydraulic oil leaks from the front differential locking
system it will flow directly into the differential housing.
A leak on the circuit can only be detected therefore by
checking that the differential housing level is not above 60 05 705 076
the maximum level.

453hsm68 Fig. 93

Ares 806 – 09.2004 – GB D2.49


"Hydraulic inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If it is to be sent to CLAAS
after-sales department, it is essential to complete:

Tractor type: ...........................................................................................................................................................................

Serial n°: ................................................................................................................................................................................

Total operating hours: ............................................................................................................................................................

Date of operation: ..................................................................................................................................................................

Suspension cylinder pressure check

Test conditions Nominal pressure at start of Recorded Nominal pressure at end of Recorded
Oil temperature at 60°C rise phase (in bar) pressure (in bar) rise phase (in bar) pressure (in bar)

Engine running at nominal


speed with suspension 130 150
deactivated

Differential locking circuit pressure check


Test conditions
Nominal pressure (in bar) Recorded pressure (in bar)
Transmission oil temperature: 60°C

Engine running at nominal speed 17

D2.50 Ares 806 – 09.2004 – GB


Electric checks

Control switches
Switch (A): Suspension automatic or manual operating
mode. B
Switch (B): Suspension up/down.
– Check control switch operation by testing continuity
with a test lamp or multimeter. II
I
Disconnect the battery before performing
any operations on the electric circuit.
A

Interpretation of lamp status

Operating mode Lamp status

Deactivated Out
Manual Out 452hsm55 Fig. 94
Automatic Steady "on"
Rapid flashing once every
Calibration
second
Error codes Alternate flashing

9 10
C

2 4 6 8 1 6

A D
1 3 5 7 12 7
2 4 6 8

B
3 5 7 E
1 2

3
452hsm65 Fig. 95

Parts list
A Automatic/manual mode switch. D 12-pin connector of the suspension control unit located
B Up/down switch. under the cab.
C Orange lamp integrated into mode switch. E Fuses 9 and 19.

Ares 806 – 09.2004 – GB D2.51


Electric checks

Wire allocation of the 12-pin connector on the suspension unit

Pin number Allocation Wire colour

1 Not used —
2 Switch in down position Purple
3 Switch in up position Green/yellow
4 Switch in deactivated position Orange
5 Switch in automatic position Grey
6 +12 V AVC Pink
7 Not used —
8 +12 V APC Brown
9 Earth Blue
10 Earth Red
11 Lamp Black
12 Not used White

Suspension control solenoids


Use the test harness to check solenoid valves n° 60 05 005 734.

U = 12 V • R = 8 Ω • I = 1,5 A U = 12 V • R = 8 Ω • I = 1,5 A
1 2

3
U = 12 V • R = 8 Ω • I = 1,5 A

452hsm66 Fig. 96

Solenoid valve power supply

LH cylinder solenoid valve (1) RH cylinder solenoid valve (2) Control solenoid valve (3)
Switch
(Blue connector) (Green connector) (Black connector)

Up Power on
Down Power on Power off

D2.52 Ares 806 – 09.2004 – GB


Breakdown diagnosis

Values to be checked

II
I

452hsm55 Fig. 97

Position Deactivated High Low Automatic centre

Engine speed 2 200


Oil temperature + 60°C
Position of automatic/manual mode switch (1) Position I Position II
Position of up/down switch (2) — Position A Position B —
Lamp status Out Lit
12 V across terminals 6 and 9 (or 10) of 12-pin connector
Electronic unit power supply
12 V across terminals 8 and 9 (or 10) of 2-pin connector
Power supply to LH cylinder solenoid valve (W-V) No Yes, 12 V No
Power supply to control solenoid valve (SV-L) No Yes, 12 V No
Power supply to RH cylinder solenoid valve (SV-R) No Yes, 12 V No
Sensor output current — 15,9 mA 7,8 mA —

Ares 806 – 09.2004 – GB D2.53


Breakdown diagnosis

Interpreting error codes


When the orange lamp starts to flash quickly, certain error Key to the table
codes can be identified. These error codes can be used to
detect the following problems.
•Flashes 0,5 second apart.
– Position sensor error (less than 4 mA or more —One-second pause.
than 19,68 mA current at sensors). N.B.: The error code is repeated after a 2-second
– Short circuit, connection problem or electrical pause.
malfunction on solenoid valves (SV-L), (SV-R), (W-V).
When one of these problems occurs, the lamp flashes Reading the table
with the respective error code. Error code numbers 21, 22, 31, 32 correspond to the
N.B.: To exit the error mode, switch the ignition off number of times the lamp lights up: For example: for
and on again. code 31, the lamp lights up 3 times, pauses for one
second then lights up once.

Error Orange lamp


Function Control
codes flashes

Check the wiring harness running from the electronic unit to the
21 ••—• LH position sensor signal
LH and RH position sensor signal.
sensors for continuity, insulation and short circuiting.
Check sensor operation.
Check the setting of the suspension position sensors.
Check the wiring harness running from the electronic unit to the
22 ••—•• RH position sensor signal.
right-hand sensor for continuity, insulation and short circuiting.
Check right-hand position sensor operation.
Check the setting of the right-hand position sensor.
Power supply to LH up/down solenoid Check the state of fuse 9 (15 A) (AVC).
31 •••—• valve (SV-L)
Power supply to control up/down
Check the power supply to the LH cylinder solenoid
valve (SV-L).
solenoid valve (W-V) Check the power supply to the control solenoid valve (W-V).
Check the power supply to the RH cylinder solenoid
32 •••—•• Power supply to RH up/down solenoid
valve (SV-R).
valve (SV-R).
Check the continuity of the RH cylinder solenoid valve (SV-R).
Change the electronic unit (ECU).

D2.54 Ares 806 – 09.2004 – GB


D3 – GPA 30 AND GPA 40 4-WHEEL
DRIVE POWER TAKE-OFF HOUSING

Ares 806 – 09.2004 – GB


Description

General
Declutched position Clutched position
The solenoid valve used to engage the front axle is When the pressure is cut out, the release of the Belleville
mounted on the right-hand hydraulic cover (see washer (26) pushes back the bell (23), connecting the
chapter "B"). It supplies the piston (39) at 17 bar pressure pinion (10) to the bell and allowing the shaft (2) to rotate.
via the internal duct (A). The piston is displaced over the
N.B.: When the engine is switched off and on braking,
hub (30) and pulls the bell (23) which compresses the
the front axle is engaged systematically.
Belleville washers (26) and releases the discs. The bell
pinion (10) then rotates freely on the shaft. Lubrication
The oil from the lubrication circuit is fed in through the
coupling (22) and lubricates the clutch via a tube (21)
(GPA 30 axle) or an internal duct (GPA 40 axle) and a
duct (B) perforated in the shaft.

Parts list (Fig. 1 to 6)


1 Lip seal. 17 Drive gear. 33 Circlip.
2 Shaft. 18 Adjustment shims. 34 Circlip.
3 Circlip. 19 O-ring. 35 Splined adjustment shim.
4 Bearing cup. 20 Seal carrier. 36 Backing plates.
5 Circlip. 21 Lubrication tube or duct. 37 Discs (6 to 9 discs according to
6 Bush. 22 Lubrication pipe. equipment).
7a Hydraulic bushing (GPA 30 axle). 23 Bell. 38 Circlip.
7b Hydraulic bushing (GPA 40 axle). 24 O-ring. 39 Piston.
8 Bearing cup. 25 O-ring. 40 O-ring.
9 Bearing cone. 26 Belleville washers. 41 Adjustment shims.
10 Bell pinion. 27 Supply pipe. 42 Dust seal (GPA 40 axle).
11 Cover. 28 Supply tube or duct, 17 bar. 43 Panel (GPA 40 axle).
12 Screw. 29 Cover. A Internal supply duct.
13 Drain plug. 30 Hub. B Internal lubrication duct.
14 Seal. 31 O-ring. T Bushing internal duct (GPA 30 axle).
15 Casing. 32 Sealing ring.
16 Bearing cone.

D3.2 Ares 806 – 09.2004 – GB


Description

Cross-sectional view of the 4-wheel drive housing (GPA 30 axle)

34

7a
T
8

11
12
5

10
17

35 41
13
36

14
37

25
26

24
23

40
38

30
39

18
4

1
19

20
3
2

472hsm03 Fig. 1

Ares 806 – 09.2004 – GB D3.3


Description

Cross-sectional view of the 4-wheel drive housing (GPA 30 axle)

22 23 24 25 26 15 27 28

21

38
29
39

40
31

7a

B 30 37 A 35 41 34 33 32

472hsm00 Fig. 2

D3.4 Ares 806 – 09.2004 – GB


Description

Exploded view of the 4-wheel drive housing (GPA 30 axle)

3
42
20
1
18
37

19
36

4
29

16
35
34

2
6 10
9

21
8

32
33
7a

40
38
24
39
31
28

30
31
11

25
26
23

472hsm01 Fig. 3

Ares 806 – 09.2004 – GB D3.5


Description

Cross-sectional view of the 4-wheel drive housing(GPA 40 axle)

8
7b
32
A
34

12
35

B
41

37
29

11
17

36
26
25
10

24
6

39
30

38
43

13
23

40
4

16
42

18
3

19
20
2

473hsm09 Fig. 4

D3.6 Ares 806 – 09.2004 – GB


Description

Cross-sectional view of the 4-wheel drive housing (GPA 40 axle)

22 27

A
B

21

28

27 22

473hsm00 Fig. 5

Ares 806 – 09.2004 – GB D3.7


Description

Exploded view of the 4-wheel drive housing (GPA 40 axle)

7b
32 9
8
6
10

34
35
41
29
36
37

23

26

25

30
2
39
24
38
16 40
4
18
19
1
20
42
3

473hsm01 Fig. 6

D3.8 Ares 806 – 09.2004 – GB


Removing/refitting the housing

Removal of clutch
– Immobilise the tractor.
– Chock the rear wheels. 29 34 30 36 10
– Apply the handbrake.
– Drain the intermediate housing.
– Disconnect the control and lubrication ducts from the
housing.
– Remove the housing and drive shaft.
– Remove the circlip (3).
– Remove the cover (11).
– Extract the seal carrier bush (20).
– Remove the adjustment shims (18) and the bearing
cup (4).
– Withdraw the shaft (2) and bearing (8) while holding
the clutch and bell pinion through the inspection port.
– Remove the clutch, bell pinion, bearing cone (9) and
Fig. 7
panel (43) assembly. 473hsm02

– Extract the cup (8) and the circlip (33) (GPA 30 axle).
– Remove the 17 bar supply pipe and the coupling.
N.B.: On the GPA 30 axle, the bushing (7) is held only
by the tube (28). If only the tube needs to be removed,
make sure that the bushing does not move.
– Extract the tube (28) with pliers (GPA 30 axle).
– Remove the bushing (7).
35 30
Removing the clutch 34

– Extract the bearing cone (9). 29


– Separate the bell pinion from the clutch assembly.
36
Using a press and a suitable jig, compress the
Belleville washers (26) to remove the circlip (34) and 41 23
the shims (35) and (41).
– Decompress the Belleville washers (26). 473hsm03 Fig. 8
– Remove the cover (29), the discs (37) and the backing
plates (36). Using a press and a suitable jig, press on
the piston (39) to compress the Belleville washers (26).
– Remove the circlip (38) with pliers.
– Remove the Belleville washers (26).

38

39

23

473hsm04 Fig. 9

Ares 806 – 09.2004 – GB D3.9


Removing/refitting the housing

Refitting the clutch


N.B.: All seals must be changed and lubricated on
refitting.
– Check and clean the parts. Replace any defective
parts.
– Make sure that the ducts are not blocked.
– Position the Belleville washers in the bell (23).
– Fit the hub (30) in the bell. 35 30
– Align the discs with the front housing and fit the
backing plates. 34
– Fit the cover (29). 29
N.B.: The cover (29) and the number of discs and
backing plates differ according to assembly options 36
(with or without proportional power take-off) and
41 23
tractor power..
473hsm03 Fig. 10

Fitting shims to the clutch "J1" 34


J1 = 1 ± 0,1 mm
– Mount the clutch without the shims (35) and (41). Using 35
a suitable jig, apply a load of approximately 2 000 daN
in order to compress the Belleville washers completely
and join the discs and backplates.
– Refit the circlip (34).
– With a set of feeler gauges, measure the space "X"
between the circlip (34) and the cover (29). X
– Remove the circlip. 35
– Select a shim thickness so that 1 mm (± 0,1 mm) of 29
play "J1" remains.
Important: Fit the splined shim (35) on the circlip (34)
side.
– Position the selected shims.
– Refit the circlip (34).
– Refit the piston (39). Using a press and a suitable jig, fit 473hsm05 Fig. 11

the circlip (38) permanently.


– Couple the clutch assembly to the bell pinion.
35
36

23

30
24
39

34
41
29
37

26
25
38
473hsm06 Fig. 12

D3.10 Ares 806 – 09.2004 – GB


Removing/refitting the housing

Fitting shims to the shaft "J2"


J2 = 0 + 0,1 mm

– Fit the tapered bearings (4), (16) and (8), and (9)
temporarily to the shaft (2).
– Fit the seal carrier bushing (20).
– Mount the shaft (2) and the circlip (3) temporarily
2 3
without the clutch assembly, pinion or shims (18).
Using pliers, turn alternately from right to left to seat the
bearings correctly.
– Place a dial gauge at the end of the shaft (2).
– Set the dial gauge to zero and push the shaft to
measure the play "J2".
– Repeat the operation bwhile pulling the shaft.
– Depending on the amount of play measured, select the 20
thickness of shims (18) required to obtain 0 to 0,1 mm
of play.
– Remove the circlip (3), the shaft (2), the bearings and
the seal carrier bushing (20). 472hsm02 Fig. 13

– Fit the shims (18) selected earlier after coating them


with miscible grease.

473hsm07 Fig. 14

Ares 806 – 09.2004 – GB D3.11


Removing/refitting the housing

Refitting the shaft


N.B.: All seals must be changed and lubricated on – Pack the cavity (A) between the dust seal (42) and the
refitting. seal (1) with grease (GPA 40 axle).
N.B.: On GPA 30 axles, fit the bushing (7) with the – Fit the dust seal with an appropriate tool (42)
orifice (T) facing down (Fig. 1). (GPA 40 axle).
– Clean the cover (11) and its contact surface with the
– Fit the bushing (7) while taking care not to damage the housing.
new rings.
– Coat the cover seal face with Loctite Formajoint (510).
– Using an appropriate tool, fit the lip seal (1) in the seal
– Refit the cover (11) by tightening the screws (12)
carrier bushing (20).
to 8 daN.m.
– Put the seal carrier bushing, equipped with its new
– Reconnect the hydraulic ducts.
seal, into place.
– Top up the housings with oil.
– Mount the full power take-off unit permanently in the
– Refit the housing and drive shaft
rear axle housing.
– Check the cover and ducts for leaks.
– Fit the circlip (3).
– Engage the front axle with the tractor running.

20

42

11

12 7b

473hsm10 Fig. 15

D3.12 Ares 806 – 09.2004 – GB


Solenoid valve measurement and checking points

On/off solenoid valve


– Connect cable n° 60 05 005 734 and tester n° 60 05 006 744 (voltmeter position) to the electric circuit of the front axle
engagement solenoid valve (see chapter "B").
– Power up the solenoid valve.
– The voltage measured across the solenoid valve must be 12 Volts.
– With power off, disconnect the solenoid valve harness.
– Connect cable n° 60 05 005 734 and tester n° 60 05 006 744 (ohmmeter position) to the solenoid valve only.
– The resistance measured must be 10 ohm.


60 05 005 734

391hsm50 Fig. 16

Ares 806 – 09.2004 – GB D3.13


Hydraulic measurement and checking point

Test conditions:
– Engine idling.
– Transmission oil temperature: 60°C.

Checking the front axle engagement pressure


– Remove the 4-wheel drive housing supply pipe and fit a hydraulic hose in its place.
– Connect pressure gauge n° 60 05 705 076 to the hose.
– Activate the front axle engagement switch.
– Measure the pressure which must be 17 bar.

HP

BP

60 05 705 076

473hsm08 Fig. 17

D3.14 Ares 806 – 09.2004 – GB


"Hydraulic inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:

Tractor type: ...........................................................................................................................................................................

Serial n°: ................................................................................................................................................................................

Total operating hours: ............................................................................................................................................................

Date of operation: ..................................................................................................................................................................

Checking the front axle engagement pressure

Test conditions
Nominal pressure in bar Measured pressure in bar
Oil temperature at 60°C

Engine idling 17

Ares 806 – 09.2004 – GB D3.15


Notes

D3.16 Ares 806 – 09.2004 – GB


TOOLS

Front axle – 4 WD power take-off housing

Ares 806 – 09.2004 – GB


Front axle – 4 WD power take-off housing

60 05 005 306 60 05 005 718

Adapter for measuring suspension cylinder pressure Adapter for measuring differential lock pressure

60 05 005 734 60 05 006 534

Solenoid valve test harness Wrench for differential nut

60 05 006 535 60 05 006 536

Tool for fitting seal to wheel hub Wrench for conical pinion nut

D3.18 Ares 806 – 09.2004 – GB


Front axle – 4 WD power take-off housing

60 05 006 537 60 05 006 538

Tool for fitting seal to conical pinion Tool for fitting bushings in axle body and steering knuckle

60 05 006 539 60 05 006 549

Tool for fitting axle body and steering knuckle seals Seal fitting tool

60 05 006 550 60 05 006 551

Bushing fitting tool Lower arm pivot locking tool

Ares 806 – 09.2004 – GB D3.19


Front axle – 4 WD power take-off housing

60 05 006 552 60 05 006 553

Socket for lower arm pivot nut Socket for upper wheel pivot nut

60 05 006 554 60 05 006 555

Socket for lower wheel pivot nut Bushing beater

60 05 006 556 60 005 006 557

Seal beater Seal beater

D3.20 Ares 806 – 09.2004 – GB


Front axle – 4 WD power take-off housing

60 05 006 558 60 05 006 559

Seal and bushing beater Seal beater

60 05 006 560 60 05 006 561

Seal beater Seal protector

60 05 006 562 60 05 006 581

Seal insertion fork Differential nut wrench

Ares 806 – 09.2004 – GB D3.21


Front axle – 4 WD power take-off housing

60 05 006 583 60 05 006 586

Bushing extraction tool Seal protector

60 05 006 744 60 05 705 076

Multimeter Pressure gauge kit

77 01 388 008 77 01 388 640

Electronic dynamometer Mandrel

D3.22 Ares 806 – 09.2004 – GB


Front axle – 4 WD power take-off housing

77 01 388 907

Compensation bar (supplied with slides)

Ares 806 – 09.2004 – GB D3.23


Notes

D3.24 Ares 806 – 09.2004 – GB


E1
CLOSED CENTRE HYDRAULICS
(110 l/min)
(except control circuit, see chapter "B2" or "B4").

Ares 806 – 09.2004 – GB


Description

Characteristics
Type of circuit Closed centre/Load sensing
Pumps
Number 2
Type Gear, variable displacement
Location In the rear axle
Circuit Boost Principal
Pump displacement (cm³/rev) 60 0 to 45
Flow rate at rated engine speed (l/min) 160 100
Flow rate at max. engine speed (l/min) — 110
Calibration pressure (bar) 5 200
Filters
Suction strainer - filtration threshold 150 microns
Filter (flow reversal) - filtration threshold 15 microns
Blockage indicator
Cooler Yes
Priority unit
Spool valves
SB 23 "Load Sensing" (mechanical control)
Type
SB 23 EHS (electro-hydraulic control)
Type of pressure take off points Break away
Flow rate control range 5 to 90 l/min
Maximum number 5
Steering unit
Type OSPQ 100/160 "Load Sensing"
Calibration pressure (bar) 155 to 165
Steering cylinder (position) Integrated into rear of front axle
Linkage
Type EHR 23 "Load Sensing"
Electronic lift TCE – 15 – 15 T – 25
Number of external cylinders 2 (single action)
Lift capacities at the swivel joints (kg)
Maximum 11 330
Over the whole stroke 6 250 to 7 430
Trailer brake valve
Type of control Control synchronised hydraulically with the tractor brakes.
Type of pressure take off points External pressure take-off point at the rear on base plate.

Parts list
High-pressure circuit. Return circuit. Lubrication system.

Charge circuit. Control circuit. Suction circuit.

E1.2 Ares 806 – 09.2004 – GB


Notes

Ares 806 – 09.2004 – GB E1.3


Description

Parts list
1 Suction tube. 40 Priority unit screws. 77 Speed sensor nut.
2 Suction strainer, 150 µ µ. 41 Steering "Load Sensing" signal "XDIR" 78 Hollow key.
3 LH hydraulic cover. pipe. 79 Pinion.
4 Boost pump, 60 cm³/rev. 42 "Load Sensing" control to pump 80 Washer.
5 Recirculation tube. regulator. 81 Centring pin.
6 High-pressure filter, 15 µ (HP). 43 Park lock, GPA 30. 82 O-ring.
7 Blockage indicator. 44 Rear PTO clutch solenoid valve. 83 Seal.
8 Return tube. 45 Rear PTO brake solenoid valve. 84 Screw.
9 Safety valve, 22 bar. 46 Rear differential locking solenoid valve. 85 Nut.
10 Safety valve, 5 bar. 47 4-wheel drive solenoid valve. 86 Stud.
11 Variable displacement pump. 48 Caps. 87 Guide pin.
12 RH hydraulic cover. 49 PTO clutch coupling. 88 LH cover screw.
13 Rear axle lubrication and boost 50 PTO brake coupling. 89 Suction strainer bowl.
pressure switch. 51 Low-pressure coupling. 90 O-ring.
14 Rear axle intermediate housing 52 Rear differential locking coupling. 91 O-ring.
partition, GPA 30. 53 Brake coupling. 92 Seal.
15 "Load Sensing" signal (LS) pressure 54 4 wheel drive coupling. 93 Suction tube attachment nut.
connector. 55 Low-pressure coupling. 94 Flat seal.
16 Variable capacity pump regulator. 56 Supply to manifold (lift and auxiliary 95 Boost pump attachment screws.
17 High-pressure spool, (HP) 200 bar. spool valve). 96 Circlip.
18 Boost pressure connector. 57 "Load Sensing" control from lift and 97 Screw.
19 Low-pressure spool, (BP) 22 bar. auxiliary spool valves.
98 Lip seal.
20 Pressure limiter, 230 bar. 58 Screw.
99 O-ring.
21 High-pressure (HP) connector. 59 Master cylinder trailer brake control. 100 O-ring.
22 "Load Sensing" signal (LS) circuit 60 Variable-displacement pump
101 Filter, 60 µ.
selector. attachment screws.
102 Hare/tortoise (high/crawl) range
23 Priority unit (braking and steering 61 Low-pressure connector.
solenoid.
circuit). 62 Guide pin.
103 Front PTO solenoid valve.
24 Priority unit (control and auxiliary 63 Centring pin. 104 Transmission control circuit
valves). 64 Hollow key. accumulator.
25 Hydraulic trailer braking connector. 65 Pinion. 105 Gearbox solenoid valve unit.
26 Valve spool, 17 bar. 66 Washer. 106 Pressure switch, 9 bar.
27 Brake valve control pipe. 67 Nut. 107 Rear axle lubrication (brakes, 4WD
28 Brake valve. 68 Seal. clutch, creep range, PTO clutch).
29 Steering priority valve. 69 O-ring. 108 Braking boost accumulator.
30 Steering/braking priority valve. 70 Seal. 109 LH cover screw.
31 Steering unit. 71 Pin. 110 O-ring.
32 Steering cylinder. 72 Coupling and tube to lubrication 111 O-ring.
33 Lift cylinder. manifold. 112 O-ring.
34 Blanking plate. 73 Rivets. 113 Oil cooler.
35 Auxiliary spool valve. 74 Plug. 114 Automatic handbrake solenoid valve.
36 Linkage spool valve. 75 Plug.
37 Supply plate. 76 Speed sensor.
38 RH cover screws.
39 Steering unit supply pipe "PDIR".

E1.4 Ares 806 – 09.2004 – GB


Description
Hydraulic circuit diagram - Quadrishift transmission

Yft 27
23
32

L R 31 33
17 bar
150 bar
28
Xdir 26 34

Pdir

35
29 30
22
22
Paux 35

24 A
P
21 T
101 60 µ 36
12 104 108
25 T P 37
15 22 bar
20 9
19
230 bar A XLS

114
22 bar 47

17 200 bar

46

18
11 76/65
3 bar 44
13
113
9 bar 45 103

5 bar 10 106

2,4 bar
6 7
15 µ 3,5 bar
107

105
5 3
2,1 bar 8 4 76/61
102
2 150 µ

391hsm01 Fig. 1

Ares 806 – 09.2004 – GB E1.5


Description
Component layout - Quadrishift transmission

31
32

25

31

23
7

32

391hsm66 Fig. 2

E1.6 Ares 806 – 09.2004 – GB


Description
Hydraulic circuit diagram - Full Powershift transmission

Yft
32 23

L R 31
17 bar 33
150 bar
28
Xdir 26 34

Pdir

35
29 30
22
22
Paux 35
P
24 A

21 T
101 60 µ 36
12 108
25 T P 37
15 22 bar
20 9
3,4 bar
250 µ 19
230 bar A XLS

15 > 200 µ
22 bar 47
18 bar
17 200 bar
6 bar
46

18
2,4 bar ˚C 11 76/65
3 bar 44

105 13
9 bar 45 103

5 bar 10 106

2,4 bar
6 7
15 µ 3,5 bar
107

5 3
2,8 bar
4 76/61
43
8 2 150 µ
9 bar
1
113

391hsm58 Fig. 3

Ares 806 – 09.2004 – GB E1.7


Description
Component layout - Full Powershift transmission

25

31

23
7

32

391hsm67 Fig. 4

E1.8 Ares 806 – 09.2004 – GB


Description

Sectional view of GPA 40 rear axle

12 11 5 4 3

10

6 13 8 1

391hsm02 Fig. 5

GPA 30 and GPA 40 right-hand cover GPA 40 left-hand cover

10 7

393hsm01 Fig. 6 391hsm04 Fig. 7

Ares 806 – 09.2004 – GB E1.9


Description

Sectional view of GPA 30 rear axle

1
5

1
9
8

8
14

393hsm02 Fig. 8

E1.10 Ares 806 – 09.2004 – GB


Removing/refitting the components

External view of right-hand cover without brake valve

39 40 41 42 24 21 16 106 15 48 44

49
20
45

50

38
52
HP

BP

76

46

54
55

57 58 56 60 18 47 48 61 55 6

391hsm05 Fig. 9

Ares 806 – 09.2004 – GB E1.11


Removing/refitting the components

External view of right-hand cover with brake valve

39 40 41 42 24 59 21 48 16 106 15 48 44

49

51

45
20

38

HP 50

52

BP 76

46

54

55

53 57 58 56 60 18 47 48 61 55 6

391hsm06 Fig. 10

E1.12 Ares 806 – 09.2004 – GB


Removing/refitting the components

Internal view of right-hand cover

62 74 73 67 66 65 64 11 12

20

62

73

74

10

72 13 75

391hsm07 Fig. 11

Ares 806 – 09.2004 – GB E1.13


Removing/refitting the components

Exploded view of right-hand cover

70
5
1
69
63
71
24
68 11
111 64
23
40

20
12
62

38
110
15
67
66
60 65
48 63
111
16

10

58
61

45

391hsm08 Fig. 12

E1.14 Ares 806 – 09.2004 – GB


Removing/refitting the components

Identification of ports and lines

I
15

F I
F
B

HP

GAV

16 H A

20 F

I H F D
J
9
20

D
E

C 10

391hsm09 Fig. 13

Parts list (Fig. 13 and 14)


A Adjustment screw, 22 bar. G High pressure outlet of variable displacement pump.
B Adjustment screw, 200 bar. H To variable displacement pump control piston.
C Main filter, 15 micron. I Regulator return.
D Boost. J Return from priority unit(s) (depending on version).
E Rear axle lubrication only. XLS LS signal (Load Sensing).
F High pressure from variable displacement pump.

N.B.: Screws (A) and (B) are factory set. Do not change these settings.

Ares 806 – 09.2004 – GB E1.15


Removing/refitting the components

Schematic diagram of the variable displacement pump regulator

15

XLS

22 bar

200 bar

G H I

Xls A

G B

H I

391hsm10 Fig. 14

E1.16 Ares 806 – 09.2004 – GB


Removing/refitting the components

Priority unit (no trailer brake)

A B C
A B C

30
J

M
G

J I J 26

K F E
K F E

391hsm11 Fig. 15

Parts list (Fig.15)


A Supply to steering unit. G Internal line.
B "Load Sensing" control to pump regulator. H 17 bar output connected to low-pressure line of right-hand
C "Load Sensing" control from steering unit. hydraulic cover, accumulator and power-assisted braking
D High-pressure supply from variable displacement pump system.
(orifice drilled in priority unit bearing surface and cover). I Plug.
E Supply to lifting spool valve and auxiliary spool valves. J Securing screw.
F "Load Sensing" control from lifting spool valve and auxiliary 26 Low-pressure slide valve. (17 bar)
spool valves. 30 High-pressure slide valve.

Ares 806 – 09.2004 – GB E1.17


Removing/refitting the components

Priority units (with trailer brake)

J B I
A J 30

C 26

29 30

H F E
A C 29
K 26

R
K
E

D H
K

D
391hsm12 Fig. 16

Parts list (Fig. 16)


A Supply to steering unit. H 17 bar output connected to low-pressure line of right-hand
B "Load Sensing" control to pump regulator. hydraulic cover, accumulator and brake boosters.
C "Load Sensing" control from steering unit. I Plug.
D Supply to trailer brake coupling. J Plug.
E Supply to lifting spool valve and auxiliary spool valves. K Control from master cylinders.
F "Load Sensing" control from lifting spool valve and auxiliary 26 Low-pressure slide valve. (17 bar)
spool valves. 29 High-pressure slide valve.
G Internal line. 30 Steering priority slide valve.

E1.18 Ares 806 – 09.2004 – GB


Removing/refitting the components

Schematic diagram of priority units


With the engine stopped

45 cc
XIs
0 cc
XIs

E
F
H

391hsm13 Fig. 17

Engine running unloaded

XIs

45 cc
XIs
0 cc
XIs

E
F
H
XIs
391hsm14 Fig. 18

Ares 806 – 09.2004 – GB E1.19


Removing/refitting the components

Engine running with use of brakes

XIs

45 cc
XIs
0 cc
XIs

E
F
H

391hsm15 Fig. 19

E1.20 Ares 806 – 09.2004 – GB


Removing/refitting the components

Removal of right cover

Make sure that the tractor is securely


immobilised.
B

– Disconnect the pipes and wiring harnesses from the


solenoid valves and switches.
N.B.: On tractors with trailer braking, remove the
unit (23) without disconnecting the hose from the
trailer brake coupling. This precaution will avoid
having to bleed the trailer brake control system on
refitting.
– Loosen screws (40) to remove the priority unit(s)
(Fig. 12).
– Remove screws (38). Free and remove the cover.
N.B.: An upper cover screw is masked by the coupling
screwed onto the regulator (16). Remove the
regulator for easier cover removal. B
– Remove tube (5) by unscrewing end (A) and the tube
from the 5-bar safety valve (8), (Fig. 20).
– To remove the 22-bar safety valve (9) (Fig. 21) from the 5 8
low-pressure circuit, compress spring (E) with a
screwdriver and remove circlip (C).
– Remove components (C) to (F), (Fig. 21). Check that
valve (F) slides freely in its housing.

Replacing the RH cover


A
N.B.: Check for rivets on the lines on the outer and
inner faces of the cover. Also ensure that the plugs
are fitted.
– Replace all removed gaskets. 391hsm16 Fig. 20

– Clean the housing and cover gasket faces.

D
9
E

10
391hsm17 Fig. 21

Ares 806 – 09.2004 – GB E1.21


Removing/refitting the components

– Check that the two pins (62) are present.


– Fit pipes (5) and (8), (Fig. 20).
62 43 G 11 20
– Coat the housing gasket face with Loctite
Formajoint (510). Position the guide studs (B),
(Fig. 20).
– Fill pump (11) with transmission oil through port (G),
(Fig. 22).
– Tighten screws (38) to a torque of 7 to 9 daN.m.
N.B.: If resistance is felt on tightening, do not
continue. Separate the cover from the housing and 62
check the positioning of tube (5) of 5-bar valve (10). 65
Also turn pinion (65).
– Tighten screws (40) coated with Loctite
Frenetanch (242) to a torque of 2 to 3 daN.m.
10 13
Pressure switches (13) and (43)
– Coat the threads lightly with Loctite Frenetanch (242). 391hsm18 Fig. 22

Tightening torques
– 3 solenoid valves: 1,8 to 2 daN.m.
– Hex nut (PTO differential solenoid valve): tighten
moderately.
38
– 5 bar valve (10): Coat the thread with Loctite
Frenetanch (242) and tighten to a torque of 1 40
to 2 daN.m.
– Pressure limiter (20): 15 daN.m.
– Repeat the hydraulic tests whenever the pump is
replaced.
– Check the seals on the gasket face and the hydraulic
connections.

391hsm29 Fig. 23

E1.22 Ares 806 – 09.2004 – GB


Removing/refitting the components

Adjusting the speed sensor


66 67
– Fit the sensor (76) with Loctite Frenetanch (242).
– Without forcing, screw the sensor until it is in contact
with the pump gear.
– Unscrew the sensor by 3/4 of a turn to obtain a gap of
approximately 1 mm between the sensor (76) and the 76
pump pinion (65).
– Tighten nut (77) to a torque of 2 daN.m.

Variable displacement pump


77
– Remove the right-hand cover.
– Remove the pump (11) with the pinion.
– Unscrew nut (67). Remove washer (66). Using a
suitable extractor, remove the pinion. Retrieve the 396msm29 Fig. 24
key (64).
11
Refitting specifications
– Clean the parts. Replace any defective parts. Make 63
sure that the cover lines are not blocked.
– Check that the two centring studs (63) are present.
– Replace the three O-rings (110) to (112). 60
N.B.: Inside the cover, apply a thin bead of Loctite 110
Formajoint (510) or an equivalent product around the
holes for the pump attachment screws (60). 60 112
– Refit the right-hand cover.
60
Tightening torques 111
– Pinion nut: 5 to 6 daN.m, Loctite Frenetanch (242).
– Pump attachment screws: 7 to 9 daN.m, Loctite 60 63
Frenetanch (242).
– RH cover screws: 7 to 9 daN.m, Loctite 391hsm19 Fig. 25

Frenetanch (242).
– Priority unit screws: 2 to 3 daN.m, Loctite
Frenetanch (242).

Ares 806 – 09.2004 – GB E1.23


Removing/refitting the components

Exploded view of the left-hand cover

82
4
81
5 87
109
78 92
79

83
84
110
87
88
3
2
80
89
85

93
109 91

391hsm20 Fig. 26

Sectional view of the left-hand cover

109 4 89 93 86 88 1

95

1 2 89

391hsm21 Fig. 27

E1.24 Ares 806 – 09.2004 – GB


Removing/refitting the components

Sectional view of the GPA 30 left-hand cover

3 78 79 80 85 81 82 5 82 4 109 83 84

93
81
86

89

86

393hsm03 Fig. 28

Sectional view of the GPA 40 left-hand cover

5 80 79 85 81 5 4 109 84

3 89

81

391hsm22 Fig. 29

Ares 806 – 09.2004 – GB E1.25


Removing/refitting the components

Removal specifications
3 109
Make sure that the tractor is securely
immobilised.

109
N.B.: Screw (88) is only accessible once the bowl (89)
and strainer have been removed. 93 109
– Unscrew the bowl (89). Remove the strainer. 89
– Remove nuts (93) and screws (109) and (88).
– Remove the cover (3) and then the intake manifold (1). 109

Refitting specifications
– Clean the housing and cover gasket faces. Coat the
housing gasket face with Loctite Formajoint (510).
– Replace all removed O-rings.
– Coat the flat gasket surface (94) on the intake
manifold (1) with silicone (resistance to hydrocarbons).
Slide the gasket onto the studs (86) with the adhesive
face on the cover side.
– Screw two diametrically opposed locating studs (A) into
the intermediate housing to refit the cover (Fig. 31).
– Check that the two centring pins (81) are present. 109 88
– Remove the locating studs (A).
– Fit screws (109) and (88) uniformly and alternately to a
torque of 9 to 12 daN.m.
N.B.: If resistance is felt on tightening, separate the
cover from the housing and check the positioning of
tube (5) with the pump. Also turn the pump driving
pinion.

391hsm23 Fig. 30

86

1 86 94
391hsm24 Fig. 31

E1.26 Ares 806 – 09.2004 – GB


Removing/refitting the components

– Fit nuts (93) coated with Loctite Frenetanch (242) and


tighten to a torque of 1,5 to 2 daN.m. 3 109
– Check the seal on the cover and bowl gasket surface.

Tightening torques
– Suction tube nuts: 1,5 to 2 daN.m with Loctite
109
Frenetanch (242).
– LH cover screw: 9 to 12 daN.m with Loctite 93 109
Frenetanch (242).
89
– Bowl (89): Tighten moderately by hand.
109

109 88

391hsm23 Fig. 32

Ares 806 – 09.2004 – GB E1.27


Removing/refitting the components

78 96 98 4

97

99

100

391hsm25 Fig. 33

Booster pump
87 95 A 92
– Remove the left cover.
– Remove screws (95) and the pump (4). If necessary,
remove the pinion from the pump. Retrieve the
key (78).

Refitting
– Clean the pump and cover bearing surfaces.
– Check that the studs (87) are present.
– Inside the cover, apply a bead (A) of Loctite
Formajoint (510) around the screw holes. The bead
must be thin so that it does not reach the groove of the
gasket (92). Fit a new gasket.
– If removed, position the key (78) and refit the pinion.
Coat the nut with Loctite Frenetanch (242) and tighten 95 A
to 5 to 6 daN.m.
391hsm26 Fig. 34
– Position the pump on the centring studs (87).
– Coat screws (95) with Loctite Frenetanch (242) and
tighten to 4 to 5 daN.m.
– Check pump rotation by hand.
– Refit the left-hand cover.

E1.28 Ares 806 – 09.2004 – GB


Removing/refitting the components

Replacement of pump seals


97
– Remove the left-hand cover and the pump.

Removal
– Clamp the pump in a vice fitted with plastic jaws.
– Remove screws (97) and the cover.
– Remove circlip (96), gasket (98) and O-rings (99)
and (100).

Refitting
– Lubricate the gasket (98) and fit it using an appropriate
jig. Refit the circlip (96).
– Coat O-rings (99) and (100) with miscible grease and
position them on the cover.
– Position the cover. Fit and tighten screws (97) to a
torque of 3 to 4 daN.m. 391hsm27 Fig. 35

– Lubricate the pump through the suction port.


– Check pump rotation by hand.
96 98
– Refit the boost pump and the left-hand cover.

391hsm28 Fig. 36

100 99

391hsm29 Fig. 37

Ares 806 – 09.2004 – GB E1.29


Removing/refitting the components

Fitting spool valves on the GPA 40 rear axle

A
B
C
D
G
F

391hsm30 Fig. 38

Ref Fitting N° 1 N° 2 N° 3 N° 4

A Supply plate 1 1 1 1
B Linkage spool valve 1 1 1 1
C 4-position auxiliary spool valve with kick-out (KO) and zero leak on one side (ZF) 2 3 2 2
D 3-position auxiliary spool valve with zero leak on one side (ZF) 1 1 0 1
E Blanking plate 1 1 0 0
F Closing plate with safety solenoid valve 0 0 1 1
G Electrohydraulic spool valve ("DEH") 0 0 2 2

E1.30 Ares 806 – 09.2004 – GB


Removing/refitting the components

Fitting spool valves on the GPA 30 rear axle

E
D
C
B

A
G

F
393hsm04 Fig. 39

Ref Fitting N° 1 N° 2 N° 3 N° 4

A Support 1 1 1 1
B Linkage spool valve 1 1 1 1
C 4-position auxiliary spool valve with kick-out (KO) and zero leak on one side (ZF) 2 3 2 2
D 3-position auxiliary spool valve with zero leak on one side (ZF) 1 1 0 1
E Blanking plate 2 2 1 1
F Closing plate with safety solenoid valve 0 0 1 1
G Electrohydraulic spool valve ("DEH") 0 0 2 2

Ares 806 – 09.2004 – GB E1.31


Removing/refitting the components

Hydraulic diagram of the lift spool valve and the electrohydraulic spool valve

7 P LS R

2
8
4

A’

9
1

391hsm31 Fig. 40

Parts list (Fig. 40 and 41)


1 Pressure reducer (only fitted with 21-24 bar electrohydraulic 7 Pressure balance.
spool valves). 8 "Load Sensing" signal circuit selector.
2 Lift cylinder. 9 Lift electrovalve (down).
3 Safety valve. 10 Three-position spool valve (zero leak "ZF" and
4 Lift electrovalve (up). kick-out "KO").
5 Valve. (zero leak) 11 Four-position spool valve (zero leak).
6 "Electropilot" electrohydraulic spool valve.

E1.32 Ares 806 – 09.2004 – GB


Removing/refitting the components

Hydraulic diagram of the lift spool valve and mechanical spool valve

2
5 10

7
A

11

A’
3

LS

391hsm32 Fig. 41

Ares 806 – 09.2004 – GB E1.33


Removing/refitting the components

Removing the spool valve block


R
– Disconnect all pipes to the auxiliary and lift spool valve
block.
– Disconnect the auxiliary spool valve control cables.
– Uncouple the wires connected to the solenoid valves.
– Remove the spool valve block and its support.
– Unscrew the spool valve stack nuts.

The auxiliary spool valve slides must


never be rotated. The flat part (M) of the
pin must be in its original position,
vertical in relation to the block (Fig. 43)

P LS
391hsm33 Fig. 42

393hsm14 Fig. 43

E1.34 Ares 806 – 09.2004 – GB


Removing/refitting the components

Refitting the spool valve unit


N.B.: The O-rings of ports (P), (R) and (LS), inserted
between each spool valve, must be changed.
– Refit the stack. A
– Refit the assembly onto its support.
– Refit the assembly onto the tractor.
– Reconnect the solenoid valve wires, the auxiliary spool
valve control cables (adjust if necessary) and the
pipes.
N.B.: The resistance of the lift solenoid valves is 1,8.

Tightening torques
A 3 ± 0,3 daN.m.
B 0,55 ± 0,2 daN.m.
C 6,7 ± 2,2 daN.m.
391hsm60 Fig. 44

C
B
391hsm59 Fig. 45

Ares 806 – 09.2004 – GB E1.35


E1.36
393hsm00
C
0,11 daN.m
17
18
19
16
13 8
7 0,46 daN.m
14
Linkage spool valve

R
15
20
21
35
34
33 LS
C 6
32
5 10
31
4
30 P 3

23

Ares 806 – 09.2004 – GB


0,15 daN.m

1 2
12
29 0,26 daN.m
0,65 daN.m
11
Removing/refitting the components

28
27 A
26
25
0,46 daN.m

B 9
24
0,26 daN.m

22

Fig. 46
Removing/refitting the components

Parts list
1 Spool valve body. 13 Circlip. 25 Plug.
2 O-ring. 14 Stop washer. 26 O-ring.
3 Circuit selector. 15 Check valve. 27 Spring.
4 O-ring. 16 O-ring. 28 Spool.
5 O-ring. 17 Plug. 29 Plug.
6 O-ring. 18 O-ring. 30 O-ring.
7 Plug. 19 Plug. 31 Thrust bearing.
8 Plug. 20 Plug. 32 Spring.
9 UP solenoid valve. 21 O-ring. 33 Pushrod.
10 O-ring. 22 DOWN solenoid valve. 34 Guide.
11 Screw. 23 O-ring. 35 O-ring.
12 Seal 24 Screw.

Ares 806 – 09.2004 – GB E1.37


Removing/refitting the components

Linkage spool valve (neutral position)

(R)
A’
A

LS
R

391hsm61 Fig. 47

E1.38 Ares 806 – 09.2004 – GB


Removing/refitting the components

Linkage spool valve (down position)

A (R)

R P

LS

391hsm62 Fig. 48

Linkage spool valve (up position)

A (R)

R P

LS

391hsm63 Fig. 49

Ares 806 – 09.2004 – GB E1.39


E1.40
10

393hsm05
48 9
49 8
50 7 C
51 6
52 5
53 4
0,14 ± 0,05 daN.m 54 3
55 0,3 ± 0,09 daN.m
57
59 0,14 ± 0,05 daN.m B
61 55 A
63 1
2 A

37
38
6,7 ± 2,2 daN.m
39
56
40
58
41
60 12
62 13

47
11

Ares 806 – 09.2004 – GB


0,55 ± 0,18 daN.m
31
B
35 14
15 1,9 ± 0,63 daN.m
16
3-position "ZF" auxiliary spool valve with optional "KO"
Removing/refitting the components

32 17
42 36
43 33 18
34 19
44
45 20
46 21
22
23 1,9 ± 0,63 daN.m
24
25
26
27
28
C 29
30

Fig. 50
Removing/refitting the components

Parts list (Fig. 50 and 51)


1 Spool valve body. 25 O-ring. 49 Circlip.
2 Distributing slide. 26 O-ring. 50 Bush.
3 Valve. 27 Retaining ring. 51 Thrust washer.
4 Ball. 28 Retaining ring. 52 O-ring.
5 Pushrod. 29 O-ring. 53 Spring.
6 Spring. 30 Seal. 54 Valve.
7 Shim. 31 O-ring. 55 Plug.
8 O-ring. 32 O-ring. 56 Slotted bushing.
9 Spacer ring. 33 Circuit selector. 57 Driving mechanism.
10 O-ring. 34 Flat seal. 58 Spring.
11 Screw. 35 Flat seal. 59 Spacer.
12 Washer. 36 O-ring. 60 Spring.
13 Sleeve. 37 Plug. 61 Ball.
14 Plug. 38 O-ring. 62 Rotary spool valve.
15 Shim. 39 O-ring. 63 Needle.
16 Spring cup. 40 Needle screw. 64 Plug*.
17 Spring. 41 Distributing slide. 65 O-ring*.
18 Spring cup. 42 Circlip. 66 Needle*.
19 Spring. 43 Spring. 67 O-ring*.
20 Indexing slide. 44 Guide. 68 Seal*.
21 Slotted washer. 45 O-ring. 69 Shim*.
22 Hollow screw. 46 Plug. 70 Spring cup*.
23 Ball. 47 O-ring. 71 Spring*.
24 Thrust bushing. 48 Plug. 72 Spring cup*.
* Without optional "KO" (see fig. 51 for version without "KO").

Ares 806 – 09.2004 – GB E1.41


E1.42
393hsm06
48
49
50 72
51 71
52 70 C
53 69
54 68
67
0,14 ± 0,05 daN.m 6,7 ± 2,2 daN.m
55 64 0,14 ± 0,05 daN.m B
65 55 6,7 ± 2,2 daN.m
66 37
A
1 2

56 A
57
Four-position "ZF" auxiliary spool valve

58 38
59 39
60 40
61 41
62

Ares 806 – 09.2004 – GB


63

11
0,55 ± 0,18 daN.m
12
B 31 13
Removing/refitting the components

C 14
35 0,55 ± 0,19 daN.m
43 15
42 36
43 33
34
44
45
46
6,7 ± 2,2 daN.m

Fig. 51
Removing/refitting the components

Parts list
1 Spool valve body. 25 O-ring*. 48 Bush.
2 Distributing slide. 26 O-ring*. 49 Thrust washer.
3 Valve*. 27 O-ring*. 50 O-ring.
4 Ball*. 28 Seal*. 51 Spring.
5 Pushrod*. 29 O-ring. 52 Valve.
6 Spring*. 30 O-ring. 53 Plug.
7 Shim*. 31 Circuit selector. 54 Slotted bushing.
8 O-ring. 32 Flat seal. 55 Driving mechanism.
9 Spacer ring. 33 Flat seal. 56 Spring.
10 O-ring*. 34 O-ring. 57 Spacer.
11 Screw. 35 Plug. 58 Spring.
12 Washer. 36 O-ring. 59 Ball.
13 Sleeve. 37 O-ring. 60 Rotary spool valve.
14 Plug. 38 Needle screw. 61 Needle.
15 Shim. 39 Distributing slide. 62 Plug.
16 Spring cup*. 40 Circlip. 63 O-ring.
17 Spring*. 41 Spring. 64 Needle.
18 Spring cup*. 42 Guide. 65 O-ring.
19 Spring*. 43 O-ring. 66 Seal.
20 Indexing slide*. 44 Plug. 67 Shim.
21 Slotted washer*. 45 O-ring. 68 Spring cup.
22 Screw*. 46 Plug. 69 Spring.
23 Ball*. 47 Circlip. 70 Spring cup.
24 Thrust bushing*.
* Optional "KO" (see Fig.50 for version with "KO").

Ares 806 – 09.2004 – GB E1.43


Removing/refitting the components

4-position "ZF" auxiliary spool valve with optional "KO"

B A R

LS

393hsm07 Fig. 52

Parts list
Pump pressure. Return pressure.

Service pressure. Control pressure.

N.B.: The above drawing is schematic. The notched component of the slide (KO) is actually located on the same
side as the flow rate control knob.

E1.44 Ares 806 – 09.2004 – GB


Removing/refitting the components

Auxiliary spool valve with electrohydraulic controls

16 0,6 – 0,1 daN.m


18
17

31
30
34 ZF
29
35 19 28
A 36 15 27
37
38 14 26
39 13 25
12 6,7 – 2,2
32 daN.m
33 R 20
21
22
23
24 RD
11
0,6 – 0,2 daN.m
2
6 3 1
4
5
10
9
8
7

6,7 – 2,2 daN.m


393hsm08 Fig. 53

Parts list
1 Spool valve body. 16 Electric control unit. 31 Plug.
2 Distributing slide. 17 Washer. 32 Slotted bushing.
3 O-ring. 18 Screw. 33 Driving mechanism.
4 Lock. 19 O-rings. 34 Spring.
5 Washer. 20 Plug. 35 Spacer.
6 Screw. 21 Shim. 36 Spring.
7 Plug. 22 Guide. 37 Ball.
8 O-ring. 23 O-ring. 38 Rotary spool valve.
9 Distributing slide. 24 Spring. 39 Needle.
10 O-ring. 25 Ball. A Power supply .
11 O-ring. 26 Spring. R Return .
12 O-rings. 27 O-ring. ZF Zero leak.
13 Circuit selector. 28 Thrust washer. RD Flow regulator .
14 O-ring. 29 Bush.
15 O-ring. 30 Circlip.

Ares 806 – 09.2004 – GB E1.45


Removing/refitting the components

Auxiliary spool valve with electrohydraulic controls

16 34 38 1 6

20 29 24 25 9 8 7 2

391hsm34 Fig. 54

E1.46 Ares 806 – 09.2004 – GB


Removing/refitting the components

Closing plate with safety solenoid valve


N.B.: The closing plate with safety solenoid valve is fitted with the optional electrohydraulic spool valve only.

1,4 ± 0,4 daN.m

2 1,4 ± 0,4 daN.m

1,1 ± 0,4 daN.m 3

0,3 ± 0,1 daN.m 5 9


8
7
6 1,1 ± 0,4 daN.m

1 11
10 1,9 ± 0,6 daN.m

12

393hsm09 Fig. 55

Parts list
1 Spool valve body. 5 Valve. 9 Ball.
2 Safety solenoid valve. 6 Plug. 10 Plug.
3 Plug. 7 Spring. 11 O-ring.
4 O-ring. 8 O-ring. 12 Caps.

Ares 806 – 09.2004 – GB E1.47


Description

Auxiliary spool valve control adjustments

393hsm10 Fig. 56

E1.48 Ares 806 – 09.2004 – GB


Removing/refitting the components

393hsm11 Fig. 57

– Put the control levers into the neutral position.


– Screw the bottom nut (1) to the end of the thread on
cable (7) on the spool valve block side.
– Check on the cab-side cable that the other nut (2) and
the coupling (6) are also at the end of the thread.
N.B.: The coupling is bored to simplify cable guiding
on the auxiliary spool valve unit side.
– Connect the two cables of the same colour and screw
the coupling (6) fully on, then tighten nut (2) and lock
nut (1).
– Screw the connecting tube (8) fully on then slacken off
slightly to avoid stress on the fasteners in the cab.
– Check that there is play on the lever in the neutral
position.
– Tighten nut (3) then black nut (4).

393hsm12 Fig. 58

Ares 806 – 09.2004 – GB E1.49


Removing/refitting the components

1 B

A
2 4

393hsm13 Fig. 59

Linkage rams
Removal
– Remove the tractor lifting rams.
– Inserting a screwdriver through port (3), remove the
retaining ring (4) from its groove and move it away
towards (A). 3
– When the retaining ring (4) is in groove B, pull the ram
rod.

The ram rod is no longer stopped at the


end of the stroke. Beware of
disconnecting

Refitting
– Replace the seals.
– Refit the plastic bushing (2), then the metal gasket (1) 393hsm15 Fig. 60

into the ram body.


– Refit the ram rod and put the retaining ring (4) back into
its groove through port (3).

E1.50 Ares 806 – 09.2004 – GB


Notes

Ares 806 – 09.2004 – GB E1.51


Removing/refitting the components

Steering unit OSPQ 100/160 LS (110 l/min circuit)


Parts list
1 Spool valve sleeve. 13 Coupling unit. 23 Pushrod.
2 Pin. 14 Screw (6 daN.m). 24 Rotary slide.
3 Bush. 15 Cylinder supply ports (left-hand 25 Spring.
4 Roller thrust bearing. chamber). 26 Cover attachment screw (3 daN.m).
5 Seal. 16 Return port. 27 Needle screw.
6 Plungers. 17 Supply port. 28 Washers.
7 Balls. 18 Cylinder supply port (right-hand 29 Cover.
8 Body. chamber). 30 O-ring.
9 Dust seal. 19 Seal. 31 Splined bush.
10 Shockproof valve (225-224 bar). 20 Ball. 32 Splined pinion.
11 Pressure limiter (160-165 bar). 21 Threaded socket. 33 Distribution plate.
12 Flow booster. 22 Ball. 34 Drive shaft.

E1.52 Ares 806 – 09.2004 – GB


Removing/refitting the components

Exploded view of steering unit OSPQ 100/160 LS (110 l/min circuit)

10

11 10
9
8 7
6
12
5
14
4

13 3
19
18 20 24
2
17 21
16 22
15 23 1

34 25

30
33

32
30

31
30
26
29
28
27

491hsm01 Fig. 61

Ares 806 – 09.2004 – GB E1.53


Removing/refitting the components

Hydraulic diagram of steering unit OSPQ 100/160 LS (110 l/min circuit)

L R
10

6 7
6 7

1 24

31 27
32

12 20 27
21 27

11 34

LS
P

491hsm02 Fig. 62

E1.54 Ares 806 – 09.2004 – GB


Removing/refitting the components

Hydraulic diagram of steering unit OSPQ 100/160 LS (110 l/min circuit)

1 2

T T

P 12 P 12

491hsm03 Fig. 63 491hsm04 Fig. 64

OPSQ is a "Load Sensing" steering system with a built-in


flow booster (12) which can be used to increase the flow
rate through the set of gears.
1. Rotation without flow boosting (less than 10 rpm).
2. Rotation with flow boosting (over 10 rpm).
The boost coefficient varies from 1,2 to 2. If the flywheel
speed is less than 10 rpm, no flow boosting occurs.
Maximum boosting occurs at flywheel speeds in excess
of 20 rpm.

Ares 806 – 09.2004 – GB E1.55


Removing/refitting the components

Steering unit OSPC 135 ON (100 l/min circuit)


Parts list
1 Spool valve sleeve. 13 Coupling unit. 23 —.
2 Pin. 14 Screw (6 daN.m). 24 Rotary slide.
3 Bush. 15 Cylinder supply ports (left-hand 25 Spring.
4 Roller thrust bearing. chamber). 26 Cover attachment screw (3 daN.m).
5 Ring seal. 16 Return port. 27 Needle screw.
6 Plungers. 17 Supply port. 28 Washers.
7 Balls. 18 Cylinder supply port (right-hand 29 Cover.
8 Body. chamber). 30 O-ring.
9 Dust seal. 19 Seal. 31 Splined bush.
10 Shockproof valve (224-225 bar). 20 Ball. 32 Splined pinion.
11 Pressure limiter (170-175 bar). 21 Threaded socket. 33 Distribution plate.
12 —. 22 —. 34 Drive shaft.

E1.56 Ares 806 – 09.2004 – GB


Removing/refitting the components

Exploded view of steering unit OSPC 135 ON (100 l/min circuit)

1
2
24
3

26
25
4
6
7

27
8

21

28
9

20
15 19
10

29
16
17
18

30
10

31
30
13

14
11

32
33
30
34

491hsm00 Fig. 65

Ares 806 – 09.2004 – GB E1.57


Removing/refitting the components

Hydraulic diagram of steering unit OSPC 135 ON (100 l/min circuit)

L R
10

6 7 6 7

1 24

31 32

20 21 27

11 34

391hsm05 Fig. 66

E1.58 Ares 806 – 09.2004 – GB


Removing/refitting the components

Access to steering unit


– Remove the two side covers. A
– Remove the heat shields between the engine and the
front of the cab.
– For the upper shield, remove the cover top screws.
– Remove the flap.
– To remove the lower shield, it is advisable to partly
remove the exhaust (A) (Fig. 67) in order to access the
shield support screws fastened to the exhaust.
– Mark and disconnect the pipes from the steering unit.
– Remove the trim under the dashboard in the cab and
unscrew the nuts (B), (Fig. 68).
– Remove the steering unit.

Beware not to lose the spacers and


rubber bushes (C), (Fig. 69). 491hsm06 Fig. 67

N.B.: On tractors, the unit can be removed without


disconnecting the pipes, especially to adjust the
service pressure.

491hsm07 Fig. 68

491hsm08 Fig. 69

Ares 806 – 09.2004 – GB E1.59


Removing/refitting the components

60 05 005 726 60 05 005 726

491hsm09 Fig. 70 491hsm10 Fig. 71

Specific points relating to


removal/refitting
Always change all seals and gaskets whenever the
unit is removed.
– Check the surface conditions of the parts (slide, sleeve,
bores in the body, etc.).

Fitting the ring seal


– Fit the ring seal (5) onto the end of tool
n° 60 05 005 726.
– Oil the seal.
– Place the fitting sheath of tool n° 60 05 005 726 on the
body (Fig. 70).
– Insert the seal holder into the sheath (Fig. 71). 491hsm12 Fig. 72
– Push fully in.
– Remove the sheath and the fitting tool (the end stays in
place).
4c
Ensure that the roller thrust bearing (4)
is fitted the right way round. 4

– Position the inner thrust washer (4b) with the chamfer 4b


facing the sleeve (1) (Fig. 73).
4. Roller bearing.
4b. Inner thrust washer. 1
4c. Outer thrust washer.
1. Distribution sleeve.
24. Rotary slide. 24

491hsm11 Fig. 73

E1.60 Ares 806 – 09.2004 – GB


Removing/refitting the components
Tightening torque of the cover screws
Screw in all screws by hand then tighten in a star
sequence to a torque of 3 ± 0,5 daN.m.

Column seal
– Fit seal (6) using the sheath of tool n° 60 05 005 726
and a soft mallet.

Flow booster (110 l/min circuit)


– Position the flow booster correctly (Fig. 76).
– Wrap Teflon or similar sealing tape around the thread
of the adjustment screw (A).

Pressure limiter and shockproof valves


– Wrap Teflon or similar sealing tape around the thread
of the adjustment screws of the valves (10) and
limiter (11).
491hsm13 Fig. 74
– Tighten each screw.
Now proceed with testing and calibrating the shockproof
valves and the pressure limiter.

491hsm14 Fig. 75

491hsm15 Fig. 76

Ares 806 – 09.2004 – GB E1.61


Hydraulic measurement and checking points

Test condition: oil temperature at 60°C.

Variable displacement pump boost


pressure check
60 05 705 076
• Connect tester n° 60 05 705 076 to the diagnostic
socket under the right-hand cover and check (P1).

Engine speed (rpm) P1 (bar)

1 000 5,2 ± 1
2 200 6,3 ± 1

Standby pressure and Xls P1


pressure check
393hsm16 Fig. 77

• Connect tester n° 60 05 705 076 to each diagnostic


socket located: P2
– On the pump regulator: Xls pressure = P2.
– On the right-hand cover: Pump pressure = P3.
Important: Do not activate any high-pressure
compoents (steering, for example) to avoid damaging
the pressure gauges connected at (P2) or (P3).

Engine speed (rpm) P2 (bar) P3 (bar)

1 000 4 26 ± 1
2 200 4 26 ± 1

N.B.: Pump pressure = Xls + 22 ± 1 bar


P3 = P2 + 22 ± 1 bar
60 05 705 076
P3
393hsm17 Fig. 78

E1.62 Ares 806 – 09.2004 – GB


Hydraulic measurement and checking points

Test condition: oil temperature at 60°C.

Maximum pressure and flow rate


check on the auxiliary spool valves
• Connect tester n° 60 05 005 736 to an auxiliary spool
valve. Keep the spool valve lever actuated to
obtain (Q1).
• Connect tester n° 60 05 705 076 to each diagnostic
socket located:
– On the pump regulator: XLS pressure = P2.
– On the right-hand cover: Pump pressure = P3.
• Set the flow regulator control for the auxiliary spool
valve concerned to maximum flow.
• Actuate the auxiliary spool valve and gradually close
the flowmeter valve to read the flow rate and increase
the pressure.

Engine speed
Q1 (l/min) P2 (bar) P3 (bar)
(rpm)

110
130
P2 =
2 200 100 ± 10 150
P3 22 ± 1
170
180
— 0 — 190

N.B.: If the flowmeter is equipped with a pressure 60 05 005 736


gauge, ignore the pressure indicated on this gauge.

393hsm18 Fig. 79

P2

60 05 705 076
P3
393hsm17 Fig. 80

Ares 806 – 09.2004 – GB E1.63


Hydraulic measurement and checking points

Test condition: oil temperature at 60°C.

Flow regulator check on the


auxiliary spool valves
• Connect tester n° 60 05 005 736 to a spool valve to
obtain (Q2).
• Connect tester n° 60 05 705 076 to each diagnostic
socket located:
– On the pump regulator: Xls pressure = P2.
– On the right-hand cover: Pump pressure = P3.

Engine
Regulator
speed Q2 (l/min) P2 (bar) P3 (bar)
position
(rpm)

Maximum 100 ± 10 P2 =
2 200 130
Minimum 5±1 P3 22 ± 1

• Turn the control of the regulator concerned slowly to


the minimum limit; (Q2) should gradually fall to a
minimum flow rate of 5 ± 1 l/min.

Trigger pressure check on the (KO)


spool valve
– Connect tester n° 60 05 005 736 to a spool valve.
– Connect tester n° 60 05 705 076 to the pump regulator
to read: Xls pressure = P2.
60 05 005 736
– Run the engine at 1 000 rpm. Actuate the spool valve
in the kick-out position, release the lever and gradually
close the flowmeter valve until the lever returns to
neutral. Read the trigger pressure: P2 = 160
to 185 bar. 393hsm18 Fig. 81

P2

60 05 705 076
P3
393hsm17 Fig. 82

E1.64 Ares 806 – 09.2004 – GB


Hydraulic measurement and checking points
Test condition:
– Engine at 1 000 rpm.
– Oil temperature at 60°C.

Maximum rear lift pressure check


– Connect tester n° 60 05 705 076 to the diagnostics sockets (P2 XLS signal) and (P3 pump pressure).
– Use the outside lift control buttons to reach the maximum raised position.
– Measured pressure (P2) and (P3) must be 190 bar.

P3 P2

HP

BP

60 05 705 076

391hsm64 Fig. 83

Braking valve check


– To check the braking valve, refer to chapter "C".

Ares 806 – 09.2004 – GB E1.65


"Hydraulic inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:

– Tractor type .........................................................................................................................................................................

– The serial number ...............................................................................................................................................................

– Total operating hours...........................................................................................................................................................

– Date of operation.................................................................................................................................................................

Variable displacement pump boost pressure check

Test conditions Nominal values Recorded values


Oil temperature at 60°C
Pressure P1 in bar Pressure P1 in bar

Engine running at 1 000 rpm 5,2 ± 1


Engine running at 2 200 rpm 6,3 ± 1

Standby pressure and Xls pressure check

Test conditions Nominal values Recorded values


Oil temperature at 60°C
Pressure P2 in bar Pressure P3 in bar Pressure P2 in bar Pressure P3 in bar
Engine running at 1 000 rpm
4 26 ± 1
Engine running at 2 200 rpm

E1.66 Ares 806 – 09.2004 – GB


"Hydraulic inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:

– Tractor type .........................................................................................................................................................................

– The serial number ...............................................................................................................................................................

– Total operating hours...........................................................................................................................................................

– Date of operation.................................................................................................................................................................

Maximum pressure and flow rate check on the auxiliary spool valves

Test conditions Nominal values Recorded values


Oil temperature at 60°C
Q1 (l/min) P2 (bar) P3 (bar) Q1 (l/min) P2 (bar) P3 (bar)
110
130
100 ± 10 P2 = P3 22 ± 1 150
Engine running at 2 200 rpm
170
180
0 190

Flow regulator check on the auxiliary spool valves

Test conditions
Nominal values Recorded values
Oil temperature at 60°C

Regulator position Engine speed (rpm) Q2 (l/min) P2 (bar) P3 (bar) Q2 (l/min) P2 (bar) P3 (bar)

Maximum 100 ± 10
2 200 P2 = P3 22 ± 1 130
Minimum 5±1

Ares 806 – 09.2004 – GB E1.67


"Hydraulic inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:

– Tractor type .........................................................................................................................................................................

– The serial number ...............................................................................................................................................................

– Total operating hours...........................................................................................................................................................

– Date of operation.................................................................................................................................................................

Trigger pressure check on (KO) spool valves

Test conditions
Nominal value (bar) Measured value (bar)
Oil temperature at 60°C

Engine running at 1 000 rpm 160 to 185

Maximum rear lift pressure check

Nominal values Recorded values


Test conditions
Oil temperature at 60°C
Pressure P2 in bar Pressure P3 in bar Pressure P2 in bar Pressure P3 in bar

Engine running at 1 000 rpm 190 190

E1.68 Ares 806 – 09.2004 – GB


Hydraulic measurement and checking points

Test conditions:
– Engine at 1 000 rpm.
– Oil temperature at 60°C.

Steering pressure check


– Connect tester n° 60 05 705 076 to diagnostic sockets (P2) and (P3).
– Turn the steering slowly and check that (P2) and (P3) increase gradually.
– Measured pressure (P2) must be 149 ± 2 bar.
– Measured pressure (P3) must be 170 ± 2 bar.

P3 P2

HP

BP

60 05 705 076

391hsm64 Fig. 84

Ares 806 – 09.2004 – GB E1.69


Hydraulic measurement and checking points

Test conditions:
– Engine at 1 000 rpm.
– Oil temperature at 60°C.

Maximum steering cylinder pressure check


– Use and connect the tools as shown in the illustration.
– Connect tester n° 60 05 705 076 and coupling n° 60 05 005 718 to the two steering cylinder supplies.
– Turn the front wheels in one direction and then the other and measure the wheel pressure at full lock.
– Pressure (P4) must be between 155 and 165 bar. If this is not the case, adjust the steering unit pressure limiter.

60 05 705 076

60 05 005 718

P4

391hsm68 Fig. 85

E1.70 Ares 806 – 09.2004 – GB


Hydraulic measurement and checking points

Test conditions:
– With the engine stopped.
– Oil temperature at 60°C.

Shockproof valve opening pressure check


– Connect a manual calibration pump to one of the two steering cylinder supplies.
– Apply pressure with the calibrating pump and note the opening pressure.
– The opening pressure (P5) must be between 225 and 245 bar. If this is not the case, adjust the shockproof valves.
– Apply the same procedure to the second steering cylinder supply.

P5

391hsm65 Fig. 86

Ares 806 – 09.2004 – GB E1.71


"Hydraulic inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:

– Tractor type .........................................................................................................................................................................

– The serial number ...............................................................................................................................................................

– Total operating hours...........................................................................................................................................................

– Date of operation.................................................................................................................................................................

Steering pressure check

Test conditions Nominal values Recorded values


Oil temperature at 60°C
Pressure P2 in bar Pressure P3 in bar Pressure P2 in bar Pressure P3 in bar

Engine running at 1 000 rpm 149 ± 2 170 ± 2

Maximum steering cylinder pressure check


Test conditions
Nominal value (bar) Measured value (bar)
Oil temperature at 60°C

Engine running at 1 000 rpm 155 to 165

Shockproof valve opening pressure check

Test conditions
Nominal value (bar) Measured value (bar)
Oil temperature at 60°C

With the engine stopped 225 to 245

E1.72 Ares 806 – 09.2004 – GB


E2
CLOSED CENTRE HYDRAULICS
100 l/min
(except driving circuit, see chapter "B")
This chapter only deals with particular features of the closed centre
circuit 100 l/min in relation to the open centre and closed centre
circuits 110 l/min.
For elements not dealt with in this chapter and common to
the 2 circuits, refer to chapter "E1".

Ares 806 – 09.2004 – GB


Description
Characteristics
Type of circuit Closed centre/Load sensing
Pumps
Number 2+1
Type Fixed capacity gear
Location In the rear axle
Circuit 1: Steering + driving + lubrication
Capacity 19 cm³
Flow at 900 rpm 23 l/min
Flow at 2 200 rpm 56 l/min
Flow at 2 350 rpm 60 l/min
Circuit 2
1 Pump: Spool valve supply
Capacity 14 cm³
Flow at 900 rpm 17,5 l/min
Flow at 2 200 rpm 42 l/min
Flow at 2 350 rpm 45,7 l/min
Maximum pressure 190 bar
2 Pump: Spool valve suuply + trailor braking
Capacity 19 cm³
Flow at 900 rpm 23,7 l/min
Flow at 2 200 rpm 58 l/min
Flow at 2 350 rpm 62 l/min
Maximum pressure 190 bar
Filters
Suction strainer - filtration threshold 150 µ
Filter (flow reversal) - filtration threshold 15 µ
Blockage indicator Yes
Cooler Yes
Priority unit Yes
Spool valves
SB 23 "Load Sensing" (mechanical control)
Type
SB 23 EHS (electro-hydraulic control)
Type of pressure take off points Break away
Flow regulator 1 per distributor
Flow rate control range 5 to 95 l/min
Maximum number 4
Steering unit
Type OSPC 135 ON
Calibration pressure 170-175 bar
Steering cylinder (position) Integrated into rear of front axle
Linkage
Type EHR 23 "Load Sensing"
Electronic lift TCE 15 - 15 T - 25
Number of external cylinders 2 (single action)
Lift capacities at the swivel joints (kg)
Maximum 11 330
Over the whole stroke 6 250 to 7 430
Trailer brake valve
Type of control Control synchronised hydraulically with the tractor brakes.
Type of pressure take off points External pressure take-off point at the rear on base plate.

E2.2 Ares 806 – 09.2004 – GB


Notes

Ares 806 – 09.2004 – GB E2.3


Description

Parts list
High-pressure circuit. Control circuit.

Service pressure. Lubrication and cooling circuit.

Return circuit. Suction circuit.

Parts list
1 RH hydraulic cover. 26 To trailer brakes.
2 Strainer (150 µ). 27 Steering unit "OSPC 135 ON".
3 Vacuum-contact. 28 Gearbox solenoid valve unit.
4 14 cm³ Pump. 29 Transmission accumulator.
5 19 cm³ Pump. 30 Braking boost accumulator (Brake boosters).
6 Limiter, "DBV2" 175 bar. 31 PTO brake solenoid valve.
7 "Load Sensing" signal from "Proactiv" axle. 32 PTO clutch solenoid valve.
8 Decompression line. 33 Differential lock solenoid valve.
9 Machine "Load Sensing" signal (external connection piece). 34 4-wheel drive solenoid valve.
10 "Load Sensing" circuit selector. 35 Rear axle lubrication.
11 Diagnosis socket 14 cm³. 36 Gearbox lubrication.
12 Spool valves high-pressure filter (15 µ). 37 Lubrication pressure limiter 1,5 bar.
13 "Proactiv" axle suspension unit supply. 38 Hare/tortoise (high/crawl) range solenoid.
14 High-pressure limiter, "DBV1" 210 bar. 39 Low-pressure circuit filter (60 µ).
15 Supply plate. 40 Oil cooler.
16 Linkage spool valve. 41 LH hydraulic cover.
17 Auxiliary spool valve. 42 By-pass cooler 5 bar.
18 Blanking plate. 43 Low pressure limiter 17 bar.
19 Diagnosis socket 19 cm³. 44 Low-pressure switch.
20 Nonreturn valve, 2 to 3 bar, "RV3". 45 Steering pump.
21 Nonreturn valve, 2 to 3 bar, "RV1". 46 Steering high-pressure filter (15 µ) with blockage indicator.
22 Nonreturn valve, 5 bar, "RV2". 47 Priority unit.
23 Brake valve.
24 Pressure balance, 24 bar, "M4PV10".
25 Braking valve control from master cylinders.

E2.4 Ares 806 – 09.2004 – GB


Description
General hydraulic circuit diagram of 100 l "Load Sensing" closed-centre circuit

28

18 25
Pp

Rp
Tp

23
29 30

VF

17
A

T
19 26 31
16 T P

32
210 bar 27 38
15 DBV1 20 RV3 M4PV10
14 39
13 RV1 33
21 RV2

46 34
12 24
11 40
175 bar 35
10
9 45 17 bar 5 bar 36
DBV2

37 1,5 bar
8 7
44
4 5 47 43 42

41
3
2

392hsm18 Fig. 1

Ares 806 – 09.2004 – GB E2.5


Description
Hydraulic circuit diagram - Quadrishift transmission

27

41

10
39
2
47
12

392hsm00 Fig. 2

E2.6 Ares 806 – 09.2004 – GB


Description

Sectional view of GPA 40 rear axle

1 4 5 45 41

12

41

57

392hsm19 Fig. 3

Ares 806 – 09.2004 – GB E2.7


Description

Exterior view of the right-hand cover

14 48 61

31

47

1 24

6 32

33

34
56

54

56

55

63
12

2 56 62

392hsm27 Fig. 4

Parts list
48 Pump return towards suction (LH cover). 57 Suction tube.
49 Supply to spool valve block. 58 Steering pump supply tube.
50 "Load Sensing" control pressure. 59 Pinion for 19 and 14 cm³ pumps.
51 Spool valve block "Load Sensing" pressure input. 60 Pump pinion nut.
52 Supply to hydraulic elements (17 bar). 61 Connecting pipe between circuit selector and priority unit.
53 Valve with restriction. 62 Right-hand cover attachment nut.
54 O-ring (return port "R"). 63 O-ring (14 cm3 pump pressure port "P").
55 O-ring (19 cm3 pump pressure port "P").
56 Priority unit attachment.

E2.8 Ares 806 – 09.2004 – GB


Description

Interior and exterior view of the right-hand cover

113 5 61 48

59
Formajoint (510)
60 4
113
1
Formajoint (510)

12 57

392hsm28 Fig. 5

Ares 806 – 09.2004 – GB E2.9


Description

Description of the circuit selector ("Load Sensing signal)

61 24

175 bar DBV2


25

16 17
7
7

16 17
8
10
9
9 8 26

392hsm20 Fig. 6

16 17 24 7

10 9
392hsm21 Fig. 7

E2.10 Ares 806 – 09.2004 – GB


Removing/refitting the components

Brake valve
A
Removal
– All seals and gaskets must be replaced whenever
components are removed. 56
– Remove the circuit selector (10).
– Disconnect hose (25) from the control head.
– Disconnect the supply hose (26) from the trailer brake
coupling.
– Remove the nuts (56) or screws (depending on the
setup) to remove the braking valve.

Refitting
– Clean the gasket faces on the hydraulic cover and
valve. 10
– Replace O-rings (54), (55) and (63), (Fig.4).
392hsm22 Fig. 8
– Refit the valve and fit and tighten the screws (56) to a
torque of 2 daN.m.
B
– Reconnect the pipes.
– Bleed the main brake and the trailer brake and check
the pressure and tightness (see chapter "C2").
A Fitting with a Bosch braking valve.
B Fitting with a "SNR" braking valve.

56

10

392hsm23 Fig. 9

Ares 806 – 09.2004 – GB E2.11


Removing/refitting the components

Sectional view of the braking valve (Bosch)

P N N

391hsm05 Fig. 10

Parts list
64 Spool. 82 Spring. 100 Valve socket.
65 Spool. 83 Washer. 101 Valve.
66 Guide bush. 84 O-ring. 102 Spring.
67 Sleeve. 85 Plug. 103 O-ring.
68 O-rings. 86 Spring. 104 Plug.
69 Pushrod. 87 Plunger rod. 105 Valve body.
70 Bleed screw. 88 Thrust washer. 106 Plug.
71 Spring. 89 Flat seal. 107 Plug.
72 O-ring. 90 Bush. 108 Seal.
73 Pushrod. 91 Valve head. 109 Plug.
74 Seal. 92 O-ring. 110 Pushrod.
75 Washer. 93 Coupling. B Supply to trailer brake coupling.
76 Screw. 94 Expanding plug. N Continuity to auxiliary spool valve.
77 Circlip. 95 Needle screw. P Pressure.
78 Spring. 96 Cap. R Return to the casing.
79 Circlip. 97 Seal. X Supply from tractor braking device.
80 Screen. 98 Plug.
81 Circlip. 99 O-ring.

E2.12 Ares 806 – 09.2004 – GB


Removing/refitting the components

Exploded view of braking valve (Bosch)

0,25 – 0,1 daN.m


70 92
91 93
90 94
69 95
89 96
67
71
88
87
86
110 3,6 – 1,2 daN.m
76
75
74
73
65 70
66 78
68
72
105
106 85 5,6 – 1,9 daN.m
107 84
83
82
81
64
80
79

109
108 1 – 0,3 daN.m
99
100
101 0,3 – 0,1 daN.m
102
103
0,4 – 0,1 daN.m
104

1,4 – 0,5 daN.m

392hsm02 Fig. 11

Ares 806 – 09.2004 – GB E2.13


Removing/refitting the components

Sectional view of the braking valve (SNR)

131 B 128 129 126 123 122 111 112 113 114 115 117

A 130 127 125 124 121 119 118 116


392hsm24 Fig. 12

Parts list
111 Valve body. 120 O-rings. 128 O-ring.
112 Spool. 121 Sealing ring. 129 Piston.
113 Seal. 122 Ring. 130 Valve head.
114 Piston. 123 Guide. 131 Screw.
115 Plug. 124 Adjustment shim. 132 Screw.
116 Adjustment screw. 125 Spring. 133 Cap.
117 Locknut. 126 O-ring. A Brake fluid inlet.
118 Seal. 127 Pushrod. B Bleed screw coupling.
119 Spring.

E2.14 Ares 806 – 09.2004 – GB


Removing/refitting the components

Exploded view of braking valve (SNR)

133
112
113
132 114

131
130
129
128
127
119
126 118
125 115
124 117
123 116
122
121
111
120

392hsm25 Fig. 13

Ares 806 – 09.2004 – GB E2.15


Removing/refitting the components

Geographical location of the hydraulic components on the priority unit

24
M4PV10
DBV1 47
14

DBV2

RV3 20
RV2 RV1 21
22
2

12

392hsm26 Fig. 14

E2.16 Ares 806 – 09.2004 – GB


Removing/refitting the components

Pressure limiter DBV1 (210 bar)

5,5 – 6 daN.m 4 – 4,5 daN.m

392hsm29 Fig. 15

Pressure limiter DBV2 (175 bar)

3 daN.m 3,5 daN.m

392hsm30 Fig. 16

Non-return valve RV2

4 – 4,5 daN.m

392hsm31 Fig. 17

Ares 806 – 09.2004 – GB E2.17


Removing/refitting the components

Removal of right cover

Make sure that the tractor is securely


immobilised.

– Disconnect and plug the hydraulic hoses and pipes.


– Remove the circuit selector (10).
N.B.: It is not necessary to disconnect the braking
valve control hose to avoid draining the trailor brake
circuit.
– Remove the suction strainer (2) and the braking 2
valve (23).
– Remove the filter (12), (Fig. 14). 23
10
– Unscrew the 3 nuts and the screw (56) to remove the
priority unit (47), (Fig. 4 and 5). 392hsm32 Fig. 18

– Identify and disconnect the solenoid connections.


– Remove the tube after unscrewing the end.
– Remove the cover.
1 110

removal/refitting the main pump


– Remove the screws (110), detach and remove the
pump.
– On refitting the driving pinion, coat the nut with Loctite
Frenetanch (242) and tighten to a torque of 7 daN.m.
– Coat the cover gasket face with Loctite
Formajoint (510).
– On refitting, tighten the pump screws (110) to a torque
of 4 to 5 daN.m.

392hsm05 Fig. 19

E2.18 Ares 806 – 09.2004 – GB


Removing/refitting the components

Replacing the RH cover


Important: Systematically replace all the seals. 135

– Fit the sensor (134) with Loctite Frenetanch (242).


– Tighten fully without forcing until it is in contact with the
pump pinion.
134
– Unscrew by ¾ of a turn to obtain a gap of
approximately 1 mm between the sensor (134) and the
pump pinion (135).
– Tighten the nut to a torque of 2 daN.m.
– Clean the housing and cover gasket faces.
– Check the presence of the 2 centring pins (113) on the
cover (Fig. 5).
– Coat the cover gasket face with Loctite
Formajoint (510).
N.B.: Be careful not to obstruct the ducts. 392hsm06 Fig. 20

– Refit the cover (1) and tighten screws (62)


to 12 daN.m, (Fig. 4). A
– Refit the solenoid valves.
– Tighten nuts (56) to 2 daN.m.
56
– Check the operation of the electrical components.
– If a hydraulic component has been dismantled or
replaced, test the hydraulic circuit. Check the seals on
the gasket face and the hydraulic connections.

10

392hsm22 Fig. 21

Ares 806 – 09.2004 – GB E2.19


Removing/refitting the components

Overall view of the left-hand cover

146 138 145 140 149 142

144 148 141

143

137

392hsm33 Fig. 22

Parts list
137 Supply to the steering unit. 144 Filter holder.
138 Return from "Load Sensing" signal circuit selector. 145 Steering pump mounting screw.
139 Return from the steering unit. 146 LH cover attachment screw
140 Supply to the 17 bar elements. 147 Steering pump driving pinion.
141 Outlet to cooler. 148 Pump return.
142 Towards lubrication if cooler blocked or oil cold. 149 17 bar supply.
143 Steering filter blockage pressure switch.

E2.20 Ares 806 – 09.2004 – GB


Removing/refitting the components

Removing the left-hand cover


146 12 daN.m
Important: Systematically change all the seals.

Make sure that the tractor is securely


immobilised.

– Disconnect and plug the hydraulic hoses and pipes. 145


4 – 5 daN.m
– Remove the filter holder (144).
– Remove the cover (41). 41
– Remove the tube.
– If necessary remove the steering pump (see following
paragraph).
144

Refitting the left-hand cover


392hsm34 Fig. 23

– To put together again, carry out the procedure in


reverse, tightening the screws (146) of the cover 510 147
at 12 daN.m.
– Coat the cover gasket face with Loctite
Formajoint (510).

Removal/refitting the
steering pump
– Remove the 4 screws (145), detach and remove the
pump.
– On refitting the driving pinion (147), coat the nut with
Loctite Frenetanch (242) and tighten to 7 daN.m.
– Coat the cover gasket face with Loctite
Formajoint (510).
– On refitting, tighten the pump screws (145) to 4 392hsm35 Fig. 24

to 5 daN.m.

Ares 806 – 09.2004 – GB E2.21


Removing/refitting the components

Table of other elements common to the 110 l/min closed-centre hydraulic circuit

Designation From page

Steering

Hydraulic diagram of the steering unit E1.58

Exploded view of the steering unit E1.56

Removing/refitting the steering unit E1.59

Spool valves

Hydraulic diagram of the spool valves E1.32 – E1.33

Removing/refitting the spool valves E1.34

Adjusting the controls E1.48

Removal/refitting the lift cylinders E1.50

E2.22 Ares 806 – 09.2004 – GB


Hydraulic measurement and checking points

Test condition:
– Engine at nominal speed.
– Oil temperature at 60°C.

Checking the standby pressure of the 14 cm³ pump


Pressure balance calibration
– Connect tester n° 60 05 705 076 to diagnostic sockets (A) and (B) of the 14 cm³ and 19 cm³ pumps respectively.
– The standby pressure measured at (A) must be 24 bar at nominal speed.
– The pressure measured at (B) must be 17 bar.
N.B.: Do not activate any high-pressure components (e.g. spool valves, lift, "Proactiv" front axle, etc.).

392hsm39 Fig. 25

Ares 806 – 09.2004 – GB E2.23


Hydraulic measurement and checking points

N.B.: On tractors equipped with a (SNR) braking


valve, the pressure coupling (B) of the 19 cm³ pump is
located vertically (Fig. 26).

A
392hsm36 Fig. 26

E2.24 Ares 806 – 09.2004 – GB


Hydraulic measurement and checking points

Test condition:
– Engine at nominal speed.
– Oil temperature at 60°C.

Pressure check for a flow rate of less than 40-l/min and a flow rate of 60 l/min
Association of pumps
– Connect a pressure gauge between the circuit selector and the priority unit (C).
– Connect tester n° 60 05 705 076 to diagnostic sockets (A) and (B) of the 14 cm³ and 19 cm³ pumps respectively.
– Connect tester n° 60 05 005 736 to the spool valve (1).

C B A

392hsm40 Fig. 27

392hsm41 Fig. 28

Ares 806 – 09.2004 – GB E2.25


Hydraulic measurement and checking points

Test at 20 l/min
– Turn the flow regulator of the spool valve concerned to obtain a flow of 20 l/min.
– The pump pressure (P 14 cm³) must be equal to PLS pressure + (22 to 24 bar) for a working pressure of 100 bar.
N.B.: These values are given as an indication only.

Pressure No working pressure Working pressure of 100 bar Working pressure of 190 bar

P 14 cm³ 20 bar 123 bar 200 bar

P 19 cm³ 10 bar 11 bar 10 bar

PLS 0 100 bar 190 bar

Test at 60 l/min
– Turn the flow regulator of the spool valve concerned to a position producing a flow of 60 l/min.
– The pump pressure (P 19 cm³) must be equal to PLS pressure + (22 to 24 bar) + 5 for a working pressure of 100 bar.
N.B.: These values are given as an indication only.
The 5 bar corresponds to the difference in pressure measured at the non-return valve RV2. The maximum flow rate
measured at the spool valve hydraulic couplings must be 100 l/min and the maximum pressure must be 190 bar.

Pressure No working pressure Working pressure of 100 bar Working pressure of 190 bar

P 14 cm³ 28 bar 122 bar 200 bar

P 19 cm³ 32 bar 128 bar 15 bar

PLS 17 bar 100 bar 190 bar

N.B.: The pumps join forces as of 40 l/min, but when the circuit is closed the flow requirement drops and the 19 cm³
pump flow is sent to the tank by the pressure balance.

E2.26 Ares 806 – 09.2004 – GB


Hydraulic measurement and checking points

Test condition:
– Engine at nominal speed.
– Oil temperature at 60°C.

Minimum/maximum flow rate check on the auxiliary spool valves


– Connect tester n° 60 05 005 736 to a spool valve.
– Slowly turn the regulator control of the spool valve concerned from the maximum end stop to the minimum end stop.
– The flow measured must go from 95 to 5 l/min.
N.B.: Do not activate any high-pressure components (e.g. lift, "Proactiv" front axle, etc.).

392hsm41 Fig. 29

Braking valve check


To check the braking valve, refer to chapter "C.2".

Ares 806 – 09.2004 – GB E2.27


"Hydraulic inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:

– Tractor type .........................................................................................................................................................................

– The serial number ...............................................................................................................................................................

– Total operating hours...........................................................................................................................................................

– Date of operation.................................................................................................................................................................

Minimum/maximum flow rate check on the auxiliary spool valves

Spool valve regulator position Nominal flow in l/min Measured flow in l/min

Maximum 95 ± 5
Minimum 5±1

Checking the standby pressure of the 14 cm³ pump


(pressure balance calibration)

Test conditions
Pressure Recorded values
Oil temperature at 60°C

Engine running at nominal speed 24 bar

Check the pressure for a required flow less than 40 l/min and a flow of 60 l/min
Test at 20 l/min

Test conditions
Oil temperature at 60°C No working pressure Working pressure of 100 bar Working pressure of 200 bar
Engine running at nominal speed

P 14 cm³
P 19 cm³
PLS

Test at 60 l/min

Test conditions
Oil temperature at 60°C No working pressure Working pressure of 100 bar Working pressure of 200 bar
Engine running at nominal speed

P 14 cm³
P 19 cm³
PLS

E2.28 Ares 806 – 09.2004 – GB


Hydraulic measurement and checking points

Test condition:
– Engine at nominal speed.
– Oil temperature at 60°C.

Checking the steering pump


– Connect the tester n° 60 05 005 736 to the steering filter outlet.
– Turn the wheels in one direction then in the other and measure the pressure when the wheels at at the end stops.
– The flow should be 60 l/min.
– The pressure should be 175 bar.

392hsm42 Fig. 30

Ares 806 – 09.2004 – GB E2.29


Hydraulic measurement and checking points

Test condition:
– Engine at nominal speed.
– Oil temperature at 60°C.

Maximum steering cylinder pressure check


– Remove the steering unit without disconnecting the hydraulic pipes.
N.B.: When any action is effected on the steering wheel, the pressure gauge connected to the return line to the
reservoir indicates pressure losses in the circuit. On turning to full right-hand or left-hand lock [the pressure gauge
indicates the service pressure plus the head losses with the aid of a spanner 16 (1)].

Pressure limiter
Connect as shown in the following illustrations:
– Start the engine.
– Connect pressure gauge n° 60 05 705 076 and coupling n° 60 05 005 718 to the cylinder supply at (A).
– Measure the pressure while supplying chamber (A): e.g. 190 bar.
– Measure the pressure in chamber (B) (return): e.g. 15 bar.
The service pressure (calibration of the pressure limiter valve) is therefore equal to the difference between these 2
pressures: 190 – 15 = 175 bar. If this value is incorrect, recalibrate or decalibrate the pressure limiter valve (2).

392hsm43 Fig. 31

E2.30 Ares 806 – 09.2004 – GB


Hydraulic measurement and checking points

2 3

392hsm37 Fig. 32

Parts list
1 16 mm key to activate the rotor. 3 Shockproof valve adjustment.
2 Pressure limiter adjustment.

Ares 806 – 09.2004 – GB E2.31


Hydraulic measurement and checking points

Test condition:
– With the engine stopped.
– Oil temperature at 60°C.

Shockproof valve opening pressure check


– Connect a manual calibration pump to one of the two steering cylinder supplies.
– Apply pressure with the calibrating pump and note the opening pressure.
– The opening pressure (D) must be between 225 and 245 bar. If this is not the case, adjust the shockproof valves.
– Apply the same procedure to the second steering cylinder supply.

D
392hsm38 Fig. 33

E2.32 Ares 806 – 09.2004 – GB


"Hydraulic inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:

– Tractor type .........................................................................................................................................................................

– The serial number ...............................................................................................................................................................

– Total operating hours...........................................................................................................................................................

– Date of operation.................................................................................................................................................................

Checking the steering pump

Test conditions Nominal values Recorded values


Oil temperature at 60°C
Flow rate Pressure Flow rate Pressure

Engine running at nominal speed 60 l/min 175 bar

Maximum steering cylinder pressure check


Difference between values
Test conditions Value measured at (A) Value measured at (B)
(A) (B)
Oil temperature at 60°C Nominal (bar) Reading (bar)
(bar)
Engine running at nominal speed 175

Shockproof valve opening pressure check

Test conditions
Nominal value (bar) Measured value (bar)
Oil temperature at 60°C

With the engine stopped 225 to 245

Ares 806 – 09.2004 – GB E2.33


Notes

E2.34 Ares 806 – 09.2004 – GB


TOOLS

Hydraulic circuit tooling

Ares 806 – 09.2004 – GB E2.35


Hydraulic circuit tooling

60 05 005 718 60 05 005 726

Hydraulic coupling Column seal fitting tool

60 05 005 736 60 05 705 076

Hydraulics test set Test set

60 05 712 800 60 05 712 971

Decontamination station Decontamination station filter

E2.36 Ares 806 – 09.2004 – GB


ITEM LIST
WIRING AND GENERAL LISTS

Ares 806 – 09.2004 – GB F1.1


Item list 125 Solenoid valve 2 2PS TWINSHIFT 240 Cross control
126 Solenoid valve 1 4PS QUADRISHIFT 244 4PS AUTO control
1 RH rotating beacon 53 Rear PTO clutch switch 127 Rear axle oil low pressure switch 245 4PS ECO/POWER control
1a LH rotating beacon 54 Rear PTO selection contact 128 Gearbox pressure sensor 254 Front lift fuse (5 A)
2 RH dipped beam / headlamps 55 Clutch pedal contact 130 Diode 255 Joystick - Solenoid pilot
3 LH dipped beam / headlamps 55a Clutch pedal contact 131 Diode 256 Front lift socket
4 RH side light 56a Lift RH external switch 132 Intermediate speed sensor 257 Front lift relay
4a RH front flashing light 56b Lift LH external switch 133 Tractor forward speed sensor 258 Front lift relay
5 LH side light 57a Lift lower RH external switch 140 Events counter 259 Front loader socket
5a LH front flashing light 57b Lift lower LH external switch 141 Electrohydraulic spool valve control unit 260 Implement socket (P125)
6 Outside RH front work light 60 Ignition switch 142 RH electrohydraulic spool valve 261 TCE programming socket (P192)
6a Inside RH front work light 61 Ventilation switch 143 LH electrohydraulic spool valve 262 Diagnostic plug (P14)
7 Outside LH front work light 62 Signalling control 144 Safety solenoid valve 263 CAN network socket (P133)
7a Inside LH front work light 63 ISC declutching +/- range control 173 Horn 264 ISO socket (J219)
8 Outside RH rear work light 64 Rear windscreen wiper switch 178 Buzzer (buzzer) 265 ISO socket unit
8a Inside RH rear work light 65 Lighting switch 180 Transmission display 267 Solenoid valve shunt
8b RH rear wing work light 66 Windscreen wiper/washer control / function selector 182 Lift central unit (TCE) 270 Air brake solenoid valve
9 Outside LH rear work light 67 Instrument panel calibration switch 184 Transmission electronic central unit (ECU) 295 Suspended front axle pilot solenoid valve
9a Inside LH rear work light 68 Park Lock control 185 Instrument panel 296 RH cylinder solenoid valve
9b LH rear wing work light 70 Ventilation/air conditioning switch 186 On board computer 297 LH cylinder solenoid valve
10 RH rear side light 77 Temperature potentiometer (air conditioning) 187 Clutch potentiometer (reverser under torque) 303 Suspension control unit
10a RH rear flashing light 79 Car-radio 188 Hydraulic shuttle reverser control 304 Suspension switch (auto)
11 LH rear side light 80 Clock 189 Bottom of clutch contact (reverser) 305 Suspension switch (manual)
11a LH rear flashing light 81 Trailer signalling socket 190 TC transmission ECU 401 Steering angle
12a Police plate RH lighting 82 25 A power socket 191 Lift electronic unit (TCE calculator) 402 Turbo pressure
12b Police plate LH lighting 83 LH loudspeaker 192 Forward drive solenoid valve 403 RH suspension sensor
13 Cab light - contact + light 84 RH loudspeaker 193 Reverse drive solenoid valve 404 LH suspension sensor
14 Lighting spot 85 Windscreen wiper timer 194 Park lock solenoid valve
16 RH side work light (step) 86 Cigar lighter 195 Park lock switch
17 LH side work light (step) 87 Radio antenna 197 Accelerator control potentiometer
21 Rear windscreen wiper 89 Electronic lift diagnostic socket 198 Oil filter clogging indicator (strainer)
22 Buzzer 90 Electric fan 199 Oil filter clogging indicator
24 Engine ECU 91 Cab top LH cooling fan 200 Engine oil pressure switch
25 Injection stop solenoid valve 92 Front screen wiper 201 Engine water temperature thermistor
27 Reverser module speed sensor 93 Cab top RH cooling fan 202 Fuel gauge
28 Outside temperature probe 94 Front PTO solenoid valve 203 RH brake pedal switch
29 Rear power take off speed sensor 95 Compressor 203a LH brake pedal switch
30 Battery 96 Front windscreen washer pump 204 Handbrake switch
31 Alternator 96a Rear windscreen washer pump 206 Air filter clogging indicator
32 Starter 97 High / crawler range solenoid valve 208 RH rabbet cab light contact
33 Radar 98 Rear PTO brake solenoid valve 209 LH rabbet cab light contact
34 Preheating sparking plugs 99 UP solenoid valve 210 Pressure switch
37 Tractor advance speed sensor (transmission) 100 DOWN solenoid valve 214 Brake fluid level contact
38 Engine speed sensor (transmission) 101 4-wheel drive solenoid valve 220a + range switch
39 Rear power take-off speed sensor 102 Differential lock solenoid valve 220b - range switch
40 Front PTO switch 103 Rear PTO clutch solenoid valve 220c Furrow gear
42 ECO rear PTO contact 104 Rear PTO brake solenoid valve 221 Flashing unit
43 Front windscreen wiper switch 110 Fuse box 222 Front work lights relay
44a RH rear PTO emergency stop 114 Transmission oil temperature sensor 223 Rear work lights relay
44b LH rear PTO emergency stop 115 Gearbox transmission oil pressure switch 223a Rear work lights relay (wings)
45 Front work light switch 117 Preheating fuse (70 A) 226 Preheating relay
46 Rear work light switch 118 Rear axle transmission oil pressure switch 232 Differential switch
47 Crawler speed contact 119 Cooling thermostat 234 4-wheel drive switch
48 High / crawler range contact 121 UP solenoid valve (semi-mounted) 235 Left force sensor (TCE)
49 Warning light switch 122 DOWN solenoid valve (semi-mounted) 236 Right force sensor (TCE)
52 Rotating beacon switch 123 Pneumatic seat engine and contact 237 Position sensor (TCE)

F1.2 Ares 806 – 09.2004 – GB


Wiring and general lists
J95
J95 J111
J111 E5B J168
72
72 223a 209
1a1a J100
J100
J106
J106 5c
5c J106
J106 119
119 5b
5b 55 79
79
J169 5a
5a J95
J95
99 77 99 223 1a
1a
J99
J99 J113J112
J113 J112 JA JB
JA J56
7a7a J105 46 J65
9a9a J105
9a
J96
J96
J105
J105 J98
J98 9a 84
84 J57 77
9292 P54 J60 J63 J57 80
P54 J60 J63 45 80
45 J104
J104 J97
J97 303
303
J97
J97 J103
J103 J64 E5E
J64 E5E 222
222 21
21 7a
7a J183 J182
6a P107 13 J183 J182
6a 8a
8a
P107 13 J170
J170 J98 305
305
J96
J96 83
83 J98
J103 92
J103 66 J107
J107 P55
P55 92
8a8a J102
J102 P108
P108 87
87 J99
J99
J184
J184
88 6a
6a 44
88
P62
P62 J108 J100 304
304
J110
J110 J108 J100
J102 E6A 66
J102 73
73
J109
J109 P61 J61 E6A J62 J184
P61 208 J62
1 1J101 P61 J61 E5A J184
P61 208 E5A
J101 E0A P62 J101
E0A P62 J101 E4B
1 E4B
P151 J151 1
56a E6A P151 J151 P185
56a J40 123 J43 J35 J27 81 J178 E6A P52
P52
P247
P247
J172
J172 P185
J40 123 J43 J35 J27 81 J178 P246
57b J41 J32 P246 P172 J185 E3C J18 J141
J41 J52 J247 32 95 J183 J141
57b J29 J32 J246 J52 J247 262 P172 J185 3/1 32 95
E3C 200 401
J29 204 P44 J246 262
P14 67 187 188
E0A
E0A 3/1 J34 E3B
E3B
3 200 401
11 204 P44 P14 67 J124
187 J59
188 J08 203 214 J142 J34 E0A
11 J120 J44 J15 J08 130 203 214 E3A 2 3/2a 206
402 J142 E3A E0A
3/2a 206
40 130 J19 2
J44 J15 J124 J59 + -
J120 J9440 J04 P08
+ - 402
44b J04 P08 209 173 206 210 J19 95
44b J123
J94
22
J248 30 209 173 206 210 401 J34 95
110 J248 E0C J01 J176 30 401J210 J226 J213
J141 J01
J123 22 110
J03
77
E0C J01 J176 J141 J210 J226 J213 J01 J34 210
9b J03 JX2 JX1 66 210
9b J05
J50 77 66
J06 J13 E0A P01 197
J05
J114 JX2 JX1 E0D
J13 P01 P02 197 J200 31
J33 J28 J114 J50 J06 E0D E0A J31 P02 32 31 173
J33 12b J28 12a 90 J12 185 P133a P02 J31 J20096a 173
32
90 J17 J12 61 96a P02 201 J52
82 J143 55 185 P133a E0B J02 201 96
8b 12b 12a 82 J143 55 J10 61 J09 E0B J212 J200 J244 J243 J218 201
J31 J52 E3C E3A
J17 J133a J131 J02 201 J22 96 E3C
8b J10 J09 E30 J212 J200 J244 J243 J218 96 J31 J53 E3A
1 68 J245 J07 J133aJ23J131 J2149 J22
J53
44a 68J130 62
55a J07 52 J23 E30 J22 96 E3B
44a J122
1 J11 J245
52J23
J2149
J21 J153 J51 94
E3B
J130 55a 5 85 J11 55a 62 J21 16J153 J5194 J22
J200 J51 94
J122 J23J25 + -
10 6 55a 5 85 60 J25 203a 4 J224 16 17 94 J200 + - J51 3 2
10 J121 6 J20 J119 4 31 30 3 J19 2
86 60 203a J224 17J152 P139 P140 J16 J139 J18
J121 J20 J119 P139 P140 J16 31 30 J139
57a J152 J18 J19
J3686 P999
263 P20 P119 184 J139 P16 31
57a J37 8a 184 J1
M8J
184
J117
J36 J999 P999 P133 P20 P119 J139 31
56aJ37 J48 263 47 E6A M8J J233 7a J39 P16
J999 P133 8a 184 J1 J117 J145 P224
3/2a
56a J26 J42 J42 P48 J48 47 E6A J2 J233 7a J116 J93 J92
27 J145 114 117 J39 P224
J26 J42
P42 J42 P42 P48
J136 J2 J116 J93 J92
27 J91 114 117 3/2a
143 143 260 J231 J232 185 126 125
9/1b J194 P42 9b 9/1a J194143 P42 9a J188
J136 J83 J9148 2 J176
143 260 J231 J232 185 126 125 38 J83
9/1b J194
J72
9b 9/1a J194
J72 261 P125 9a J188
J236 J235 E7D E7A J149 48
2 226 34 J220 J176
J72 100 M9i E6A J192
TCE 15T TCE J72 100 E6A
261 TCE E7D E7A 38 J149 97 226 34 J220
J222
TCE 15T J193 J193 J236 J235 P221
100
J76 M9i E6A J192 15/25/35 J76100 E6A P192 P125 15/25/35 J90 J222
TCE 15T J193 142 TCE 15T TCE J193 142 TCE
42 54 97 P221
J76 99 J76 99 P192 J189 J223 J216
142 J189 15/25/35 142 15/25/35 202 J90 J139 J140
99 J7799 J189 42 54 J68 131 J234
J139 J140 M7B M7K J223 J216
J189 P189 J237 202 J84 J150 J151 J94 J95 J225 7c J218
J77 122 J68 134 J234
131 39 M7B M7K J217
J78122 P189
134
J237 J84 J150 J151 J94 J95 J225
270 7c J218
121 E9A 265 39 J82 J82 J217 P217
33 J71 J186 144 33 J78 37 115 270 J214
J71
E9A J47 265
J207 J80 J82 270 37 3/2c
121 J49 J45 J46 J85 J86 J87 J88 J89 J202 J82 J225 P217
14433 J79 236 E9C J71 J186
J70 144 33 J79
J204 E9C J71 J70 63 234 232 J80 P80
37 115 37 270 3/2cJ212
J214 J211
J49 J45 J46 J4753 J207 E7C
J204
144 J79 J74
236 J204 J79 236 J134 J67 98J85103J86199J87102 J88101J89J201 J202 J225 J10J211
E9C 191 182 J70 E9C 182 J70 63 234 232J137 J208 J209
J212
J204 J74 E9B J74 E9B 53 J67 P80 E7C 202 J213
J187 236 J187 J134 J137 J208 98 103 199 102 101 J201 J16
J10
191 182 182 J209
E9B J74 E9B M9I P80 202 P138 J213
235 J187 235 J187 P999 P20 193 J16
J75 P69 J75 P69
M9I 263 P119 M8J J117
184 J1 P80
235 J69 235 J69 P999
J48
P133 P20
47 8b 7b 193 J138 P138
J75 J73 P69 J75 J73 P69 263 P119 E6A J117
J191 J191 P133 8b 184 J2
J1 M8J
7b J116 J93 J92 E7B 7d J138 132
237 J69 J190 J173 237 J69 J190 J48 47 E6A J136 270
J73 J73 192 J160
J191 J191 J188 J2 J225 115
J116126 J93 J92 J145 27 E7B 7d L J91 1 C J83 132
E90B 258 237
257 E90A
J190
P190 P191 J173 237 J190
P190 P191 J136 270 R
9/3 J198 9/3 J198 J202 192 J91 114
J145 27 114 38 J160
J129 J128 J188 J132J225 115 126 L J91 1 C J83 BR
258 257 P190 P191 141 P190 P191 141 101 194 102 98 103 195
E90B E90A 267 114J86 J159 38 128
J129 J128
9/3 J198 9/3 J198 J202 J9148
J149 114 J89 J158 J88 J85 B133
J132 E7C E7E
141 141 42 54 267
E7A 101 194 102 98 103 195
J197 J199 J197 J199 J86 J85 J88 J90 J149 48 J89 J158 J88 J85 J86 J159 E7B E7D J161 128
E7G
202 E7A EF7
J205 J126 J68 131 J234 J89 E7C E7E 133
9/2a J197 J199 P199 J197 J199 P189 42 54 103 98 102 97
256 259 P197 255 134 39
J84 J86 J85 J88 J90 101 EF7
E7B E7D J161 E7G
J205 J126 254 5A J68 131 J234
265 202 J89 A
J82 J83 J201 127
256 259 9/2a P197 P199
255 P189
J49 J45 J46 J47
J207 134 J80 37
39
J84 103
38 98 102 97
101
J87 115 J/P
234 127
254 5A 63 232 265 J82 J83 J201 127 163 2A
J134
J49 J45 J46 J137 J4753 J67 J207 J208 J80 37 38 199J87
115
J84
130 J162 J/P
P80 127 39
63 234 232 E7C
J87 163 M2
J134 P134 53 254 199 J84
220 J137 P137 J67 5A J208 P208 199 29 130 J162
J206 P80 E7C 39
E6A J81 C B M1 A D E
244a EP1 254 J87 TC HM
E1 P134 P137 5A 199 29
220
220 J206 P208 190
J195 EP2 E6A J81 C B M1 A D E
140 244a EP1J126 TC H
E1 E8A J129
220 J195 244
J147 258 J219 190
J195 259
EP2
140 264
28 J148 E8A J126 J129
J128
J195 244
J147 258 J219
259 257
186 J150 264
28 J148 J127 J128
8/2 9/2b257 8/1
10
186
180 240
605hsm00 J150
J127
10 8/2 180 240 9/2b 8/1
605hsm00

1 Instrument panel harness (001 - 185/M0A - M0V) 7a Closed centre circuit transmission harness - 110 litres (701-735/M7A-M7S) 9/1b TCE 15T Harness (960 - 979/M9K - M9R)
2 Preheating control harness (colours) 7b Closed centre circuit transmission harness - 100 litres (701-735/M7A-M7S) 9/2a Cross control harness with Electropilot (9100 - 9110/M90A - M90F)
3/1 Front harness (DE10 engine) (300 - 336/M3A - M5P) 7c GTA 303 transmission link harness (44/M22-M27) 9/2b Cross control harness (colours)
3/2a Front harness (VP44 engine) (300 - 336/M3A - M5P) 7d GTA 303 transmission harness (710-728/M7B-M7K) 9/3 Electrohydraulic spool valve control harness (9000 - 9018/M9X - M9Z)
3/2b Injection harness (350 - 372/M30A - M30H) 8a GTA 103/202 - GPA 40 transmission control harness (801-8043/M8A-M8S) 10 On-board computer harness (colours)
3/2c Injection control harness (400 - 440/M4A - M4F) 8b Full Powershift transmission control harness (801-823/M8A-M8Q) N.B.: The figures indicated in brackets correspond to the marks of the wires used
4 Front axle suspension control harness (482 - 485/M4E - M4F) 8/1 ISO socket harness (801-8043/M8A-M8S) according to the harness type
5 Instrument panel / cab top harness (500 - 599/M5A - M5NN) 8/2 Quadrishift 2/Quadractiv/Full Powershift display harness(8100-8134/M8Y-M8Z) Diode
5a Cab top / front lights harness (550 - 562/M5AA - M5XX) 9a TCE 15/25/35 Control harness (900-960/M9A-M9J) J27
Shunts
5b Cab top / air conditioning + rear lights harness (570 - 587/M5DD - M5YY) 9b TCE 15T Control harness (690-979/M9A-M9F) Optional components
5c Cab top / rear light harness without air conditioning (576 - 587/M5DD - M5ZZ) 9/1a TCE 15/25/35 Harness (965-997/M9M-M9R) Follow the arrow to resume the corresponding interconnection
6 Rear harness (601 - 660/M6A - M6PN)

Ares 806 – 09.2004 – GB F1.3


F1.4 Ares 806 – 09.2004 – GB
CONTENTS

FUSE AND RELAY BOX .................................................................................................................................................................. F1.8


DE10 STARTING/CHARGING/PREHEATING CIRCUIT ............................................................................................................... F1.12
VP44 STARTING/CHARGING/PREHEATING CIRCUIT ............................................................................................................... F1.13
DIPPED HEADLIGHTS - HEADLIGHTS - HORN -
SIDE LIGHTS - INSTRUMENT PANEL LIGHT .............................................................................................................................. F1.14
ROTATING BEACONS .................................................................................................................................................................. F1.15
FRONT WORK LIGHTS ................................................................................................................................................................. F1.16
REAR WORK LIGHTS ................................................................................................................................................................... F1.17
STOP LIGHTS - FRONT AXLE ENGAGEMENT -
AIR BRAKE SYSTEM SOLENOID VALVE CONTROL.................................................................................................................. F1.18
FLASHING LIGHTS AND WARNING LIGHTS............................................................................................................................... F1.19
CIGAR LIGHTER - CLOCK - RADIO - CAB LIGHT AND SPOT.................................................................................................... F1.20
PNEUMATIC SEAT - FRONT POWER TAKE OFF CLUTCH........................................................................................................ F1.21
FRONT AND REAR WINDSCREEN WIPER / WASHER .............................................................................................................. F1.22
INSTRUMENT PANEL VENTILATION........................................................................................................................................... F1.24
INSTRUMENT PANEL VENTILATION AND AIR CONDITIONING ............................................................................................... F1.25
INFOTRAC ON-BOARD COMPUTER / ISO SOCKET .................................................................................................................. F1.26
FUEL GAUGE - ENGINE TEMPERATURE OIL PRESSURE -
AIR FILTER BLOCKED .................................................................................................................................................................. F1.28
HANDBRAKE - BRAKE FLUID LEVEL .......................................................................................................................................... F1.29
ENGINE SPEED ............................................................................................................................................................................ F1.30
INSTRUMENT PANEL CALIBRATION - DIAGNOSTIC SOCKET INSTRUMENT PANEL AND TCE 15T ................................... F1.31

SCHEMATIC DIAGRAMS ACCORDING TO ELECTROPILOT/DRIVETRONIC/GTA 103-202/GPA 40 DIAGNOSTIC SOCKET ....................................................................... F1.32


ELECTROPILOT/DRIVETRONIC/FPS DIAGNOSTIC SOCKET ................................................................................................... F1.33

FUNCTIONS
25 A POWER SOCKET.................................................................................................................................................................. F1.34
TRANSMISSION HYDRAULIC PRESSURE - OIL FILTER BLOCKED (HP) -
OIL FILTER BLOCKED (SUCTION)............................................................................................................................................... F1.35
THEORETICAL SPEED ................................................................................................................................................................. F1.36
INSTRUMENT PANEL - REAR POWER TAKE-OFF SPEED ...................................................................................................... F1.37
TCE 15T LIFT................................................................................................................................................................................. F1.38
ELECTROPILOT (WITH TCE 15T) ................................................................................................................................................ F1.42
LIFT TCE - 15/25/35/ RADAR ........................................................................................................................................................ F1.44
ELECTROPILOT (WITH TCE 15/25/35) ........................................................................................................................................ F1.46
GTA 103-202 - GPA 40 CLUTCH AND DRIVE CONTROL ........................................................................................................... F1.48
AUTOMATIC HAND BRAKE .......................................................................................................................................................... F1.51
FPS CLUTCH AND DRIVE CONTROL.......................................................................................................................................... F1.52
FPS PARK LOCK ........................................................................................................................................................................... F1.55
QUADRISHIFT II ........................................................................................................................................................................... F1.56
QUADRACTIV GTA 103-202 - GPA 40.......................................................................................................................................... F1.60
FPS QUADRACTIV ........................................................................................................................................................................ F1.64
DE10 ENGINE CONTROL ............................................................................................................................................................. F1.68
VP44 ENGINE CONTROL ............................................................................................................................................................. F1.70
SUSPENDED FRONT AXLE.......................................................................................................................................................... F1.72
FRONT AXLE ENGAGING - DIFFERENTIAL AND REAR POWER TAKE OFF ........................................................................... F1.74
OIL TEMPERATURE SENSORS - ENGINE SPEED - FORWARD SPEED -
REAR POWER TAKE-OFF SPEED - REVERSER MODULE SPEED - DRIVETRONIC .............................................................. F1.76
CROSS CONTROL WITH SOLENOID PILOT ............................................................................................................................... F1.77
CROSS CONTROL ........................................................................................................................................................................ F1.78
DE10 CAN ...................................................................................................................................................................................... F1.79
VP44 CAN ...................................................................................................................................................................................... F1.80

Ares 806 – 09.2004 – GB F1.5


CONTENTS

FUSE AND RELAY BOX ..................................................................................................................................................................F1.8


DE10 STARTING/CHARGING/PREHEATING CIRCUIT ...............................................................................................................F1.12
VP44 STARTING/CHARGING/PREHEATING CIRCUIT ...............................................................................................................F1.13
DIPPED HEADLIGHTS - HEADLIGHTS - HORN -
SIDE LIGHTS - INSTRUMENT PANEL LIGHT ..............................................................................................................................F1.14
ROTATING BEACONS...................................................................................................................................................................F1.15
FRONT WORK LIGHTS .................................................................................................................................................................F1.16
REAR WORK LIGHTS....................................................................................................................................................................F1.17
STOP LIGHTS - FRONT AXLE ENGAGEMENT -
AIR BRAKE SYSTEM SOLENOID VALVE CONTROL ..................................................................................................................F1.18
FLASHING LIGHTS AND WARNING LIGHTS...............................................................................................................................F1.19
CIGAR LIGHTER - CLOCK - RADIO - CAB LIGHT AND SPOT ....................................................................................................F1.20
PNEUMATIC SEAT - FRONT POWER TAKE OFF CLUTCH........................................................................................................F1.21
FRONT AND REAR WINDSCREEN WIPER / WASHER...............................................................................................................F1.22
INSTRUMENT PANEL VENTILATION...........................................................................................................................................F1.24
INSTRUMENT PANEL VENTILATION AND AIR CONDITIONING................................................................................................F1.25
INFOTRAC ON-BOARD COMPUTER / ISO SOCKET ..................................................................................................................F1.26
FUEL GAUGE - ENGINE TEMPERATURE OIL PRESSURE -
AIR FILTER BLOCKED ..................................................................................................................................................................F1.28
HANDBRAKE - BRAKE FLUID LEVEL ..........................................................................................................................................F1.29
ENGINE SPEED ............................................................................................................................................................................F1.30
INSTRUMENT PANEL CALIBRATION - DIAGNOSTIC SOCKET INSTRUMENT PANEL AND TCE 15T....................................F1.31
ELECTROPILOT/DRIVETRONIC/GTA 103-202/GPA 40 DIAGNOSTIC SOCKET .......................................................................F1.32
ELECTROPILOT/DRIVETRONIC/FPS DIAGNOSTIC SOCKET ...................................................................................................F1.33
25 A POWER SOCKET ..................................................................................................................................................................F1.34
TRANSMISSION HYDRAULIC PRESSURE - OIL FILTER BLOCKED (HP) -
OIL FILTER BLOCKED (SUCTION)...............................................................................................................................................F1.35
THEORETICAL SPEED .................................................................................................................................................................F1.36
INSTRUMENT PANEL - REAR POWER TAKE-OFF SPEED.......................................................................................................F1.37
TCE 15T LIFT .................................................................................................................................................................................F1.38
ELECTROPILOT (WITH TCE 15T) ................................................................................................................................................F1.42
LIFT TCE - 15/25/35/ RADAR ........................................................................................................................................................F1.44
ELECTROPILOT (WITH TCE 15/25/35).........................................................................................................................................F1.46
GTA 103-202 - GPA 40 CLUTCH AND DRIVE CONTROL............................................................................................................F1.48
AUTOMATIC HAND BRAKE ..........................................................................................................................................................F1.51
FPS CLUTCH AND DRIVE CONTROL ..........................................................................................................................................F1.52
FPS PARK LOCK ...........................................................................................................................................................................F1.55
QUADRISHIFT II ...........................................................................................................................................................................F1.56
QUADRACTIV GTA 103-202 - GPA 40..........................................................................................................................................F1.60
FPS QUADRACTIV ........................................................................................................................................................................F1.64
DE10 ENGINE CONTROL .............................................................................................................................................................F1.68
VP44 ENGINE CONTROL..............................................................................................................................................................F1.70
SUSPENDED FRONT AXLE..........................................................................................................................................................F1.72
FRONT AXLE ENGAGING - DIFFERENTIAL AND REAR POWER TAKE OFF ...........................................................................F1.74
OIL TEMPERATURE SENSORS - ENGINE SPEED - FORWARD SPEED -
REAR POWER TAKE-OFF SPEED - REVERSER MODULE SPEED - DRIVETRONIC...............................................................F1.76
CROSS CONTROL WITH SOLENOID PILOT ...............................................................................................................................F1.77
CROSS CONTROL ........................................................................................................................................................................F1.78
DE10 CAN ......................................................................................................................................................................................F1.79
VP44 CAN ......................................................................................................................................................................................F1.80

F1.6 Ares 806 – 09.2004 – GB


Ares 806 – 09.2004 – GB F1.7
FM30 / 10A

F1.8
605hsm02
FM34 / 10A
FM9 / 15A
FM16 / 10A
FM6 / 15A

J15
FM7 / 5A
FM4 / 15A
FM2 / 5A
FM17 / 10A

1 2 3 4 5 6 7 8 10 9 11 12
FA8 / 25A

1 2 4
3
R5
FA5 / 20A

6
5
J04
R12
FM18 / 10A
FM15 / 15A
FM19 / 15A

7 12 11 9 8
10
R10
FM20 / 10A

12
10
R14

FM22 / 15A

5
R11

8
J248
FM28 / 10A

4 6 11 9
FM21 / 5A

7 2 3 1
R2

FM11 / 20A
FA3 / 20A

-------- Optional
R7

Ares 806 – 09.2004 – GB


+APC
+AVC

MASSE
Fuse and relay box

12 8
R4

2
6

FA1 / 20A
FM32 / 10A
J03

FM31 / 5A
FM33 / 10A
FM27 / 10A

FM14 / 10A
7 9 5 10 4 11 1 3
R6

FM12 / 10A
FM13 / 10A
6 2 8 4 5 1
R9

J05
R15

FM26 / 10A
R3

10 7 9 3 12 11
R1

FA24 / 25A
R8

15A

FA29B / 25A

FM25 / 10A
R13

J114

FM23 / 15A
221

3 4 1 5 6 8 7 2 9 10 12 11
6 5 4
3 2 1
49 C 49
C3 C2 31
Fuse box and relay basic version Conductor allocations
Top view Bottom view
Standard Rating
Fuses Ref
MINI ATO (A)
FM17

FM16

FM30

FM34
2 4 6 8 10 12

FM2

FM4

FM6

FM7

FM9
+APC

J15 X Fan top cab right 20 FA1


10A

10A

15A

15A

15A

10A

10A
Roof light/Radio
5A

5A
+AVC X 5 FM2
FM18 10A
1 3 5 7 9 11 X Fan top cab left 20 FA3
FM20 10A
2 4 6 8 10 12 X Engine ECU 15 FM4
FM15 15A
R10 R12 R5 20A FA5 X Ventilation 20 FA5
FM19 15A J04
25A FA8 X Headlights (dipped/main beam) 15 FM6
FM22 15A
20A FA11 X Instrument panel 5 FM7
FM21 5A 1 3 5 7 9 11
R2 20A FA3 2 4 6 8 10 12 X Implement electrical socket 25 FA8
FM28 10A R14 R11
20A FA1
X Transmission calculator 15 FM9
FM32 10A
J248
FM27 10A
X Working headlight rear wing 10 FM10
5A FMR1
FM31 5A 10A FMR2
X Rear work light 20 FA11
R7 1 3 5 7 9 11
FM33 10A
R4 R6
15A FMR3 X Work headlight front inside 10 FM12
2 4 6 8 10 12
FA24 25A
FAR1
FAR2 X Work headlight front outside 10 FM13
FM14
Cigar lighter/Radio
10A

J03 X 10 FM14
25A

20A

X Engine ECU 15 FM15


1 3 5 7 9 11
R9 R15 R1
10A FM10 X Rotating beacon 10 FM16
2 4 6 8 10 12
FA29A X Front PTO - Seat 10 FM17
(25A)
FM25 FM26 FM12 FM13 J05 X Rear windscreen wiper 10 FM18
FM23 15A 10A 10A 10A 10A
10 R13
X Transmission calculator 15 FM19
1 3 5 7 9 11 X Lift calculator 10 FM20
2 4 6 8 10 12
X Instrument panel 5 FM21
221
25A FA29B J114 X Stop 15 FM22
H1 FMT X Flashing indicators / Hazard warning lights 15 FM23
FAT 1 3 5 7 9 11 X Start-up 25 FA24
1
R X Left-hand lights 10 FM25
X Right-hand lights 10 FM26
X Front windscreen wiper, self-parking 10 FM27
605msm37 605msm38 X Front screen wiper 10 FM28
Start-up* 25 FA29A
Quadrishift Full Powershift* X Start-up 25 FA29B
X Lift calculator 10 FM30
17 16 2 4 6 7 9 30 34
17 16 2 4 6 7 9 30 34
X Implement electrical socket 10 FM31
10A 10A 5A 15A 15A 5A 15A 10A 10A
X Electrohydraulic spool valve 10 FM32
10A 10A 5A 15A 15A 5A 15A 10A 10A
X Suspended front axle 10 FM33
10A 18
10A 18
X Suspended front axle 10 FM34
10A 20 20A 5
10A 20 20A 5
15A 15
15A 15
25A 8
25A 8 Connectors Ref Standard
Relays Ref
15A 19
15A 19
20A 11 Brown J03 MINI MAXI
11
20A R10 R12 R5 Black J04
R10 R12 R5 15A 22 X Frong work headlights R1
15A 22
20A 3 Blue J114
20A 3 X Rear work light R2
5A 21 Grey J05
5A 21 Not used R3
20A 1
20A 1 Green J15 X Air conditioning R4
10A 28
10A 28 Red J248 X Ventilation R5
10A 32 R14 R11 R2
10A 32 R14 R11 R2 X Fan HDC right R6
14
14
X Fan HDC left R7
10A 27
10A 27
Standard X Start-up* R8
Spare fuses Rating Ref
5A 31 10A
5A 31 10A MINI ATO X Working headlight rear wing R9
X Spare fuse 5A FMR1 X Linkage R10
10A 33 R7 R4 R6
10A 33 R7 R4 R6
X Spare fuse 10 A FMR2 X Shuttle reverser R11
25A 24 X Spare fuse 15 A FMR3 X Hydraulic pressure R12
24
25A
R9 R15 R3 R1
R9 R15 R1
10A 10 X Spare fuse 25 A FAR1 X Start-up R13
10A 10
X Spare fuse 20 A FAR2 X Side light indicator R15
X X Flashing unit 221
R8
R8 MINI = small fuse
15A 23 10A 25 10A 26 10A 12 10A 13
23 10A 25 10A 26 10A 12 10A 13
15A
ATO = standard fuse
R13
R13

25A 29
25A 29 221
221

605msm36 605hsm47

Ares 806 – 09.2004 – GB F1.9


Conductor allocations

Green Brown

1 + AVC TCE 30 A/B 1 P + cigar lighter


2 + AVC hazard warning signal control 2 + AVC RH cab top ventil.
3 + AVC front axle 3 P + clock radio
4 +AVC transmission 4 Cab top ventil. ctrl
5 + APC rotating beacon 2 4 6 8 10 12 5 + APC front axle
6 + AVC stalk switch 6 Air conditioning thermostat
7 + AVC control panel J15 7 + APC Electrohydraulic spool valve (DEH)
8 + AVC TCE 30 A/B 8 A/C compressor control
9 + APC seat 9 +APC implement socket
1 3 5 7 9 11
10 + APC cab top 2 4 6 8 10 12
10 +APC wiper park position
11 + APC front power take-off 11 Start-up controls
12 +APC J04 12 + AVC LH cab top ventil.

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

Black J248 Grey

1 + AVC socket 25 A 1 3 5 7 9 11 1 + AVC inside front work lights


2 + AVC socket 25 A 2 4 6 8 10 12 2 —
3 Instrument panel fan control 3 —
4 + AVC ventilation controls PDB J03 4 —
5 Hydraulic pressure 5 + AVC outside front work lights
6 Hydraulic pressure manometer 1 3 5 7 9 11 6 + P panel
7 +APC rear wiper 2 4 6 8 10 12 7 RH rear light
8 +APC TCE (RH + relayed) 8 Side light indicator
9 +APC transmission J05 9 RH front light
10 D + alternator 10 + AVC rear lower work lights
11 + APC RH brake light 1 3 5 7 9 11
11 —
12 Electric pump 2 4 6 8 10 12 12 —

J114

1 3 5 7 9 11
Red Blue

1 + AVC Outside rear work lights controls 1 —


2 Rear work light ctrl 2 Start-up
3 + AVC inside rear work lights 605msm38 3 Earth
4 — 4 Starter safety
5 Reverser relay ctrl engaged (not neutral) 5 Instrument panel lighting
6 Shuttle reverser 6 LH rear light
7 + APC IP indicators 7 Flashing unit
8 Reverser engaged 8 LH front light
9 +APC wiper stalk switch 9 TA steering
10 Rear stop 10 Hazard light switch
11 + APC timer 11 Trailer 1 steering
12 Rear stop 12 Trailer 2 steering

F1.10 Ares 806 – 09.2004 – GB


Ares 806 – 09.2004 – GB F1.11
Starting / charging / preheating circuit (DE10 engine) Ref Item
Wire 2 JX1 Ending
24 Engine ECU markers
30 Battery
EOA M3G 324 300 31 Alternator
32 Starter 3 007 0.35 Preheating indicator P08 B2
E3D 34 Preheating resistance 8 108 0.35 D+ alternator 130
60 Key operated ignition
30 110 Fuse box 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
117 Preheating fuse
068 067 066 065 136 061 108 106 064 063 111 007 062
302 304 130 Diode
32 185 Instrument panel
M3A

226 Preheating relay


RG

NO Battery under lateral exhaust pipe


M P02 P16
31 B+ B+ W D+ V S A

117 J01 30 E0A 1


604msm01
2 1 P01 226
30 J39 J01
J39 70A 34
+ – P02
1 2 Wire 2
303

31 E3D J218 Ending


markers
P16
J16
226 J31 A2 308 1 + APC engine calculator P02 B
VE J1 341 1 Preheating indicator P02 V
K1 323 1 + AVC engine calculator P02 G
32 K3 316 1 Preheating control J16 A
BC A
OR
P16 K J H G F E D C B A
316 355 326 333 352 338 3
J16 344 308
34 337 M3H 308 343 354 2
323 341 340 339 331 332 1
K3 316
24 J218
A2 308
24 J218

K
J1 341 606hsm1A

J
H
G
F
K1 323

E
D
012

C
001

B
A
004

1 2 3
303
604hsm42
C G V B
P02
J08 130
J02 J15
P08
J131
130
013 J04
004

179
073 JX1
J59 178
B2 JX2 J09
B2 4 1 J114
J08 J25
190

P08 P25
J25
2 1 4 8 12 E0A
J114 J15 J04 58 15/54 19 17/50a 30
J11
007
108

P01
II J02
110 III
I
29b /25A R13 0
8 3
+ AVC
JX1 P
+ AVC
4/15A
+ APC 60
185 15/15A 5 606hsm1B

605hsm03

F1.12 Ares 806 – 09.2004 – GB


Starting / charging / preheating circuit (VP44 engine) Ref Item
Wire 2 JX1 Ending
24 Engine ECU markers
30 Battery
EOA M3G 324 300 31 Alternator
32 Starter 3 007 0.35 Preheating indicator J224 4
34 Preheating resistance 8 108 0.35 D+ alternator 130
E3D
60 Key operated ignition
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
30 110 Fuse box
117 Preheating fuse 068 067 066 065 136 061 108 106 064 063 111 007 062
302 304 130 Diode
32 137 Diesel electric pump
M3A

185 Instrument panel


RG 226 Preheating relay
241 Safety relay
NO
M A Battery under lateral exhaust pipe
31 B+ B+ W D+ V S
1
117 J01 604msm01
A P02 P16
2 1 P01
+ –
J39 70A Wire 2 J218 Ending
1 2 markers
303

30 226 J39
J01
34 19 427 1 + APC ECU J222 A7
BC 137 34 30 22 407 1 Electric pump supply E4A
OR
23 415 2 +AVC (constant source) J222 A2
31 J16 35 419 1 + AVC switched J216 5
P16
J16 62 413 1 Safety relay J216 1
VE 32 63 418 1 Preheating controls J217 1
A P217 66 409 1 Preheating indicator control P224 4
J213 68 416 1 +AVC (constant source) J222 B2
P16 J217
226 356 A B 416 68

M3OD
24 J16 45
372 23 415
359

J218 1 18 12
P217
66 23 68 19 62 35 22 63 418 J217 7 E3H
303

606hsm5K
407

001
419

420 J214
E4A
413
427
415

416

E0A 24
A7
B2 417
409

B1 3 1 2 5
A2
J216
414 A1 B7 604hsm0Z
426 J222
J08
C 4 1 2 J15 P08
P02 P224 J224
012 J04
J02 J224
241 004 JX1
4 1
013

082 J59
B2 J25
190

081 P25 J114


1 12 1 2 4
130
J15 J04 J114 58 15/54 19 17/50a 30
108

007

110
+ AVC II
30/10A III
I P01
0
8 3 + APC
15/15A
JX1 P
29b /25A R13
+ AVC 60
185
606hsm5L
605hsm29

Ares 806 – 09.2004 – GB F1.13


Dipped headlights - Headlights - Horn - Side lights - Instrument panel light Ref Item
Wire 2 JX2 Ending
2 RH dipped beam / headlamps markers
3 2 3 LH dipped beam / headlamps
E3C 4 RH side light
M M3D M3E M 5 LH side light 11 019 0,35 Headlights indicator J07 A2
10 RH rear side light 26 022 0,35 Instrument panel light J09 B5
J18 E3B J19 R 11 LH rear side light 30 M0M 0,35 Instrument panel earth J13 B6
C R 313 315 C
312 314 12a Police plate RH lighting
12b Police plate LH lighting 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
E3A 31 Alternator
J13
M3C
042 083 043 019 044 105 104 059 113 M0T M0A
173 65 Lighting switch
80 Clock M0M 075 074 022 072 071 070 069 109 091 107 054 110 060
5 A6 B6 A7 A5 4 81 Trailer signalling socket
M3B

M3A 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16

MOM
MOH MOG Cigar lighter

MOK
86
M3B
M3C 110 Fuse box
M3I 173 Horn
M3K B+ W D+ 185 Instrument panel
185
31 EOA
306

+
310

311

021

+ –

020
1
JX2 J09
11 26 30 B5 B4 A6 B7 16
090 604msm02
J12/A4 J247
022 J248 J21
J03 J133

096
J05 J23
W X JX2 J09
J114
J01 J07 P44
F P01 7 M26/10A J12 E0A
P02 9 J13
J02 J05
6 M14/10A R15 P01 E0B J120
8 86
J02
016

014

015

017

018

019

J33 J28
1
+ AVC J03 J43
B3 A1 A5 A4 A2
3 5 J27
J07 606hsm1C E6A
+ AVC J121
M25/10A 606hsm1R
5
8 J114 A Battery under lateral exhaust pipe
65 6
30 49 58 56b 56a 54s 54d L 110
115

116

A P02
JA JB E0A
80
137

J63 J01
J95
J247 J65 P02
21 20 5 511 31
1
514

J246 P247
J27 P246
A5 B3 J65 P247 E3B
J63 E0A E3A
B1 B4 A2 B2 A3 B5 A5 B3 A1
J107 E3C
601 J19
605 J43
J18
609 173
86 A3 A2 B3 A1 A6 606hsm1D
603

606

602
604
608
607

M6G
M6C

P52 E6A
M6L
M6D

606hsm1Y
M6E

A D 2 1 2 1 A D
J32
J120 J33 J28 J121 E6A
5 7

11 81 12b M6G 12a 10


605hsm04

F1.14 Ares 806 – 09.2004 – GB


Rotating beacons Ref Item
1 RH rotating beacon
1a LH rotating beacon
52 Rotating beacon switch
110 Fuse box
1 1A E5A
J62
P62
J101 J95
JA JB
2 1 1 2 J95
M50HH J95
J62
556 P62
M5FF

J101
550

P247

606hsm2D
A7 B7
P62
J62 E0A
M5H
517

E5A

6
P247
606msm1Z
J247

J15

J247
093

102
J23
5 6 9
J13
B3 A7
10 MOQ MOK
1 E0A

J23 E0A
52 J13
7 2 8

110

092 16
5
J15 + APC
10A
606hsm1E

605hsm05

Ares 806 – 09.2004 – GB F1.15


Front work lights Ref Item
6 Outside RH front work light J96
J97
6a Inside RH front work light
7 7a 6a 6 7 Outside LH front work light J99
7a Inside LH front work light J100
6 16 Outside RH front work light J62 P62
17 Inside RH front work light
45 Front work light contact
J96 J97 J99 J100 110 Fuse box
2 1 2 1 1 2 1 2 222 Front work lights relay
M5XX
16 17 606msm31
562
M5BB
552 E0A
J152 J153

M5AA
M5EE

553

551
A B A B
M3M P02 J62E5A
334

335

J60 JA JB P62
A6 A5 B1 A1
M3N
P62 J95
W X J62 P52
P02 J153
EOE M5E
J02
J02 J170 J57 E0A
J152
E5A M5A
171

170

J107
169 J62 J172
222 E0B
45 2 E5E

M5LL 2 1 590 B1 P172


J172
1 P52
606msm0F
5 2 506
3 B4 606hsm1N
4
3 B5 595
A3
J170 J57
C1 M5I
504

500

A2
516
J60
J52
E5E B6 B4
M5CC

+ M5G

6 1 4 J05
P52
J07
J52 J07
A5
MOJ
015

133

126

E0A
8 1 5

J05 EOA
E0B
13/10A

12/10A

110 J02

P172
R15
R1

606hsm1F

EOR

+ AVC
605hsm06

F1.16 Ares 806 – 09.2004 – GB


Rear work lights Ref Item
8 Outside RH rear work light J106
8a Inside RH rear work light J109
+ AVC 8b RH rear wing work light
P61
110 R2 11/20A 9 Outside LH rear work lights J105
9a Inside RH rear work light
9b LH rear wing work light
46 Rear work light switch J103
110 Fuse box J102
223 Rear work lights relay
223a Rear work lights relay (wings) 606hsm2E
R15
R9
J248 J05
3 1 2 8 10 E5A
EOA
J60 JA JB
+ P151 J61
J63
9 J95
137 A6
MOJ
134
127

128
095
J09 +
P52
J168
4 9 3 2 19 5 J169 J56
J63 J60 E5B
P247 E0A
J52 J247
P52 P247 A5 B4 B4 B6 A3 8 J107
511
507 606hsm1S
M5G J62
M5CC
E5E J151
223a
503

544

M5J
P52
606hsm2A
M5JJ 2 1 546 B1
E5E
1
540 5 2 J56
3 B4
J168
505 A5 3 B5 J52
223 J247
M5KK 2 549 598
1 C1 J248
Diode 46
5
3
548 J05
596 J09
E5B
J169

539 E0A
597

E5A M5F
M5NN
B3 B1 A1 A3
J61 J109
P61
M5D

578 B7 B6 B5 B2 B1 B3
577
4 3 576
J151 M5FF
P151 M5VV
4 3 579
587

586

606hsm1G
M5DD
M6N
M6M

M6M
653
654

M5UU
2 1 2 1 1 2 1 2
J106 J105 J103 J102

9b 8b 9 9a 8a 8

605hsm07

Ares 806 – 09.2004 – GB F1.17


Stop lights - Front axle engagement - Air brake system solenoid valve control Ref Item
Wire 2 J32 Ending
10 RH rear side light markers
11 LH rear side light
FPS 832 P80 10 710 81 Trailer signalling socket
101 4-wheel drive solenoid valve 3 M6F 2 Trailer socket earth J43 A5
835 11 711 6 611 1 Trailer brake lights J27 A7
110 Fuse box
874 28 728 184 Transmission electronic central unit
J136 B1 A7 B5 B C A 203a RH brake pedal switch
234 32 203b LH brake pedal switch
P138 270 Air brake solenoid valve
35 618 4
+APC J80 J138
A1 B7 A5 5 606 M6F 3 3

32b
33
31
2
7 4
Wire

880

881

882
2
J1 Ending 602 5
855

7
13 36 12 E7G M1 markers 6 611 2 1 6

32
4 615

MA
BU
B2 1
LH stop

8021
J1

M8Q
9 810 0,75 P20 13
H G K A 19 816 0,75 RH brake light P20 12 604msm5E
J67 J45
184 D
A3 5 1
845 J225 E7C
J2 190
814 20 29 6 M25 J2
810

816
J1
25 36
2
13 12 1 2 836 835 831 830 889 827 M8L 841 834 80008001
P20
P20 P999 J89 24 892 8008 818 809 877 816 896 814 812 811 897 876 13
1 875 866 865 861 815 817 819 810 885 869 870
604hsm64

J20 J999 270 101 1 12 J2


184
+APC +APC J1
Wire 2 J2 Ending
J68
J68 markers P999 J80
19 / 15A

110 E7A
22 / 15A

B3 A6 M8E 31 J80 M7B 3 825 0,75 4-wheel drive solenoid valve J80 6 606hsm1T
825 6 706
M8J

32
3
R14 35 P44
J23 P80
8021

M8Q

M7H
MA
BU
184 2 1 1 2 25 36
J120
M8G M8H 839 805 856 852 813 837 878 851 806 807
J248 J04 J1 J225 J89 24 850 804 803 802 801 864 808 874 832 8022M8S 13 J999
604hsm65
867 868 825 826 822 823 821 871 884 872 862 824
12 10 11 9 19
810

816

1 12
023 J43 J32
025

J27
132

027

13 12 1 2 E6A
P20 P999 J121
J999 J246 606hsm1U
J20
203b 203a 270 101 J20
024
J225
M6P

026 P80
19
J246 E7A
J27 J43
P246
A6 B7 B6 A7 660 B5 A6 A5 B3 A1
M6C

610
M6L
613

612

611

A
J89
M6G 203
J04
E6A
M6F
C D D C J248

J120 J121
J32
6 3 606hsm2F

11 81 10 606hsm1H
605hsm08

F1.18 Ares 806 – 09.2004 – GB


Flashing lights and warning lights Ref Item
Wire 2 J32 Ending
4a RH front flashing light markers
5a LH front flashing light
+ AVC + APC 10a RH rear flashing light
11a LH rear flashing light 1 615 1 Trailer LH flashing light J35 A2
22 Buzzer 3 M6F 2 Trailer socket earth J43 A5
110 49 Warning light switch 4 618 1 Trailer RH flashing light J35 B2
65 Lighting switch
6 221 1 81 Trailer signalling socket
23 110 Fuse box
15A 185 Instrument panel 618 4
221 Flashing unit
5 606 M6F 3 3
7 4
2 5
602 7
6 611 2 1 6
25
t 10A 615
1
604msm5E
4 5 2 3

7 9 11 12 3 10 8 2 12 9 P246 Wire 2 J114 Ending


markers
J114 J15 J05 J13
M01

J120 3 M01 1,4 Panel EOR


7 031 1,4 Flashing unit J10 A1
A1 A6 A5 A7
028
029

8 021 1 LH front light 5a


030
042
043
044

MOG
MOH

MOK
9 080 0,6 Buzzer J246 9
020 J43 10 030 1,4 Hazard warning lights control J21 6
J32
J35 Trailer 1 steering
031

EOR 021 11 043 0,35 JX2 12


E6A 12 044 0,35 Trailer 2 steering JX2 10
12 10 MOC
2 8 5 J21 10 J121
JX2 EOA 606hsm1V
5a 4a

11
T R1 R2

9
7
J10

5
11 9 7 5 3 1

3
080

1
A1 043 042 031 096 MO1 004
185
044 030 021 115 190 012
A7 039 6 3 1 49
12 10 8 6 4 2 604hsm16
B1 033
A2 032
B7 040
22
J15
B3 035
036 J246
A5
J21
080 9 659
P246
J05
B5 037 18 614 A1 JX2
B4 034 J114
M60

J07
B6 041 17 617 B1
A6 038 J246
E0A
619 B3 J13

B4 B1 B2 J32 B4
4 618 B2 A5 J10
J07 81
3 1 615 A2
M6L B3
616 A3
65 M6G A6
30 49 58 56b 56a 54s 54d L
J35 A1
M6F
M6C

11a B
J43 606hsm1J
B
J120 10a J121 E6A
D D
605hsm09

Ares 806 – 09.2004 – GB F1.19


Cigar lighter - Clock - Radio - Cab light and spot Ref Item
Wire 2 JB Ending
13 Cab light - contact + light markers
60 Ignition switch
79 Car-radio
83 84 80 Clock 3 529 0,6 + Right-hand loudspeaker P54 2
79 83 LH loudspeaker 4 521 0,6 - RH loudspeaker P54 1
84 RH loudspeaker 5 527 0,6 + Left-hand loudspeaker P55 2
P54 JA P55 86 Cigar lighter 6 528 0,6 - LH loudspeaker P55 1
JB
110 Fuse box
1 2 529 8 7 4 3 4 5 6 528 1 2 208 RH door cab light contact
521 527 209 LH door cab light contact
1 3 5 7

13 3 Wire 2 YL Ending
529 527
86 markers 521 528
209 208 2 4 6 8
4 538 1 +AVC radio J63 B2 604msm81
7 525 1 + P radio J63 A7
8 M5K 1 Radio earth J60 B1

J36 209
1 3 5 7 P55
3 1 JA JB
M5N

J60

M6J
523 522 4 2 J64 525
B2 J63 J95
538 M5K
A5 J60
J43 2 4 6 8 604msm80 P52 208
M5L

519

525

538
A1 P247
2

M6C
Wire J65 E0A
B3 B4 B1 A6 B2 J65 Ending P54
markers
M5O J107
M5K E6A 1 514 0,6 Clock lighting J63 B3
2 526 1 + P clock J63 A6 J62
M5G
3 520 0,6 + AVC clock J63 B1 JB
4 M5M 0,6 Clock earth J60 B3 J64
208 JA
P52 E6A
J63 606hsm2B
621

A6 B1 B3 A5 A1 B2 A2 B7 A7 J247
1 2 3 4 5 J52
538

514 526 520 M5M J44


1
2
3
4
511

518

5
524

J25
2 4 5 7 P44
9
P52 P247 P44 EOA
J52 J247 J44
137
MOJ
M5M

526

520

514

J36

+ 110
14 / 10A
4 2 3 1 118 1
E0A 130 3 J03 J43
J65 2 / 5A +AVC
129 10
J15 E6A 606hsm1W 606hsm1K

80 60 P 58 10 010 6
25 / 10A
0 I
J25 J05
15/54

19
II
17/50a
III
30 1 001
P25 +AVC
605hsm10

F1.20 Ares 806 – 09.2004 – GB


Pneumatic seat - Front power take off clutch Ref Item
40 Front PTO contactor
94 Front PTO solenoid valve
+ APC 110 Fuse box
123 Pneumatic seat engine and contact
185 Instrument panel

110
10A

17

185 J15
J41
11 9

JX2
20
94

J43
131

120

U E6A
091

J02

606hsm1X

086
J15
7 8 5

J44
J44
P44
631

630

JX2
J43
633

M6I B1

1 5 1 2

J94 J41

A1 J02

40 123
M6C

M
606hsm1L
E6A

605hsm11

Ares 806 – 09.2004 – GB F1.21


Front and rear windscreen wiper / washer Ref Item
Wire 2 J104 Ending
21 Rear windscreen wiper markers
66 Windscreen wiper / washer control
92 85 Windscreen wiper timer
92 Front screen wiper 1 M5Q 1 Rear windscreen wiper J60 B7
5 559 Rear windscreen wiper
96 Front windscreen washer pump 2 502 1 P247 1
2 557 96a 96 96a Rear windscreen washer pump 3 599 1 Rear windscreen washer P247 9
110 Fuse box
M J98 558
1
M M
4 M5PP Wire 2 J11 Ending
1 2
1
markers M5Q 502

2
B2 B3 A3 A2
599
J200 J22 1 M0F 1,4 Windscreen wiper timer E0A
P62
2 052 1 Windscreen washer control J06 B4 3
21 J62 3 1 M3P 1 3 3 051 1 Intermit. windscreen wiper ctrl J06 B3 604msm90
J60 4 049 1 Windscr. wiper eng. park. pos. J247 3

M3K
5 047 1 +APC windscreen wiper timer J248 11

320
+ -
M 6 050 1 Windscr. wiper ctrl park. pos. J06 B2 J98
B7 B4 A7 M5P
C1

509

508

510
M5Q

L1 J62
M5G E0A
JA JB P62
J104 J60
338 J95
1 1 P52
1 2 3 4 5 6 1
2
3 3 599 3
4
M0F 052 051 049 047 050 5
6
604msm14
P247 E0A
2 2 502
P54
J107
J104 4 5 1 9 3 4 W H Wire 2 J98 Ending
J62
P52 P247 P02 markers
J52 J247 J02
+APC windscreen wiper park P52 606hsm2C
1 558 1 P62 A3
pos.
MOJ

182
2 557 1 Windscreen wiper fixed stop P62 B3 A - Battery under lateral exhaust pipe
4 M5PP 1 Windscreen wiper earth P62 B2
5 559 1 Windscreen wipers P62 A2 P02 P16
A

MOF
E0A
3 2 1

+APC 557 558

559 M5
094

049

PP
110 E0A 85
6 5 4
J22
J200

3
2
27 / 10A

1
10 135 J11
J03
4 5 3 2 6 1 94
604msm2B
18 / 10A
7 094
J04
J52
J247
051
052

050

048

28 / 10A
053

11 047
J248 9 046
J04
606hsm1P
J248 J06
J03
A1 B4 B3 B2 B1
E0A
J06
J11
J02
LAV A 1 AF 2
2 1 0

B + 66
605hsm12 606hsm1M

F1.22 Ares 806 – 09.2004 – GB


Notes Notes

Ares 806 – 09.2004 – GB F1.23


Instrument panel ventilation and air conditioning

M M
91 93
M5C

+ APC + AVC
110

J111 J110
- + - +
1 3 4 2 1 3 4 2

5 / 20A

3 / 20A

1 / 20A

575
573
E0A
119

M5WW

M5TT
A5 585
R5 R7 R4 R6

571

570
A6
J112 J113
A2
90 J109 A7 A1 A3 584 A C B A B

M5YY
M

582

581

580

583
574

572
6 4 3 1 5 2 A3 B1 A1 B3 B2
1 4 2 3 P108 P107
J04 J15 J03 J108 J107
J17
4 3 12 4 8 6 2 12

M5W
M5C

M5T
532

531

534

533
148

139

M5Y
MOO
MOK

536

535

530

537
009
M5B
B5
J60
087

089

E6A E5A 8 7 11 10 13 12 8 14 B6
J13
P52 P247 P247
A7 B5 MON

M5CC
J52 J247 J247
147
146
088

143

142

141

145
144
138
140 2 1
J09 E5E
B7 090 J50
0 0 R = 1 kW 70
A4 A5 A2 A1 B5 B1 B4 B2
1 330 W 77 N
B4 2 520 W J02
J12 3 750 W
D 4 820 W
5 P02
820 W
6 95 210
096

A 318 317
J34

P P
BP HP
+
605hsm13

HP: High pressure - BP: Low pressure

F1.24 Ares 806 – 09.2004 – GB


Instrument panel ventilation and air conditioning
J111 119
Ref Item
Wire 2 J111 Ending
70 Ventilation/air conditioning switch markers J112
77 Temperature potentiometer J109 P107
90 Electric fan J113
91 Air conditioning LH fan 1 M5WW 3 LH fan earth P108 6 P61
93 Air conditioning RH fan 2 573 0,6 LH fan potentiometer cursor J109 A2 J110
95 Compressor 3 571 3 + LH fan P108 3 E5A
110 Fuse box 4 575 0,6 LH potentiometer fan J109 A6
119 Cooling thermostat
210 Pressure switch J60 JA JB P108
J107 606hsm2H
Wire 2 J17 Ending M5 573 2 1
J61
J63
markers 1 WW J95
3
3 571 575 4
1 M00 3 Ventilation earth E0A 2 J108
2 139 0,6 IP potentiometer cursor J12 A1 J107
3 009 3 + AVC ventilation controls PDB J04 4 4 604msm4C P52
4 148 0,6 Instrument panel potentiometer J12 A2 P247
Wire 2 J112 Ending J62
markers
1 M0O 139 2

3 009 148 4 1 A 582 1 +12 V thermostat P107 A3


3 B 580 1 Temperature potentiometer P107 A1 E0A
C 581 1 Temperature potentiometer P107 B1
2

4 604msm19

C B A
Wire 2 J110 Ending 581 580 582
markers P52
CB 606hsm2J
A
1 M5TT 3 RH fan earth P108 4 604msm5C
E6A
2 584 0,6 RH fan potentiometer cursor J109 A3
3 570 3 + RH fan P108 1 Wire 2 J113 Ending
Instrument panel potentiometer markers
4 585 0,6 J109 A5
RH fan potentiometer
606hsm2G
A 583 1 Pressure switch P107 B3
B M5YY 1 Thermostat earth P107 B2

M5 584 2 1
1
TT
J08
3 P08
3 570 585 4 B A
M5 583 J52
2
YY J247
4 604msm3C B
A
604msm6C

P02 P16 J15


A
J04
J50 J09
E0A
J03
J17
E0A
P02 J13

J02
J34

94

606hsm2K

210
606hsm5H
A - Battery under lateral exhaust pipe

Ares 806 – 09.2004 – GB F1.25


INFOTRAC on-board computer / ISO socket

864
+APC 8012
P20
110 TCE 15/25/35 19
J20
069 22
071 24 JX2 185
R10
124 J131 FPS J42 J04 J13 JX2
19 / 15A B6 9 B2 22
9 A7 A6 155
J04 8 121 J178

MOR
155

069
6 13 B5
10
J44 J246 J119 P20
J178
14
P44 P246 B1 P119 J20
J119 14 3 6
184
P119

632

637

855
640

644

651
184
J1
A2

855
A1/B4
J178 15 A1 B2 B3
J2 J1 B6 P42 920 42
J71 182 P48 B2

808
19 18 10 J42 J67
B5
651
B1 B2
J48
644
864

808

885

J67 857
B4

640
B1 B5

8011
B1 A2 J136 B2 B3 A1 859 B4 J136
47

8011
P48 B2 B7 B4
J207 J207
J48 9
8018 1
B2 A3 A1
857 J207 J207 3 8012
8019 10
8018 9 1
8013 4
8019 10 265
3 8012 J68
8013 4 B3 M8K 2
265
J68 B7 2
M80

838
856
864
842
A1 J207
M8K 7 8 12 6 11 5
838
888
886

887

B4 A1

M8A
M8K
7 8 12 6 11 5
J207

8016
8017
8020
8015

8014
M8L
A1 A3 B1 B2 B3
8016
8017
8020
8015

8014
M8P
M8A

J134
A1 A3 B1 B2 B3
P134 E6A
E1 F1.51 J134
NO1 F1.55
186 J148 E6A 1 2 6 4 7 3
P134 1 2 6 4 7 3
1 VI
NO3

J208 J208
7 BC
140 P208 P208
6 VE
MA

RG
OR
NO

RG1
JA
VI

11 RG2
28 1 2 6 4 7 3
10 NO4 NO2 B
2 BU J219
J147 T˚
5 MA A
264
605hsm14

F1.26 Ares 806 – 09.2004 – GB


INFOTRAC on-board computer / ISO socket

Ref Item J246 J44


Wire 2 J148 Ending J15 J20
28 Outside temperature probe markers
110 Fuse box J04 J119
140 Events counter
182 Lift central unit (TCE) 1 VI 0,6 Trip computer tractor speed P134 A1
184 Transmission central unit (UCE) 2 BL 0,6 Counter 140
185 Instrument panel 5 BR 0,6 Outside air temperature probe J147 A
186 On board computer Trip computer lift up position JX2
ISO socket 6 GN 0,6 P134 B1
264 TCE
265 ISO socket unit 7 WH 0,6 Trip computer radar speed P134 A3
8 RG1 0,6 +APC trip computer TCE P134 B2
10 NO4 0,6 On-board computer earth E1
Wire 2 JX2 Ending 11 RG2 0,6 +APC trip computer TCE P134 B2
markers
14 13 12 11 10 9 8 7 6 5 4 3 2 1
22 069 0,35 Rear power take-off speed J20 19 RG2 NO4 RG1 BC VE MA BU VI
24 071 0,35 Real speed (radar) J246 13

14
13
12
11
10
9
8
7
6
5
4
3
2
1
1 606hsm2L
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
042 083 043 019 044 105 104 059 113 M0T M0A 16 604msm1T
604msm02
M0M 075 074 022 072 071 070 069 109 091 107 054 110 060

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16

J208
J147 J147
J134
Wire 2 J1 Ending
P208
P20
markers J219
J148
10 885 0,75 Up position TCE J136 A2 E6A J119

1 12

J2
184 P208
J1
25 36
J136
836 835 831 830 889 827 M8L 841 834 80008001 J68 J67
24 892 8008 818 809 877 816 896 814 812 811 897 876 13 P134 140
604hsm64
J207
875 866 865 861 815 817 819 810 885 869 870
606hsm2M
1 12

Wire 2 J2 Ending
606hsm5J
markers P44
Colour legend
18 808 0,75 Forward speed J136 B1
19 864 0,75 Rear PTO speed (TDB) P20 19 WH White
J71
BL Blue
YL Yellow
BR Brown
BK Black
OR Orange P42
GN Green
25 36 VI Purple
M8G M8H 839 805 856 852 813 837 878 851 806 807 RD Red J42
J178
24 850 804 803 802 801 864 808 874 832 8022M8S 13
604hsm65
867 868 825 826 822 823 821 871 884 872 862 824

1 12
P48
606hsm2N 606hsm2S

Ares 806 – 09.2004 – GB F1.27


Fuel gauge - Engine temperature - Oil pressure - Air filter blocked Ref Item
Wire 2 JX2 Ending
31 Alternator markers
185 Instrument panel
31 200 Engine oil pressure switch
201 Engine water temperature thermistor 1 M0A 0,35 Fuel level J119 1
202 Fuel gauge 2 M0T 0,35 Engine water temperature P08 B3
206 Oil filter clogging indicator 16 060 0,35 Fuel level J20 17
17 110 0,35 Engine water temperature P08 A4
201 202
Wire 2 JX1 Ending
FPS markers

4 111 0,35 Air filter blocked P08 A5


B6
– + 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
7 106 0,35 Engine oil pressure P08 B1 042 083 043 019 044 105 104 059 113 M0T M0A
1

M0M 075 074 022 072 071 070 069 109 091 107 054 110 060 16
3 2 1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
604msm02
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
31
068 067 066 065 136 061 108 106 064 063 111 007 062
D+

M3A
D+ W B+
22 21 20 J31
P180 1 2
M3J

M3I
J180
150 P20
472

471

470

1
604msm01

J08
P08
22 21 20

M3F

M7J
307

723
J179 206 200
307 J31
1 J20 JX1
EMR J80
J119
JX2
333

319

305

J174 606hsm2U

15
M L K T 23 34
401

K
P02 P02 P80
J02 J02 J80
P175
J175 J02
A1
MOB
191

058

057

056

854

M8I
606hsm2T P02
E0E 31
057

B1 A5 B1 A4 B3 17 1 J31
202
J08 J08 P20 P119
P08 P08 J20 J119
94

P80

206 200
MOA
MOT
111

106

110

060

4 7 17 2 16 1
606hsm2W
JX1 JX2

606hsm2V

185

605hsm15

F1.28 Ares 806 – 09.2004 – GB


Handbrake Ref Item
185 Instrument panel
204 Handbrake switch
J43 214 Brake fluid level contact
2 1
J196 P44
A1 A7

M6C

M6H
204

MOU
214

E6A
B1

J13 J43

A7
E6A

185
MOK

204

606hsm2X

E0A
J08
P08
620

J246
J44
16 A1 JX1
P246 J08
J246 P08
JX2
136
059

E0A
J13

214
5 10

JX2 JX1

185

606hsm2Y

605hsm16

Ares 806 – 09.2004 – GB F1.29


Engine speed Ref Item A - Battery under lateral exhaust pipe
31 Alternator
185 Instrument panel

31
P02 P16
A

P02

31

D+ 309 W B+

J
P02
J02
055

606hsm1Z

A2 P08 J08
J08
P08

JX2
109

21

JX2
J02

185

605hsm17 606hsm3A

F1.30 Ares 806 – 09.2004 – GB


Instrument panel calibration - Diagnostic socket instrument panel and TCE 15T Ref Item
Wire 2 J186 Ending
66 Windscreen wiper / washer control markers
67 Instrument panel calibration switch
262 110 Fuse box
182 TCE (Lift central unit ) 17 925 0,6 Transport mode indicator J187 A6
191 182 185 Instrument panel
J13 P14
191 Lift electronic unit (TCE calculator) 13 12 11 10 9 8 7 6 5 4 3 2 1
262 Diagnostic plug 919 929 920 928 927 930 926 904
A7 B7 B6 A3 A2 B D C A
J71 J186 922 931 925 M9F 938 923

25 24 23 22 21 20 19 18 17 16 15 14
MOD
7 11 17 Wire 2 P14 Ending
J187 markers

925
924
25
24
23

A5 A6 A 085 1 Line L J246 2


22
21
20
19

Diagnostic socket earth


18

B M0D 1 J13 A2 17
16
15

Line K
14

C 084 1 J246 3
A7 D 076 1 +APC diagnostic socket J09 A1

+ APC
+ AVC 604msm0N
MOK

076

084

085
FPS
110
J71 J187

917

916
A B C D
7 A7 D J15
5A 5A 085 M0D 084 076 C
B
7 21 A J246

917

916
J44
J248
E0A B7 A7 B7 A7
604msm50 JX1
J15 J248 P42 P42 C D J06
7 7
J42 J42 D
C JX2 J09
84 076
B
A
MOM

MOE
MOL

J174
604msm50
099

E0A
639

638

639

638
10 11 J13
67 J09

405

404
A1
A3 2 3 2 3 B3 B2
A2 P246 P246 P175
J246 J246 J175
67 P14
084
085
065

066

177

176
074
075
072

JX1 JX1 J14 J14


065

066

606hsm3B
11 12 A C
054

A5 A4 18 30 25 29 28 11 12 P44

J06 JX2 JX1

185 J71

J186
J186 J71
A B
P42 J42
J42
66

606hsm3C 606hsm3D

605hsm18

Ares 806 – 09.2004 – GB F1.31


Electropilot/DRIVETRONIC/GTA 103-202/GPA 40 diagnostic socket Ref Item
142 RH electrohydraulic spool valve
143 LH electrohydraulic spool valve
F1.42 F1.42 184 Transmission electronic central unit
F1.46 F1.46 255 Joystick - Solenoid pilot
263 CAN network socket
142 143 143 142 263 184
J193 J194 J194 J193 Wire 2 J199 Ending
3 2 3 2 2 3 3 2 P133 J1 J237 markers

2 1 35 34 39 40 6 9005 0,6 CAN-High P190 2


10 9004 0,6 CAN-Low P190 1

880

881

8001

8000

8024

8023
7
3 11
1 9010 15
J199
9002 9013
9006 9011 9016
9014
1 2 9007 9012 9018
941

945

942

946

952

948

947

951
9017 M9X
2 16
J234 9004
9005 9015
1 10
6 14 604msm7S
J236 2
J192 J87 P190
A2 A6 B2 B6 B6 B2 A2 A6 Wire 2 J1 Ending
606hsm3E

J235 markers

1 2 1 2 34 8000 0,75 CAN-High J234 2


B1 B7 A1 A7 B7 B1 A1 A7 CAN-Low

8026

8025
35 8001 0,75 J234 1
J231
1
J233 2
J190
943

947

940

944

P189
J232 J189

1 2
953

949

946

950

25 36

836 835 831 830 889 827 M8L 841 834 80008001
J87
604hsm64
24 892 8008 818 809 877 816 896 814 812 811 897 876 13

875 866 865 861 815 817 819 810 885 869 870
606hsm3F
1 12
8006

8005
948
954

2 1 3 3 2 1 1 2 3 1 2 3
J235 J234
J190 J189 J190 P189 J236
P190 P189 P190 J189 P133
J237

J231 J233
9004

9004
9005

9005

J232
6 10 10 6

J199 J199 184


P199
P199 P199 J188
J1

255 606hsm3G

F1.42
F1.46
605hsm19

F1.32 Ares 806 – 09.2004 – GB


Electropilot/FPS diagnostic socket Ref Item
142 RH electrohydraulic spool valve
143 LH electrohydraulic spool valve
F1.42 184 Transmission electronic central unit
190 190 TC transmission ECU
F1.46 255 Joystick - Solenoid pilot
263 CAN network socket
143 142
J194 J193 D
2 3 3 2
Wire 2 J199 Ending
A G markers

32
E7G 6 9005 0,6 CAN-High P190 2
CAN-Low

31
10 9004 0,6 P190 1

32b
P138 3
7
11 J199
9010
J138 1
9002 9013
15

9006 9011 9016


B A 9014
9007 9012 9018

728

710
9017 M9X
2 9004 16
9005 9015
28 10 10
952

948

947

951
6 14
604msm7S
P80
J80 P190
Wire 2 J1 Ending
606hsm5M

J87 263 184 markers


B6 B2 A2 A6
36 881 0,75 CAN-Low J188 B7
P133 J1
1 12

B7 B1 A1 A7 3 36

881

874

832
873

J190
P189
J189
J188 25 36

B4 B7 B5 B1 839 813 M8H 805 806 807 829 881

804 833 862 M8J 808 880 13


604hsm78
867 868 802 840 836 815 837 830 8023 882 J87
953

949

946

950

1 12
B6 B2 B3
606hsm5N
8006

8005

8007

954

1 2 3 1 2 3
J190 P189
P190 J189 P133
9004

9005

10 6
184
J199
P199 J188
J1

255 606hsm5P
F1.42
F1.46
605hsm71

Ares 806 – 09.2004 – GB F1.33


25 A power socket Ref Item
82 25 A power socket
110 Fuse box
+ AVC
P44

110
25A

J04
82
1 2

E6A
117

119

606hsm3H

J15
1 3
J04
J44
P44 J44
623

622

M6A

M6B

82 E6A

605hsm21
606hsm3J

F1.34 Ares 806 – 09.2004 – GB


Transmission hydraulic pressure - Oil filter blocked (HP) - Oil filter blocked (suction) Ref Item P80
110 Fuse box P80
115 Gearbox oil pressure switch
127 Rear axle oil pressure switch E7A
131 Diode
185
FPS 184
185
Transmission electronic central unit
Instrument panel
199 Oil filter clogging indicator
+ APC

A
JX1 180 Wire 2 J201
markers
J1 Ending
110 6 064
6 2
1 867 0,75 Transmission display data J137 B2
R12 158 2 868 0,75 Transmission display clock J137 B4
J04 J150 5 840 0,75 Transmission oil filter P20 3 606hsm3K
12 882 0,75 CAN - J188 A5
5 125 062 B1 B3 21 833 0,75 Hydraulic pressure P20 4

8103

8102
36 881 CAN-Low J188 B7
J20 0,75

16 11 3
P20
E6A 3 4 P137
J20 J137 P20
P20 867 B2 B4 25 36

868 836 835 831 830 889 827 M8L 841 834 80008001
863
M8A

840
833 24 892 8008 818 809 877 816 896 814 812 811 897 876 13

881 B7 B5 875 866 865 861 815 817 819 810 885 869 870

A1 1 12 604hsm64
882 A5 A7
J68 131 184
B2 B1 J68 131
J1
894
842

A6 A7
J188 J80

832

835

874
5 21 1 2 36 12 606hsm3L
833

834

33 J1
10 11 28
J1
J80
184 P80
M8E
M8F

184 J15
710

711

728
A C B J04
P189
P138 J20
31 36 3 25 4
F1.33 J138 JX1

J80 J05
P80
32b
31

33

M7B
E7G
704

34
M7F 35
32

E0A
A K G J
M7K

1 2
D J91
703

E7K 199 114


E7A 199 190
M7E

J87
J87
E
725

2 1
43
J202 2 1 J B J A
38
115
M27

127 M26 44
37

P
J201 M21
E7C
M11

P M1
M7R 128 127 115
606hsm3M

605hsm26

Ares 806 – 09.2004 – GB F1.35


Theoretical speed Ref Item
Wire 2 J2 Ending
37 Displacement speed sensor markers
184 Transmission electronic central unit
1 185 Instrument panel
18 808 0,75 Forward speed J136 B1
37 J82 2 Wire 2 J1 Ending
markers
25 36
28 830 0,75 + Forward speed sensor J80 12

M7N

712
31 M8L 0,75 Frequency earth J80 15 M8G M8H 839 805 856 852 813 837 878 851 806 807

24 850 804 803 802 801 864 808 874 832 8022M8S 13

867 868 825 826 822 823 821 871 884 872 862 824

1 12 604hsm65

25 36

836 835 831 830 889 827 M8L 841 834 80008001
M7A

24 892 8008 818 809 877 816 896 814 812 811 897 876 13

FPS 875 866 865 861 815 817 819 810 885 869 870

1 12 604hsm64

P80 P80 P20


J80 J80
15 12 13 12
186
ha / h
M8L

830
829 km
830

31 28 34 10 15
J148
J1 J1
1

J2

VI
184 184 184
A1
J2 P134 J1
808

J134 J136
18
808

838
J136
B1
J136
606hsm3N
B1
B3
B2

B3
828

828

8013

J20
14 14 4 P80
P20 P20 JX2
J20 J20
J207
070

23
J82
JX2
E7C

185 606hsm3R 606hsm3P

605hsm27

F1.36 Ares 806 – 09.2004 – GB


Instrument panel - Rear power take-off speed Ref Item
Wire 2 J2 Ending
39 Rear power take-off speed sensor markers
42 ECO rear PTO contact
54 Rear PTO selection contact
19 864 0,6 Rear PTO speed (IP) P20 19
FPS 184
185
Transmission electronic central unit
Instrument panel
+ APC 185
JX2
22
Wire 2 J1 Ending 25 36
813

069

markers M8G M8H 839 805 856 852 813 837 878 851 806 807

24 850 804 803 802 801 864 808 874 832 8022M8S 13
JX2 8 819 0,75 ECO PTO contact 42
A1 867 868 825 826 822 823 821 871 884 872 862 824
18 896 0,75 1 000 rpm PTO 54
J67 J20 22 30 827 0,75 + Rear PTO speed sensor J80 14
1 12 604hsm65

P20 31 M8L 0,75 Frequency earth J80 15


+ APC

069
B5 6
25 36

836 835 831 830 889 827 M8L 841 834 80008001
14 19
879

845

24 892 8008 818 809 877 816 896 814 812 811 897 876 13
J119 J20 J20
875 866 865 861 815 817 819 810 885 869 870
P119 P20
1 12
JX2

J80
P80
25 16 190
725

716

B E

855
604hsm64
J G H D
J138 39
P138 1
H K
P163 B2
42b
R01 J162 J67 606hsm3S

B6 A7
AC1

E7B 42a
E7E
39a

AC11
P20
42

895

849
R05

864
E7C
AC12 M22
E7D
1 2 3 1 2

J81 M1 J84
54 42

29 39

J2
896

819

184

J1
J67
J80
1 714 14 827

39 J84 M7P M7A M8L


2 15 31 30 18 8 19
E7C P80
606hsm3T

J1 J2

184
605hsm28

Ares 806 – 09.2004 – GB F1.37


TCE 15T Lift

8 108 110
185 130
JX1 C P02 013 149 10 R10
J02

303
121 8
31 J04 20 / 10A
B+ B+ W D+
19 / 15A
+ APC
124 9

+ –

A7
121
J131
A5

098
8019
J136
10
J178 J44
P44 A3 J207
A6 B6 A7 B7 B5 A5 B4 6 4 A1 A2
632

857

885

886
634 236
237 235 100 99
644
10
J48 J134 J73 J74 J75 J72 J76
J35 J1

652
P48 P134 A B C 3 2 1 1 2 3 2 1 1 2
A1 B1
B6 B7 B5 A6 A7 A5

VE
184

M9N

M9K
640

M9L
969

970

966

965

967

968

971

961

960

962
6
627
624

J148

J42 P69
186
645
646

P42
629
647
628

648

625

626

J69
A2 A3 A1 A6 B6 B2 14
3 1 2 10 11 12 7 6 5 8 4 9 902* 902
J192
E6A

933

906

907

910

911

935

934

909

908

914

912

913

915
F1.41
939

M9A
J187
J29 A B J40 A B
B3 A1 B5 B7

A B A B B6
J70
B1 B2 A2 B4
B6 A3 A6 A7 B3

M9F
920

923

57b 56b B7

M9E
936
14 16

902*
J186 B5

919 A2
8
182
J37 A B J26 A B 6 922 B2
4 7 3 1 2 5 18 15 19
A1 B4 A5 B1
949 J192

918

932

937

921
A B A B
F1.41
938 1 15 19 18 17 14 13 6 2 5
24
57a 56a 931 21
928 8
926 J71
4
904 3
930 22
929 9
927 16
905 191
12
903
25
901 20
900 10
605hsm30

F1.38 Ares 806 – 09.2004 – GB


TCE 15T Lift

Ref Item
Wire 2 J71 Ending
Wire 2 J148 Ending
31 Alternator markers markers
56a Lift RH external switch
56b Lift LH external switch
57a Lift lower RH external switch 1 M9E 1 TCE earth J187 A2 6 GN 0,6 Up position TCE (trip computer) P134 B1
57b Lift lower LH external switch 2 921 1 V + upwards valve - light J70 B1
99 UP solenoid valve 3 904 0,6 V REF 1,6 V J186 1 14 13 12 11 10 9 8 7 6 5 4 3 2 1

100 DOWN solenoid valve 4 926 0,6 Mixed check control J186 2 RG2 NO4 RG1 BC VE MA BU VI

110 Fuse box 5 949* 0,6 +APC (RH+ relayed) J192 A5


130 Diode 5 902** 1 +APC (RH+ relayed) P42 A1
182 Lift central unit (TCE) 6 937 0,6 Return - V lift /Lower valves J70 A5

14
Mode selector

13
184 Transmission electronic central unit 8 928 0,6 J186 5

12
11
Instrument panel 9 929 0,6 Diagnostic indicator J186 7

10
185

9
On board computer 10 900 0,6 Rise - lift ctrl P42 A2

8
186

7
12 905 0,6 V REF 9,5 V J187 B1

6
191 Lift electronic unit (TCE calculator)

5
V REF posit. / RH and LH force

4
235 LH draft sensor 13 932 0,6 J70 B4

3
2
RH draft sensor

1
236
237 TCE position sensor 14 918 1 V + down valve - light J70 A1
15 936 0,6 V REF posit. / RH and LH force J187 B4 604msm1T
16 927 0,6 Depth control J186 4 Colour legend
17 909 0,6 LH draft signal J69 6
Wire 2 JX1 Ending 18 911 0,6 RH draft signal J69 11 WH White
markers 19 907 0,6 Position signal J69 2 BL Blue
20 901 0,6 Lower - lift ctrl P42 A3 BR Brown
8 108 0,35 D + alternator 130 21 931 0,6 Transport mode ctrl J186 18 BK Black
22 930 0,6 Position ctrl (upper stop) J186 3
24 938 0,6 Lower speed control J186 15 OR Orange
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 25 903 1 +APC lift unit P42 A6 GN Green
068 067 066 065 136 061 108 106 064 063 111 007 062 VI Purple
* TCE 15T with electrohydraulic spool valves
RD Red
** TCE 15T without electrohydraulic spool valves

13 12 11 10 9 8 7 6 5 4 3 2 1 Wire 2 J186 Ending


932 905 924 900 929 928 917 937 902 926 904 921 M9E
markers
903 938 930 931 901 907 911 909 927 936 918

25 24 23 22 21 20 19 18 17 16 15 14 1 904 0,6 V REF 1,6 V J71 3


1 2 926 0,6 Mixed check control J71 4
604msm01 3 930 0,6 Position ctrl J71 22
13 12 11 10 9 8 7 6 5 4 3 2 1 4 927 0,6 Depth control J71 16
932 905 924 900 929 928 917 937 949 926 904 921 M9E 5 928 0,6 Mode selector J71 8
6 920 0,6 Lift up position P42 B6
Wire 2 J1 Ending
903 938 930 931 901 907 911 909 927 936 918
7 929 0,6 Diagnostic indicator J71 9
markers 25 24 23 22 21 20 19 18 17 16 15 14 8 919 0,6 Down valve indicator J70 A2
14 923 0,6 V REF 9,5 V J187 B2
10 885 0,75 TCE lift high position J136 A2 15 938 0,6 Lower speed control J71 24
25
16 M9F 1 Unit earth J187 A2
24
23
22
18 931 0,6 Transport mode ctrl J71 21
25 36 21
20
19 19 922 0,6 Up valve indicator J70 B2
18
836 835 831 830 889 827 M8L 841 834 80008001 17
16
15
24 892 8008 818 809 877 816 896 814 812 811 897 876 13 14
13 12 11 10 9 8 7 6 5 4 3 2 1
875 866 865 861 815 817 819 810 885 869 870
919 929 920 928 927 930 926 904
1 12

922 931 925 M9F 938 923

25 24 23 22 21 20 19 18 17 16 15 14

604msm9M

25
24
23
22
21
20
19
18
604hsm64 17
16
15
14

604msm0N

Ares 806 – 09.2004 – GB F1.39


TCE 15T Lift
A - Battery under lateral exhaust pipe
P16
A P02 J15
J04 130
J131
30 J134
P02 J44
J05
31 JX1

94

184
J1
J136
J02
J48
606hsm3U 606hsm3X

P44 606hsm3Z

P69

J194
J178 J42 J193

J35

P48 J204

J37 J26
606hsm3Y
606hsm3V

P134
J71

J186
J186
J71
J187
P42
J42

J69 J192 J70


E6A
606hsm4A

606hsm3W

F1.40 Ares 806 – 09.2004 – GB


Notes Notes

Ares 806 – 09.2004 – GB F1.41


Electropilot (with TCE 15T)

110

149 10 R10 144 142 143 255


31
F1.38 J04
8 P199
20 / 10A J204 J193 J194
+ APC J199
121

1 2 2 3 4 1 4 1 3 2 6 10 1 2 3 5 7 8 9 11 12 13 16 15 14

M9Q
M9R

M9P
979

975

974
E9C

978
J44
P44

973

977
M90
972
9015 A1
6 J197
J178
632

9016 A5
E9B

976
B4 A4
31 32 33 37 29 28 27
P69 A2
A5 P197
634

J69
B1

J42 F1.75
B5
P42

945

941

950

942

946
A1
902

E6A M9A M9H

9006

9007

9002

9017

9010

9011

9012

9013

9014

9018

9001

9009
9008
M9Y
M9X
M9G A3 A6 A2 B5 J192 B2 B6

949 A5
A1 A3 J71
J187 F1.38 191 B4
A2
951
952

B7 B1 A1 A7
J186 J71
947

943

940

944
182 191 948

3 1 2 1 2 3 3 2 1
F1.38 J191 J190 J189

P191 P190
F1.32
F1.33 263
9005
9004
9000

9003
M9Z

17 12 1 9 10 3 11 7 5 6 13 16 19 8 18 2 14 15

J198

141
605hsm31

F1.42 Ares 806 – 09.2004 – GB


Electropilot (with TCE 15T) J147

Ref Item
Wire 2 J198 Ending
31 Alternator markers
110 Fuse box
141 Electrohydraulic spool valve control unit
142 RH electrohydraulic spool valve 1 9000 1 + Hydraul. engine ctrl P191 2 P69
143 LH electrohydraulic spool valve 2 9001 0,6 +APC cross control J197 A2
3 9002 0,6 +APC joystick J199 3 J204
144 Safety solenoid valve
182 Lift central unit (TCE) 5 9011 0,6 Joystick on/off control J199 8
191 Lift electronic unit 6 9012 0,6 LED output on / off J199 9
255 Joystick - Solenoid pilot 7 9010 0,6 Hydraul. motor ctrl (on) J199 7
263 CAN network socket 8 9011 0,6 Hydraul. motor ctrl (off) J199 16
9 9012 0,6 Pot. X J199 1 J194
10 9004 0,6 Pot. X J199 2 J193
11 9013 0,6 Safety SV (on) J199 5
Wire 2 J199 Ending 12 9014 1 Safety SV (off) P191 1
markers 13 M9X 0,6 Raise extension command J199 11
14 9008 0,6 Lower outside ctrl return J197 B1
1 9006 0,6 Pot. X J198 9 15 9009 0,6 Lower outside ctrl return J197 B5 P134
2 9007 0,6 Pot. X J198 10 16 9014 0,6 Raise extension command J199 12
3 9002 0,6 +APC joystick J198 3 17 M9Z 1 Electro./ dist. ctrl module earth P191 3
5 9017 0,6 Safety SV (on) J198 11 18 M9Y 0,6 Cross control earth J197 A4
6 9005 0,6 CAN-High P190 2 19 M9X 0,6 Joystick earth J199 13
7 9010 0,6 Hydraul. engine ctrl (on) J198 7
8 9011 0,6 Joystick on/off control J198 5 606hsm4C
9 9012 0,6 LED output on / off J198 6 1 5 9 13 17
P20 606hsm4D
10 9004 0,6 CAN-Low P190 1
11 9013 0,6 Raise extension command J198 13 9000 9011 9006 9013 M9Z
12 9014 0,6 Raise extension command J198 16 9001 9012 9007 9008 M9Y
4

Joystick earth
5
13 M9X 0,6 J198 19 3 9
13
Relay output 1
6
14 9015 0,6 J197 A1 9002 9010 9017 9009 M9X 2 10
14
17

+APC radar (RH + relayed)


7
15 9016 0,6 J197 A5 1 11 18
9018 9003 9014
Hydraul. motor ctrl (off)
15
16 9018 0,6 J198 8 8
12 19 P44
16
4 8 12 16 20 20
604msm6S

7
3 11
1 9010 15
9002 9013
9006 9011 9016 J15 J40
9014
9007 9012 9018 J04
J44
9017 M9X J29
2 16
9004 J178 J42
9005 9015
10 604msm7S J05
6 14
J35

P48

Wire 2 J189 Ending J37 J26


markers 606hsm4E

1 944 0,6 CAN-Low, Control J192 A7


2 940 0,6 CAN-High, Control J192 A1
3 948 0,6 CAN - J190 3

606hsm4B
4
2
954 946
3 J71
950
1 J186
J186
604msm1M J71
J187 P42
J42

J69
J192 J70
E6A

606hsm4F

Ares 806 – 09.2004 – GB F1.43


Lift TCE - 15/25/35/ radar

31

+ –
B+
B+ 110
W 130
D + 303 P02 C 013 149 10 R10
J02 P79
1
8
J04 20 / 10A 3
9 + APC 33 2
124
P119 19 / 15A J79
27 839 15 4 9 / 15A
184 J2 123 + AVC 186
1
J15 30 / 10A
103 J148 TCE 35 TCE 35
J131 A7
J119 6 237 236 235 99 122 121 100
121

VE
B1 J73 J74 J75 J76 J77 J78 J72

121
A5 185
P134 3 21 3 21 3 21 1 2 1 2 1 2 1 2
108 8
J134

963ou 968 *
964ou 969 *
068 14 JX1
067 13

886
098

M9M

969
970
976

966

965

977

968
967
978

960

962

972

974

973
975

961
971
071 24 J136 A3
104 6 JX2
J178 105 7
A1 A2 17 16 18 1 2 3 10 11 12 5 6 7 9 14 15 20 22 21 4 8
6 4 2 13 12 15 14 11
A6 B6 A7 B7 A5 A1 B4 A2 J44 J246 P69

857

885
P44 P246 J69
637
632 A1 10

M9G
656

907
J48

911
924

906

908

909

934

913
915

926

928

927

929

912

914
955 * ou 925

933

910

935
634 J1
P48
J35 184
652

655

649
635
636
650
J71
656
15 23 19 17 24 21 16 51 20 5 29 33 1 32 28 6 2
B6 B7 B5 A6 A7 A5
640
627
624

B4
645
646

629
647
628
648

625

626

J42
P42
A2 A3 A6 A1 B1 A5 B2 B5 B6 B3
924 J71 182
920 42
922 13
J29 A B J40 A B
919 41
918 40
A B A B 921 12
901 37
900 38 J71 J71 49
31 30 47 34 7 3 4 52 45
P192
902

917
916

M9E

M9F
57b 56b 958
959 1 261 M9G M9I

936

930

931
2 932
904 E9A

M9A
903
J37 A B J26 A B 923 P125
905
925 V2 U1 PE4
A B A B TCE 35
A6 B1 B2 A1 A7 A5 B4 A3 B7 E6A
J70 260
57a 56a
605hsm32

955*/959*/969*: Version with Electropilot

F1.44 Ares 806 – 09.2004 – GB


Lift TCE - 15/25/35/ radar
J15
J04 J246 J131
Ref Item
Wire 2 P192 Ending
J44
31 Alternator markers JX1
33 Radar
56a Lift RH external switch J119
56b Lift LH external switch 1 958 0,6 Programming CAN-Low P42 B5 JX2
57a Lift lower RH external switch 2 959 0,6 Programming CAN-High P42 A5
57b Lift lower LH external switch
99 Half-up
4
100 DOWN solenoid valve
110 Fuse box 2
130 Diode 959
121 UP solenoid valve (semi-mounted) 3
958
122 DOWN solenoid valve (semi-mounted) J02
1
182 Lift central unit (TCE) 604msm6M
184 Transmission UCE
185 Instrument panel
186 On board computer Wire 2 J71 Ending
606hsm4G
235 LH draft sensor markers A - Battery under lateral exhaust pipe
236 RH draft sensor
237 TCE position sensor 1 928 0,75 V + lowering valve 1/2 J69 20 P02
260 Implement socket 2 914 0,75 V + lowering valve J69 8 A J134
261 TCE programming socket 3 M9E 1,4 TCE earth E9A
4 M9F 1,4 TCE earth E9A
Wire 2 J1 Ending
5 913 0,75 V + raising valve J69 9
markers 6 912 0,75 V - lowering valve J69 4 31
7 905 0,6 +APC TCE lighting J70 A3 P20
10 885 0,75 Up position TCE J136 A2 12 921 0,6 CAN-High return P42 A5
13 922 0,6 CAN-Low return P42 B5
15 906 0,6 V REF. rear position J69 1
16 908 0,6 V REF. LH draft J69 5
25 36
17 910 0,6 V REF RH draft J69 10
19 933 0,6 V - rear position J69 3 J1 J136
836 835 831 830 889 827 M8L 841 834 80008001 20 934 0,6 V - LH rear draft J69 7
24 892 8008 818 809 877 816 896 814 812 811 897 876 13 21 935 0,6 V - RH rear draft J69 12 J48
875 866 865 861 815 817 819 810 885 869 870 23 907 0,6 Rear position signal J69 2 606hsm4H 606hsm4J
24 911 0,6 RH draft signal J69 11
1 12
V + raising valve 1/2
604hsm64
28 929 0,75 J69 21
29 915 0,75 V + raising valve J69 14
Wire 2 J148 Ending 30 904 1,4 +AVC TCE J70 A1
markers 31 932 1,4 +AVC TCE J70 B2
32 927 0,75 V - up valve 1/2 J69 22 P44
6 GN 0,6 Up position TCE (trip computer) P134 B1 33 926 0,75 V - down valve 1/2 J69 15
34 923 0,6 +APC TCE J70 A5
37 901 0,6 Rear lowering ext ctrl P42 A3
38 900 0,6 Rear raising ext ctrl P42 A2
14
13

40 918 0,6 CAN-High network P42 B2 P69


12
11
10

CAN-Low network
9

41 919 0,6 P42 B4


8
7

TCE lift high position J178 J42


6

42 920 0,6 P42 B6


5

J77
4

Implement position VREF


3

45 931 0,6 P125 PE4


2

14 13 12 11 10 9 8 7 6 5 4 3 2 1
1

RG2 NO4 RG1 BC VE MA BU VI


604msm1T
47 903 0,6 + APC TCE (D + RELAY) J70 A7 J35
49 936 0,6 V - implement position P125 V2 P48
51 909 0,6 LH draft signal J69 6 J77
Wire 2 P125 Ending
52 930 0,6 Implement position signal P125 U1
markers J37 J26 606hsm4K 606hsm4L

U1 930 0,6 Implement position signal J71 52


V2 936 0,6 V - implement position J71 49
PE4 931 0,6 Implement position VREF J71 45
J71
J148
J198
P42
U1 PE4
930 931
J71
936
E9A P192
V2 W3
J70 P42

604msm5M 604msm9L P134


J69 P125
E6A

606msm16 606hsm4N

Ares 806 – 09.2004 – GB F1.45


Electropilot (with TCE 15/25/35)

142 143 144

J173 J193 J194 J204


33
D C A B E F 3 2 1 4 4 1 2 3 2 1

M9Q
M9P

996
995
2 3 1
E9C
P79 255

E9B
M9R
J79

M9M

M90
P199
969
968

987

986

984

985

988

989

991

990

994

992

993

997
J199
6 10 1 2 3 5 7 8 9 11 12 13 16 15 14
17 16 18 24 23 13 19 25 26 33 32 29 37 27 28 31 9015 A1
J197
110 P69 9016 A5
J69
M9Y A4
124 9 19 / 15A
J04 + APC

M9H
M9G

9001 A2
924

943

942

938

937

944

945

947

951

956

952
948
955

A7 9008 B1

J131 9009 B5 P197


F1.75
A5
098

A2 A6 B5 B6 B2
4 J178 26 18 35 36 22 J87
J44
P44 J71 182
A5 A1

9006
9007
9002
9017
9010
9011
9012
9013

9014

9018
B4

M9X
47 34 7
652

634

656

9005
9004
A5 A3 B7 B1 A1 A7

953
949

946

950
J42
P42 954

957
960
M9G

A6 A1 B3 1 2 3 3 2 1
M9H
J190 J189
E9A
P190
916

902

3 2 1
263 J191
M9A

903 F1.32
9004
9005

923 F1.33 P191


905
E6A

9000
9003
M9Z
A6 A7 A5 B4 A3 M9J

B5
J70 B7 925
17 1 12 9 10 3 11 7 5 6 13 16 19 8 18 2 14 15
J198

141
605hsm33

F1.46 Ares 806 – 09.2004 – GB


Electropilot (with TCE 15/25/35)

Ref Item
Wire 2 J199 Ending
33 Radar markers
110 Fuse box J04
141 Electrohydraulic spool valve control unit
142 RH electrohydraulic spool valve 1 9006 0,6 Pot. X J198 9
143 LH electrohydraulic spool valve 2 9007 0,6 Pot. Y J198 10 P69
3 9002 0,6 +APC joystick J198 3 J72
144 Safety solenoid valve J77
182 Lift central unit (TCE) 5 9017 0,6 Safety SV (on) J198 11 J76 J131
255 Joystick - Solenoid pilot 6 9005 0,6 CAN-High P190 2
7 9010 0,6 Hydraul. motor ctrl (on) J198 7 J44
263 CAN network socket
8 9011 0,6 Joystick on/off control J198 5 J194 J78 J173
LED output on / off
Wire 2 J198 Ending
9
10
9012
9004
0,6
0,6 CAN-Low
J198
P190 1
6 J193
markers 11 9013 0,6 Raise extension command J198 13 J79
12 9014 0,6 Raise extension command J198 16 J75
1 9000 1 +APC remote control module P191 2 13 M9X 0,6 Joystick earth J198 19
2 9001 0,6 +APC cross control J197 A2 14 9015 0,6 Relay output 1 J197 A1
3 9002 0,6 +APC joystick J199 3 15 9016 0,6 APC radar (D + relayed) J197 A5 J74 J73
5 9011 0,6 Joystick on/off control J199 8 16 9018 0,6 Hydraul. motor ctrl (off) J198 8
6 9012 0,6 LED output on / off J199 9
7 9010 0,6 Hydraul. motor ctrl (on) J199 7
8 9018 0,6 Hydraul. motor ctrl (off) J199 16 7
3 11
9 9006 0,6 Pot. X J199 1 1 9010 15
10 9007 0,6 Pot. Y J199 2 9002 9013
J74 606hsm4P
9006 9011 9016
11 9017 0,6 Safety SV (on) J199 5 9014
12 9003 1 Safety SV (off) P191 1 9007 9012 9018
606hsm5R
13 9013 0,6 Raise extension command J199 11 2
9017
9004
M9X
16
14 9008 0,6 Lift outside ctrl return J197 B1 9005 9015
15 9009 0,6 Lower outside ctrl return J197 B5 6
10
14
16 9014 0,6 Raise extension command J199 12 604msm7S
17 M9Z 1 Electro./ dist. ctrl module earth P191 3
18 M9Y 0,6 Cross control earth J197 A4 Wire 2 J71 Ending P44
19 M9X 0,6 Joystick earth J199 13 markers
J134
7 905 0,6 APC TCE lighting J70 A3
18 942* 0,6 VREF front position J69 23
22 944* 0,6 V - forward position J69 25 J40 82 40
1 5 9 13 17 26 943* 0,6 Front position signal J69 24
34 923 0,6 +APC TCE J70 A5 J29
J178 J42
4
9000 9011 9006 9013 M9Z
3
5
9 35 938* 0,6 Front lower outside ctrl J69 13
Front rise outside ctrl
13
9001 9012 9007 9008 M9Y 2
6
10 17
36 937* 0,6 J69 19 J35
7 14
18
47 903 0,6 + APC TCE (D + RELAY) J70 A7 P48
9002 9010 9017 9009 M9X 1 11
15
8
12 19
* TCE 35 with electrohydraulic spool valves only 184
9018 9003 9014 16
20
** TCE 35 only
604msm6S J37 J26 J1
4 8 12 16 20
J136

Wire 2 J189 Ending


markers 25
24
23
22 606hsm4S
21
20
1 950 0,6 CAN-low transmission control J187 A7 19
18
606hsm4R
17
2 946 0,6 CAN-high transmission control J187 A1 16
15
3 954 0,6 CAN - J190 3 14

4
2
948 940
3 J71 J198
944
604msm9M
1
P42
604msm2N
J71

P192 J190
E9A
J189 J70 P42
J191
J87 P134
J69
P125
E6A

606hsm4U
606hsm4T

Ares 806 – 09.2004 – GB F1.47


GTA 103/202 - GPA 40 clutch and drive control

110 160
J131 B6 188
+APC 19 / 15A AV N
180 J04 9 124 A7 B7 1
187 55a
AR R
A6
29B / 25A D2 D1 2
Ve 1 004 2 3 1
867 26 726 1 J25 4
P80 R13
J116 +AVC 29A / 25A J114 J59 J124
2 012 J245
832 10 710 190 P01 V 161
192 4
2 B3 A2 A4 B2 B5 B4 B1 A B C 3 2
150
868 27 727 1

153
154
MOP MOW
874 30 730 2
J117 B4
193 190
+AVC 9 / 15A 4 J13
164
820 J15
E8C 167
1 701 E7A 717 A 48 A7

MOK
8022 2 702 B J149 8
P150 R11
J150 J248 6 MOS
6 5 7 10 9 8 5 156
EOA
823 5 705 1 Bc
8106
8105
8107

8110
8109
8108

J90
J80 31 M7B M7I 2

MOA
107

157

123
155

162

159

154
153
97
P137 E7A 166

168
J137 J20
6 5 7 10 9 8 862 21 113 1 3 2 12 15 14 1 13
4 19 1
860
806
805

872
884
871

47 J119 J20
P20 J130
47 JX2 P119 P20
1 7 8 6 10 9 5
860

870
869

845
865
844
877
878

883

890
876
839
855
185 P 189
878
841
35 28 10 9 8 1 15 2 16 6 11 14 33 27
J67
J2 B4 859
B2 855
A2 829

184 B1 853
861

839
876
877
J1 870
1 3 5 4 11 12 20 13 32 869
865

J136

841
861

829
866 B7 B6 844 M8M
875 A7 A6 845 B5 A5 A1 B3 B2 B1

M8M
J49 P49
B5
M8E A6 A1 M8A 8 7 6 5 3 4 2 1
-
J68
63
E6A
+

605hsm34

F1.48 Ares 806 – 09.2004 – GB


GTA 103/202 - GPA 40 clutch and drive control
Wire 2 JX2 Ending
Wire 2 J59 Ending
markers markers
Ref Item
47 Crawler speed contact 1 M0A 0,35 Fuel level J119 1 A2 153 0,6 Forward drive control J20 8
55a Clutch switch 4 113 0,35 Outside buzzer J20 21 A4 154 0,6 Reverse drive control J20 7
63 ISC declutching +/- range control 19 107 0,35 Reverser engaged J248 8
97 High / crawler range solenoid valve B1 150 1,4 + APC N relay contact J131 B7
110 Fuse box 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B2 159 0,6 Neutral control J20 1
180 Transmission display B2 190 0,6 Starter safety J114 4
042 083 043 019 044 105 104 059 113
184 Transmission electronic central unit
M0T M0A
B3 162 0,6 Declutching control J119 13
185 Instrument panel M0M 075 074 022 072 071 070 069 109 091 107 054 110 060 B4 156 1,4 Reverser relay ctrl engaged J248 5
187 Clutch potentiometer B5 M0P 0,6 Reverser relay J13 B4
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
188 Hydraulic shuttle reverser control
189 Bottom of clutch contact
1 2 3 4 5
192 Reverse drive solenoid valve
193 Forward drive solenoid valve A 153 154

B 150 159
190
162 156 M0P

Wire 2 J1 Ending Wire 2


markers markers
J2 Ending 1

1
A

2
16
1 875 0,75 Potentiometer (REF+) J136 A7

4
604msm02
1 867 0,75 Forward drive solenoid valve J80 26 B

5
3 866 0,75 Potentiometer (REF-) J136 B7 2 868 0,75 Reverse drive solenoid valve J80 27
4 865 0,75 Clutch pot. cursor P20 10 6 823 0,75 Range solenoid valve J80 5
5 861 0,75 Crawler speed contact 47 Forward drive indicator light
11 869 0,75 Buzzer P20 8
8
9
871
884
0,75
0,75 Neutral light
J137
J137
8
9
Wire 2 J49 Ending
604hsm15
12 870 0,75 Reversing control P20 7 10 872 0,75 Reverse drive indicator light J137 10 markers
13 876 0,75 Neutral control P20 1 11 862 0,75 Buzzer P20 21
20 877 0,75 Info clutched P20 5 Neutral Reverser declutching ctrl
32 841 0,6 Range J49 B2
14
15
8022
832
0,75
0,75 Forward drive - SV return
J80
J80
2
10
A1
A5
883
890
0,6
0,6 Neutral
P119
P20
13
1
Wire 2 J130 Ending
16 874 0,75 Reverse drive - SV return J80 30 B1 829 0,6 +APC range change J67 A2 markers
27 839 1,5 + AVC DRIVETRONIC P119 15 B2 841 0,6 Range change J80 2
25 36 28 805 0,75 Crawler range light J137 5 B3 853 0,6 +APC +/- range control J67 B1 1 157 1,4 Not neutral J248 5
33 878 1,5 + APC solenoid valve supply P119 12 B5 M8M 0,6 Declutching ctrl earth J68 B5 2 168 1,4 +APC solenoid valve supply J119 12
836 835 831 830 889 827 M8L 841 834 80008001
35 806 0,75 Rapid range light J137 6
24 892 8008 818 809 877 816 896 814 812 811 897 876 13

875 866 865 861 815 817 819 810 885 869 870 1 2 3 4 5
25 36 A 883 811 812
890
1 12 8003 8004
M8G M8H 839 805 856 852 813 837 878 851 806 807 B 829 841 853 M8M 1 2 3
1
24 13 157 168 2
850 804 803 802 801 864 808 874 832 8022M8S 3

867 868 825 826 822 823 821 871 884 872 862 824 604hsm21

1
1 12 A

4
B

5
604msm2j

604hsm64

604hsm65

Ares 806 – 09.2004 – GB F1.49


GTA 103/202 clutch and drive control
J15 J131
J04
J248
J20

P80 J119

JX2
P80 J114

J93 E7A J59


P80
J13

J132

A
J124
J90 187
48 J130
55a
J92 J245

606hsm4V

606hsm4X

J137
P20

J47
J49

J150 J119

J150

J137
J195

J2
P137 184

J1
J136
J68 J67
J80

606hsm4W

606hsm4Y

F1.50 Ares 806 – 09.2004 – GB


Automatic hand brake Ref Item
68
110
Park lock control
Fuse box
Wire 2 J143 Ending
markers
+ APC + AVC 184 Transmission electronic central unit
68
1 186 0,6 Park lock control J119 4
5 122 0,6 + APC Park Lock J131 B5
110

19/15A

19/15A
7 5 3 1
J143 J137 122 186

1 5
J04 J15
8 6 4 2
9 4 3

124
122 9
E6A 604hsm30
B5 A7
186

J236 P119
A6 J131 J237
Wire 2 J237 Ending
123 markers
155

J119 7 8041 1 Park Lock IN (sol. valve) J80 28


8 8040 1 Park Lock OFF (sol. valve) J80 16
P119 10 8035 0,6 Park Lock IN light J137 22
J68
14 4 15 11 8036 0,6 Park Lock use light J137 13
855

20 8043 0,6 Park Lock disengaged J80 24


B2 28 M8R 1 Auto 5 earth J68 A5
29 8029 1 +AVC auto 5 P119 15
J67 34 8034 0,6 Park lock control P119 4
8029 29 606hsm6W 35 8042 0,6 Park Lock IN light J80 18
39 8024 0,6 CAN-Low J236 1
A5 8034 34 40 8023 0,6 CAN-High J236 2
8040 8
1 29
8027

8028 42
8043 20
E8C
8041 7 J237
8042 35
8024 39
8023 40
184
8035 10
8036 11
J1 604hsm75
28
35 34
M8R
8001

8000

J15
8041

8042

22 13
820

1 2 A5 J04 J08
J137
P137 A1 M8A
M8E J234
1 J224
16 31 28 18 1 24
A6
8133
8134

J236 J68 E6A


J80 2
P80
22 14
J235
732

M7B

733

734

701

735

J150
1 2
8026

8025

E7A E7D J143


M7S

M7D

716

715

J233
1 2 2 1 1 2 2 1 F1.32

J95 J94 J151 J150


606hsm6V
605hsm46

Ares 806 – 09.2004 – GB F1.51


FPS clutch and drive control

32 G
A 21
K
EOA D B 22
110 160
A C 23 J131 B6 188
E 25
+APC 19 / 15A AV N
J04 9 124 A7 B7 187 55a
E 190 C F 26 1
E G 27 AR R
D 24 A6
H 28 29B / 25A D2 D1 2
B 1 004 J25 2 3 1
B J 29
R13 4

150
+AVC 29A / 25A J114 J59 J124
2 012 J245
A 1
P01 161
K J H G F E C B A 4 V B3 A2 A4 B2 B5 B4 B1 A B C 3 2
1 2
C
1 MOP MOW
2
B4
2 190
3 A +AVC 9 / 15A
1 4 J13
5 J15
6 2 A7

MOK
7 B 8
1
8 R11
10

9
J248 6 MOS
2 EOA
H

164

167
5 156

123
155
162

153

154

159
J20

107
166

157
2 1 2 1 2 1 2 1 2 1 168
809 21 113
4 19 1 3 2 12 15 14 13
P20 J119 J20
JX2 J130
P119 P20
R 2 1 M L 9 8 7 1 10 5

877
865
869
220B

870

876
878
8023
806
839
855
887
185 P 189

8108
PS1 G P138 724 P80 24

+
220C

220A 47 J188
45 E 714 14 861 M8D
31 A 710 10 832
7 2 24 1 36 19 26 21
8105

884
8106 8107 33 C 711 11 835
J67 B2
32b B 728 28 874 J2 B6 883
8104 J138 J80
E6A A1
A2 B1 853
184
P137 892
J137 B5 A7 B1 B3 B2 B1

813
A5 B1 A1 B5 B2 P189 J1 J49
J188 P49
12 36 26 25 29 11
893

B7 A5 B3
F1.30 5 3 4 2 1
-
J49 J49 882
881 63
A4 A2
+

605hsm39

F1.52 Ares 806 – 09.2004 – GB


FPS clutch and drive control
Wire 2 J59 Ending
markers
Ref Item
47 Crawler speed contact A2 153 0,6 Forward drive control J20 8
55a Clutch switch Reverse drive control
A4 154 0,6 J20 7
63 ISC declutching +/- range control
110 Fuse box
184 Transmission electronic central unit B1 150 1,4 +APC neutral relay contact J131 B7
185 Instrument panel B2 159 0,6 Neutral control J20 1
187 Clutch potentiometer B2 190 0,6 Starter safety J114 4
188 Hydraulic shuttle reverser control B3 162 0,6 +APC Forward/reverse control J119 A7
189 Bottom of clutch contact B4 156 1,4 Reverser relay ctrl engaged J248 5
190 TC transmission ECU B5 M0P 0,6 ISC controls J13 B4

1 2 3 4 5

2
A 153 154
Wire 2 J1 Ending
Wire
J2 Ending B 150 159 162 156 M0P
markers markers 190

11 8023 0,6 +APC EVP P119 12 1 876 0,75 Neutral control P20 1
12 882 0,75 CAN - J188 A5 2 869 0,75 Declutching information P20 8

1
+APC B + solenoid valve 7 809 0,75 RH brake light P20 21 A

2
25 839 1,5 P119 15
26 813 1,5 +APC electronic unit J67 A1 19 877 0,75 Clutch position P20 5

4
B
Functional fault

5
29 806 0,75 Gearbox engaged P119 9 21 887 0,75 P119 13
36 881 0,75 CAN-Low J188 B7 24 870 0,75 Reversing control P20 7
26 884 0,75 Power ratio J49 B2
25 36
36 865 0,75 Clutch cursor pot P20 10 604hsm15

839 813 M8H 805 806 807 829 881


25 36
24 804 833 862 M8J 808 880 13
801 884 811 843 810 M8G 821 824 865
Wire 2 J130 Ending
867 868 802 840 836 815 837 830 8023 882 markers
24 870 819 812 887 814 877 822 825 875 13
1 12
876 869 817 818 863 816 809 823 826 866 1 157 1,4 Not neutral J248 5
1 12 2 168 1,4 +APC solenoid valve supply J119 12

1 2 3
1
157 168 2
3

604hsm21

604hsm78

604hsm79

Wire 2 JX2 Ending


markers
Wire 2 J49 Ending
4 113 0,35 Outside buzzer J20 21 markers
19 107 0,35 Reverser engaged J248 8
B1 883 0,6 +APC fork ratio control J67 B6
B2 884 0,75 Fork ratio J2 26
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Fork ratio
B2 892 0,75 J137 B1
042 083 043 019 044 105 104 059 113 M0T M0A B3 853 0,6 +APC +/- range control (gears) J67 B1
M0M 075 074 022 072 071 070 069 109 091 107 054 110 060
1 2 3 4 5
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
811 812
A
890 891
B 883 884 853
892
1

A
2

1
4

B
5

16
604msm02

604hsm81

Ares 806 – 09.2004 – GB F1.53


FPS clutch and drive control

J15 J131
J04
J248
J20
P80
J119
P80
JX2
J114
J93 E7A
P80 J59

J13

J132

A
J90 J124
48 187
J92 J130
55a
J245
606hsm4Z

606hsm5B

J137
P20

J47
J150
J49
J150 J119

J137
J195

P137
J2
184

J1
J136
J68 J67
J80

606hsm5A

606hsm5C

F1.54 Ares 806 – 09.2004 – GB


FPS Park Lock Ref Item
Wire 2 J143 Ending
68 Park lock control markers
110 Fuse box
+ APC + AVC + AVC 130 Diode
133 Displacement speed sensor 1 77 0,6 Park lock control J119 4
184 Transmission electronic central unit 5 156 0,6 +APC Park Lock control J131 B5
68 189 Bottom of clutch contact
190 Transmission control ECU
194 Park lock solenoid valve
R3

19/15A
7 5 3 1
Park lock switch

9/15A
195
110 122 186

J143 8 6 4 2
3

1 5
J04 J05 J15 E7G 9
604hsm30
9 2 3 4 4
077

156

124

079

078

123
E7E
B5 B4 Wire 2 J1 Ending
J159 J138 D markers
J131 P138
J80
P80 4 802 0,75 Park lock relay P119 5
E7C J161 22 804 0,75 Park lock light P119 7
E7F

J158
J119
P119
6 4 5 15 804 22
802 4 J1 606hsm9H
25 36
604hsm5D
839 813 M8H 805 806 807 886 885 829 881

4 804 833 862 M8J 808 880 13


801 25
J2 867 868 802 840 836 815 837 830 8023 882
184
1 12
36
12 J1
715 15 P80 803 J188 13 J15
J131
711 11 835 A7 A5 881
728 28 874 B5 B7 882 J20
710 10 832 b1 A1 880
J224
J80 J05
P138
J138
F C B A
31 A
32b E7G 32b B
D
P2

33 K
F

16b
130 16 C
E7F B
E7C 190
M24 M23 36
16a

2 1 2 1 606hsm9G
M1
J161
J158 J159 1 41 F

E
2 R04 R01 H

133 E7E
194 195 J161
605hsm48

Ares 806 – 09.2004 – GB F1.55


QUADRISHIFT 2

180
826 P80 22 722 1 1 M
J93 QUADRISHIFT -EV1
M7M 2 2
126

21 721 1 1 B
822
QUADRISHIFT
J92 EV2
M8F 36 M7K M7L 2 2 TWINSHIFT
J80 125
2

P150
24 8104
P137 E7B 110
1 2 3 4 4 804
J67 J131
8103 3 803 B2 J119 155 A6 A7 124 9 19 / 15A
855 + APC
J04
8102
837 B7 B1 P119
2 802
813 A1
8101 1 801
20 21 22 23 4 5 32 31 B5 B1

J2
220B 220A
- + 184

8123 8116 16 8003


J1
8117 17 8004 14 16 15
8122

811
8118 20 897
24 812
M8Z M8B
8100 19 879
M8Y 8003
8120
J137 8004
M8F 853
9 10 1 5 B3 A4 A2
A2 A7 J49
J195 A1 M8A P49

J68 8 7 6 5 3 4
E6A
-
244 63
+
605hsm35

F1.56 Ares 806 – 09.2004 – GB


QUADRISHIFT 2

Ref Item
Wire 2 J1 Ending
63 ISC declutching +/- range control markers
110 Fuse box
125 Solenoid valve 2 2PS TWINSHIFT
126 Solenoid valve 1 4PS QUADRISHIFT 14 897 0,75 Quadrishift 2 auto 4PS ctrl J137 20
180 Transmission display 15 811 0,75 Control + Ranges J49 A2
184 Transmission electronic central unit 16 812 0,75 Control - Ranges J49 A4
220a Control + Ranges
220b Control - Ranges
25 36
244 4PS AUTO control
836 835 831 830 889 827 M8L 841 834 80008001
24 13
2
892 8008 818 809 877 816 896 814 812 811 897 876
Wire
markers
J2 Ending 875 866 865 861 815 817 819 810 885 869 870

1 12
4 826 0,75 EV 1 4PS J80 22
5 822 0,75 EV 2 PS - EV 2 4 PS J80 21
20 801 0,75 Speed 1 light J137 1
21 802 0,75 Speed 2 light J137 2
22 803 0,75 Speed 3 light J137 3
23 804 0,75 Speed 4 light J137 4
31 813 1,5 + APC DRIVETRONIC J67 A1
32 837 1,5 + APC DRIVETRONIC J67 B7

25 36

M8G M8H 839 805 856 852 813 837 878 851 806 807
604hsm64
24 850 804 803 802 801 864 808 874 832 8022M8S 13

867 868 825 826 822 823 821 871 884 872 862 824

1 12
Wire 2 J49 Ending
markers

A2 811 0,75 Range ctrl J1 15


A2 8003 0,6 Range ctrl J137 16
A4 812 0,75 Range ctrl J1 16
A4 8004 0,6 Range ctrl J137 17
B3 853 0,6 APC +/- range ctrl J67 B1

1 2 3 4 5
A 883 811 812
890
8003 8004
B 829 841 853 M8M
604hsm65
1

A
2

B
5

604msm2j

Ares 806 – 09.2004 – GB F1.57


QUADRISHIFT 2

J08 130 J185 D2


P08 D1
J52 J131
J15
J247 J246
J04 J224
J248 J44 J21 J150
J20 JX1
J03
J150
J119 J133
J05
J137
J23 J195
J114 J50 JX2 J09 J06

J07
J59
J12 J25
J17 P137
J10 E0A
J13
J143
214
P01 E0B 203
J11
J02 4
J124
187
P14 P172
J130 67 P133A
55a 606hsm5F
J245
55

5 J137
P20

J47
J49

606hsm5D J119

P80

P80
J2
J93 E7A
184
P80

J1
J136
J132 J68 J67
A

J80
J90
48
J92

J149 606hsm5E
606hsm5G

F1.58 Ares 806 – 09.2004 – GB


Notes Notes

Ares 806 – 09.2004 – GB F1.59


Quadractiv GTA 103/202 - GPA 40

180

826 P80 22 722 1 1 M


M7M 2 J93 2 QUADRISHIFT -EV1
126

822 21 721 1 1 B
QUADRISHIFT
M8F 36 M7K M7L 2
J92 2 EV2
TWINSHIFT
J80 125
2

E7B
P150
21 20 24 1 2 3 4 110
8104 P137 4 804
8103 3 803 J67 J119
8102 2 802 J131
A1 14 19 / 15A
8101 1 801 813 B2 855 155 A6 A7 124 9 J04 + APC
8117 17 8004 B7
837
220B 220A 20 21 22 23 4 5 31 32 P119
A2
– + B5 B1
J2
E8A
8123 8122 8116 16 8003
184
8124
8125
8126 J1
8131

8121

M8Y
8119 21 809
21 14 16 15 24
8129
B 2
8130

20 8010
8118 897
892 C 3 197
M8Z 24 M8B A J176 1
M8C
8100 19 879
8128

J137 811
8127 812
8003
8120
8004
4 2 6 3 1 5 8 9 10 1 5
M8F 853
B3 A4 A2
J206 J195
J49
A2 A3 A7
P49
2 1 0 A1 M8A

J68 5 3 4 2 1

E6A -

245 244
63
+

605hsm22

F1.60 Ares 806 – 09.2004 – GB


Quadractiv GTA 103/202 - GPA 40

Ref Item
63
110
ISC declutching +/- range control
Fuse box
Wire 2 J1 Ending
markers
125 Solenoid valve 2 2PS TWINSHIFT
126 Solenoid valve 1 4PS QUADRISHIFT
180 Transmission display (UCE) 14 897 0,75 Quadrishift 2 auto 4PS ctrl J137 20
184 Transmission central unit 15 811 0,75 Control + Ranges J49 A2
197 Accelerator control potentiometer 16 812 0,75 Control - Ranges J49 A4
220a Control + Ranges Automatic control 4 PS
21 809 0,75 J137 21
220b Control - Ranges QUADRACTIV
244 4PS AUTO control 24 892 0,75 Accelerator potent. cursor J176 C
245 4PS ECO/POWER control
25 36

Wire 2 J2 Ending 24
836 835 831 830 889 827 M8L 841 834 80008001
13
892 8008 818 809 877 816 896 814 812 811 897 876
markers
875 866 865 861 815 817 819 810 885 869 870
4 826 0,75 EV 1 4PS J80 22 1 12
5 822 0,75 EV 2 PS - EV 2 4 PS J80 21
20 801 0,75 Speed 1 light J137 1
21 802 0,75 Speed 2 light J137 2
22 803 0,75 Speed 3 light J137 3
23 804 0,75 Speed 4 light J137 4
31 813 1,5 + APC DRIVETRONIC J67 A1
32 837 1,5 + APC DRIVETRONIC J67 B7

25 36

M8G M8H 839 805 856 852 813 837 878 851 806 807

24 850 804 803 802 801 864 808 874 832 8022M8S 13
604hsm64
867 868 825 826 822 823 821 871 884 872 862 824

1 12

Wire 2 J49 Ending


markers

A2 811 0,75 Range ctrl J1 15


A2 8003 0,6 Range ctrl J137 16
A4 812 0,75 Range ctrl J1 16
A4 8004 0,6 Control - Ranges J137 17
B3 853 0,6 +APC +/- range control J67 B1

1 2 3 4 5
604hsm65 A 883 811 812
890
8003 8004
B 829 841 853 M8M
1

A
2

B
5

604msm2j

Ares 806 – 09.2004 – GB F1.61


Quadractiv GTA 103/202 - GPA 40

P80
P80

J93 E7A
J150
P80

J150

J137

A
J206 J195

J92

P137
J149
J117
E7B
J116
J93
606hsm6G

606hsm6J
J131

J04

J137
J119

J49 P20

J119

J176
J2

184

J1
J136
J68 J67
J80

606hsm6K
606hsm6H

F1.62 Ares 806 – 09.2004 – GB


Notes Notes

Ares 806 – 09.2004 – GB F1.63


FPS unit control
715
101 104 102 103 194 725 J59
A' C' R 2 1 M L H B' F1.40
724
710
711
J89 J85 J88 J86 J158 728
714
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 M24
M7K

16a
M25
P138
J138
P80
22

21

10
29

28

24

27

26

25

23

13
20

18

30

17
14
E7F
2

3
P2 F H G A C B E J119
J80

32b
P119

31

33
16b 130 36 14 28 11 10 24 25 15

AC1
6 12 15 5 4 14

M8F
E7D 803

861
874
835
832
878
879
E7A

AC11
PS1
M13

16
M12 M1
H F E G D C J B K A
E7C
B
D

155
C
E J131
114
F
A6
G B5 A7 A1 J188
H A
J B4
B5 B4
K

077

156

124

079

078

123
A B6 B7 A5 A6 A2 A3
B 9 2 3 4 4

8006

8005
8007
873

834
1 5
K 190 J04 J05 J15
C
A
J91 J143
E
K 2 1
F P133 P189 P133 P189

19/15A

9/15A
G G 32 34 F1.55 F1.30 F1.55 F1.30 R3
C D 110
D
H J 35 E7G
J F 36
68
A
B
47
E + APC + AVC + AVC
180
D E F G H R01 J K A B C 45
42a

F1.52 JX2 42b


E7B
22
39
1

8023

855
804
881

882

802

801
P163 R03 E7E
M23
B5 B2 J67
867 813 A1
J163 J162 868
AC12

B7 B1
M22

M27

M26

M21
39a 837
R05

R02

R04

2 1 M8H
43

44

37

38
1 1 M11
40

41

42

39b 27 2 1 36 12 11 22 4 26 9
1 2 2 1 2 1 1 2 2 3 1 1 2 3 2 4 1 3 E7C J159

M1
A2 A7
J1
J160 J84 J83 J161 J81
P150 184

853
B2 A1 A3 B3 B1
195
199 127 115 128 J2
132 39 37 133 29 J87 30 26 22 27 25

M8G
8103 P137 B2
8102 B4 811
8101 A4 827 812
884
220b 9
J68 B5 B6 B7
- J20
A1 M8A
8108 P20
E6A
A2
220c 220a B2 B3 A4 A2
8109

+ + J49
8107 B5 893 P49
8105 A1 890
5 3 4 2 1
8106 B1 892 -
8104 A5 891 63
8100 A2 849 +
M8Z B3 M8B
605hsm23 J137

F1.64 Ares 806 – 09.2004 – GB


FPS unit control
Wire 2 A Ending
Wire 2 C Ending
markers markers

Ref Item A 1 1 Gearshift solenoid valve "C" C’ 2 A 21 1 Gearshift solenoid valve "C" C’ 1
Gearshift solenoid valve
Wire 2 J2 Ending B 2 1 Gearshift solenoid valve "A" A’ 2 B 22 1 Gearshift solenoid valve "A" A’ 1
1 markers
2 Gearshift solenoid valve C 3 1 Gearshift solenoid valve "B" B’ 2 C 23 1 Gearshift solenoid valve "B" B’ 1
29 Rear power take-off speed sensor (Instrument panel) D 18 1 Solenoid valve differential control J88 1 D 24 1 Gearshift solenoid valve "1" 1 1
37 Engine speed sensor (transmission) 11 826 0,75 Steering angle J80 22 E 5 1 Gearshift solenoid valve "H" H 2 E 25 1 Gearshift solenoid valve "H" H 1
39 Rear power take-off speed sensor (transmission) 14 825 0,75 + Steering angle J80 21
63 ISC declutching +/- range control 22 812 0,75 - control (gears) J49 A4 F 6 1 Gearshift solenoid valve "I" L 2 F 26 1 Gearshift solenoid valve "L" L 1
68 Park lock control 26 884 0,75 Fork ratio J49 B2 G 7 1 Gearshift solenoid valve "M" M 2 G 27 1 Gearshift solenoid valve "M" M 1
101 Front axle solenoid valve 27 811 0,75 + control (speed) J49 A2 H 8 1 Gearshift solenoid valve "1" 1 2 H 28 1 Gearshift solenoid valve "2" 2 1
102 Differential lock solenoid valve 30 M8G 1 Electronic unit J68 B7 J 9 1 Gearshift solenoid valve "2" 2 2 J 29 1 Gearshift solenoid valve "R" R 1
103 Rear PTO clutch solenoid valve K 10 1 Gearshift solenoid valve "R" R 2 K 30 1 Differential control solenoid valve J88 2
104 Rear PTO brake solenoid valve 25 36
110 Fuse box
114 Transmission oil temperature sensor 801 884 811 843 810 M8G 821 824 865
K J H G F K J H G F
115 Oil pressure switch 24 870 819 812 887 814 877 822 825 875 13
127 Low-pressure switch 825 10 9 8 7 6 30 29 28 27 26
128 Gearbox pressure sensor 876 869 817 818 863 816 809 823 826 866
826 21 22 23 24 25
132 Intermediate speed sensor 1 2 3 18 5
133 Displacement speed sensor 1 12 A
A A B C D E
A B C D E B B
180 Transmission display C C
184 Transmission central unit D D
E E
190 TC transmission ECU 604hsm3E 604hsm3G
194 Park lock solenoid valve
195 Park lock switch
199 High-pressure oil filter Wire 2 Wire 2 D Ending
220a + range switch
markers
B Ending markers
220b - range switch
220c Furrow gear
A’ Gearshift solenoid valve A M12 1 Earth E7C A 31 1 CAN-high (TC+) J138 A
B’ Gearshift solenoid valve B PS1 1 +APC solenoid valve supply J138 G B — — —
C’ Gearshift solenoid valve C 16 1 Differential diode Diode C — — —
L Gearshift solenoid valve D 14 1 Solenoid valve PTO J86 1 D — — —
H Gearshift solenoid valve 604hsm5E E 20 1 Solenoid valve rear PTO brake J85 1 E — — —
M Gearshift solenoid valve
R Gearshift solenoid valve Solenoid valve rear PTO brake F 36 0,6 Park lock control J159 1
F 13 1 J85 2 Transmission oil temperature
control G 32 1 E7G
Wire 2 J49 Ending G 17 1 Solenoid valve rear PTO J86 2 H — — —
Wire 2 J1 Ending
markers Front/rear PTO solenoid valve J 35 0,6 Transmission oil temperature J91 1
markers H 4 1 J89 2
earth K 33 1 CAN-low (TC+) J138 C
A2 890 0,75 + control (speed) J137 A1 J AC11 1.4 Earth E7D
1 867 0,75 Transmission display data J137 B2 A2 811 0,75 Control + Ranges J2 27 K M13 1.4 Earth E7C
2 868 0,75 Transmission display clock J137 B4 A4 812 0,75 Control - Ranges J2 22
9 837 0,75 +APC seat safety J67 B7 A4 891 0,75 - control (speed) J137 A5 K J H G F
26 813 1,5 +APC electronic unit J67 A1 33 35 32 36
27 M8H 1 Electronic unit J68 B6 B2 884 0,75 Fork ratio J2 26 K J H G F
B2 892 0,75 Fork ratio J137 B1 31
B3 853 0,6 +APC +/- range control J67 B1 M13 AC11 4 17 13
A B C D E A
25 36 M12 PS1 16 14 20 B
C
A D
839 813 M8H 805 806 807 886 885 829 881 1 2 3 4 5 A B C D E E
B 604hsm3H
811 812 C
24 13 A
804 833 862 M8J 808 880 890 891 D
B 883 884 853 E 604hsm3F
867 868 802 840 836 815 837 830 8023 882 892

1 12
1

A
2

B
5

604hsm81

604hsm5D

Ares 806 – 09.2004 – GB F1.65


FPS unit control

J128
R J160
J138 E7G
B' 128
J160 A'
C' J83 2
1 E7E

E7D J162
J150
J1 M7B J163 M
J159 J138 M7K D P163
P138 M1 A J140 J150
J80 P42 E7B B 190 E J139
L P80 P20 J137 220a
E7C J161
C 220b
H 220c
J82 E7A
115 E7F
J86
J85 P137

J89 J88
J84
J158

127
J81
J87
606hsm9J

606hsm9L

J131 J137
J15

J04

J119
J49

J15
J119

J143
J2

184

J1
J68 J67
J80

606hsm9M

606hsm9K

F1.66 Ares 806 – 09.2004 – GB


Notes Notes

Ares 806 – 09.2004 – GB F1.67


DE10 engine control

+AVC +APC
185
110

FM4 FM15 FM19

15A 15A 15A JX1


3

J15 J04

007
8 12 9 201

124
B2
A7
P08
197 J08
J131
A6

073
155
14
1 3 2 J02
J176 J119 P02
A C B P119 405 J210 V
M8C 855
B 349 A B
A3
892 B2 J209
A 331
J68 347 353
J67 E3F
A1
184 406 351 E3G
8010 A2
M8A

B 348

EOA J1 J226 A 333 197

326

341
332
24 35 34
B 2
8001

8000

J237 A 1
226 C
J176
1 2 3
39 40 NO VE
J234 31
8024

8023

F1.32 J190 1 F1.12 117 BC


C3 D1 D3 B1 J1
OR
352
J236 B3
2 P16 A
J218
316
8006

8005

K3 354
J16 A2
1 2 J235 25
337 A
K2
1 2 34 J213
8026

8025

J232 338 B
J218 A3
1
J233 2 24 J218
178 J02 B 308 139
344 A
J231 179 G 323 B2
K1
J212
343 B
1 2 D2
P133
881
880

1 077 EOC 081 A 345 1 1 339 F1


082 P 346 J244 J243 M3H
2 151 2 2 340 G1 J2 EOA
EOD P02
J133
605hsm24 120 Ω

F1.68 Ares 806 – 09.2004 – GB


DE10 engine control P02 P16
A

Ref Item
Wire 2 J218 Ending
24 Engine ECU markers
25 Injection stop solenoid valve
31 Alternator 226
34 Preheating sparking plugs A2 308 1 + APC engine calculator P02 B 30
J39
110 Relay and fuse panel A2 354 1 + APC engine calculator E3G
117 Preheating fuse (70 A) A3 338 1 Injection pump J213 B
EOA J218
139 Engine speed sensor B1 332 1 Engine water temperature J210 A
184 Transmission electronic central unit (ECU) B2 344 Engine speed J212 A 34
B3 352 1 + APC accelerator sensor J176 C J209
185 Instrument panel
197 Accelerator control potentiometer C3 333 1 Fuel temperature J226 A J176
201 Engine water temperature thermistor D1 331 1 Air temperature J209 A
D2 343 1 Engine speed J212 B J213
226 Preheating relay P16
405 Outside air temperature sensor D3 326 1 (Ref-) sensors E3F J16
406 Fuel temperature sensor F1 339 1 CAN-Low J243 1
G1 340 1 CAN-High J243 2
G3 355 1 Diagnostic indicator P02 D
J1 341 1 Preheating indicator P02 V J210
Wire 2 JX1 Ending J2 M3M 1 Engine ECU EOA
markers K1 323 1 + AVC engine calculator P02 G
K2 337 1 Injection pump J213 A
3 007 0,35 Preheating indicator P08 B2 K3 316 1 Preheating controls J16 A

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 K J H G F E D C B A

068 067 066 065 136 061 108 106 064 063 111 007 062 316 355 326 333 352 338 3

337 M3H 308 343 344 308


354 2
J212
323 341 340 339 331 332 1

606hsm6N

K
A - Battery under lateral exhaust pipe
J
H
G
1 F

E
604msm01 J08
P08

D
J131

C
J15

B
A
J04

1 2 3
Wire 2 J1 Ending
markers JX1
604hsm42
J119
24 892 0,75 Accelerator potent. cursor J176 C
34 8000 0,75 CAN-High J234 2
35 8001 0,75 CAN-Low J234 1

25 36

836 835 831 830 889 827 M8L 841 834 80008001 J13
24 892 8008 818 809 877 816 896 814 812 811 897 876 13

875 866 865 861 815 817 819 810 885 869 870

1 12

J02

604hsm64

606hsm6P

Ares 806 – 09.2004 – GB F1.69


VP44 engine control

139 405 201 137 24

J212 J209 J213 J214


A B A B 1 3 5 8 2 7 4 6
A B J210
M3OC

M3OD
B A
M3OH

357

358
E3H
E3F

354
355
J211

M3OA

M3OB
A B

365

367

363

364
366

372
P16

350

361

351

356

352
353
VE A 359
226 1 24 25 20 22 21 18 26 27 31 8 6 30 12 15 16
F1.13 17
J16 P217 J217

400

401

402
403

421

423

410

411
422
420

M4D

M4E
404

405
418

412
408
E4A

407
406
409
63 9 34 50 24 6 67 22 10 36 59 60 18 17 58 66

J218

42 44 21 31 19 23 68 1 62 35

M4B
M4E
M4D
419
413
417
M4C
427

415
416 B4 A5 A3 B3 3 1 2 5
438 B5 M4A
B1 J216
439 434 B2 A1 414
R1 A2 B7 426
430
J222
437
433

A7 A6 2 1 3 4

B3 B4 B5 B1 B2 B7 B6 P224
J224
197 241
J176

M0X
082

081
440

J223 2 B 428
007
1 A M4F
3 12 1 B2 3
C
A1 A2 A6 A7
435 J04 J15 JX1
436

432

J13
431 429
A7

M0K
3 2 1 3 2 1 FM15 FM30
15A 15A 185
P221 J220 EOA
110
605hsm25 +APC +AVC

F1.70 Ares 806 – 09.2004 – GB


VP44 engine control P02 P16
A

Ref Item
Wire 2 J218 Ending
24 Engine ECU markers
110 Relay and fuse panel J220
137 Diesel electric pump 226
139 Engine speed sensor 1 M4B 2 ECU earth J222 B4 30 J39
6 401 1 Engine water temperature J217 21 J216 P221
185 Instrument panel
197 Accelerator control potentiometer 9 404 1 Engine speed (+) J217 24
10 402 1 Pump synchronisation (+) J217 26 J218
201 Engine water temperature thermistor J223
226 Preheating relay 17 411 1 Speed output J217 6 P224 J222
18 410 1 Fuel feed cut-out J217 17 J209
241 Safety relay
405 Outside air temperature sensor 19 427 1 + APC ECU J222 A7 J176
21 430 1 CAN-Low (diagnostic) J223 B6
22 407 1 Electric pump supply E4A J213
P16
23 415 2 +AVC (constant source) J222 A2 J16
Wire 2 JX1 Ending 24 408 1 Sensors return J217 22
markers 31 429 1 Accelerator potent. cursor J176 C
34 405 1 Engine speed (-) J217 25 P217
3 007 0,35 Preheating indicator J224 4 35 419 1 + AVC switched J216 5 J210
36 403 1 Pump synchronisation (-) J217 27 J217
42 438 1 Shielding CAN J223 B5 J214
44 434 1 CAN-High (diagnostic) J223 B1
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
50 400 1 Air temperature J217 20
068 067 066 065 136 061 108 106 064 063 111 007 062 58 422 0,8 CAN-High J217 30
59 421 0,8 CAN-Low J217 31
60 423 0,8 Pump GND CAN J217 8
62 413 1 Safety relay J216 1 J211
63 418 1 Preheating control J217 1
66 409 1 Preheating indicator control P224 4 J212
67 406 1 Electric pump supply E4A
68 416 1 +AVC (constant source) J222 B2
606hsm6L
1
604msm01
45
416 68 A - Battery under lateral exhaust pipe
23 415

Wire 2 J214 Ending


markers J15
J04 J224
1 365 CAN-Low P217 31
2 366 CAN-High P217 30
3 367 1 Pump GND CAN P217 8 JX1
4 M3OH 1 Injection pump earth E3H
5 363 1 Fuel feed cut-out P217 17
6 M3OC 2 Injection pump earth E3H
7 372 1,4 + AVC switched P217 12
8 364 1 Speed output P217 6

E0A
3 4 5 6 604hsm0Z J13
2 366 M3OH 363 M3OC
367
1 365 364 372
9 8 7

604hsm0V

606hsm6M

Ares 806 – 09.2004 – GB F1.71


Suspended front axle Ref Item
Wire 2 J182 Ending
110 Fuse box markers
295 Suspended front axle pilot solenoid valve
297 296 295 296 RH cylinder solenoid valve
297 LH cylinder solenoid valve 2 482 1 Front axle lower ctrl J183 1
303 Suspension control unit 3 483 1 Front axle rise ctrl J183 7
304 Suspension switch (auto) 4 484 1 Lock ctrl J184 8
305 Suspension switch (manual) 5 485 1 Automatic ctrl J184 2
2 1 2 1 2 1 403 RH suspension sensor 6 486 1 + AVC suspended front axle P185 1
404 LH suspension sensor 8 488 1 + APC suspended front axle E4B
9 M4E 1 Front axle controller earth P185 3
C
10 M4F 1 Front axle controller earth P185 3
B 11 491 1 Front axle indicator light J184 10
A

303 404
C 1 2 3 4 5 6
B 482 483 484 485 486
1
A 491 M4F M4E 488 12 2
11 3
10 4
12 11 10 9 8 7 9 5 6
8
403 7

10 9 6 3 2 8 11 5 4 604msm6A

J182

J184 J183 J184


484 8
P185
485 2
488
482

495 4

491 10
J131

493 9 J182
M4E
M4F

J184
486
483

E4B
E4B

2 0 1
492

303
J183 304
494 3
1 J182
P182
7
606hsm5T

J185
3 1 2 J15 J131
2 0 1

P185
J185
305 J03
MOV

180

181

E0A
EOA
3 5

J15 J03

34 33

10A 10A 110

+APC
+AVC
605hsm41 606hsm5S

F1.72 Ares 806 – 09.2004 – GB


Notes Notes

Ares 806 – 09.2004 – GB F1.73


Front axle engaging / differential and rear power take off

180 110
J131
13 7 1 19
855 P119 14 155 A6 A7 124 9
J04 +APC
B2 J119 15A
14 8 2
B3

15 9 3 A7 849

847
232 42
A5 5 1
16 10 4
J46

817

858
J67
17 11 5 234
A3 846 5 1
J45
18 12 6 848 B1 A3
A6
J48

898

814

815

819
B6 895
11 13 14 12 24
P48
P150
8134 P137 13 643

641
8111 11
642
8114 14 899 896
54
22 18 17 6 8 7 A B B A
8112 12
J1 J123 J122
M8Y

M8Z 24 M8B
184
J137 44b 44a
53 J
818
J2
9
1 851 34 24 12 7 3 36
J195 850
J47
843
C2

807
P80
J85 1 709 9

104
1 M7C 15
2
J68 A2 P20
J86 1 708 8 824
M8J B3 J20
103
2 713 13 M8N B6
2

083
J88 1 707 7 821
102
A6
3 M7G 13
2

J89 1 706 6 825 JX2


101
4 2
M7H M7B
J80
31 M8E 185
605hsm42 E7A

F1.74 Ares 806 – 09.2004 – GB


Front axle engaging / differential and rear power take off

Ref Item
42 ECO rear PTO contact
44a RH rear PTO emergency stop J131
44b LH rear PTO emergency stop J04 P80
53 Rear PTO clutch switch J20
54 Rear PTO selection contact P80
J119
101 4-wheel drive solenoid valve
102 Differential lock solenoid valve JX2 J89
103 Rear PTO clutch solenoid valve P80 J86
104 Rear PTO brake solenoid valve
110 Fuse box J85
180 Transmission display J88

A
184 Transmission electronic central unit J89
185 Instrument panel
232 Differential switch
234 4-wheel drive switch

Wire 2 J1 Ending
markers

6 815 0,75 Differential control J46 1 606hsm5Y


7 817 0,75 Rear PTO stop (wing) J48 B1
8 819 0,75 Eco PTO switch 42
17 814 0,75 4-wheel drive control J45 1
18 896 0,75 1 000 rpm PTO 54
22 818 0,75 Rear PTO clutch control 53
606hsm5U

J150
J150
J137
25 36

836 835 831 830 889 827 M8L 841 834 80008001
24 892 8008 818 809 877 816 896 814 812 811 897 876 13
J123 P137
604hsm64
875 866 865 861 815 817 819 810 885 869 870

1 12

Wire 2 J2 Ending P48


markers

606hsm5Z
3 825 0,75 4-wheel drive solenoid valve J80 6 J122
7 821 0,75 Differential solenoid valve J80 7
12 824 0,75 Rear PTO solenoid valve J80 8 606hsm5V
24 850 0,75 4 wheel drive light J137 11
34 851 0,75 Differential indicator J137 12
36 807 0,75 Rear PTO light P20 15
J137
J45 P20
J47
J46
J2
J1 J119
42 54

25 36

M8G M8H 839 805 856 852 813 837 878 851 806 807

24 850 804 803 802 801 864 808 874 832 8022M8S 13 J2
604hsm65
867 868 825 826 822 823 821 871 884 872 862 824 184
1 12
J1
J136
J68
J67
J80

J48
606hsm5W

Ares 806 – 09.2004 – GB F1.75


Oil temperature sensors, engine speed, forward speed, rear power take off speed, Ref Item
reverser module speed / DRIVETRONIC 27
37
Reverser module speed sensor
Tractor advance speed sensor J20
38 Engine speed sensor
114 Oil temperature sensor JX1
184 Transmission electronic central unit
185 Instrument panel
185
Wire 2 J2 Ending
markers
JX1
29 856 0,75 Transm. oil temp. indicator P20 20
5
063

20
J20
P20
25 36

M8G M8H 839 805 856 852 813 837 878 851 806 807
856

24 850 804 803 802 801 864 808 874 832 8022M8S 13
604hsm65 606hsm6A
867 868 825 826 822 823 821 871 884 872 862 824

1 12
29
P20
J2
Wire 2 J1 Ending
markers

184 25 836 0,75 Transm. oil temp. signal J80 20


26 835 0,75 Transmission oil temperature J80 19
27 831 0,75 + Engine speed sensor J80 11
28 830 0,75 + Forward speed sensor J80 12 J2
29 889 0,75 + Reverser module speed J80 29 184
J1 31 M8L 0,75 Frequency earth J80 15
J1

26 25 27 28 31 29 J80
M8L
835

836

831

830

889

606hsm6B

19 20 11 12 15 29
J80 25 36
P80
P80 836 835 831 830 889 827 M8L 841 834 80008001
P80
24 892 8008 818 809 877 816 896 814 812 811 897 876 13
604hsm64
875 866 865 861 815 817 819 810 885 869 870 J91
P80
M7D

J83
719

720

711

712

729

1 12
J84 J82

A
E7C J145
J91
J84
F1.37
M7O

M7Q
M7N

E7B
1 2 1 2 1 2 2 1 606hsm6C

J91 J83 J82 J145

38 37 27

114
605hsm43

F1.76 Ares 806 – 09.2004 – GB


Cross control with solenoid pilot Ref Item
Wire 2 J128 Ending
141 Electrohydraulic spool valve control unit markers
254 Front lift fuse (5 A)
EV2 EV1 255 Joystick - Solenoid pilot
256 Front lift socket 1 9100 0,6 R1 relay control P197 A1
257 Front lift relay 2 M90B 0,6 Relay R1 earth E90B
258 Front lift relay 3 9106 0,75 + APC relay R1 E90A
259 Front loader socket 5 9108 0,75 EV1 Controls J126 1

259 256 3
Wire 2 J126 Ending 9106
markers
J126 J205 4 3
1 9108 0,75 EV1 Controls J128 5 2
4
2 4 1 3 2 1 4 3 2 9109 0,75 EV2 Controls J129 5 2 M90B 9100 1
1
3 M90D 0,75 Solenoid valve 1 E90B 9108
5
4 M90E 0,75 Solenoid valve 2 E90B

M90D
M90E

M90F
9108
5 604msm7R

E90B Wire 2 J129 Ending


markers
9109

4
M90C 2 M90E
9109 M90D 1 9102 0,6 R2 relay control P197 A5

M90B
3 2 M90C 0,6 Relay R2 earth E90B
9108
1 3 9107 0,75 + APC relay R2 E90A
257 5 9109 0,75 EV2 Controls J126 2
3
5 604msm6R

M90A

9110

9104

9103
258 5 2 3
1 2
9107

J128 4 3
3 1 2
J129 2 M90C 9102 1 4
1
5
9109
9106 5 604msm8R
9107 E90A
9105

J198
9102

9100

254 5A

J129
J128
9101

P197
E90A
J199
A5 A1 A4 A2 B5 B1
J197
P197 B5
J197 B1

606hsm6D J126 E90B


9001

9009

9008
M9Y
9016

9015

J205 606hsm6E

15 14 18 2 15 14

J199 J198

255
141

605hsm44

Ares 806 – 09.2004 – GB F1.77


Cross control Ref Item
Wire 2 J128 Ending
240 Cross control markers
254 Front lift fuse
EV2 EV1 257 Front lift relay
258 Front lift relay 1 BL 1 A relay control J127 A1
259 Front loader socket 2 BK/GN 1 Relay A earth EP2
259 2 BK/VI 1 Relay B earth J129 2
3 RD/VI 1 +APC J129 3
3 RD/GN 1 +APC EP1
Wire 2 J126 Ending 5 RD/WH 1 + Solenoid valve A J126 1
J126 markers

2 4 3 1 1 RD/WH 1 + Solenoid valve A J128 5 3


2 RD/BL 1 + Solenoid valve B J129 5

NO/BC
RG/VE
RG/VI
3 BK/WH 1 Solenoid valve A EP2
4 BK/BL 1 Solenoid valve B EP2 4 3
2
EP2 2 NO/VE
BU 1 4
NO/VI 1
5
NO/BU RG/BC

5 604msm3S
4

NO
2 NO/BU
RG/BU NO/BC
RG/BC
3
Wire 2

NO/VE
RG/BU

RG/BC
1
markers
J129 Ending
E6A
604msm1S
1 YL 1 B relay control J127 A3
2 BK/VI 1 Relay B earth J128 2
258 Wire 2 J127 Ending
3 RD/VI
RD/BL
1 +APC
+ Solenoid valve B
J128 3
257 markers
5 1 J126 2

3 RG/VI 3 A1 BL 1 A relay control J128 1


5 5 3
A3 YL 1 B relay control J129 1
B2 RD/OR 1 +APC cross control EP1 RG/VI

1 2 NO/VI 2 1 4 3
2
J129 J128 2 NO/VI JA 1 4
1
1 2 3
5
RG/VE

RG/BU

1
BU A
A JA 604msm4S
5

3
B RG/OR B

604msm2S
EP1
RG
RG/OR

240
BU

5A 254
JA

OR

B2

J67
J127
J128 J129
A3 B2 A1 EP2
EP1
J127
F-5A

J67
BC
JA

RG/OR

E6A
240
+ –

J126

606hsm6F

605hsm45

F1.78 Ares 806 – 09.2004 – GB


DE10 CAN Ref Item
24 Engine ECU
184 Transmission UCE

J133A
Wire 2 J1 Ending
2 1 markers
152 P20
J189 1 8006 880 P133 2 151
082 34 8000 0,75 CAN-Low J234 2
35 8001 0,75 CAN-High J234 1
J235 J234
078 J236
2 8005 881 1 077 P133
25 36 J237
P189 J133 081
J231 J233
836 835 831 830 889 827 M8L 841 834 80008001
J232
24 13
J49
892 8008 818 809 877 816 896 814 812 811 897 876
184 P208
875 866 865 861 815 817 819 810 885 869 870

2 1 2 1 A P A P J41 J42
1 12 J1
J02 J02
J232 J231 P189
P02 P02
J190

345

346

345

346
J233
606hsm4Q
2 1

604hsm64

P02
Wire 2 J218
8025

8026

Ending
markers

F1 339 1 CAN-Low J243 1


G1 340 1 CAN-High J243 2

K J H G F E D C B A
2 1 1 2 1 2 316 355 326 333 352 338 3

337 M3H 308 343 344 308


354 2
J235 J244 J244 323 341 340 339 331 332 1

K
J234 J236 J243 J243

J
H
G
J243

F
2 1 1 2 1 2 1 2 J244

E
D
24 J218

C
B
A
8000

8001

8024

8023

1 2 3
606hsm2Q
339

340

339

340

604hsm42

Wire 2 J237 Ending


markers
34 35 39 40 F1 G1 F1 G1
39 8024 0,6 CAN-Low J236 1
J1 J237 J218 J218 40 8023 0,6 CAN-High J236 2

1 29

DRIVETRONIC 3 DRIVETRONIC 5 DE 10 DE 10
184 24 24

605hsm49

604hsm75

Ares 806 – 09.2004 – GB F1.79


VP44 CAN Ref Item
Wire 2 J214 Ending
24 Engine ECU markers
184 Transmission UCE
190 TC transmission ECU
190 837 1 365 1 CAN-Low P217 31
2 366 1 CAN-High P217 30
3 367 1 Pump GND CAN P217 8
Wire 2 J1 Ending
D markers
184
G A K 12 882 0,75 CAN - J188 A5
13 880 0,75 CAN-High J188 A1
32

J1 36 881 0,75 CAN-Low J188 B7


E7G
31

33
32b

13 12 36
25 36
B A C

880

882

881
839 813 M8H 805 806 807 829 881
P138
24 804 833 862 M8J 808 880 13
J138
867 868 802 840 836 815 837 830 8023 882
728

710

711

A1 A5 B7 A7
1 12
604hsm0V
28 10 11 J188
P80 B1 A2 B2 B4 B5 B3 B6 A6
J80

832
831
873
874
604hsm78
8007
P133

8005
8006

2 1 3
Wire 2 J218 Ending
markers
P189
J189 21 430 1 CAN-Low (diagnostic) J223 B6 184
834 42 438 1 Shielding CAN J223 B5 J1
44 434 1 CAN-Low (diagnostic) J223 B1 J188
58 422 0,8 CAN-High J217 30 J80
59 421 0,8 CAN-Low J217 31
60 423 8 Pump GND CAN J217 8 P189
P133 J221
J190
J220 P221 434
3 2 1 2 1 3 22 407 406
24 439 606hsm5Q
435

431 416 68
45
432
J214 23 415
440

2 1 3 436
P220
366

365

367

A2 A1 B3 B4 A7 A6
J223 P221
30 31 8 J223 J218
J217
B1 B2 B5 B6 B7
P217
437

433

R1
434

438 P217
422

421

423

J217
430
58 59 60 44 42 21 J214

J218 604hsm0Z

VP44
605hsm72
606hsm3Q

F1.80 Ares 806 – 09.2004 – GB


CONTENTS
1 - Instrument panel harness....................................................................................................................................................... F2.4
2 - Preheating control harness .................................................................................................................................................. F2.12
3/1 - Front harness ....................................................................................................................................................................... F2.12
3/2a - Front harness ....................................................................................................................................................................... F2.12
3/2b - Injection harness .................................................................................................................................................................. F2.12
3/2c - Injection control harness ...................................................................................................................................................... F2.12
4 - Front axle suspension control harness................................................................................................................................. F2.22
5 - Instrument panel / cab top harness ...................................................................................................................................... F2.24
5a - Cab top / front lights harness ............................................................................................................................................... F2.28
5b - Cab top / rear light harness with air conditioning ................................................................................................................. F2.28
5c - Front and rear light harness ................................................................................................................................................. F2.32
6 - Rear harness........................................................................................................................................................................ F2.36
7a - Closed centre circuit transmission harness - 110 litres ........................................................................................................ F2.40
7b - Closed centre circuit transmission harness - 100 litres ........................................................................................................ F2.40
7c - GTA 303 transmission link harness...................................................................................................................................... F2.40
7d - GTA 303 transmission harness ............................................................................................................................................ F2.40
8a - GTA 103/202 - GPA 40 transmission control harness ......................................................................................................... F2.52
8b - Full Powershift transmission control harness ....................................................................................................................... F2.52
8/1 - ISO socket harness .............................................................................................................................................................. F2.52
8/2 - Quadrishift 2/Quadractiv/Full Powershift display harness .................................................................................................... F2.52
9a - TCE 15/25/35 Control harness............................................................................................................................................. F2.66
9b - TCE 15T Control harness..................................................................................................................................................... F2.70
9/1a - TCE 15/25/35 Harness......................................................................................................................................................... F2.74

F2 - HARNESS AND CONNECTOR PATHS 9/1b - TCE 15T Harness................................................................................................................................................................. F2.78


9/2a - Cross control harness with Electropilot ................................................................................................................................ F2.82
9/2b - Cross control harness .......................................................................................................................................................... F2.82
9/3 - Electrohydraulic spool valve control harness ....................................................................................................................... F2.84
10 - On-board computer harness ................................................................................................................................................ F2.84

Ares 806 – 09.2004 – GB F2.1


CONTENTS
1 - Instrument panel harness .......................................................................................................................................................F2.4
2 - Preheating control harness...................................................................................................................................................F2.12
3/1 - Front harness .......................................................................................................................................................................F2.12
3/2a - Front harness .......................................................................................................................................................................F2.12
3/2b - Injection harness ..................................................................................................................................................................F2.12
3/2c - Injection control harness.......................................................................................................................................................F2.12
4 - Front axle suspension control harness.................................................................................................................................F2.22
5 - Instrument panel / cab top harness ......................................................................................................................................F2.24
5a - Cab top / front lights harness................................................................................................................................................F2.28
5b - Cab top / rear light harness with air conditioning..................................................................................................................F2.28
5c - Front and rear light harness .................................................................................................................................................F2.32
6 - Rear harness ........................................................................................................................................................................F2.36
7a - Closed centre circuit transmission harness - 110 litres ........................................................................................................F2.40
7b - Closed centre circuit transmission harness - 100 litres ........................................................................................................F2.40
7c - GTA 303 transmission link harness......................................................................................................................................F2.40
7d - GTA 303 transmission harness ............................................................................................................................................F2.40
8a - GTA 103/202 - GPA 40 transmission control harness..........................................................................................................F2.52
8b - Full Powershift transmission control harness .......................................................................................................................F2.52
8/1 - ISO socket harness ..............................................................................................................................................................F2.52
8/2 - Quadrishift 2/Quadractiv/Full Powershift display harness ....................................................................................................F2.52
9a - TCE 15/25/35 Control harness .............................................................................................................................................F2.66
9b - TCE 15T Control harness.....................................................................................................................................................F2.70
9/1a - TCE 15/25/35 Harness .........................................................................................................................................................F2.74
9/1b - TCE 15T Harness.................................................................................................................................................................F2.78
9/2a - Cross control harness with Electropilot ................................................................................................................................F2.82
9/2b - Cross control harness...........................................................................................................................................................F2.82
9/3 - Electrohydraulic spool valve control harness .......................................................................................................................F2.84
10 - On-board computer harness.................................................................................................................................................F2.84

F2.2 Ares 806 – 09.2004 – GB


Harness and connector paths

Connectors...............................................................Pages Connectors .............................................................. Pages Connectors .............................................................. Pages Connectors .............................................................. Pages Connectors .............................................................. Pages Connectors ..............................................................Pages
1 .................................................................................................2.50 J130 .............................................................................................2.9 J190 .......................................................................................... 2.68 J248 ...........................................................................................2.10 J75 ............................................................................................ 2.79 P02 ........................................................................................... 2.17
115 .............................................................................................2.51 J131 .............................................................................................2.9 J190 .......................................................................................... 2.72 J25 ...............................................................................................2.8 J76 ............................................................................................ 2.75 P08 ........................................................................................... 2.10
127 .............................................................................................2.51 J132 ...........................................................................................2.46 J191 .......................................................................................... 2.68 J26 .............................................................................................2.37 J76 ............................................................................................ 2.75 P107 ......................................................................................... 2.30
128 .............................................................................................2.51 J133 .............................................................................................2.9 J191 .......................................................................................... 2.72 J27 .............................................................................................2.37 J76 ............................................................................................ 2.79 P108 ......................................................................................... 2.30
2 .................................................................................................2.50 J134 ...........................................................................................2.55 J192 .......................................................................................... 2.72 J28 .............................................................................................2.37 J76 ............................................................................................ 2.79 P119 ......................................................................................... 2.58
97 ...............................................................................................2.33 J134 ...........................................................................................2.60 J193 .......................................................................................... 2.76 J29 .............................................................................................2.37 J77 ............................................................................................ 2.75 P119 ......................................................................................... 2.62
A ................................................................................................2.50 J136 ...........................................................................................2.56 J193 .......................................................................................... 2.79 J31 .............................................................................................2.14 J77 ............................................................................................ 2.75 P125 ......................................................................................... 2.69
A’ ...............................................................................................2.50 J136 ...........................................................................................2.61 J194 .......................................................................................... 2.76 J31 .............................................................................................2.16 J78 ............................................................................................ 2.75 P133 ......................................................................................... 2.58
B ................................................................................................2.50 J137 ...........................................................................................2.56 J194 .......................................................................................... 2.80 J32 .............................................................................................2.37 J78 ............................................................................................ 2.76 P133 ......................................................................................... 2.62
B’ ...............................................................................................2.50 J137 ...........................................................................................2.61 J195 .......................................................................................... 2.63 J33 .............................................................................................2.37 J79 ............................................................................................ 2.76 P133a ....................................................................................... 2.11
C ................................................................................................2.50 J138 ...........................................................................................2.49 J195 .......................................................................................... 2.63 J34 .............................................................................................2.14 J79 ............................................................................................ 2.79 P134 ......................................................................................... 2.86
C’ ...............................................................................................2.51 J139 ...........................................................................................2.42 J196 ............................................................................................ 2.9 J34 .............................................................................................2.16 J79 ............................................................................................ 2.79 P137 ......................................................................................... 2.63
D ................................................................................................2.50 J139 ...........................................................................................2.46 J197 .......................................................................................... 2.85 J35 .............................................................................................2.37 J80 ............................................................................................ 2.55 P137 ......................................................................................... 2.64
E ................................................................................................2.50 J139 ...........................................................................................2.48 J198 .......................................................................................... 2.85 J36 .............................................................................................2.37 J80 ............................................................................................ 2.60 P138 ......................................................................................... 2.48
H ................................................................................................2.51 J140 ...........................................................................................2.48 J199 .......................................................................................... 2.85 J37 .............................................................................................2.37 J81 ............................................................................................ 2.49 P139 ......................................................................................... 2.15
J01 .............................................................................................2.13 J141 ...........................................................................................2.14 J2 .............................................................................................. 2.54 J39 .............................................................................................2.13 J82 ............................................................................................ 2.41 P139 ......................................................................................... 2.15
J01 .............................................................................................2.16 J141 ...........................................................................................2.17 J2 .............................................................................................. 2.59 J40 .............................................................................................2.37 J82 ............................................................................................ 2.45 P139 ......................................................................................... 2.17
J0................................................................................................2 25 J142 ...........................................................................................2.14 J20 .............................................................................................. 2.7 J41 .............................................................................................2.37 J82 ............................................................................................ 2.48 P14 ........................................................................................... 2.10
J03 ...............................................................................................2.5 J143 .............................................................................................2.9 J200 .......................................................................................... 2.14 J42 .............................................................................................2.38 J83 ............................................................................................ 2.41 P140 ......................................................................................... 2.15
J04 ...............................................................................................2.5 J145 ...........................................................................................2.42 J200 .......................................................................................... 2.17 J43 .............................................................................................2.38 J83 ............................................................................................ 2.45 P151 ......................................................................................... 2.39
J05 ...............................................................................................2.6 J145 ...........................................................................................2.46 J201 .......................................................................................... 2.43 J44 ...............................................................................................2.8 J83 ............................................................................................ 2.49 P16 ........................................................................................... 2.13
J06 ...............................................................................................2.6 J147 ...........................................................................................2.86 J202 .......................................................................................... 2.43 J45 .............................................................................................2.54 J84 ............................................................................................ 2.41 P163 ......................................................................................... 2.51
J07 ...............................................................................................2.6 J148 ...........................................................................................2.86 J202 .......................................................................................... 2.46 J45 .............................................................................................2.59 J84 ............................................................................................ 2.45 P172 ......................................................................................... 2.11
J08 ...............................................................................................2.6 J149 ...........................................................................................2.42 J204 .......................................................................................... 2.76 J46 .............................................................................................2.54 J84 ............................................................................................ 2.49 P185 ......................................................................................... 2.23
J09 ...............................................................................................2.6 J149 ...........................................................................................2.46 J204 .......................................................................................... 2.80 J46 .............................................................................................2.59 J85 ............................................................................................ 2.41 P189 ......................................................................................... 2.58
J1 ...............................................................................................2.53 J15 ...............................................................................................2.7 J205 .......................................................................................... 2.83 J47 .............................................................................................2.54 J85 ............................................................................................ 2.45 P189 ......................................................................................... 2.62
J1 ...............................................................................................2.58 J150 ...........................................................................................2.42 J206 .......................................................................................... 2.63 J47 .............................................................................................2.59 J85 ............................................................................................ 2.49 P190 ......................................................................................... 2.85
J10 ...............................................................................................2.6 J150 ...........................................................................................2.46 J207 .......................................................................................... 2.56 J48 .............................................................................................2.54 J82 ............................................................................................ 2.41 P191 ......................................................................................... 2.85
J100 ...........................................................................................2.29 J150 ...........................................................................................2.63 J207 .......................................................................................... 2.61 J48 .............................................................................................2.59 J87 ............................................................................................ 2.45 P192 ......................................................................................... 2.69
J100 ...........................................................................................2.33 J150 ...........................................................................................2.63 J208 .......................................................................................... 2.56 J49 .............................................................................................2.54 J87 ............................................................................................ 2.49 P197 ......................................................................................... 2.83
J101 ...........................................................................................2.29 J151 ...........................................................................................2.26 J208 .......................................................................................... 2.61 J49 .............................................................................................2.59 J87 ............................................................................................ 2.68 P20 ........................................................................................... 2.57
J101 ...........................................................................................2.33 J151 ...........................................................................................2.43 J209 .......................................................................................... 2.14 J50 ...............................................................................................2.8 J88 ............................................................................................ 2.42 P20 ........................................................................................... 2.61
J102 ...........................................................................................2.29 J151 ...........................................................................................2.46 J209 .......................................................................................... 2.17 J51 .............................................................................................2.14 J88 ............................................................................................ 2.45 P208 ......................................................................................... 2.62
J102 ...........................................................................................2.33 J152 ...........................................................................................2.14 J21 .............................................................................................. 2.7 J51 .............................................................................................2.17 J88 ............................................................................................ 2.49 P217 ......................................................................................... 2.18
J103 ...........................................................................................2.29 J152 ...........................................................................................2.17 J210 .......................................................................................... 2.14 J52 ...............................................................................................2.8 J89 ............................................................................................ 2.42 P221 ......................................................................................... 2.20
J103 ...........................................................................................2.33 J153 ...........................................................................................2.14 J210 .......................................................................................... 2.17 J56 .............................................................................................2.25 J89 ............................................................................................ 2.45 P224 ......................................................................................... 2.20
J104 ...........................................................................................2.26 J153 ...........................................................................................2.17 J211 .......................................................................................... 2.18 J57 .............................................................................................2.25 J89 ............................................................................................ 2.49 P246 ......................................................................................... 2.39
J105 ...........................................................................................2.29 J158 ...........................................................................................2.49 J212 .......................................................................................... 2.14 J59 ...............................................................................................2.8 J90 ............................................................................................ 2.42 P247 ......................................................................................... 2.27
J105 ...........................................................................................2.33 J159 ...........................................................................................2.49 J212 .......................................................................................... 2.18 J60 .............................................................................................2.25 J90 ............................................................................................ 2.45 P42 ........................................................................................... 2.69
J106 ...........................................................................................2.30 J16 .............................................................................................2.13 J213 .......................................................................................... 2.14 J61 .............................................................................................2.25 J91 ............................................................................................ 2.42 P42 ........................................................................................... 2.72
J106 ...........................................................................................2.33 J16 .............................................................................................2.17 J213 .......................................................................................... 2.18 J62 .............................................................................................2.26 J91 ............................................................................................ 2.45 P44 ........................................................................................... 2.39
J107 ...........................................................................................2.26 J160 ...........................................................................................2.49 J214 .......................................................................................... 2.18 J63 .............................................................................................2.26 J91 ............................................................................................ 2.49 P48 ........................................................................................... 2.39
J108 ...........................................................................................2.26 J161 ...........................................................................................2.49 J216 .......................................................................................... 2.18 J64 .............................................................................................2.26 J92 ............................................................................................ 2.42 P52 ........................................................................................... 2.27
J109 ...........................................................................................2.30 J162 ...........................................................................................2.49 J217 .......................................................................................... 2.19 J65 .............................................................................................2.26 J92 ............................................................................................ 2.46 P54 ........................................................................................... 2.27
J11 ...............................................................................................2.7 J163 ...........................................................................................2.50 J218 .......................................................................................... 2.15 J67 .............................................................................................2.55 J93 ............................................................................................ 2.42 P55 ........................................................................................... 2.27
J110 ...........................................................................................2.30 J168 ...........................................................................................2.26 J218 .......................................................................................... 2.19 J67 .............................................................................................2.59 J93 ............................................................................................ 2.46 P61 ........................................................................................... 2.30
J111 ...........................................................................................2.30 J169 ...........................................................................................2.26 J219 .......................................................................................... 2.62 J68 .............................................................................................2.55 J94 ............................................................................................ 2.38 P61 ........................................................................................... 2.33
J112 ...........................................................................................2.30 J17 ...............................................................................................2.7 J22 ............................................................................................ 2.14 J68 .............................................................................................2.60 J94 ............................................................................................ 2.42 P62 ........................................................................................... 2.29
J113 ...........................................................................................2.30 J170 ...........................................................................................2.27 J22 ............................................................................................ 2.16 J69 .............................................................................................2.67 J94 ............................................................................................ 2.46 P62 ........................................................................................... 2.34
J114 .............................................................................................2.8 J172 ...........................................................................................2.27 J220 .......................................................................................... 2.20 J69 .............................................................................................2.71 J95 ............................................................................................ 2.29 P69 ........................................................................................... 2.76
J116 ...........................................................................................2.42 J173 ...........................................................................................2.76 J222 .......................................................................................... 2.20 J70 .............................................................................................2.67 J95 ............................................................................................ 2.33 P69 ........................................................................................... 2.77
J116 ...........................................................................................2.46 J176 ...........................................................................................2.14 J223 .......................................................................................... 2.20 J70 .............................................................................................2.71 J95 ............................................................................................ 2.42 P69 ........................................................................................... 2.80
J117 ...........................................................................................2.42 J176 ...........................................................................................2.18 J224 ............................................................................................ 2.9 J71 .............................................................................................2.68 J95 ............................................................................................ 2.46 P69 ........................................................................................... 2.80
J117 ...........................................................................................2.46 J176 ...........................................................................................2.56 J225 .......................................................................................... 2.43 J71 .............................................................................................2.71 J96 ............................................................................................ 2.29 P80 ........................................................................................... 2.43
J119 .............................................................................................2.9 J178 ...........................................................................................2.38 J225 .......................................................................................... 2.48 J72 .............................................................................................2.75 J96 ............................................................................................ 2.33 P80 ........................................................................................... 2.47
J12 ...............................................................................................2.7 J178 ...........................................................................................2.39 J226 .......................................................................................... 2.15 J72 .............................................................................................2.75 J97 ............................................................................................ 2.29 P80 ........................................................................................... 2.48
J120 ...........................................................................................2.38 J18 .............................................................................................2.13 J23 .............................................................................................. 2.8 J72 .............................................................................................2.79 J98 ............................................................................................ 2.29 P999 ......................................................................................... 2.58
J121 ...........................................................................................2.38 J18 .............................................................................................2.16 J231 .......................................................................................... 2.56 J72 .............................................................................................2.79 J98 ............................................................................................ 2.33 P999 ......................................................................................... 2.62
J122 ...........................................................................................2.38 J182 ...........................................................................................2.23 J232 .......................................................................................... 2.57 J73 .............................................................................................2.75 J99 ............................................................................................ 2.29 R ............................................................................................... 2.51
J123 ...........................................................................................2.38 J183 ...........................................................................................2.23 J233 .......................................................................................... 2.57 J73 .............................................................................................2.75 J99 ............................................................................................ 2.33
J124 .............................................................................................2.9 J184 ...........................................................................................2.23 J234 .......................................................................................... 2.57 J73 .............................................................................................2.79 J999 .......................................................................................... 2.39
J126 ...........................................................................................2.83 J185 .............................................................................................2.9 J235 .......................................................................................... 2.57 J73 .............................................................................................2.79 JA .............................................................................................. 2.25
J126 ...........................................................................................2.83 J186 ...........................................................................................2.72 J236 .......................................................................................... 2.57 J74 .............................................................................................2.75 JB .............................................................................................. 2.25
J127 ...........................................................................................2.83 J187 ...........................................................................................2.72 J237 .......................................................................................... 2.57 J74 .............................................................................................2.75 JX1 .............................................................................................. 2.5
J128 ...........................................................................................2.83 J188 ...........................................................................................2.61 J243 .......................................................................................... 2.15 J74 .............................................................................................2.79 JX2 .............................................................................................. 2.5
J128 ...........................................................................................2.83 J189 ...........................................................................................2.68 J244 .......................................................................................... 2.15 J74 .............................................................................................2.79 L ................................................................................................ 2.51
J129 ...........................................................................................2.83 J189 ...........................................................................................2.72 J245 ............................................................................................ 2.9 J75 .............................................................................................2.75 M ............................................................................................... 2.51
J129 ...........................................................................................2.83 J19 .............................................................................................2.13 J246 .......................................................................................... 2.10 J75 .............................................................................................2.75 P01 ............................................................................................ 2.10
J13 ...............................................................................................2.7 J19 .............................................................................................2.16 J247 .......................................................................................... 2.10 J75 .............................................................................................2.79 P02 ............................................................................................ 2.15

Ares 806 – 09.2004 – GB F2.3


1 - Instrument panel harness Connectors Designation
JX1 Instrument panel

J23
JX2 Instrument panel

J25
J21
J02 Front harness connection (engine)

J131
J03 Fuse box connection
J04 Fuse box connection
D1
J05 Panel connection
J06 Windscreen wiper / washer control
D2

Signalling control

J06
J07

203
J13
J185

J08 P08 connector connection

P172
4
J09 Shunt receptacle (black)

E0B
J10 Shunt receptacle (white)
J09

J07
J11 Windscreen wiper timer
JX1
130

J133

J59
J12 Ventilation switch

E0A
J13 Shunt receptacle (brown)
J08

JX2

Panel connection

P14
J15

J02
P01
P08

P133A
J17 Electric fan

214
J20 Transmission control harness connection

67
J21 Warning light switch
J143

55a J245
Rotating beacon switch
J12

J23
J50

J11
J44

J25 Key operated ignition


J10

J44 Rear harness connection


J246

J50 Temperature potentiometer


J124

Cab top / instrument panel harness connection


J52

J52
187

J59 Hydraulic shuttle reverser control


J247

J114 Fuse box connection


55
J130
J224

Transmission control harness


J17

J119
J20

5 Clutch pedal potentiometer


J119

J124
J130 Clutch pedal contact
J131 Shunt receptacle (black)
J133 CAN link
P133a CAN link
J143 Park lock control
J185 Front axle suspension control harness connection
J196 Brake fluid level
J224 Injection control/instrument panel harness connection (VP44 engine)
J11

J245 Clutch switch


J246 Rear harness connection
J247 Cab top harness connection
J248 Panel connection
J114
J248

J05
J03

Front harness connection (engine)


J04

P01
J15

P08 J08 connector connection


P14 Diagnostic plug
P172 Cab top / instrument panel harness connection

606hsm01

F2.4 Ares 806 – 09.2004 – GB


1 - Instrument panel harness
Wire 2 J02 Ending X
H
J
markers 053
170 055 K
W 171 G B 056
A 081 1 CAN-Low EOC
Wire 2 JX1 Ending
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B 178* 1 + APC engine calculator J04 12 179 178
markers 068 067 066 065 136 061 108 106 064 063 111 007 062 C 013 1,4 D + alternator 130 V 073 F A C 057 L
D — — — 016 081 013
1 — — — E — — — U 086 058 M
2 062 0,35 Transmission oil filter J20 3 F 016 1 Horn J07 B3
3 007 0,35 Preheating indicator J224 4 G 179 2 + AVC engine calculator J15 8 MOB 145
E D
3 007* 0,35 Preheating indicator P08 B2 H 053 1 Windscreen washer pump J06 B4
T 182 082 N
4 111 0,35 Air filter blocked P08 A5 J 055 0,6 W alternator J08 A2 101
5 063 0,35 Transmission oil temperature J20 20 K 056 0,6 Engine water temperature J08 A4 S P
R
6 064 0,35 Hydraulic pressure J04 6 L 057 1 Engine oil pressure J08 B1
7 106 0,35 Engine oil pressure P08 B1 M 058 0,6 Air filter blocked J08 A5
8 108 0,35 D + alternator 130 N 145 1 Air condit. pressure switch J247 14
9 061 0,35 Battery condition J20 18
1 P 082 1 CAN-High EOD
604msm01
10 136 0,35 Brake fluid level P08 A1 R 101 1 +APC Diesel heater relay J09 B1
11 065 0,35 Diagnostic (L) J246 2 S 182 1 Rear windscreen washer J247 9
12 066 0,35 Diagnostic (K) J246 3 T M0B 0,6 Engine water temperature J08 B3
13 067 0,35 CAN - network J246 14 U 086 1 Front power take-off control J44 7
14 068 0,35 CAN + network J246 15 V 073 1 Preheating indicator J08 B2
15 — — — W 171 1 RH side work light E0B 604hsm01
X 170 1 LH side work light E0B
* VP44 engine only
* VP44 engine only

Wire 2 JX2 Ending


15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Wire 2 11 9 7 5 3 1
markers 042 083 043 019 044 105 104 059 113 M0T M0A J03 Ending
markers 100 097 181 130 118
M0M 075 074 022 072 071 070 069 109 091 107 054 110 060
1 M0A 0,35 Fuel level J119 1 147 135 143 144 088 146
2 M0T 0,35 Engine water temperature P08 B3 1 118 1,4 + Parking, cigar lighter J44 9
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16
3 — — — 2 146 3 + AVC RH cab top ventilation J52 7 12 10 8 6 4 2
4 113 0,35 Outside buzzer J20 21 3 130 1,4 + Parking clock/radio J247 7
5 059 0,35 Handbrake J246 16 4 088 0,6 Cab top ventilation controls J12 B4
6 104 0,35 CAN + return J246 12 5 181 1 + APC front axle J185 2
6 144 1 Air conditioning thermostat J247 13

11
7 105 0,35 CAN - network J246 11
+ APC Electrohydraulic spool

9
8 — — — 7 097 1 J119 2

7
9 — — — valve (DEH)

5
Air conditioning compressor

3
10 044 0,35 Trailer 2 steering J114 12 8 143 0,6 J12 B2

1
11 019 0,35 Headlights indicator J07 A2 control
12 043 0,35 Trailer 1 steering J114 11 1 9 100 1 +APC implement socket (5 A) J246 1
13 083 0,35 Rear PTO clutch engaged light J20 15 +APC windscreen wiper park
10 135 1 J52 5
14 042 0,35 Tractor steering J114 9 pos. 604hsm02
15 — — — 16 11 — — —
604msm02
16 060 0,35 Fuel level J20 17 12 147 3 + AVC LH cab top ventilation J52 8
17 110 0,35 Engine water temperature P08 A4
18 054 0,35 IP display selector J06 A4
19 107 0,35 Reverser engaged J248 8
20 091 0,35 Engaged FR PTO indicator J44 7
21 109 0,35 W alternator P08 A2 Wire 2 J04 Ending 025 124 094 125 087 117
22 069 0,35 Rear power take-off speed J20 19 markers
23 070 0,35 Tractor advance speed J20 14 082 064
178 149 121 158 009 119
24 071 0,35 Real speed (radar) J246 13
1 117 3 + AVC socket 25 A J44 1 12 10 8 6 4 2
25 072 0,35 Speed calibration 67
2 119 3 + AVC socket 25 A J44 3
26 022 0,35 Instrument panel light J09 B5
3 087 0,6 Ventilation controls PDB J12 B5
27 — — —
4 009 3 + AVC ventilation controls PDB J17 3
28 074 0,35 + APC control panel J09 A2
5 125 0,6 Hydraulic pressure J20 16

11
29 075 0,35 + AVC control panel J15 7
6 064 0,35 Hydraulic pressure JX1 6

9
30 M0M 0,35 Instrument panel earth J13 B6

7
6 158 0,6 Pressure manometer J20 11

5
7 094 1 + APC rear window wiper J247 1

3
8 121 1,4 +APC TCE (RH+ relayed) J44 6

1
9 124 2 +APC transmission J131 A7
10 149 0,6 D + alternator 130
11 025 2 + APC RH brake light 203
604hsm4F
12 082 1 +APC J224 2
12 178* 1 + APC engine calculator J02 B
* VP44 engine only

Ares 806 – 09.2004 – GB F2.5


1 - Instrument panel harness
Wire 2 J08 Ending
1 2 3 4 5
markers A 185 055 056 058

B 057 073 MOB


A1 185 0,6 Brake fluid level J196 1
Wire 2 J05 Ending
11 9 7 5 3 1
A2 055 0,6 W alternator J02 J
markers 020 116 126 133 A3 — — —
A4 056 0,6 Engine water temperature J02 K
095 015 010 A5 058 0,6 Air filter blocked J02 M
1 133 3 +AVC interior front work lights J52 6

1
A

2
2 — — — 12 10 8 6 4 2
3 — — — B1 057 1 Engine oil pressure J02 L

4
B2 073 1 Preheating indicator J02 V B

5
4 — — —
5 126 3 + AVC front outside work lights J52 1 B3 M0B 0,6 Engine water temperature J02 T
6 010 1,4 + Parking J25 10 B4 — — —

11
RH rear light B5 — — —

9
7 116 1,4 J246 20

7
8 015 1,4 Side light indicator J07 A5 604hsm06

5
9 020 1 RH front light 4

3
Instrument panel lighting

1
10 095 1 J247 19
11 — — —
12 — — — Wire 2 J09 Ending
1 2 3 4 5 6 7
604hsm04 markers
A

A1 076 1 +APC diagnostic socket P14 D B


+ APC control panel
Wire 2 J06 Ending
1 2 3 4 5 A2
A3
074
099
0,35
1 + APC IP/utilities indicators
JX2
J248
28
7
604msm54
markers A 046 054 MOL A4 — — —
1 2 3 4 5 6 7

B 048 050 051 053 A5 — — — A 076 074 099 137


+ APC windscreen wipers 052 A6 137 0,6 + Cab top lights J247 5
A1 046 2 J248 9 A7 — — — B 101 096 022 090
controls
A2 — — —
A3 — — — B1 101 1 +APC Diesel heater relay J02 R
A4 054 0,35 IP display selector JX2 18 B2 — — —

1
A B3 — — —

2
A5 M0L 0,6 IP display selector J13 B7
B4 096 1 Instrument panel lighting J114 5

1
4
B

2
B1 048 1 1st speed windscr. wiper ctrl J247 4 B5 022 0,35 Instrument panel light JX2 26 A

3
B2 050 1 Windscr. wiper ctrl park. pos. J11 6 B6 — —
Intermit. windscreen wiper ctrl B7 090 0,6 Ventilation ctrl lighting J12 A4 B

5
B3 051 1 J11 3

6
B4 052 1 Windscreen washer control J11 2

7
B4 053 1 Front windscreen washer pump J02 H 604msm09
B5 — — —

604hsm07

Wire 2 12 3 4 5
markers
J07 Ending
A 014 018 017 015 Wire 2 J10 Ending
1 2 3 4 5 6 7
019
markers
A
B 038 032 016 034
A1 014 3 + AVC hazard warning control J15 6
A2 018 2 Headlights P01 X A1 031 1,4 Flashing unit J114 7 B
A2 019 0,35 Headlights indicator JX2 11 A2 032 1,4 Flashing light supply J07 B2 604msm2A
A3 — — — A3 077 0,6 CAN-Low J133 1
1 2 3 4 5 6 7
A4 017 2 Dipped headlights P01 W A4 — — —
1

Side light indicator A A5 036 1 Front LH indicator 5 A 031 032 077 036 038 039
2

A5 015 1,4 J05 8


A6 038 1,4 RH flashing lights J07 B1
4

B A7 039 1,4 RH flashing lights J21 5 B 033 035 034 037 041 040
B1 038 1,4 RH flashing lights J10 A6
5

B2 032 1,4 Flashing light supply J10 A2


B3 016 1 Horn J02 F B1 033 1,4 Flashing light supply J21 3
B4 034 1,4 LH flashing lights J10 B4 B2 — — —
B5 — — — 604hsm05
B3 035 1,4 LH flashing lights J21 1
B4 034 1,4 LH flashing lights J07 B4

1
2
B5 037 1,4 LH rear flashing light J246 18 A

3
B6 041 1,4 RH RR flashing light J246 17
B7 040 1 Front RH indicator 4 B

5
6
7
604hsm08

F2.6 Ares 806 – 09.2004 – GB


1 - Instrument panel harness
Wire 2 J15 Ending
11 9 1 7 5 3
markers 081
131 120 075 092 180 103
029 129 179 014 123 028
1 081* 3 +APC J224 1 089
Wire 2 J11 Ending
1 2 3 4 5 6
1 103 2 +AVC TCE 30 A/B J44 2 12 10 8 6 4 2
markers M0F 052 051 049 047 050 + AVC hazard warning light
2 028 1,4 J21 2
control
1 M0F 1,4 Windscreen wiper timer E0A 3 180 1 + AVC front axle J185 1
+AVC transmission

11
2 052 1 Windscreen washer control J06 B4 4 123 2 J119 15
+ APC rotating beacon

9
3 051 1 Intermit. windscreen wiper ctrl J06 B3 5 092 1,4 J23 1

7
4 049 1 Windscr. wiper eng. park. pos. J247 3 + AVC hazard warning signal

5
6 014 3 J07 A1
+APC windscreen wiper timer control

3
5 047 1 J248 11

1
6 050 1 Windscr. wiper ctrl park. pos. J06 B2 7 075 0,35 + AVC control panel JX2 29
1
2
8 179 2 + AVC engine calculator J02 G
3
4 9 120 1 + APC seat J44 5
5
6 10 129 1 + AVC cab top inside J52 2 604hsm4H
604msm14 11 131 1 + APC front power take-off J44 8
+ APC hazard warning light
12 029 1,4 J21 8
control
Wire 2 J12 Ending
1 2 3 4 5 12 089 1 + APC Fan/AC control J12 B1
markers A 139 138
140 148 090 M0N
M0R
* VP44 engine only
B 009 089 089 088 087
A1 139 0,6 IP potentiometer cursor J17 2 143
A1
A2
140
138
0,6
0,6
Cab top potentiometer cursor
Cab top potentiometer
J247
J247
10
11
Wire 2 J17 Ending 1 M0O 139 2
markers
A2 148 0,6 Instrument panel potentiometer J17 4
3 009 148 4 1
A3 — —

1
A4 090 0,6 Ventilation ctrl lighting J09 B7 A 1 M00 3 Ventilation earth E0A 3

2
A5 M0N 0,6 Ventilation ctrl indicator J13 B5 2 139 0,6 IP potentiometer cursor J12 A1
3 009 3 + AVC ventilation controls PDB J04 4

4
B 2

5
B1 089 1 + APC Fan/AC control J15 12 4 148 0,6 Instrument panel potentiometer J12 A2
B2 143 0,6 Air cond. compressor ctrl J03 8 4 604msm19
B3 — — —
B4
B5
088
087
0,6
0,6
Cab top fan control
Instrument panel fan control
J03
J04
4
3 604hsm4G Wire 2 J20 Ending
4 7 10 13 16 19
markers 1 159 154 164 024 125 069

2 167 153 158 070 060 063 20


1 159 0,6 Neutral control J59 B2
2 — — — 3 062 026 083 061 113
Wire 2 J13 Ending
1 2 3 4 5 6 7 3 062 0,35 Transmission oil filter JX1 2
6 9 12 15 18 21
markers 4 — — —
A 5 167 0,6 Clutched position J245 3
6 — — —
A1 M0C 0,6 Warning light ctrl indicator J21 10 B 7 154 0,6 Reverse drive control J59 A4
A2 M0D 1 Diagnostic plug P14 B 604msm3A
8 153 0,6 Forward drive control J59 A2
A3 M0E 0,6 IP calibration speed 67 9 — — —
A4 — — 1 2 3 4 5 6 7
10 164 0,6 Clutch pot. cursor J124 C
A5 M0G 1 RH front side light 4 A MOC MOD MOE MOG MOH MOK 11 158 0,6 Oil pressure switch J04 6
A6 M0H 1 LH front side light 5 12 026 0,6 DRIVETRONIC RH brake light 203
A7 M0K 1,4 Instrument panel earth E0A B MOU MOX MOQ MOP MON MOM MOL
MOW 13 024 0,6 DRIVETRONIC LH brake light 203
14 070 0,35 Tractor speed JX2 23
B1 M0U 0,6 Brake fluid level J196 2 15 083 0,35 Rear PTO light JX2 13 3
B2 MOX* 3 Injection ECU J224 3 16 125 0,6 Hydraulic pressure J04 5
6
9
B3 M0Q 0,6 Rotating beacon indicator J23 10 17 060 0,35 Fuel level JX2 16
B4 M0P 0,6 Reverser relay J59 B4 15
1

18 061 0,35 Battery condition JX1 9 18


2

B4 MOW 0,6 Clutch potentiometer J124 A A 19 069 0,35 Rear PTO speed (IP) JX2 22 21
3

604hsm09
B5 M0N 0,6 Ventilation ctrl indicator J12 A5 20 063 0,35 Transmission oil temperature JX1 5
B6 M0M 0,35 Instrument panel JX2 30 B
5

21 113 0,35 Outside buzzer JX2 4


6

B7 M0L 0,6 IP display selector J06 A5


7

* VP44 engine only


Wire 2 J21 Ending
604hsm19 markers 2 4 6 8

2
028 030 029
LH flashing lights

4
1 035 1,4 J10 B3

6
+ AVC hazard warning signal 035 033 039

8
2 028 1,4 J15 2
control 1 3 5 7
3 033 1,4 Flashing light supply J10 B1
4 — —
5 039 1,4 RH flashing lights J10 A7
6 030 1,4 Hazard warning signal ctrl J114 10
7 — —
+ APC hazard warning signal 9 10
8 029 1,4 J15 12 9
control
M0C

10
9 — —
Hazard warning signal ctrl
10 M0C 0,6 J13 A1
indicator 604hsm10

Ares 806 – 09.2004 – GB F2.7


1 - Instrument panel harness
Wire 2 J52 Ending 1
markers
1 126 MOJ 146 7

1 126 3 + AVC front outside work lights J05 5


Wire 2 J23 Ending 2 129 1 + AVC cab top inside J15 10
2 129 135 147 8

markers 3 127 3 + AVC rear outside work lights J248 1 3 127 133 134 9
2 4 6 8
4 MOJ 2 Cab top inside EOA 1 3

2
+ APC rotating beacon +APC windscreen wiper park

4
1 092 1,4 J15 5 5 135 1 J03 10 9

6
pos. 604hsm14
2 — — — 093

8
092
3 — — — 102 6 133 3 +AVC interior front work lights J05 1
4 — — — 1 3 5 7 7 146 3 + AVC RH cab top ventilation J03 2
5 093 1,4 Rotating beacon control J247 6 8 147 3 + AVC LH cab top ventilation J03 12
5 102 0,6 Rotating beacon indicator J23 9 9 134 3 + AVC rear outside work lights J248 3
6 — — —
7 — — —
8 — — —
9 10
10 Wire 2 1 2 3 4 5

9
9 102 0,6 Rotating beacon indicator J23 5 102 M0Q J59 Ending
10 M0Q 0,6 Rotating beacon indicator J13 B3 markers A 153 154
604hsm11 B 150 159
190
162 156 M0P
A1 — — —
A2 153 0,6 Forward drive control J20 8
A3 — — —
A4 154 0,6 Reverse drive control J20 7
Wire 2 J25 Ending
1 3 5 7 9
A5 — — —

1
markers 001 A

2
B1 150 1,4 +APC neutral relay contact J131 B7
004 006 010

4
1 001 7 + AVC general P01 S B2 159 0,6 Neutral control J20 1 B

5
2 — — — 2 4 6 8 10 B2 190 0,6 Starter safety J114 4
3 — — — B3 162 0,6 Declutching control J119 13
4 004 3 Starter control J114 1 B4 156 1,4 Reverser relay ctrl engaged J248 5
5 — — — B5 M0P 0,6 Reverser relay J13 B4
604hsm15
6 006 7 + APC panel 110 1

5
6
7 — — —
8 — — — 2 10 9
9 — — — 4 3 7
10 010 1,4 + Parking J05 6
8
604hsm12
Wire 2 J114 Ending
11 9
080
7 5 3 1
markers 043 042 031 096 MO1 004

044 030 021 115 190 012


1 004 3 Starter control J25 4
2 012 3 Start-up P01 V 12 10 8 6 4 2
Wire 2 J44 Ending 3 M01 1,4 Panel EOR
markers 4 4 190 0,6 Starter safety J59 B2
1 117 098 086 7
5 096 1 Instrument panel lighting J09 B4
+ AVC socket 25 A 091 6 115 1,4 LH rear light J246 21

11
1 117 3 J04 1
Flashing unit

9
2 103 2 +AVC TCE 30 A/B J15 1 2 103 120 131 8 7 031 1,4 J10 A1

7
3 119 3 + APC socket 25 A J04 2 8 021 1 LH front light 5

5
4 098 0,6 +APC TCE 30 A/B J131 A5 3 119 121 118 9 9 042 0,35 Tractor steering JX2 14

3
Buzzer

1
5 120 1 + APC seat J15 9 6 9 080 0,6 J246 9
6 121 1,4 + APC TCE (D+) J04 8 604hsm13 10 030 1,4 Hazard light switch J21 6
7 086 1 PDF front controls J02 U 11 043 0,35 Trailer 1 steering JX2 12
7 091 0,35 Engaged FR PTO indicator JX2 20 12 044 0,35 Trailer 2 steering JX2 10 604hsm16
8 131 1 + APC PDF front J15 11
9 118 1,4 + Parking, cigar lighter J03 1

Wire 2 J50 Ending 2 1


markers 2
142 141
1

1 141 0,6 Temperature Potential curser J247 8


2 142 0,6 Temperature potentiometer J247 12
604msm28

F2.8 Ares 806 – 09.2004 – GB


1 - Instrument panel harness
Wire 2 J133 Ending
1 077 3
markers
2 151 4

1 77 0,6 CAN-Low EOC


Wire 2 J119 Ending
4 7 10 13
2 151 0,6 CAN-High EOD 1
markers 1 M0A 186 162 3 2
4 2
2 097 155 14
1 MOA 0,35 Fuel level JX2 1 166
+ APC Electrohydraulic spool 604hsm23
3 168 123
2 097 1
valve (DEH) 6 9 12 15
3 — — —
4 186 0,6 Park lock control J143 1 Wire 2 J143 Ending
5 — — — markers 7 5 3 1
6 — — — 3
6
7 — — — 122 186
8 — — — 12 1 186 0,6 Park lock control J119 4
15 2 — — —
9 — — — 604hsm17
10 — — — 3 — — — 8 6 4 2
11 — — — 4 — — — 3
12 168 1,4 +APC solenoid valve supply J130 2 5 122 0,6 + APC Park Lock J131 B5 9
13 162 0,6 Declutching control J59 B3 6 — — — 604hsm30
14 155 1,4 +APC transmission J131 A6 7 — — —
14 166 0,6 + APC clutch potentiometer J124 B 8 — — —
15 123 2 +AVC transmission J15 4

Wire 2 J185 Ending


Wire 2 J124 Ending
markers 2 1
markers 2
181 180 1
1 180 1 + AVC front axle J15 3
A MOW 0,6 Clutch potentiometer J13 B4
C B A 2 181 2 + APC front axle J03 5 M0V
C
B 166 0,6 +APC clutch pot J119 14 164 166 MOW B 3 M0V 1 Front axle controller E0A
A 3
C 164 0,6 Clutch potentiometer cursor J20 10
604hsm18 604msm42

Wire 2 J130 Wire 2 1 185


markers
Ending
markers
J196 Ending
2 MOU
1 157 1,4 Not neutral J248 5 1 2 3 1 185 0,6 Brake fluid level J08 A1
+APC solenoid valve supply 1
2 168 1,4 J119 12 157 168 2 2 MOU 0,6 Brake fluid level J13 B1
3 — — — 3
604msm9U
604hsm21

VP44
Wire 2 J131 Ending
1 2 3 4 5 6 7 Wire 2 J224 Ending
markers markers
A
1 081 082 2 1
A1 — — — B 1 081 3 +AVC (constant source) J15 1 3 M0X 007 4 3
A2 — — — 604msm54 2 082 1 +APC J04 12 2
A3 — — — 3 M0X 3 Injection ECU earth J13 B2
A4 — — — 1 2 3 4 5 6 7 4 007 0,35 Preheating indicator JX1 3 4 604hsm1G
A5 098 0,6 +APC TCE 35 J44 4 A 098 155 124
A6 155 1,4 +APC transmission J119 14
A7 124 2 +APC transmission J04 9 B 122 161 150

B1 — — —
B2 — — — Wire 2 J245 Ending
B3 — — — markers
B4 — — — 1 2 3
1

B5 122 0,6 + APC Park Lock J143 5


2

A 1 — — — 161 167
3

B6 161 1 +APC switch engaged J245 2 2 161 1 + APC clutched contact J131 B6 1
B7 150 1,4 +APC neutral relay contact J59 B1 B Clutched position
2
5

3 167 0,6 J20 5 3


6
7

604hsm24

604hsm22

Ares 806 – 09.2004 – GB F2.9


1 - Instrument panel harness
Wire 2 J248 Ending
11 9 5 7
3 1
markers 157
047 046 099 156 134 127

132 027 107 MOS 128


1 127 3 + APC outside rear work lights J52 3
Wire 2 J246 Ending
4 7 10 13 16 19
2 128 0,6 Rear work lights controls J247 2 12 10 8 6 4 2
markers 1 100 071 059 132 3 134 3 + AVC inside rear work lights J52 9
4 — — —
2 065 105 067 041 116 20 5 157 1,4 Not neutral J130 1
1 100 1 +APC implement socket J03 9 085
5 156 1,4 Reverser relay ctrl engaged J59 B4

11
2 085 1 Line L P14 A 3 066
084 080 104 068 037 115
Shuttle reverser

9
2 065 0,35 Diagnostic (L) JX1 11 6 M0S 0,6 EOA

7
3 084 1 Line K P14 C
6 9 12 15 18 21 7 099 1 + APC IP/utilities indicators J09 A3

5
8 107 0,35 Reverser engaged JX2 19

3
3 066 0,35 Diagnostic (K) JX1 12
+APC wiper control

1
4 — — — 9 046 2 J06 A1
5 — — — 10 027 2 Rear stop 203
6 — — — 11 047 1 +APC windscreen wiper timer J11 5
7 — — — 12 132 2 Rear stop J246 19
604hsm29
8 — — —
9 080 0,6 Buzzer J114 9
10 — — —
11 105 0,35 CAN - return JX2 7
12 104 0,35 CAN + return JX2 6 Wire 2 P01 Ending
S T U
13 071 0,35 Radar speed JX2 24 3
markers 001 002
14 067 0,35 CAN - JX1 13 6
9 R
15 068 0,35 CAN + JX1 14 R 003 10 + AVC general 110
Handbrake Z 003 012 V
16 059 0,35 JX2 5 15
18
S 001 7 + AVC general J25 1
17 041 1,4 RH RR flashing light J10 B6 21 T — — —
LH rear flashing light 604hsm25
18 037 1,4 J10 B5 U 002 7 + AVC general 110 018 017
19 132 2 Rear stop J248 12 V 012 3 Start-up J114 2 Y X W 604msm47
20 116 1,4 RH rear light J05 7 W 017 2 Dipped light J07 A4
21 115 1,4 LH rear light J114 6 X 018 2 Headlight J07 A2
Y — — —
Z — — —

Wire 2 J247 Ending


4 7 10 13 16 19
markers 1 094 048 130 140 144 095
Wire 2 P08 Ending
1 2 3 4 5
2 128 137 141 138 145 20
1 094 1 + APC rear window wiper J04 7 markers A 136 109 110 111
2 128 0,6 Rear work light controls J248 2 3 049 093 182 142
B 106 007 MOT
3 049 1 Windscr. wiper eng. park. pos. J11 4 A1 136 0,35 Brake fluid level JX1 10
6 9 12 15 18 21
First speed windscreen wiper A2 109 0,35 W alternator JX2 21
4 048 1 J06 B1
controls A3 — — —
+ Cab top lights Engine water temperature A

1
5 137 0,6 J09 A6 A4 110 0,35 JX2 17

2
6 093 1,4 Rotating beacon control J23 5 A5 111 0,35 Air filter blocked JX1 4

3
7 130 1,4 + Parking clock/radio J03 3 B

4
Temperature potent. cursor B1 106 0,35 Engine oil pressure JX1 7

5
8 141 0,6 J50 1
9 182 1 Rear windscreen washer pump J02 S B2 007* 0,35 Preheating indicator JX1 3
10 140 0,6 Cab top potentiometer cursor J12 A1 B3 M0T 0,35 Engine water temperature JX2 2
11 138 0,6 Cab top potentiometer J12 A2 B4 — — — 604hsm26
12 142 0,6 Temperature potentiometer J50 2 B5 — — —
13 144 1 Air conditioning thermostat J03 6 3 * VP44 engine only
14 145 1 Air condit. pressure switch J02 N 6
9
15 — — —
16 — — — 15
17 — — — 18
21 Wire 2 P14 Ending
18 — — — 604hsm28 markers
19 095 3 + AVC rear low work lights J05 10
20 — — — A B C D
A 085 1 Line L J246 2 D
21 — — —
B M0D 1 Diagnostic socket earth J13 A2 085 M0D 084 076 C
B
C 084 1 Line K J246 3 A
D 076 1 +APC diagnostic socket J09 A1
604msm50

F2.10 Ares 806 – 09.2004 – GB


1 - Instrument panel harness Notes

Wire 2 P133a Ending


1 078 3
markers
2 152 4

1 078 0,6 CAN-Low EOC


2 152 0,6 CAN-High EOD

604hsm27

Wire 2 P172 Ending


markers
1 2 2
1
1 — — — 169
2 169 2 Lower lateral lights E0B
604msm53

Ares 806 – 09.2004 – GB F2.11


F2.12
P16 P02

606hsm02
P02 P16

E0A
30

226 226
A B
30 30
J01

34 P02
J39 J142
J34
J22 E3D
31 J176
J200

P16
J16
J31
J153
P139
P140
J51
J209 J210
94 J213
J226 32
E3B J152
E3A

210
2 - Preheating control harness

J19 E3C
3/1 - Front harness (DE10 engine)

206
200

J243
J18 J244
J212
J218
173
24

J141

Ares 806 – 09.2004 – GB


606hsm03
P16 P02
P02 P16

P220
226 226
A B
30 30 P02
J216
J01 P221
J39 J223 J218
E0A

P224 J222
34 30
J209
J176

31
J213
P16 J200
J16

32 J31
J22
J34 J153
95 P139
J152 P217
J210
J51 J217
94
3/2b - Injection harness

210
J214
3/2c - Injection control harness

E3A E3B
E3C
3/2a - Front harness (VP44 engine)

J19
200
206
J18
173 J211

J212

J141
2 - Preheating control harness 2 - Preheating control harness

Connectors Designation Wire 2


J39 Preheating fuse (70 A) markers
J39 Ending
1

P16 Engine harness connection 1 2


1 OR 10 Preheating relay 226 30 2
2 RD 10 + Battery 31 OR RG

3/1 - Front harness (DE10 engine) 604msm55

Connectors Designation
J01 Connection to instrument panel harness Wire 2 P16 Ending
J16 Preheating control harness connection markers
A
J18 LH dipped beam / headlamps A GN 1 Preheating control 226 85 VE
J19 RH dipped beam / headlamps
J22 Front windscreen washer pump 604msm56
J31 Engine water temperature
J34 Compressor
Front PTO solenoid valve
J51
3/1 - Front harness (DE10 engine)
J141 Steering angle
J142 Turbo pressure
J152 LH side work light (step)
J153 RH side work light (step)
Wire 2 J01 Ending
S T U
markers 300 301
J176 Throttle control potentiometer R
J200 Rear windscreen washer pump R 322 10 + AVC general E3D
Z 322 304 V
S 300 7 + AVC general E3D
J209 Air temperature T — — —
U 301 7 + AVC general E3D 311 310
J210 Engine water temperature V 304 2 Starter solenoid 32 Y X W 604msm57
J212 Engine speed W 310 2 Dipped light E3A
X 311 2 Headlight E3B
J213 Injection pump Y — — —
J218 Injection pump Z — — —

J226 Fuel temperature


J243 ADC
J244 ADC Wire 2 J16 Ending
markers
P02 Connection to instrument panel harness A
316
P139 Connection to transmission harness A 316 1 Preheating control J218 K3
P140 Connection to transmission harness A
604msm58

Wire 2 J18 Ending


markers C
312 C
C 312 1 LH dipped light E3A
313 M3D
M M3D 1 LH light earth E3C
R 313 1 LH headlight E3B R M
M
604msm59

Wire 2 J19 Ending


markers C
C
314
C 314 1 RH dipped light E3A
M M3E 1 RH light earth E3C 315 M3E
R 315 1 RH headlight E3B R M M
604msm60

Ares 806 – 09.2004 – GB F2.13


3/1 - Front harness
Wire 2 J153 Ending
markers
A B
A M3N 1 RH side work light earth E3E
Wire 2 J22 Ending B 335 1 RH side work light P02 X M3N 335
markers A
B
3 2 1
320 M3K
1 M3K 1 FR windscr. washer pump earth E0A M3P 604hsm35
1 M3P 1 RR windscr. washer pump earth J200 1 3
2
2 — — — 1

3 320 1 Front windscreen washer pump P02 H 604hsm31 Full Powershift


Wire 2 J176 Ending
markers
C B A
A 351 1 - REF, accelerator sensor E3F 1
Wire 2 J31 Ending B 353 1 Accelerator sensor signal E3G 351 353 352
markers C 352 1 + APC accelerator sensor J218 B3 CB
A
1 2 604hsm36
1 307 1 Engine water temperature P02 K

1 2
2 M3F 1 Engine water temperature earth P02 T 307 M3F

Wire 2 J200 Ending


markers
604msm62 3 2 1

1 M3P 1 RR windscr. washer pump earth J22 1 336 M3P


2 — — — 3

Wire 2 J34 Ending


3 336 1 Rear windscreen washer pump P02 S
2
1
604hsm37
markers A
318
A 318 1 Air conditioning compressor 210
A
604msm63 Wire 2 J209 Ending
markers
A B
A 331 1 Air temperature J218 D1 A
Wire 2 J51 Ending B 349 1 - REF, air temperature E3F
331 349
B
markers
B A 604hsm38
A 321 1 + Front PTO solenoid valve P02 U M3L 321
B M3L 1 Front PTO solenoid valve earth E3E
B
A
604msm64 Wire 2 J210 Ending
markers
A B
A 332 1 Engine water temperature J218 B1
2 332 347 A
Wire REF, engine water temperature B
markers
J141 Ending B 347 1 E3F
3 2 1
604hsm39
1 328* 1 - Steering angle P139 C 330 329 328
3
1 328** 1 - Steering angle P139 B 2
1
2 329* 1 Steering angle signal P139 A Wire 2 J212 Ending
A B
2 329** 1 Steering angle signal P140 D 604hsm32 markers 344 343
3 330* 1 + Steering angle P139 B
3 330** 1 + Steering angle P140 C
A 344 1 Engine speed J218 B2 A
* Only on Quadrishift B 343 1 Engine speed J218 D2 B
** Only on Full Powershift
604hsm40

Wire 2
markers
J142 Ending Wire 2 J213 Ending
1 2
C B A markers 337 338 1
A 325 1 - Turbo supply P139 A 327 350 325 2
C
B 350 1 Turbo pressure signal P140 A B 1 337 1 Injection pump J218 K2
A
C 327 1 + Turbo supply P140 B 2 338 1 Injection pump J218 A3
604hsm33

604hsm41

Wire 2 J152 Ending


markers
A B
A M3M 1 LH side work light earth E3E
B 334 1 LH side work light P02 W M3M 334
A
B

604hsm34

F2.14 Ares 806 – 09.2004 – GB


3/1 - Front harness (DE10 engine)
Wire 2 P02 Ending X
H
J
markers 335
309 K
320

334 G B 307
W
A 345 1 CAN-Low J244 1
Wire 2 J218 Ending
K J H G F E D C B A
B 308 1 + APC engine calculator J218 A2
V 341 F
323 308
A C 305 L
markers 316 355 326 333 352 338 3 C 303 1 D+ alternator 31
D 355 1 Diagnostic indicator J218 G3 306 345 303
337 M3H 308 343 344 308
354 2 E — — — U 321 319 M
A1 — — —
A2 308 1 + APC engine calculator P02 B F 306 1 Horn 173 355
323 341 340 339 331 332 1
A2 354 1 + APC engine calculator E3G G 323 1 + AVC engine calculator J218 K1 M3F E D 317
A3 338 1 Injection pump J213 2 H 320 1 Windscreen washer pump J22 3 T 346 N
336
B1 332 1 Engine water temperature J210 A J 309 1 W alternator 31
K 307 1 Engine water temperature J31 1 S R P
B2 344 Engine speed J212 A
+ APC accelerator sensor L 305 1 Engine oil pressure 200

K
B3 352 1 J176 C
Air filter blocked

J
M 319 1 206

H
C1 — — —

G
N 317 1 Pressure switch 210

F
C2 — — —
C3 333 1 Fuel temperature J226 A P 346 CAN-High J244 2

E
D1 331 1 Air temperature J209 A R — — —

D
C
Engine speed S 336 1 Rear windscreen washer pump J200 3

B
D2 343 J212 B
Engine water temperature

A
D3 326 1 REF, sensors E3F T M3F 1 J31 2
E1 — — — U 321 1 PDF front J51 A

1 2 3
E2 — — — V 341 1 Preheating indicator J218 J1
E3 — — — W 334 1 LH side work light J152 B 604hsm46
F1 339 1 CAN-Low J243 1 X 335 1 RH side work light J153 B
604hsm42
F2 — — —
F3 — — —
G1 340 1 CAN-High J243 2
Quadrishift
G2
G3

355

1

Diagnostic indicator P02 D Wire 2 P139 Ending
H1 — — — markers
H2 — — —
H3 — — — A 329 1 Steering angle signal J141 2 C B A
J1 341 1 Preheating indicator P02 V B 330 1 + Steering angle J141 3 328 330 329
J2 M3H 1 Injection pump EOA C 328 1 - Steering angle J141 1 C
BA
J3 — — —
K1 323 1 + AVC engine calculator P02 G
604hsm47
K2 337 1 Injection pump J213 A
K3 316 1 Preheating controls J16 A

Full Powershift
Wire 2 P139 Ending
markers
Wire 2 J226 Ending
A B
markers A 325 1 Turbo supply J142 A 325 328
B 328 1 - Steering angle J141 1
A 333 1 Fuel temperature J218 C3 A B A A
B 348 1 - REF, fuel temperature E3F B B
333 348
604hsm43 604hsm48

Wire 2 J243 1 339


Ending Full Powershift
markers
2 340 Wire 2 P140 Ending
markers
1 339 1 CAN-Low J218 F1
2 340 1 CAN-High J218 G1 A 350 1 Turbo pressure signal J142 B A B C D
B 327 1 + Turbo supply J142 C D
C
350 327 330 329
604hsm44 C 330 1 - Steering angle J141 3 B
D 329 1 + Steering angle signal J141 2 A

Wire 2 J244 Ending


1 345
604hsm49

markers
2 346
1 345 1 CAN-Low P02 A
2 346 1 CAN-High P02 P

604hsm45

Ares 806 – 09.2004 – GB F2.15


3/2a - Front harness (VP44 engine) 3/2a - Front harness (VP44 engine)

Connectors Designation Wire 2 S T U


J01 Connection to instrument panel harness markers
J01 Ending
300 301
J18 LH dipped beam / headlamps R
R 322 10 + AVC general E3D
J19 RH dipped beam / headlamps S 300 7 + AVC general E3D Z 322 304 V
T — — —
J22 Front windscreen washer pump U 301 7 + AVC general E3D 311 310
J31 Engine water temperature V 304 2 Starter solenoid 32
Y X W 604msm57
W 310 2 Dipped light E3A
J34 Compressor X 311 2 Headlight E3B
J51 Front PTO solenoid valve Y — — —
Z — — —
J141 Steering angle
J152 LH side work light (foot plate)
J153 RH side work light (foot plate)
Wire 2 J18
J200 Rear windscreen washer pump markers
Ending C
P02 Connection to instrument panel harness 312 C
C 312 1 LH dipped light E3A
P139 Connection to transmission harness M M3D 1 LH light earth E3C 313 M3D
R 313 1 LH headlight E3B R M
M
604msm59

3/2b - Injection harness


Wire 2 J19 Ending
Connectors Designation markers C
C
314
J16 Preheating control harness connection C 314 1 RH dipped light E3A
J209 Air temperature M M3E 1 RH light earth E3C 315 M3E
R 315 1 RH headlight E3B R M
J210 Engine water temperature M
604msm60
J211 Injection pump synchronisation
J212 Engine speed
J213 Electric pump Wire 2 J22 Ending
markers
J214 Injection pump 3 2 1
320 M3K
P217 Connection to engine control harness 1 M3K 1 FR windscr. washer pump earth E0A M3P
1 M3P 1 RR windscr. washer pump earth J200 1 3
2
2 — — — 1

3 320 1 Front windscreen washer pump P02 H 604hsm31

4/1a - Injection control harness


Connectors Designation
Wire 2 J31 Ending
markers
J176 Throttle control potentiometer
1 2
J216 Safety relay 1 307 1 Engine water temperature P02 K

1 2
2 M3F 1 Engine water temperature earth P02 T 307 M3F
J217 Connection to injection harness
J218 Injection ECU
J220 Connection to transmission control harness 604msm62

J222 Shunt receptacle, white


J223 Shunt receptacle, white Wire 2
P221 Connection to TCE control harness markers
J34 Ending
A
P224 Connection to instrument panel harness A 318 1 Air conditioning compressor 210
318

A
604msm63

F2.16 Ares 806 – 09.2004 – GB


3/2a - Front harness
Wire 2 P02 Ending X
H
J
markers 335
320
309 K
G B
W 334 307
A — — —
Wire 2 J51 Ending B — — —
V F A C 305 L
markers C 303 1 D+ alternator 31
B A D — — — 306 303
E — — — U 321 319 M
A 321 1 + Front PTO solenoid valve P02 U M3L 321
B M3L 1 Front PTO solenoid valve earth E3E F 306 1 Horn 173
B G — — — M3F E 317
A D
604msm64 H 320 1 Front windscreen washer pump J22 3 T N
336
J 309 1 W alternator 31
K 307 1 Engine water temperature J31 1 S R P
L 305 1 Engine oil pressure 200
Wire 2 J141 Ending
M 319 1 Air filter blocked 206
markers N 317 1 Pressure switch 210
3 2 1 P — — —
R — — —
1 328 1 - Steering angle P139 C 330 329 328
3 S 336 1 Rear windscreen washer pump J200 3
2 329 1 Steering angle signal P139 A 2
1 T M3F 1 Engine water temperature earth J31 2
3 330 1 + Steering angle P139 B
U 321 1 PDF front J51 A
604hsm32
V — — —
W 334 1 LH lateral work light J152 B 604hsm0M
X 335 1 RH lateral work light J153 B
Wire 2 J152 Ending
markers
A B
A M3M 1 LH side work light earth E3E Wire 2 P139 Ending
LH side work light M3M 334
B 334 1 P02 W markers
A
B C B A
A 329 1 Steering angle signal J141 2
604hsm34 B 330 1 + Steering angle J141 3 328 330 329 C
BA
C 328 1 - Steering angle J141 1
604hsm47
Wire 2 J153 Ending
markers
A B
RH side work light earth
A
B
M3N
335
1
1 RH side work light
E3E
P02 X M3N 335 3/2b - Injection harness
A
B

604hsm35

Wire 2 J16 Ending


markers
Wire 2 J200 Ending
A

markers 359
3 2 1 A 359 1 Preheating control P217 1
336 M3P A
1 M3P 1 RR windscr. washer pump earth J22 1 604hsm0N
2 — — — 3
2
3 336 1 Rear windscreen washer pump P02 S 1
604hsm37

Wire 2 J209 Ending


markers
A B
A 350 1 Air temperature P217 20 350 357 A
B 357 1 - REF, air temperature E3F B

604hsm0P

Wire 2 J210 Ending


markers
A B
A 351 1 Engine water temperature P217 21 351 358 A
B 358 1 - REF, engine water temperature E3F B

604hsm0R

Ares 806 – 09.2004 – GB F2.17


3/2b - Injection harness
Wire 2 P217 Ending
31 20
markers 30 365 8 350 21
366 19 367 9 351
1 359 1 Preheating control J16 A
Wire 2 J211 Ending 2 — — —
18 2 10
markers 3 — — — 29 356 7 3 22
A B 4 — — — 17 1 11 361
A 352 1 Pump synchronisation (+) P217 26 352 352 A 5 — — — 363 359
28 6 4 23
B 353 1 Pump synchronisation (-) P217 27 B 6 364 1 Speed output J214 8
7 — — — 16 364 5 12
604hsm0S 8 367 1 Pump GND CAN J214 3 M30B15 13 372
9 — — — 27 M30A 14 24
10 — — —
11 — — — 353 26 25 354
Wire 2 J212 Ending
12 372 1,4 + AVC switched J214 7 352 355
markers 13 — — —
A B 14 — — —
A 354 1 Engine speed (+) P217 24 A
15 M30A 1 Power earth E3H
354 355
B 355 1 Engine speed (-) P217 25 B 16 M30B 1 Power earth E3H
17 363 1 Fuel feed cut-out J214 5
604hsm0T 18 356 1 Electric pump supply J213 A
19 — — —
20 350 1 Air temperature J209 A
21 351 1 Engine water temperature J210 A
Wire 2 J213 Ending
1 2 22 361 1 Sensors return E3F
markers 356 M3D 1
23 — — —
2 24 354 1 Engine speed (+) J212 A
1 356 1 Electric pump supply P217 18 25 355 1 Engine speed (-) J212 B
2 M3D 1 Electric pump earth E3H 26 352 1 Pump synchronisation (+) J211 A
27 353 1 Pump synchronisation (-) J211 B
28 — — —
29 — — — 604hsm0W
604hsm0U
30 366 1 CAN-High J214 2
31 365 1 CAN-Low J214 1

Wire 2 J214 Ending


3 4 5 6
markers 2 366 M3OH 363 M3OC
367
364 372
1
2
365
366
1
1
CAN-Low
CAN-High
P217
P217
31
30
1 365
9 8 7
4/1a - Injection control harness
3 367 1 Pump GND CAN P217 8
4 M3OH 1 Injection pump earth E3H
5 363 1 Fuel feed cut-out P217 17
Injection pump earth
6
7
M3OC
372
2
1,4 + AVC switched
E3H
P217 12
Wire 2 J176 Ending
8 364 1 Speed output P217 6 markers
C B A
9 — — —
A M4F 1 Potentiometer earth J222 B3 429 428 M4F
B 428 1 + APC potentiometer J222 A6 CB
C 429 1 Accelerator potent. cursor J218 31 A
604hsm1B

604hsm0V

Wire 2 J216 Ending 5


markers 419 5
420 4
1
1 413 1 Safety relay J218 62 1 413 M4C 2 4
2 M4C 1 Relay earth J222 B3 2
3 417 3 +AVC (constant source) J222 B1 417 3
4 — —
3 604hsm0Y
5 419 1 + AVC switched J218 35
5 420 1,4 + AVC switched J217 12

F2.18 Ares 806 – 09.2004 – GB


4/1a - Injection control harness
Wire 2 J218 Ending 1 M4B
markers
24
46
1 M4B 2 ECU earth J222 B4 418
Wire 2 J217 Ending
20 31 2 — — — 2
markers 21 400 8 421 30 3 — — —
401 423 422
4 — — —
9 19
1 418 1 Preheating control J218 63 5 — — —
2 — — —
10 2 18 6 401 1 Engine water temperature J217 21
3 — — — 22 3 7 412 29 7 — — — 5 400 50
4 — — — 408 11 1 17
8 — — —
5 — — — 9 404 1 Engine speed (+) J217 24 401
23 4 418 6 410 28 10 402 1 Pump synchronisation (+) J217 26
6 411 1 Speed output J218 17
7 — — — 12 5 411 16 11 — — —
8 423 0,8 Pump GND CAN J218 60 420 13 15 M4E
12 — — —
9 — — — 13 — — —
24 14 M4D 27 14 — — — 429
10 — — — 404
11 — — — 404 25 26 403 15 — — —
12 420 1,4 + AVC switched J216 5 405 402 16 — — —
10 402 55
13 — — — 17 411 1 Speed output J217 6
14 — — — 18 410 1 Fuel feed cut-out J217 17
15 M4D 1 Power earth J222 A3 19 427 1 + APC ECU J222 A7 405
16 M4E 1 Power earth J222 A5 20 — — —
17 410 1 Fuel feed cut-out J218 18 21 430 1 CAN-Low (diagnostic) J223 B6 419
18 412 1,4 Electric pump supply E4A 22 407 1 Electric pump supply E4A 422
19 — — — 23 415 2 +AVC (constant source) J222 A2 403
20 400 1 Air temperature J218 50 24 408 1 Sensors return J217 22 421
21 401 1 Engine water temperature J218 6 25 — — —
26 — — — 15 423 60
22 408 1 Sensors return J218 24
23 — — — 27 — — —
24 404 1 Engine speed (+) J218 9 28 — — —
25 405 1 Engine speed (-) J218 34 29 — — —
411 413
26 402 1 Pump synchronisation (+) J218 10 30 — — —
27 403 1 Pump synchronisation (-) J218 36 31 429 1 Accelerator potent. cursor J176 C 410 418
28 — — — 604hsm0X
32 — — —
29 — — — 33 — — — 427
30 422 0,8 CAN-High J218 58 34 405 1 Engine speed (-) J217 25 438
31 421 0,8 CAN-Low J218 59 35 419 1 + AVC switched J216 5 20 65
36 403 1 Pump synchronisation (-) J217 27
37 — — — 430 409
38 — — — 434
39 — — — 22 407 406
40 — — —
41 — — — 416 68
45
42 438 1 Shielding CAN J223 B5
23 415
43 — — —
44 434 1 CAN-High (diagnostic) J223 B1
45 — — —
46 — — —
47 — — —
48 — — —
49 — — —
50 400 1 Air temperature J217 20
51 — — —
52 — — —
53 — — —
54 — — —
55 — — —
56 — — —
57 — — —
58 422 0,8 CAN-High J217 30
59 421 0,8 CAN-Low J217 31
60 423 0,8 Pump GND CAN J217 8
61 — — —
62 413 1 Safety relay J216 1
63 418 1 Preheating control J217 1 604hsm0Z
64 — — —
65 — — —
66 409 1 Preheating indicator control P224 4
67 406 1 Electric pump supply E4A
68 416 1 +AVC (constant source) J222 B2

Ares 806 – 09.2004 – GB F2.19


4/1a - Injection control harness
Wire 2 P224 Ending 2
markers 2 426 414 1
4
1 414 3 +AVC (constant source) J222 A1 4 409 M4A 3 1
Wire 2 J220 Ending 2 426 1 +APC J222 B7
markers 4 3 M4A 3 Earth J222 B5 3 604hsm1A

2 4 409 1 Preheating indicator control J218 66


1 432 1 CAN-Low J223 A7 440 436
2 436 1 CAN-High J223 A2 3
432
3 440 1 Shielding CAN J223 B3
4 — — — 1
604hsm1C

Wire 2 J222 Ending


1 2 3 4 5 6 7

markers A

A1 414 3 +AVC (constant source) P224 1 B


A2 415 2 +AVC (constant source) J218 23 604msm2A
A3 M4D 1 Power earth J217 15
1 2 3 4 5 6 7
A4 — — —
A5 M4E 1 Power earth J217 16 A 414 415 M4D M4E 428 427
A6 428 1 + APC potentiometer J176 B
A7 427 1 + APC ECU J218 19 B 417 416 M4C M4B M4A 426
M4F

B1 417 3 +AVC (constant source) J216 3


B2 416 1 +AVC (constant source) J218 68
B3 M4C 1 Relay earth J216 2
B3 M4F 1 Potentiometer earth J176 A

1
2
B4 M4B 2 ECU earth J218 1 A

3
B5 M4A 3 Earth P224 3
B6 — — —

5
B

6
B7 426 1 +APC P224 2

7
604hsm1E

Wire 2 J223 Ending


1 2 3 4 5 6 7
markers A

A1 435 1 CAN-High (diagnostic) P221 2 B


604msm2A
A2 436 1 CAN-High (diagnostic) J220 2
A3 — — — 1 2 3 4 5 6 7
A4 — — —
A 435 436 431 432
A5 — — —
A6 431 1 CAN-Low (diagnostic) P221 1 B 434 437 440 439 438 430 433
A7 432 1 CAN-Low (diagnostic) J220 1

B1 434 1 CAN-High (diagnostic) J218 44


B2 437 1 CAN-High (diagnostic) R1
B3 440 1 Shielding CAN J220 3
1

B4 439 1 Shielding CAN P221 3


2

B5 438 1 Shielding CAN J218 42 A


3

B6 430 1 CAN-Low (diagnostic) J218 21


5

B
B7 433 1 CAN-Low (diagnostic) R1
6
7

604hsm1F

Wire 2 P221 Ending


4
markers
3
435 439
1 431 1 CAN-Low (diagnostic) J223 A6 2
2 435 1 CAN-High (diagnostic) J223 A1 431
3 439 1 Shielding CAN J223 B4 1
4 — — 604hsm1D

F2.20 Ares 806 – 09.2004 – GB


Notes Notes

Ares 806 – 09.2004 – GB F2.21


4/2 - Front axle suspension control harness Connectors Designation
J182 Suspension control unit
J183 Suspension switch (manual)
J184 Suspension switch (auto)
P185 Instrument panel harness connection

E4B
P185

J184
J131

303

J182
P182
J184
J183

J182

606msm06

F2.22 Ares 806 – 09.2004 – GB


4/2 - Front axle suspension control harness Notes

Wire 2 J182 Ending


1 2 3 4 5 6
markers 482 483 484 485 486

491 M4F M4E 488


1 — — —
2 482 1 Front axle lower ctrl J183 1 12 11 10 9 8 7
3 483 1 Front axle rise ctrl J183 7
4 484 1 Locking control J184 8
5 485 1 Automatic control J184 2
6 486 1 + AVC suspended front axle P185 1
7 — — —
8 488 1 + APC suspended front axle E4B
9 M4E 1 Front axle controller earth P185 3 1
12 2
10 M4F 1 Front axle controller earth P185 3 11 3
10 4
11 491 1 Front axle indicator light J184 10 9 5 6
8
12 — — — 7

604msm6A

Wire 2 J183 Ending


markers
2 4 6 8

2
Front axle lower ctrl

4
1 482 1 J182 2

6
2 — — —

8
482 494 483
3 494 1 + APC suspended front axle E4B
4 — — — 1 3 5 7
5 — — —
6 — — — 604msm7A
7 483 1 Front axle rise ctrl J182 3
8 — — —

Wire 2 J184 Ending


markers
2 4 6 8
2
4
1 — — — 485 495 484 6
2 485 1 Automatic control J182 5 8
3 — —
4 495 1 + APC suspended front axle E4B 1 3 5 7
5 — — —
5 — — —
6 — — —
7 — — —
8 484 1 Locking control J182 4
9 493 1 + APC suspended front axle E4B 9 10
10 491 1 Front axle indicator light J182 11
9

493 491
10

604msm78

Wire 2 P185 Ending


markers 1 2
486 492
1 486 1 + AVC suspended front axle J182 6
M4E
2 492 1 + APC front axle E4B M4F
3 M4E 1 Front axle controller earth J182 9 3
3 M4F 1 Front axle controller earth J182 10
604msm79

Ares 806 – 09.2004 – GB F2.23


5 - Instrument panel / cab top harness Connectors Designation
YL Car-radio
JB Car-radio
J56 Rear work light switch
J57 Front work light switch
J60 Shunt receptacle (brown)
J61 Cab top / rear light harness connection
J62 Cab top / front light harness connection
J63 Shunt receptacle (white)
J64 Roof lamp
J65 Clock
J104 Rear windscreen wiper
J107 Cab top / air conditioning + rear light harness connection
J108 Cab top / air conditioning + rear light harness connection
J151 Rear harness connection
J168 Rear work lights switch (wings)
P62
E5A

J95

J169 Rear work lights relay (wings)

J172
J170 Front work lights relay
J62

E0A
J172 Instrument panel harness connection
208

P52 Instrument panel harness connection


P54 RH loudspeaker
JA JB

E6A
P52
87

P55 LH loudspeaker

J151
P247 Superstructure harness
P247
J60

J63
J61

J108
J107

J107
P54
209

P55

JB
J57 J56

JA

P52
E5B J65
J104

J64 E5E
208
J169
J168

J62
J170

606msm05

F2.24 Ares 806 – 09.2004 – GB


5 - Instrument panel / cab top harness
Wire 2 J57 Ending
1 2 3 4 5
markers C M5I

A1 — — — B 590 506 595


Wire 2 YL Ending
1 3 5 7
A2 — — —
markers 525 A 500
A3 500 3 + AVC outside front work lights P52 1
M5K
A4 — — —
538
1 — — — A5 — — —
2 — — — 2 4 6 8
3 — — — B1 590 0,6 Inside FR work light ctrl J170 1

1
4 538 1 +AVC radio J63 B2 B2 — — — C

2
5 — — — B3 — — —

3
B4 506 3 Front work lights J62 A1 B
6 — — —

4
7 525 1 + Parking, radio J63 A7 B5 595 3 Lower front work lights J172 2 A

5
8 M5K 1 Radio earth J60 B1
C1 M5I 0,6 Front work light indicator J60 A2
604msm80 C2 — — —
C3 — — —
C4 — — — 604msm83
C5 — — —
Wire 2 JB Ending
1 3 5 7
markers 529 527
521 528
1 — — —
2 4 6 8
Wire 2 J60 Ending
1 2 3 4 5 6 7
2 — — — markers
3 529 0,6 + Right-hand loudspeaker P54 2 A
4 521 0,6 - RH loudspeaker P54 1
5 527 0,6 + Left-hand loudspeaker P55 2 A1 M5S 1 Antenna 87 B
6 528 0,6 - LH loudspeaker P55 1 A2 M5I 0,6 Front work light indicator J57 C1 604msm3A
7 — — — A3 M5J 0,6 Rear work light indicator J56 C1 1 2 3 4 5 6 7
8 — — — A4 — — —
A5 M5N 0,6 LH door contact 209 M5S M5I M5J M5N M5O M5P A
A6 M5O 0,6 RH door contact 208
604msm81
A7 M5P 0,6 Front screen wiper J62 B2 M5K M5L M5M M5G M5Y M5 M5Q B
CC

B1 M5K 1 Radio earth YL 8


B2 M5L 1 Roof lamp J64 2
Wire 2 J56 Ending
1 2 3 4 5
B3 M5M 0,6 Clock earth J65 4
markers

1
C M5J B4 M5G 3 Utilities P52 4

2
Thermostat A

3
B5 M5Y 1 J107 B2
B 546 548 596 B6 M5CC 0,6 Relays E5E
A1 — — — B

5
B7 M5Q 1 Rear windscreen wiper J104 1

6
A2 — — — A 505

7
A3 — — —
A4 — — —
A5 505 3 Up ins. RR work lights P52 9

B1 546 0,6 Wings RR work light ctrl J168 1 604hsm4A


1

B2 — — — C
2

B3 — — —
3

B
Outs. RR work light ctrl
2
4

B4 548 0,6 J169 1


A Wire
Rear work lights J61
5

B5 596 3 E5B Ending 1 2 3


markers
539 597 A
C1 — —

1
C1 M5J 0,6 Rear work light indicator J60 A3 A1 539 3 Rear outside cab top work lights J169 5 M5F M5 B
NN A

3
C2 — — — A2 — — —
C3 — — — 604msm82 A3 597 3 Inside rear work lights E5B B
C4 — — —
C5 — — — B1 M5F 3 Rear work lights E5A
B2 — — — 604msm85
B3 M5NN 3 Rear work lights E5A

Ares 806 – 09.2004 – GB F2.25


5 - Instrument panel / cab top harness
Wire 2 J104 Ending
markers 1 2
1
M5Q 502

2
1 M5Q 1 Rear windscreen wiper J60 B7
Wire 2 J62 Ending
1 2 3 4 5 6 7
2 502 1 Rear windscreen wiper P247 1 599
markers 506 510 508 516 M5E 517 A 3 599 1 Rear windscreen washer P247 9 3
M5A M5P 509 M5H B 604msm90
A1 506 3 Front work lights J57 B4
A2 510 1 Front windscreen wiper control P247 4
A3 508 1 Windscreen wiper fixed stop P247 3
A4 — — — Wire 2 J107 Ending
A5 516 3 Rear work lights J170 5 markers
A6 M5E 3 Front work lights E5A

1
1 2 3

2
Rotating beacon

1
A7 517 1,4 P247 6 A Temperature potentiometer

3
A1 530 0,6 P247 8 530 536 A A

3
B1 M5A 3 Front work lights E5A B A2 — — —

5
+12 V thermostat

6
B2 M5P 0,6 Front screen wiper J60 A7 A3 536 1 P247 13 535 M5Y 537 B B

7
+APC windscreen wiper park
B3 509 1 P52 5 B1 535 0,6 Temperature potentiometer P247 12
pos. B2 M5Y 1 Thermostat J60 B5 604msm91
B4 — — — B3 537 1 Pressure switch P247 14
B5 — — — 604msm86
B6 — — —
B7 M5H 1 Rotating beacon E5A

Wire 2 J108 Ending 3 2 1


markers
Wire 2 1 2 3 4 5 6 7 532 533 531

3
markers
J63 Ending 1 531 3 + RH fan P52 7

2
A M5W 534 M5T
Ventilation potent. cursor

1
2 533 0,6 P247 10
3 532 3 + LH fan P52 8 6 4
A1 518 1 + AVC cab top inside P52 2 B
4 M5T 3 Electric fan 1 E5A 604msm9V
A2 519 0,6 + AVC cab light J64 3 604msm2A
5 534 0,6 Ventilation potentiometer P247 11
A3 — — — 6 M5W 3 Electric fan 2 E5A
A4 — — —
A5 511 1 + Lights P247 5 1 2 3 4 5 6 7
A6 526 1 + Parking, clock J65 2
518 519 515 511 526 525 A
A7 525 1 + Parking, radio YL 7

B1 520 0,6 + AVC clock J65 3


520 538 514 507 524 B Wire 2 J151 Ending
B2 538 1 +AVC radio YL 4 markers
B3 514 0,6 Clock lighting J65 1
B4 507 0,6 Work lights relay (+) P247 2 1 — — — 1 2 1
B5 — — — 2 — — — 3
Rear work lights 3 M5D 540 4
1

B6 — — — 3 M5D 3 E5A
2

B7 524 1,4 + Parking, cab top inside J247 7 A 4 540 3 Wings rear work lights J168 5
3

2
B
5

604msm92
6

4
7

Wire 2 J168 Ending


604msm87
markers 5
5
540
4
1 546 0,6 Wings RR work light ctrl J56 B1 1
M5 2
2 M5JJ 0,6 Relays E5E 1 546 4
Wire 2 J64 Ending 3 544 3 Wings rear work lights P247 19
JJ
3
2

markers 4 — — — 544
5 540 3 Wings rear work lights J151 4 3 604msm93
1 2 3 4 5
1 — — —
2 M5L 1 Roof lamp J60 B2 M5L 519 522
3 519 0,6 + AVC cab light J63 A2 1
4 522 0,6 RH door contact 208 2
5 — — —
3
4
5 Wire 2 J169 Ending 5
604msm88 markers 539
4 5
1 548 M5 2 1
1 548 0,6 Outs. RR work light ctrl J56 B4 549 KK 4
1 549 0,6 Outs. RR work light ctrl Diode
Wire 2 J65 Ending 2 M5KK 0,6 Relays E5E 503
3
2

markers 3 503 3 + AVC outside rear work lights P52 3 3


4 — — — 604msm94

1 514 0,6 Clock lighting J63 B3


1 2 3 4 5 5 539 3 Rear outside cab top work lights J61 A1
2 526 1 + Parking, clock J63 A6 514 526 520 M5M
3 520 0,6 + AVC clock J63 B1 1
4 M5M 0,6 Clock earth J60 B3 2
3
5 — — — 4
5

F2.26 Ares 806 – 09.2004 – GB


5 - Instrument panel / cab top harness
Wire 2 P247 Ending
4 7 10 13 16 19
markers 1 502 510 524 533 536 544

1 502 1 Rear windscreen wiper J104 2 2 507 511 530 534 537 20
Wire 2 J170 Ending 5 2 507 0,6 Work lights relay (+) J63 B4
markers 3 508 517 599 535
516 3 508 1 Windscreen wiper fixed stop J62 A3
4 5 4 510 1 Front windscreen wiper control J62 A2 6 9 12 15 18 21
1 590 0,6 Rotating beacon controls J57 B1 1 590 M5 2 1 5 511 1 + Lights J63 A5
LL 4
Rotating beacon
2 M5LL 0,6 Relays E5E 6 517 1,4 J62 A7
3 504 3 + AVC inside front work lights P52 6 504 2
7 524 1,4 + Parking, cab top inside J63 B7
3
4 — — — 3
8 530 0,6 Temperature potentiometer J107 A1
5 516 3 Rear work lights J62 A5 604msm95 9 599 1 Rear windscreen washer J104 3 19
10 533 0,6 Ventilation potent. cursor J108 2 16
13
11 534 0,6 Fan potentiometer J108 5 10
12 535 0,6 Temperature potentiometer J107 B1 7
13 536 1 Thermostat (+ 12 V) J107 A3 4
1
Wire 2 J172 Ending
14 537 1 Pressure switch J107 B3
markers 15 — — —
1 2 1 16 — — —
595 17 — — —

2
1 — — — 18 — — —
2 595 3 Lower front work light J57 B5 19 544 3 Wings rear work lights J168 3
604msm96 20 — — —
21 — — — 604hsm51

Wire 2 P52 Ending


markers

1 500 3 + AVC outside front work lights J57 A3 1 500 518 503 3
2 518 1 + AVC cab top inside J63 A1 4 M5G 509 504 6
3 503 3 + AVC outside rear work lights J169 3
4 M5G 3 Utilities J60 B4 7 531* 532* 505 9
+APC windscreen wiper park 1
5 509 1 J62 B3
pos. 2
6 504 3 + AVC front inside work lights J170 3 3
7 531* 3 + RH fan J108 1 604hsm50
8 532* 3 + LH fan J108 3
9 505 3 Top rear inside work lights J56 A5

Wire 2 P54 Ending


markers
1 2 1
2

1 521 0,6 - RH loudspeaker JB 4 521 529


2 529 0,6 + Right-hand loudspeaker JB 3
604msm00

Wire 2 P55 Ending


markers
1 2 1
1 528 0,6 - LH loudspeaker JB 6
2

528 527
2 527 0,6 + Left-hand loudspeaker JB 5
604msm0A

Ares 806 – 09.2004 – GB F2.27


5a - Cab top / front lights harness 5a - Cab top / front lights harness

5b - Cab top / rear light harness with air conditioning


Connectors Designation
J95 LH rotating beacon
J96 Outside LH front work light
J97 Inside LH front work light
J98 Front screen wiper
J99 Inside RH front work light
J100 Outside RH front work light
J101 RH rotating beacon
P62 Cab top / instrument panel harness connection

5b - Cab top / rear light harness with air conditioning


J100
J99

Connectors Designation
P62

J102 Outside RH rear work light


J62

J103 Inside RH rear work light


J101

J105 Inside LH rear work light


J106 Outside LH rear work light
J98

J109 Shunt receptacle (grey)


J110 RH cooling fan
J111 LH cooling fan
J112 Cooling thermostat
J113 Cooling thermostat
P61
J97

P61 Cab top / instrument panel harness connection


P108

P107 Cab top / instrument panel harness connection


J96

P108 Cab top / instrument panel harness connection


P107
J113
J112

J110
J102
J109

J103
J95

J105
J111

J106

606msm07

F2.28 Ares 806 – 09.2004 – GB


5a - Cab top / front lights harness
Wire 2 J101 Ending
markers M5HH
1 M50HH 1

2
550
1 M5FF 1,4 RH rotating beacon earth P62 B7 2 556
Wire 2 J95 Ending 1 M5OHH 1,4 LH rotating beacon earth J95 1
604msm5B
markers 1 2 1
2 550 1,4 RH rotating beacon P62 A7
M5O 2 556 1,4 LH rotating beacon J95 2

2
556
1 M50HH 1,4 LH rotating beacon earth J101 1 HH
2 556 1,4 Rotating beacon J101 2 604msm8A

Wire 2 P62 Ending


1 2 3 4 5 6 7
markers A 551 559 557 553 M5 550
EE
Wire 2 J96 Ending B M5 M5 558 M5
markers
1 A1 551 2 RH outside front work light J100 2 AA PP FF
M5BB A2 559 1 Windscreen wipers J98 5
1 M5BB 1 LH outside front work light earth J100 1 Front windscreen wiper,
552 A3 557 1 J98 2
2 552 1 LH outside front work light J100 2 self-parking
2 604msm9A A4 — — —
A

1
A5 553 2 RH inside front work light J99 2

2
RH inside front work light earth

3
A6 M5EE 2 J99 1 B

4
A7 550 1,4 RH rotating beacon J101 2

5
Wire 2

6
1
J97 Ending

7
markers B1 M5AA 2 RH outside front work light earth J100 1
M5XX
B2 M5PP 1 Front screen wiper J98 4
1 M5XX 1 LH inside front work light earth J99 1 562 +APC windscreen wiper park 604hsm4B
LH inside front work light B3 558 1 J98 1
2 562 1 J99 2 2 pos.
604msm1B
B4 — — —
B5 — — —
B6 — — —
B7 M5FF 1,4 RH rotating beacon earth J101 1
Wire 2 J98 Ending
3 2 1
markers 557 558

+APC windscreen wiper park 559 M5


PP
1 558 1 P62 B3
pos. 6 5 4
2 557 1
Front windscreen wiper,
P62 A3
5b - Cab top / rear light harness with air conditioning
self-parking
3

3 — — —
2

4 M5PP 1 Windscreen wiper earth P62 B2


1

5 559 1 Windscreen wipers P62 A2


6 — — — Wire 2 J102 Ending
1
markers M5FF
M5VV
604msm2B
1 M5FF 2 RH outside rear work light earth P61 B1 586
1 M5VV 1 LH outside rear work light earth J106 1 2
2 586 1 RH outside rear work light J109 B3 604msm7B
Wire 2 J99 Ending 1
markers
M5EE
M5XX
1 M5EE 2 RH inside front work light earth P62 A6
1 M5XX 1 LH inside front work light earth J97 1
562
553 Wire 2 J103 Ending
1
2 553 2 RH inside front work light P62 A5 2 604msm3B markers M5DD
M5UU
2 562 1 LH inside front work light J97 2
1 M5DD 2 RH inside rear work light earth P61 B3 587
1 M5UU 1 LH inside rear work light earth J105 1
Wire 2 J100 Ending 1
2 587 1 RH inside RR work light J109 B5 2 604msm8B
markers
M5AA
M5BB
1 M5AA 2 RH outside front work light earth P62 B1 551
LH outside front work light earth 552
1
2
M5BB
551
1
2 RH outside front work light
J96
P62
1
A1 2 604msm4B
Wire 2 J105 Ending
1
markers
2 552 1 LH outside front work light J96 2 M5UU

1 M5UU 1 LH inside rear work light earth J103 1 579


2 579 1 LH inside rear work light J109 B6
2 604msm9B

Ares 806 – 09.2004 – GB F2.29


5b - Cab top / rear light harness with air conditioning
Wire 2 J113 Ending
markers
B A
A 583 1 Pressure switch P107 B3 M5 583
Wire 2 J106 Ending
1
B M5YY 1 Thermostat earth P107 B2
YY
markers M5VV B
A
604msm6C

1 M5VV 1 LH outside rear work light earth J102 1 577


2 577 1 LH outside rear work light J109 B2
2
604msm0C Wire 2 P61 Ending
markers
1 2 3

Wire 2 A1 576 2 + AVC Rear work lights J109 B1 A 576 578

1
1 2 3 4 5 6 7 A
J109 Ending

2
markers A2 — — —
B M5 M5

3
B
A A3 578 2 + AVC Rear work lights J109 B7 FF DD

A1 572 1 Fan potentiometer cursor P108 2 B B1 M5FF 2 RH outside rear work light earth J102 1 604msm7C
A2 573 0,6 LH fan potentiometer cursor J111 2 604msm1C B2 — — —
A3 584 0,6 RH fan potentiometer cursor J110 2 B3 M5DD 2 RH inside rear work light earth J103 1
A4 — — —
1 2 3 4 5 6 7
A5 585 0,6 RH fan potentiometer J110 4
A6 575 0,6 LH potentiometer fan J111 4 A 572 573 584 585 575 574
A7 574 1 Fan potentiometer P108 5 B 576 577 586 587 579 578
Wire 2 P107 Ending
B1 576 2 + AVC Rear work lights P61 A1 markers
B2 577 1 LH outside rear work lights J106 2 1 2 3
B3 586 1 RH outside rear work lights J102 2 A1 580 1 Temperature potentiometer J112 B A 580 582

1
A
B4 — — —

2
A2 — — —

1
B 581 M5 583

3
B

2
B5 587 1 RH inside rear work lights J103 2 A A3 582 1 +12 V thermostat J112 A YY

3
B6 579 1 LH inside RR work lights J105 2 B1 581 1 Temperature potentiometer J112 C
+ AVC Rear work lights

5
B7 578 2 P61 A3 B B2 M5YY 1 Thermostat earth J113 B

6
Pressure switch

7
B3 583 1 J113 A
604msm8C

604msm2C
Wire 2 P108 Ending
markers 3 2 1
Wire 2 J110 Ending 1 570 3 + RH fan J110 3
571 572 570

3
markers

2
2 572 1 Fan potentiometer cursor J109 A1 M5 M5
WW 574 TT

1
3 571 3 + LH fan J111 3 6 5 4
1 M5TT 3 RH fan earth P108 4 1 M5 584 2 1
TT 4 M5TT 3 RH fan earth J110 1
2 584 0,6 RH fan potentiometer cursor J109 A3 3 5 574 1 Fan potentiometer J109 A7 604msm9C
3 570 585 4
3 570 3 + RH fan P108 1 6 M5WW 3 LH fan earth J111 1
4 585 0,6 RH fan potentiometer J109 A5 2

4 604msm3C

Wire 2 J111 Ending


markers

1 M5WW 3 LH fan earth P108 6 M5 573 2


1 WW 1
2 573 0,6 LH fan potentiometer cursor J109 A2 3
3 571 575 4
3 571 3 + LH fan P108 3
4 575 0,6 LH potentiometer fan J109 A6 2

4 604msm4C

Wire 2 J112 Ending


markers
C B A
A 582 1 +12 V thermostat P107 A3 581 580 582
B 580 1 Temperature potentiometer P107 A1
C 581 1 Temperature potentiometer P107 B1 CB
A
604msm5C

F2.30 Ares 806 – 09.2004 – GB


Notes Notes

Ares 806 – 09.2004 – GB F2.31


5c - Front and rear light harness Connectors Designation
J95 LH rotating beacon
J96 Outside LH front work light
J97 Inside LH front work light
J98 Front screen wiper
J99 Inside RH front work light
J100 Outside RH front work light
J101 RH rotating beacon
J102 Outside RH rear work light
J103 Inside RH rear work light
J105 Inside LH rear work light
J106 Outside LH rear work light
J100

P61 Cab top / instrument panel harness connection


P62 Cab top / instrument panel harness connection
J99

J62 P61

P62

J101
J52
J98
J97
J96

J102
J103
J95

J105
J106

606msm09

F2.32 Ares 806 – 09.2004 – GB


5c - Front and rear light harness
Wire 2 J101 Ending
markers M5HH
1 M50HH 1

2
1 M5HH 1,4 RH rotating beacon earth P62 B7 550
Wire 2 J95 Ending 1 M50HH 1,4 LH rotating beacon earth J95 1
2 556
markers 1 2 1 2 550 1,4 RH rotating beacon P62 A7 604msm5B
M5O 2 556 1,4 LH rotating beacon J95 2

2
556
1 M50HH 1,4 LH rotating beacon earth J101 1 HH
2 556 1,4 LH rotating beacon J101 2 604msm8A

Wire 2 J102 Ending


1
markers M5FF
Wire 2 J96 Ending 1
M5VV
markers 1 M5FF 2 RH outside rear work light earth P61 B3 554
555
M5BB 1 M5VV 1 LH outside rear work light earth J106 1
1 M5BB 1 LH outside front work light earth J100 1 2 554 2 RH outside rear work light P61 A1 2 604msm6D
552
2 552 1 LH outside front work light J100 2 2 555 1 LH outside rear work light J106 2
2 604msm9A

Wire 2 J97 Ending 1 Wire 2 1


markers markers
J103 Ending
M5DD
M5XX M5UU
1 M5XX 1 LH inside front work light earth J99 1 562 1 M5DD 2 RH inside rear work light earth P61 B1 560
561
2 562 1 LH inside front work light J99 2 2 1 M5UU 1 LH inside rear work light earth J105 1
604msm1B 2
2 560 2 RH inside rear work lights P61 A3 604msm7D
2 561 1 LH inside rear work light J105 2

Wire 2 J98 Ending


3 2 1
markers 557 558 Wire 2 J105 Ending
1
+APC windscreen wiper park 559 M5 markers M5UU
1 558 1 P62 B3 PP
pos. 6 5 4
2 557 1 Windscreen wiper fixed stop P62 A3 1 M5UU 1 LH inside rear work light earth J103 1 561
2 561 1 LH inside rear work light J103 2
3 — — — 2
3

604msm8D
4 M5PP 1 Windscreen wiper earth P62 B2
2

5 559 1 Windscreen wipers P62 A2


1

6 — — —
Wire 2 J106 Ending
1
markers M5VV
604msm2B

1 M5VV 1 LH outside rear work light earth J102 1 555


2 555 1 LH outside rear work light J102 2
Wire 2 J99 Ending 1
2 604msm9D
markers
M5EE
M5XX
1 M5EE 2 RH inside front work light earth P62 A6 562
553
Wire 2 P61 Ending
1 M5XX 1 LH inside front work light earth J97 1 markers
2 553 2 RH inside front work light P62 A5 2 604msm3B 1 2 3
2 562 1 LH inside front work light J97 2 A 554
RH outside rear work lights 560

1
A1 554 2 J102 2 A

2
A2 — — — B M5 M5

3
B
A3 560 2 RH inside rear work lights J103 2 DD FF

Wire 2 J100 Ending 1 B1 M5DD 2 RH inside rear work light earth J103 1 604msm0E

markers M5AA B2 — — —
M5BB B3 M5FF 2 RH outside rear work light earth J102 1
1 M5AA 2 RH outside front work light earth P62 B1 551
552
1 M5BB 1 LH outside front work light earth J96 1 2 604msm4B
2 551 2 RH outside front work light P62 A5
2 552 1 LH outside front work light J96 2

Ares 806 – 09.2004 – GB F2.33


5c - Front and rear light harness Notes

Wire 2 P62 Ending


1 2 3 4 5 6 7
markers A 551 559 557 553 M5 550
EE
A1 551 2 Exterior front working lights J100 2 B M5 M5 558 M5
AA PP HH
A2 559 1 Front windscreen wiper ctrl J98 5
Front windscreen wiper,
A3 557 1 J98 2
self-parking
A4 — — —
A5 553 2 RH inside FR work lights J99 2 A

1
2
A6 M5EE 2 RH inside FR work lights J99 1

3
B
RH rotating beacon

4
A7 550 1,4 J101 2

5
6
7
B1 M5AA 2 RH outside FR work lights J100 1
B2 M5PP 1 Front screen wiper J98 4
+APC windscreen wiper park
B3 558 1 J98 1 604msm6B
pos.
B4 — — —
B5 — — —
B6 — — —
B7 M5HH 1,4 RH rotating beacon J101 1

F2.34 Ares 806 – 09.2004 – GB


Notes Notes

Ares 806 – 09.2004 – GB F2.35


6 - Rear harness Connectors Designation
J26 Lift RH external switch
J27 Shunt receptacle (white)
J28 Plate right lighting
J29 Lift lower LH external switch
J32 Trailer signalling socket
J33 LH plate light
J35 Shunt receptacle (grey)

22
J36 Cigar lighter
Lift lower RH external switch

P151
J37
J40 Lift LH external switch
J41 Pneumatic seat engine and contact

J94
40
J42 TCE control harness connection
Shunt receptacle (brown)
P246 P44

J43
J94 Front PTO switch

E6A
J120 LH rear side lights

J42
J121 RH rear side lights
J122 Rear PTO RH emergency stop
J41

P48
82 J123 Rear PTO LH emergency stop
J178 Shunt receptacle (black)

J178
86

J121
J999* Transmission control harness connection
P44 Instrument panel harness connection
J36

J26
P48 Transmission control harness connection
J999

P151* Cab top / instrument panel harness connection


J32

J37
P246 Instrument panel harness connection
204

* According to equipment (long wings)


J27

J122
8
J28

J35
J33

J43
9
J120

J123
J40

J29

606msm10

F2.36 Ares 806 – 09.2004 – GB


6 - Rear harness
Wire 2 J33 Ending
markers 1 2 1

2
M6E 604
1 M6E 1 LH plate light earth J43 A3
Wire 2 J26 Ending 2 604 1 LH plate light J27 B2
604msm6E
markers
C B A
A 646 1 RH + RH control (TCE) J178 B6 626 646
Lift rise RH ctrl
B
C
626

1
— —
J35 A7 CB
A
Wire 2 J35 Ending
1 2 3 4 5 6 7
604msm1E markers
A
A1 614 1,4 LH rear flashing light P246 18 B
A2 615 1 Trailer LH flashing light J32 1 604msm1C
Wire 2 J27 Ending
1 2 3 4 5 6 7 A3 616 1 LH rear flashing light J120 B
markers A4 — — —
A A5 624 0,6 Lift rise control J42 A2 1 2 3 4 5 6 7
A1 601 1,4 LH side light P246 21 B
A6 625 1 Lift rise LH ctrl J40 B A 614 615 616 624 625 626
A2 602 1 Trailer LH side light J32 7 604msm2A A7 626 1 Lift rise RH ctrl J26 B
B 617 618 619 627 628 629
A3 608 1 Plate RH light J28 2
A4 — — — B1 617 1,4 RH RR flashing light P246 17
A5 609 0,6 Cigar-lighter light 86 1 2 3 4 5 7 6 B2 618 1 Trailer RH flashing light J32 4
A6 610 2 Rear stop P246 19 A 601 602 608 609 610 611 B3 619 1 RH RR flashing light J121 B
660
A7 611 1 Trailer brake lights J32 6 B4 — — —

1
B 603 604 605 606 607 612 613 Lift lower control
Air brake solenoid valve B5 627 0,6 J42 A3

2
A7 660 1 J999 1 A

3
B6 628 1 Lift lower LH ctrl J29 B
LH rear side light B7 629 1 Lift lower RH ctrl J37 B

5
B1 603 1 J120 A B

6
B2 604 1 LH plate light J33 2

7
B3 605 1,4 RH side light P246 20
Trailer RH side light

1
B4 606 1 J32 5

2
B5 607 1 RH rear side light J121 A A

3
B6 612 1 LH rear brake light J120 C 604msm7E

5
B7 613 1 RH rear brake light J121 C B

6
7
Wire 2 J36 Ending
markers
604msm2E 3 2 1
1 M6J 1 Cigar lighter earth J43 B2 621 M6J
2 — — — 3
3 621 1 + Cigar lighter parking P44 9 2
Wire 2 J28 Ending
1
604msm8E
markers
1 2 1
2

1 M6D 1 Plate RH light earth J43 A2 M6D 608


2 608 1 Plate RH light J27 A3 Wire 2 J37 Ending
604msm3E markers
C B A
A 645 1 RH + LH control (TCE) J178 A6 629 645
Lift lower RH ctrl
Wire 2 J29 Ending
B
C
629

1
— —
J35 B7
CB
markers A
604msm9E
C B A
A 647 1 RH + LH control (TCE) J178 A7 628 647
B 628 1 Lift lower LH ctrl J35 B6
C — — — CB
A Wire 2 J40 Ending
604msm4E markers
C B A
A 648 1 RH + LH control (TCE) J178 B7 625 648
B 625 1 Lift rise LH ctrl J35 A6
Wire 2 J32 Ending C — — — CB
markers A
604msm0F
618 4
1 615 1 Trailer LH flashing light J35 A2
2 — — — 5 606 M6F 3 3
3 M6F 2 Trailer socket earth J43 A5
7
2
4
5
Wire 2 J41 Ending
1
4 618 1 Trailer RH flashing light J35 B2 602 7 markers 633
6 611 2 1
5 606 1 Trailer RH side lights J27 B4 6
6 611 1 Trailer brake lights J27 A7 615 1 633 1 + APC seat P44 5 M6I
1
7 602 1 Trailer LH side lights J27 A2 2 M6I 1 Air-sprung seat earth J43 B1
2 604msm1F
604msm5E

Ares 806 – 09.2004 – GB F2.37


6 - Rear harness
Wire 2 J120 Ending
markers
D C B A
TCE 15/25/35 A 603 1 LH rear side light J27 B1
Wire 2 J42 Ending 1 2 3 4 5 6 7 B 616 1 LH rear flashing light J35 A3
M6G 612 616 603
D
markers C
A 634 624 627 649 652 638 C 612 1 LH rear brake light J27 B6 B
A
D M6G 1 LH rear light earth J43 A6 604msm5F
B 655 635 656 636 650 640 639
A1 634 1,4 +APC TCE (RH + relayed) J178 A5
A2 624 0,6 Lift rise control J35 A5
A3 627 0,6 Lift lower control J35 B5 TCE 15T
A4
A5

649*

0,6

CAN + return P246 12
1 2 3 4 5 6 7 Wire 2 J121 Ending
A 634 624 627 652 638 markers
A6 652 0,6 +APC TCE 15/25/35 P44 4
B D C B A
A7 638 0,6 Line K P246 3 658 640 639
A 607 1 RH rear side light J27 B5 M6L 613 619 607
B 619 1 RH RR flashing light J35 B3 D
B1 655* 2 +AVC TCE 15/25/35 P44 2 C
C 613 1 RH rear brake light J27 B7 B
B2 635* 0,6 CAN + network P246 15 A
D M6L 1 RH rear light earth J43 B3 604msm6F
REF 9,5 V lift ext control J178 B4

1
B2 658** 0,6 A

2
Radar speed

3
B3 656* 0,6 J178 A1 B
B4 636* 0,6 CAN - network P246 14

5
6
B5 650* 0,6 CAN - return P246 11

7
B6 640 0,6 TCE high position (lifting) P48 A1 Wire 2 J122 Ending
B7 639 0,6 Line L P246 2 604msm2F markers
TCE 15/25/35 C B A
TCE 15T A 641 1 + LH rear PTO stop P48 A3 642 641 C
B 642 1 Rear PTO stop J123 B B
A
C — — —
604msm7F
Wire 2 J43 Ending
1 2 3 4 5 6 7
markers
A
A1 M6C 2 Earth E6A B
Wire 2 J123 Ending
A2 M6D 1 RH plate light earth J28 1 604msm3A
markers
A3 M6E 1 LH plate light earth J33 1 C B A
A4 — — — 1 2 3 4 5 6 7 A 643 1 + RH rear PTO stop P48 B1 642 643 C
A5 M6F 2 Trailer socket earth J32 3 A M6C M6D M6E M6F M6G M6H B 642 1 Rear PTO stop J122 B B
A
A6 M6G 1 LH rear light earth J120 D C — — —
B M6I M6J M6L M6O M6P
A7 M6H 0,6 Handbrake earth 204 604msm8F

B1 M6I 1 Air-sprung seat earth J41 2


Cigar lighter earth
B2
B3
M6J
M6L
1
1 RH rear light earth
J36
J121
1
D
Wire 2 J178 Ending
1 2 3 4 5 6 7
markers
1

Buzzer earth Buzzer


2

B4 M6O 0,6 A A
3

B5 M6P 1 Air brake solenoid valve earth J999 2


A1 656 0,6 Radar speed J42 B3 B
5

B6 — — — B
Instrument panel radar speed
6

B7 — — — A2 637 1 P246 13 604msm54


7

A3 — — —
A4 — — —
1 2 3 4 5 6 7
A5 634 1,4 +APC TCE (RH+ relayed) J42 A1
604msm3F A6 645 1 RH + RH control (TCE) J37 A A 656 637 634 645 647
A7 647 1 RH + LH control (TCE) J29 A B 651 632 644 646 648

B1 651 0,6 Trip computer radar speed P48 B3


Wire 2 J94 Ending
2 4 6 8 B2 — — —
markers B3 — — —

1
B4 632 1,4 +APC TCE (RH+ relayed) P44 6

2
631 630 657 +APC trip computer (RH+) A

3
1 631 1 Front power take-off control P44 7 B5 644 0,6 P48 B2
1 3 5 7 B6 646 1 RH + RH control (TCE) J26 A
2

5
2 — — — B
RH + LH control (TCE)

6
B7 648 1 J40 A
4

3 — — —

7
6
8

4 — — — 2 4 6 8 TCE 15/25/35 only


5 630 1 + APC front power take-off P44 8
6 — — —
604msm9F
7 657* 1 Front PTO brake P246 10 631 630
8 — — —
1 3 5 7 604msm4F
According to equipment

F2.38 Ares 806 – 09.2004 – GB


6 - Rear harness
Wire 2 P151 Ending
markers

2
1 — — —
Wire 2 J178 Ending
1 2 3 4 5 6 7
2 — — —
2 1

markers 4
3 M6M 1 LH wing work light 9b 4 653 M6N
654 M6M 3
A 1
3 M6N 1 RH wing work light 8b
A1 632 1,4 +APC TCE (RH + relayed) P44 6 B 4 653 1 RH wing work light 8b 3
604msm4G
A2 634 1,4 +APC TCE (RH + relayed) J42 A1 604msm2A 4 654 1 LH wing work light 9b
A3 645 1 RH + RH control (TCE) J37 A
A4 — — —
1 2 3 4 5 6 7
A5 648 1 RH + LH control (TCE) J40 A
A6 — — — A 632 634 645 648
A7 — — — Wire 2 P246 Ending
4 7 10 13 16 19
B 644 646 658 647 markers 1 661 620 610
B1 644 0,6 +APC trip computer (RH+) P48 B2 2 639 617 605 20
B2 — — — 1 661 1 + APC implement socket (5 A) 82
B3 646 1 +APC lift RH control (RH+) J26 B2 2 639 0,6 Line L J42 B7 3 638 659 614 601
B4 658 0,6 REF 9,5 V lift ext control J42 B2 3 638 0,6 Line K J42 A7 6 9 12 15 18 21

1
B5 647 1 RH + LH control (TCE) J29 A 4 — — —

2
A 5 — — —

3
B6 — — —
B7 — — — 6 — — —

5
B
7 — — —

6
TCE 15T only

7
8 — — — 19
16
9 659 0,6 Buzzer 22 13
10 657 1 Front PTO brake J94 7 10
7
11 650 0,6 CAN - return J42 B5 4
604hsm52
12 649 0,6 CAN + return J42 A5 1

13 637 1 Instrument panel radar speed J178 A2


14 636 0,6 CAN - network J42 B4
Wire 2 J999 Ending 15 635 0,6 CAN + network J42 B2
markers 16 620 0,6 Handbrake 204
1 2 1
17 617 1,4 RH RR flashing light J35 B1

2
1 660 1 Air brake solenoid valve J27 A7 660 M6P 18 614 1,4 LH rear flashing light J35 A1
2 M6P 2 Trailer socket earth J43 B5 19 610 2 Rear stop J27 A6 604hsm54
604msm1G
20 605 1,4 RH side light J27 B3
21 601 1,4 LH side light J27 A1

Wire 2 P44 Ending


markers
1 623 655 622 3
1 623 3 + AVC socket 25 A 82
2 655 2 +AVC TCE 15/25/35 J42 B1 4 652 633 632 6
3 622 3 + AVC socket 25 A 82
7 631 630 621 9
4 652 0,6 +AVC TCE 15/25/35 J42 A6 1
5 633 1 + APC seat J41 1 2
6 632 1,4 +APC TCE (RH + relayed) J178 B4 3 604hsm53
7 631 1 Front power take-off control J94 1
8 630 1 + APC front power take-off J94 5
9 621 1 + Parking, cigar lighter J36 3

TCE 15T
Wire 2 P48 Ending 1 2 3
markers
A 640 641

A1 640 0,6 TCE high position (lifting) J42 B6 B 643 644


A2 — — —
TCE 15/25/35
A3 641 1 + LH rear PTO stop J122 A

B1 643 1 RH rear PTO stop J123 A


1 2 3
B2 644 0,6 +APC trip computer (RH+) J178 B5
1

A 640 A
B2 644** 0,6 PTO stop J178 B1 641
2

Trip computer radar speed


3

B3 651* 0,6 J178 B1 B 643 644 651 B

* TCE 15/25/35 only


604msm3G
** TCE 15T only

Ares 806 – 09.2004 – GB F2.39


7a - Closed centre circuit transmission harness (110 litres) 7c - GTA 303 transmission link harness
7d - GTA 303 transmission harness
J2
J1
202
J128

P20 J91
R
J138 E7G
J151 128
P80 J94
J225
B'
J150 J160 A'
C'
J83 2
1
J95 E7E
202
J91
J225 E7D J162
J163
J202 J1 J2 M
E7A J159 M7B D
J83 J138 M7K P163
J82
J84 E7D P138 M1 A J140
198
E7C P42 B E
J86 J80 E7B J139
L P80 P20 E7C
J161
C

A
J85 J132
H
J88
J139 115
J89 J82
J90 E7F
J201 J145 J86
E7B 48 J91
J85
J92
J87

J149 J88
J89
J84
J117
J158

J116
J93
127
J81
J87
606msm12

606hsm7L

7b - Closed centre circuit transmission harness (100 litres)

J2
J1
202

J87
P20

P80
J225

P80

J83 E7A J87


J93 J202
P80
J86
J82
J84 J83 198
198
E7C J85

J88 J132
A

J89

J90 J145

J91
J92

J149

J117
E7B
J116

J93

606msm13

F2.40 Ares 806 – 09.2004 – GB


7a - Closed centre circuit transmission harness (110 litres)
Wire 2 J82 Ending
markers
1 2
1 712 0,75 + Forward speed sensor P80 12
Connectors Designation 2 M7N 0,75 - Displacement speed sensor E7C
712 M7N

J82 Tractor advance speed sensor (transmission)


604msm5G
J83 Engine speed sensor (transmission)
J84 Rear power take off speed sensor (transmission)
J85 Rear PTO brake solenoid valve Wire 2 J83 Ending
markers
J86 Rear PTO clutch solenoid valve 1 2
J87 Oil filter clogging indicator 1 711 0,75 + Engine speed sensor P80 11 711 M7O
J88 Differential lock solenoid valve 2 M7O 0,75 Engine speed sensor earth E7C

J89 4-wheel drive solenoid valve 604msm6G

J90 High / crawler range solenoid valve


J91 Transmission oil temperature sensor
J92 Solenoid valve 2 2PS TWINSHIFT
Wire 2 J84 Ending
markers
J93 Solenoid valve 1 4PS QUADRISHIFT 1 2
J94 Park lock solenoid valve 1 714 0,75 + Rear PTO speed sensor P80 14 714 M7P
2 M7P 0,75 Rear PTO speed sensor earth E7C
J95 Park lock solenoid valve
J116 Forward drive solenoid valve 604msm7G

J117 Reverse drive solenoid valve


J139 Front harness connection Wire 2
J140 Front harness connection markers
J85 Ending

J145 Reverser module speed sensor 1 2


1 709 0,75 RR PTO brake solenoid V. ctrl P80 9 709 M7C
J149 High / crawler range contact Rear PTO brake solenoid valve
2 M7C 0,75 E7A
J150 Park lock switch earth

1 2
J151 Park lock switch 604msm8G

J201* Rear axle oil low pressure switch


J202 Gearbox transmission oil pressure switch Wire 2
J225** Air brake solenoid valve markers
J86 Ending

P80 Transmission control harness connection A B


A 708 0,75 Rear PTO solenoid valve P80 8
B 713 0,75 Rear PTO solenoid valve return P80 13 708 713 A
* Only «LS» Closed centre circuit B
** Version with air brake system
604hsm5F

Wire 2 J87 Ending


markers
1 2
1 704 0,75 Oil filter blocked P80 4 704 M7F
2 M7F 0,75 Oil filter clogging earth E7A

1 2
604msm0F

Ares 806 – 09.2004 – GB F2.41


7a - Closed centre circuit transmission harness (110 litres)
Wire 2 J94 Ending
markers
1 2
1 733 0,75 Park Lock ON solenoid valve P80 28
Wire 2 J88 Ending 2 M7D 0,75 Park Lock ON sol. valve earth E7A
733 M7D
markers

1
1 2

2
604hsm55
1 707 0,75 Differential solenoid valve P80 7 707 M7G
2 M7G 0,75 Differential solenoid valve earth E7A

1
Wire 2

2
604msm1H
markers
J95 Ending

1 2
1 732 0,75 Park Lock OFF solenoid valve P80 16
Wire 2 J89 Ending 2 M7S 0,75 Park Lock OFF sol. valve earth E7A
732 M7S

markers

1
1 2

2
604hsm56
1 706 0,75 4-wheel drive solenoid valve P80 6 706 M7H
2 M7H 0,75 4WD solenoid valve earth E7A

1
Wire 2 J116

2
604msm2H Ending
markers
A B
A 726 0,75 Forward drive solenoid valve P80 26 726 710 A
Wire 2 J90 Ending
B 710 0,75 Forward drive - SV return P80 10 B

markers
604msm7H
1 2
1 705 0,75 Range solenoid valve P80 5 705 M7I
2 M7I 0,75 Range solenoid valve earth E7B
Wire 2

1
markers
J117 Ending

2
604msm3H
A B
A 727 0,75 Reverse drive solenoid valve P80 27 727 730 A
Reverse drive - solenoid valve
Wire 2 J91 Ending
B 730 0,75
return
P80 30
B

markers 604msm8H
1 2
1 719 0,75 Transmission oil temperature P80 19 719 720
2 720 0,75 Transm. oil temp. signal P80 20
Wire 2
1

604msm4H markers
J139 Ending
2

C B A

A 718 0,75 Steering angle signal P80 17 731 728 718


C
B 728 0,75 + Steering angle P80 37 B
A
Wire 2 J92 Ending
C 731 0,75 - Steering angle P80 33
markers 604hsm60
1 2
1 721 0,75 EV 2 4PS P80 21 721 M7L
2 M7L 0,75 Solenoid valve earth 2 4PS E7B
Wire 2 J145 Ending
1

markers
2

604msm5H
1 2
1 729 0,75 + Reverser module speed P80 29
729 M7Q
2 M7Q 0,75 Reverser module speed earth E7C
Wire 2 J93 Ending
markers 604msm0i
1 2
1 722 0,75 EV 1 4PS P80 22 722 M7M
2 M7M 0,75 Solenoid valve earth 1 4PS E7B
Wire 2 J149 Ending
1

markers
2

604msm6H
1 2
1 702 0,75 Range change P80 2 702 717
2 717 0,75 +APC E7D
2
1
604hsm57

F2.42 Ares 806 – 09.2004 – GB


Closed centre circuit transmission harness
Wire 2 P80 Ending
markers
4 704 703 702 701 1
1 701 0,75 +APC E7D
Wire 2 J150 Ending 2 702 0,75 Range change J149 1 9 709 708 707 706 705 5

markers 3 703 1 Hydraulic pressure J202 1 15 M7A 714 713 712 711 710 10
1 2 4 704 0,75 Oil filter J87 1 22 722 721 720 719 734 718 732 16

1 735 0,75 Park Lock OFF P80 24 735 715 1 5 705 0,75 Range solenoid valve J90 1 28 733 727 726 725 735 723 23
2 715 0,75 +APC E7D 2 6 706 0,75 4-wheel drive solenoid valve J89 1 33 731 MA M7B 730 729 29
7 707 0,75 Differential solenoid valve J88 1
37 728 M7K BU M7J 34
604hsm59 8 708 0,75 Rear PTO solenoid valve J86 A
9 709 0,75 RR PTO brake solenoid V. ctrl J85 1
10 710 0,75 Forward drive - SV return J116 B
11 711 0,75 + Engine speed sensor J83 1
Wire 2 J151 Ending
12 712 0,75 + Forward speed sensor J82 1
markers 13 713 0,75 ECO power take-off light J86 B
1 2 14 714 0,75 + Rear PTO speed sensor J84 1
1 734 0,75 Park Lock use P80 18 734 716 1
15 M7A 0,75 Frequency earth E7C
2 716 0,75 +APC E7D 2 16 732 0,75 Park Lock OFF solenoid valve J95 1
17 718 0,75 Steering angle signal J139 A
604hsm58 18 734 0,75 Park Lock use J151 1
19 719 0,75 + Transmission oil temp. J91 1
20 720 0,75 Transm. oil temp. signal J91 2
21 721 0,75 EV 2 4PS J92 1 604hsm4D
Wire 2 J201 Ending
22 722 0,75 EV 4PS J93 1
markers 1 2 23 723 0,75 Fuel level 202
725 M7R 24 735 0,75 Park Lock OFF J150 1
25 725 1 Oil pressure switch J201 1
1 725 1 Oil pressure switch P80 25 26 726 0,75 Forward drive solenoid valve J116 A
2 M7R 1 Oil pressure switch earth E7A 27 727 0,75 Forward drive solenoid valve J117 A
3 — — — 3 4 28 733 0,75 Park Lock ON solenoid valve J94 1
604msm2i
4 — — — 29 729 0,75 + Reverser module speed J145 1
Reverse drive - solenoid valve
30 730 0,75 J117 B
return
31 M7B 0,75 Solenoid valve earth E7A
32 BR 1 Air brake solenoid valve J225 1
Wire 2 J202 Ending 1 2
33 731 0,75 Steering angle J139 C
markers 34 M7J 0,75 Fuel level earth 202
703 M7E 35 BL 1 Air brake solenoid valve earth J225 2
36 M7K 1 Solenoid valve earth E7B
1 703 1 Hydraulic pressure P80 3
37 728 0,75 Steering angle signal J139 B
2 M7E 1 Hydraulic pressure earth E7B
3 4
3 — — — 604msm3i
4 — — —

Wire 2 J225 Ending


markers
1 2
1 BR 1 Air brake solenoid valve P80 32 MA BU
2 BL 1 Air brake solenoid valve earth P80 35

604msm4i

Ares 806 – 09.2004 – GB F2.43


Notes Notes

F2.44 Ares 806 – 09.2004 – GB


7b - Closed centre circuit transmission harness
Wire 2 J85 Ending
markers
1 2
1 709 0,75 Solenoid valve brake PdF rear P80 9
Connectors Designation 2 M7C 0,75 Rear PTO sol. valve earth E7A
709 M7C

J82 Tractor advance speed sensor (transmission)

1 2
J83 Engine speed sensor (transmission) 604msm8G

J84 Rear power take off speed sensor (transmission)


J85 Rear PTO brake solenoid valve Wire 2
J86 Rear PTO clutch solenoid valve markers
J86 Ending

J87 Oil filter clogging indicator A B


A 708 0,75 Rear PTO solenoid valve P80 8
J88 Differential lock solenoid valve B 713 0,75 Rear PTO solenoid valve return P80 13 708 713 A
J89 4-wheel drive solenoid valve B

J90 High / crawler range solenoid valve 604hsm5F

J91 Transmission oil temperature sensor


J92 Solenoid valve 2 2PS TWINSHIFT
Wire 2 J87 Ending
J93 Solenoid valve 1 4PS QUADRISHIFT markers
J94 Park lock solenoid valve 1 2
1 704 0,75 Oil filter P80 4
J95 Park lock solenoid valve 2 M7F 0,75 Oil filter earth E7A 704 M7F
J116 Forward drive solenoid valve

1 2
J117 Reverse drive solenoid valve 604msm0F
J132 Solenoid valve shunt
J139 Front harness connection
J145 Reverser module speed sensor
Wire 2 J88 Ending
markers
J149 High / crawler range contact 1 2
J150 Park lock switch 1 707 0,75 Differential solenoid valve P80 7
2 M7G 0,75 Differential sol. valve earth E7A 707 M7G
J151 Park lock switch

1
J202 Gearbox transmission oil pressure switch

2
604msm1H
P80 Transmission control harness connection

Wire 2 J89 Ending


markers
Wire 2 J82 Ending
markers 1 2
1 706 0,75 4-wheel drive solenoid valve P80 6
1 2 2 M7H 0,75 4 WD solenoid valve earth E7A 706 M7H
1 712 0,75 + Tractor speed P80 12 712 M7N

1
2 M7N 0,75 Tractor speed earth E7C

2
604msm2H
604msm5G

Wire 2 J90 Ending


Wire 2 J83 Ending
markers
markers 1 2
1 705 0,75 Range solenoid valve P80 5
1 2 705 M7I
1 711 0,75 + Engine speed sensor P80 11 2 M7I 0,75 Range solenoid valve earth E7B
711 M7O
2 M7N 0,75 Engine speed sensor earth E7C

1
2
604msm3H
604msm6G

Wire 2
Wire 2 J84 Ending markers
J91 Ending
markers 1 2
1 2 1 719 0,75 - Transmission temperature P80 19 719 720
1 714 0,75 + Rear PTO speed P80 11 2 720 0,75 + Transmission temperature P80 20
714 M7P
2 M7P 0,75 Rear PTO speed earth E7C

1
604msm4H

2
604msm7G

Ares 806 – 09.2004 – GB F2.45


7b - Closed centre circuit transmission harness (100 litres)
Wire 2 J139 Ending
markers
C B A

A 718 0,75 Steering angle signal P80 17 731 728 718


Wire 2 J92 Ending B 728 0,75 + Steering angle P80 37
C
B
A
markers C 731 0,75 - Steering angle P80 33
1 2 604hsm60
1 721 0,75 EV 2 4PS P80 21 721 M7L
2 M7L 0,75 Solenoid valve earth 2 4PS E7B

1
Wire 2

2
604msm5H
markers
J145 Ending

1 2
1 729 0,75 + Module speed ISC P80 29
Wire 2 J93 Ending 2 M7Q 0,75 Module speed ISC E7C
729 M7Q
markers
1 2 604msm0i
1 722 0,75 EV 1 4PS P80 22
2 M7M 0,75 EV 1 4PS E7B 722 M7M

1
Wire 2

2
604msm6H
markers
J149 Ending
1 2
A 701 0,75 Range contact P80 1
Wire 2 J94 Ending B 702 0,75 Range contact P80 2
702 717
markers 2
1
1 2 604hsm57
1 733 0,75 Park Lock ON solenoid valve P80 28 733 M7D
2 M7D 0,75 Park Lock ON sol. valve earth E7A

1
Wire 2

2
604hsm55
markers
J150 Ending
1 2
1 735 0,75 Park Lock OFF P80 24 735 715 1
Wire 2 J95 Ending 2 715 0,75 +APC E7D 2
markers
604hsm59
1 2
1 732 0,75 Park Lock OFF solenoid valve P80 16 732 M7S
2 M7S 0,75 Park Lock OFF sol. valve earth E7A
2
1

Wire
J151 Ending
2

604hsm56 markers
1 2
734 716
1 734 0,75 Park Lock use P80 18 1

Wire 2 2 716 0,75 +APC E7D 2

markers
J116 Ending
604hsm58
A B
1 726 0,75 Forward drive solenoid valve P80 26 726 710 A
2 710 0,75 Forward drive - SV return P80 10 B
Wire 2 J202 Ending 1 2
604msm7H markers
703 M7E

1 703 1 Hydraulic pressure P80 3


2 M7E 1 Hydraulic pressure earth E7A
Wire 2 J117 Ending 3 — — —
3 4
604msm3i
markers 4 — — —
A B
1 727 0,75 Reverse drive solenoid valve P80 27 727 730 A
2 730 0,75 Reverse drive - SV return P80 30 B

604msm8H

Wire 2 J132 Ending


markers
A

1 724 0,75 Solenoid valve shunt P80 24 724

A 604msm9H

F2.46 Ares 806 – 09.2004 – GB


7b - Closed centre circuit transmission harness 7c - GTA 303 transmission link harness

Wire 2 Connectors Designation


markers
P80 Ending
J82 Tractor advance speed sensor (transmission)
4 704 703 702 701 1 J139 Front harness connection
1 701 0,75 +APC E7D
2 702 0,75 Range contact J149 B
9 709 708 707 706 705 5
J140 Front harness connection
3 703 1 Hydraulic pressure J202 1 15 M7A 714 713 712 711 710 10

4 704 0,75 Oil filter J87 1 22 722 721 720 719 734 718 732 16 P80 Transmission control harness connection
5 705 0,75 Range solenoid valve J90 1 28 733 727 726 725 735 723 23 P138 Transmission harness connection
6 706 0,75 4-wheel drive solenoid valve J89 1 33 731 M7B 730 729 29
7 707 0,75 Differential solenoid valve J88 1 37 728 M7K M7J 34
8 708 0,75 Rear PTO solenoid valve J86 A
9 709 0,75 Solenoid valve brake PdF rear J85 1
10 710 0,75 Forward drive - SV return J116 2 7d - GTA 303 transmission harness
11 711 0,75 + Engine speed sensor J83 1
12 712 0,75 + tractor sensor J82 1
13 713 0,75 Rear PTO solenoid valve return J86 B
14 714 0,75 + Rear PTO speed J84 1
15 M7A 0,75 Frequency GND E7C Connectors Designation
16 732 0,75 Park Lock OFF solenoid valve J95 1
17 718 0,75 Steering angle signal J139 A
J81 Rear power take-off speed sensor (Instrument panel)
18 734 1 Park Lock use J151 1 J83 Engine speed sensor (transmission)
19 719 0,75 Transmission oil temperature J91 1
20 720 0,75 + Transmission temperature J91 2 J84 Rear power take off speed sensor (transmission)
21 721 0,75 EV 2 4PS J92 1 604hsm4E J85 Rear PTO brake solenoid valve
22 722 0,75 EV 1 4PS J93 1
23 723 0,75 Fuel level 202 J86 Rear PTO clutch solenoid valve
24 735 0,75 Park Lock OFF solenoid valve J150 1
25 725 1 Oil filter 198
J87 High-pressure oil filter
26 726 0,75 Forward drive solenoid valve J116 1 J88 Differential lock solenoid valve
27 727 0,75 Reverse drive solenoid valve J117 1
28 733 0,75 Park Lock ON solenoid valve J94 1 J89 Front axle solenoid valve
29 729 0,75 Reverser module speed (ISC) J145 1 J91 Transmission oil temperature sensor
30 730 0,75 Reverse drive - SV return J117 2
31 M7B 1,4 Solenoid valve earth E7A J138 Transmission link harness connection
32 — — —
33 731 0,75 Steering angle J139 C
J158 Park lock solenoid valve
34 M7J 0,75 Fuel level 202 J159 Park lock switch
35 — — —
36 M7K 1 Solenoid valve earth E7B J160 Intermediate speed sensor
37 728 0,75 + Steering angle J139 A J161 Displacement speed sensor
J162 Calibration
J163 Calibration connection
115 Oil pressure switch
127 Low-pressure switch
128 Gearbox pressure sensor
A TC connector
B TC connector
C TC connector
D TC connector
E TC connector
1 Gearshift solenoid valve
2 Gearshift solenoid valve
A’ Gearshift solenoid valve
B’ Gearshift solenoid valve
C’ Gearshift solenoid valve
H Gearshift solenoid valve
M Gearshift solenoid valve
L Gearshift solenoid valve
R Gearshift solenoid valve

Ares 806 – 09.2004 – GB F2.47


7c - GTA 303 transmission link harness
Wire 2 P80 Ending
markers

1 — — —
Wire 2 J82 Ending 2 — — —
4 1

markers 3 — — — 9
1 2
4 — — — 15 715 714 713 712 711 710
1 712 0,75 + Forward speed sensor P80 12 712 713 5 — — — 22 722 721 720 719 718 717 716
2 713 0,75 - Tractor speed sensor P80 13 6 — — —
28 728 725 724 723
7 — — —
8 — — — 33 MA M7B
604hsm2L
9 — — — M7K BU M7J 34
37
10 710 1 CAN-high (TC) P138 A
11 711 1 CAN-low (TC) P138 C
+ Forward speed sensor
Wire 2 J139 Ending B A
12
13
712
713
1
1 - Displacement speed sensor
J82
J82
1
2
markers 14 714 1 + Crawler speed sensor P138 E
722 719 15 715 1 Park lock solenoid valve control P138 F
A 719 1 - Turbo P80 19 B 16 716 1 Rear PTO speed (IP) P138 K
B 722 1 - Steering angle P80 22 A
17 717 1 Turbo signal J140 A
18 718 1 + Turbo J140 B
604hsm2M
19 719 1 - Turbo J139 A
20 720 1 Steering angle signal J140 D
21 721 1 + Steering angle J140 C
22 722 1 - Steering angle J139 B 604hsm2Q
Wire 2 J140 Ending 23 723 1 Fuel level 202
markers D C B A 24 724 1 +APC solenoid valve supply P138 G
720 721 718 717 25 725 1 +APC harness (TC) P138 H
A 717 1 Turbo signal P80 17 26 — — —
B 718 1 + Turbo P80 18 D
C
27 — — —
C 721 1 + Steering angle P80 21 B 28 728 1 CAN - (TC) P138 B
A
D 720 1 Steering angle signal P80 20 604hsm2N 29 — — —
30 — — —
31 M7B 1 Solenoid valve earth E7A
32 BR 1 Air brake solenoid valve J225 1
33 — — —
Wire 2 J225 Ending
34 M7J 1 Fuel level earth 202
markers 35 BL 1 Air brake solenoid valve earth J225 2
36 M7K 1 Solenoid valve earth E7A
1 2
37 — — —
1 BR 1 Air brake solenoid valve P80 32 MA BU
2 BL 1 Air brake solenoid valve earth P80 35

604msm4i

Wire 2 P138 Ending


markers A B C D E
A
710 728 711 714 B
A 710 1 CAN-high (TC) P80 10 C
D
B 728 1 CAN - (TC) P80 28 716 725 724 715 E
C 711 1 CAN-low (TC) P80 11
D — — — K J H G F
E 714 1 Crawler speed control P80 14
604hsm2N
F 715 1 Park lock solenoid valve control P80 15
G 724 1,5 +APC solenoid valve supply P80 24
H 725 1,5 +APC TC harness P80 25
J — — —
K 716 1 Rear PTO speed (IP) P80 16

F2.48 Ares 806 – 09.2004 – GB


7d - GTA 303 transmission harness
Wire 2 J91 Ending
markers 1 2

Wire 2 J81 Ending 1 35 0.6 TC "D" pin J D J


35 34

markers 2 34 0.6 m7a earth E7G 1


1 2 3 2
604hsm2Z

1 AC12 0.6 +APC rear PTO E7D AC12 42 M22


Rear PTO speed sensor

1
2 42 0.6 E7B
3 M22 0.6 Earth E7C

2
Wire 2 J138 Ending

3
604hsm2R
markers K J H G F

Wire 2 J83 Ending A 31 1 CAN-high (TC+) D A


42b AC1 PS1 P2

markers 1 2 B 32b 1 CAN - (TC+) E7G 31 32b 33 45

R02 40 C 33 0.6 CAN-low (TC+) D K A B C D E A


B
1 R02 0.6 - Engine speed sensor E7E D — — — C
2 40 0.6 + Engine speed sensor E E D
1
2
604hsm2S
E 45 1 Crawler speed control E C E 604hsm3W

F P2 1 Park lock solenoid valve control E7F


G PS1 1,4 +APC solenoid valve supply B B
Wire 2 J84 Ending H AC1 1,4 +APC TC harness E7D
markers J — — —
1 2 K 42b 0.6 Rear PTO speed (IP) E7B
1 R05 0.6 Rear PTO sensor return E7E R05 39a
2 39a 0.6 Rear PTO sensor J162 1

604hsm2T
Wire 2 J158 Ending
markers
Wire 2 J85 Ending
1
16a M24
2

markers 1 2 1 M24 1 Earth E7C


2 16a 1 Lock control solenoid valve E7F

1
13 20
1 20 1 Differential solenoid valve B E

2
604hsm3A
2 13 1 Differential solenoid valve B F

1
2
604hsm2U

Wire 2 J159 Ending


markers
Wire 2 J86 Ending
1 2
markers 1 2 36 M24
1 36 0.6 Park lock control D F 2
1
17 14 2 M24 1 Earth E7C
1 14 1 Rear PTO brake solenoid valve B D 604hsm3B
2 17 1 Rear PTO brake solenoid valve B F
1
2
604hsm2V

Wire 2 J160 Ending


Wire 2 J87 Ending
markers
1 2
markers 1 2
39b R03
1 39b 0,6 Intermediate speed sensor J163 1
43 M27
1 43 0.6 High-pressure oil filter B D 2 R03 0,6 Intermediate speed sensor E7E 1
2
604hsm3C
2 M27 0.6 Earth B G
1
2

604hsm2W

Wire 2 Wire 2 J161 Ending


markers
J88 Ending
1 2
markers
1 2
18 30 41 R04
1 41 0.6 + Forward speed sensor E F
1 18 1 Differential solenoid valve A D
2 R04 0.6 - Displacement speed sensor E7E 1
2 30 1 Differential solenoid valve C K 2
1

604hsm3D
2

604hsm2X

Wire 2 J162 Ending


Wire 2 J89 Ending
markers 1
markers 1 2 39a
1 39b 0.6 Rear PTO speed sensor J160 1
4 M25
1 M25 1 Earth E7C 604hsm3J
2 4 1 Front axle ctrl solenoid valve B H
1
2

604hsm2Y

Ares 806 – 09.2004 – GB F2.49


7 d - GTA 303 transmission harness
Wire 2 C Ending
markers K J H G F

30 29 28 27 26
A 21 1 Gearshift solenoid valve "C" C’ 1
Wire 2 J163 Ending B 22 1 Gearshift solenoid valve "A" A’ 1 21 22 23 24 25
markers C 23 1 Gearshift solenoid valve "B" B’ 1 A
1 A B C D E
D 24 1 Gearshift solenoid valve "1" 1 1 B
C
1 39a 0.6 Intermediate speed sensor J84 2
39b E 25 1 Gearshift solenoid valve "H" H 1 D
E 604hsm3G

604hsm3K F 26 1 Gearshift solenoid valve "L" L 1


G 27 1 Gearshift solenoid valve "M" M 1
H 28 1 Gearshift solenoid valve "2" 2 1
J 29 1 Gearshift solenoid valve "R" R 1
Wire 2 A Ending
K 30 1 Differential control solenoid valve J88 2
markers K J H G F

10 9 8 7 6
A 1 1 Gearshift solenoid valve "C" C’ 2
B 2 1 Gearshift solenoid valve "A" A’ 2 1 2 3 18 5
C 3 1 Gearshift solenoid valve "B" B’ 2 A Wire 2 D Ending
D 18 1 Solenoid valve differential control J88 1 A B C D E B
C markers K J H G F
E 5 1 Gearshift solenoid valve "H" H 2 D
E 604hsm3E 33 35 32 36
A 31 1 CAN-High J138 A
F 6 1 Gearshift solenoid valve "I" L 2 B — — — 31
G 7 1 Gearshift solenoid valve "M" M 2 C — — — A
H 8 1 Gearshift solenoid valve "1" 1 2 D — — —
A B C D E B
C
J 9 1 Gearshift solenoid valve "2" 2 2 E — — — D
K 10 1 Gearshift solenoid valve "R" R 2 E 604hsm3H

F 36 0.6 Park lock switch J159 1


G 32 1 Transmission oil temperature E7G
H — — —
J 35 0.6 Transmission oil temp. sensor J91 1
Wire 2 B Ending
K 33 1 CAN-Low J138 C
markers K J H G F

M13 AC11 4 17 13
A M12 1 Earth E7C
B PS1 1 +APC solenoid valve supply J138 G M12 PS1 16 14 20
C 16 1 Differential diode Diode A
Wire 2 E Ending
A B C D E
D 14 1 Solenoid valve PTO J86 1 B
C
markers K J H G F
E 20 1 Solenoid valve rear PTO brake J85 1 D
E 604hsm3F 44 43 R01 42a 41
A 37 1 Transmis. oil pressure switch 115 4
Solenoid valve rear PTO brake B 38 0.6 Gearbox oil pressure sensor 128 2 37 38 45 39 40
F J85 2
13 1 control C 45 1 Crawler speed control J138 E A
A B C D E
G 17 1 Solenoid valve rear PTO J86 2 D 39 0.6 Calibration connector P163 1 B
C
Front/rear PTO solenoid valve E 40 0.6 Engine speed sensor J83 2 D
E
H J89 2 604hsm3I
4 1 earth
J AC11 1.4 Earth E7D F 41 0.6 Forward speed J161 1
K M13 1.4 Earth E7C G 42a 0.6 Rear PTO speed (IP) E7B
H R01 0.6 Sensor return E7E
J 43 0.6 Vacuum switch J87 1
K 44 1 Axle oil pressure switch 127 3

Wire 2 1 Ending
markers 1 2
24 8
1 24 1 TC "C" pin "D" C D
2 8 1 TC "A" pin "H" A H 1
2
604hsm3M

F2.50 Ares 806 – 09.2004 – GB


7d - GTA 303 transmission harness
Wire 2 R Ending
markers 1 2
29 10
1 29 1 TC "C" pin "J" C J
Wire 2 2 Ending 2 10 1 TC "A" pin "K" A K 1
2
markers 1 2 604hsm3V

28 9
1 28 1 TC "C" pin "J" C H
2 9 1 TC "A" pin "J" A J 1
2 Wire 2 115 Ending
604hsm3N
markers 1 2
M21
1 M21 1 Oil pressure switch earth E7C
37
Wire 2 A’ Ending
2 — — —
3 4
markers 1 2 3 — — —
604hsm3X
22 2
4 37 1 Oil pressure switch E A
1 22 1 TC "C" pin "B" C B
2 2 1 TC "A" pin "B" A J 1
2
604hsm3P

Wire 2 127 Ending 1 2


markers
M26
Wire 2 B’ Ending 1 — — — 44
markers 1 2
2 M26 1 Greasing pressure switch earth E7C 3 4
23 3
3 44 1 Greasing pressure switch E K 604hsm3Y
1 23 1 TC "C" pin "C" C C 4 — — —
2 3 1 TC "A" pin "B" A C 1
2
604hsm3Q

Wire 2 128
Wire 2 C’ Ending markers
Ending 1 2
markers 1 2 M11
21 1
1 — — — 38
1 21 1 TC "C" pin "A" C A 2 M11 0,6 Gearbox pressure sensor earth E7C 3 4
2 1 1 TC "A" pin "A" A 1 1
2 3 38 0,6 Gearbox pressure sensor E B 604hsm3Z
604hsm3R
4 — — —

Wire 2 H Ending
markers 1 2 Wire 2 P163 Ending
25 5 markers 1
39
1 25 1 TC "C" pin "E" C E
2 5 2 TC "C" pin "E" A E 1
2 1 39b 1 Calibration E D
604hsm3S
604hsm3L

Wire 2 M Ending
markers 1 2
27 7
1 27 1 TC "C" pin "G" C G
2 7 2 TC "A" pin "G" A G 1
2
604hsm3T

Wire 2 L Ending
markers 1 2
26 6
1 26 1 TC "C" pin "F" C F
2 6 1 TC "A" pin "F" A F 1
2
604hsm3U

Ares 806 – 09.2004 – GB F2.51


8a - GTA 103 / 202 - GPA 40 transmission control harness 8/2 - Display harness

8b - FPS transmission control harness

8/1 - ISO socket harness

J80
220A
J195
J150

J206

220B
J67

P137
J49
J119

P20
J176
P20

P208

J42
P133

J48

J190
J41

J207
P189
131

J150
J80
J233

J188
J234

J68

P999
J208
P208

J48
J136
J231
J232
J219
J207

J2
J235
J236

J1
J237
54
J47

184
J1
J2

42

E6A
J45
J46

47
J137

J137
J67
J134

E8A
P20
J49

606msm15

N.B.: The diodes and the splice E8A only exist on the Quadractiv Display harness.

606hsm04

F2.52 Ares 806 – 09.2004 – GB


8a - GTA 103 / 202 - GPA 40 transmission control harness 8/1 - ISO socket harness
Connectors Designation
J219 ISO socket
8b - FPS transmission control harness P208 Transmission control harness connection

Connectors Designation
J1 Transmission electronic central unit (ECU)
J2 Transmission electronic central unit (ECU) 8/2 - Display harness
J45 4-wheel drive switch
J46 Differential switch
J47 Rear PTO clutch switch Connectors Designation
J48 Rear harness connection J150 Transmission display
J49 ISC declutching +/- range control J195 4PS AUTO control
J67 Shunt receptacle (brown) for cross control harness connection, according to equipment J206 4PS ECO/POWER control
J68 Shunt receptacle (brown) P137 Transmission control harness connection
J80 Transmission harness connection
J134 On-board computer harness connection
J136 Shunt receptacle (grey) 8a - GTA 103 / 202 - GPA 40 transmission control harness
J137 Display harness connection
J176 Accelerator pedal position potentiometer
J188 Shunt receptacle (grey)
J207* ISO socket unit Wire
J208* ISO socket harness connection identifica
2 J1 Ending
25 36

tion 836 835 831 830 889 827 M8L 841 834 80008001
J231**
1 875 0,75 Potentiometer (REF+) J136 A7 24 892 8008 818 809 877 816 896 814 812 811 897 876 13
J232**
2 — — —
J233** 3 866 0,75 Potentiometer (REF-) J136 B7 875 866 865 861 815 817 819 810 885 869 870
4 865 0,75 Clutch pot. cursor P20 10
J234** 5 861 0,75 Crawler speed contact 47 1 12
J235** 6 815 0,75 Differential control J46 1
7 817 0,75 Rear PTO stop (wing) J48 B1
J236** 8 819 0,75 Ignition. PTO Eco 42
J237** 9 810 0,75 LH stop P20 13
10 885 0,75 TCE lift high position J136 A2
P20 Instrument panel harness connection 11 869 0,75 Forward motion control P20 8
12 870 0,75 Reverse drive control P20 7
P119 Instrument panel harness connection
P133 CAN network socket 13 876 0,75 Neutral control P20 1
14 897 0,75 Quadrishift 2 auto 4PS ctrl J137 20
P189 TCE control harness connection 15 811 0,75 Control + Ranges J49 A2
P999 Rear harness connection 16 812 0,75 Control - Ranges J49 A4
17 814 0,75 4-wheel drive control J45 1
18 896 0,75 1000 rpm PTO 54
* According to equipment. 19 816 0,75 RH brake light P20 12
** GTA 103/202 - GPA 40 transmission control only 20 877 0,75 Info clutched P20 5 604hsm64
Automatic control 4 PS
21 809 0,75 J137 21
QUADRACTIV
22 818 0,75 Rear PTO clutch control 53
23 8008 0,75 Steering angle J80 17
24 892 0,75 Accelerator potent. cursor J176 C

25 836 0,75 Transm. oil temp. signal J80 20


26 835 0,75 Transmission oil temperature J80 19
27 831 0,75 + Engine speed sensor J80 11
28 830 0,75 + Forward speed sensor J80 12
29 889 0,75 + Reverser module speed J80 29
30 827 0,75 + Rear PTO speed sensor J80 14
31 M8L 0,75 Frequency earth J80 15
32 841 0,6 Range change J49 B2
33 834 0,75 Hydraulic pressure (LED) 131
34 8000 0,75 CAN-High J234 2
35 8001 0,75 CAN-Low J234 1
36 — — —

Ares 806 – 09.2004 – GB F2.53


8a - GTA 103 / 202 - GPA 40 transmission control harness Wire
identifica
2 J47 Ending
tion 1 2 1

2
848
Wire + APC rear PTO clutch engaged
identifica
2 J2 Ending
25 36 1 848 1
controls
J67 A6
604msm0j
tion M8G M8H 839 805 856 852 813 837 878 851 806 807 2 — — —

1 867 0,75 Forward drive solenoid valve J80 26 24 850 804 803 802 801 864 808 874 832 8022M8S 13
2 868 0,75 Reverse drive solenoid valve J80 27
4-wheel drive solenoid valve 867 868 825 826 822 823 821 871 884 872 862 824
3 825 0,75 J80 6 Wire With ISO socket
4 826 0,75 EV 1 4PS J80 22
1 12 identifica
2 J48 Ending
5 822 0,75 EV 2PS - EV 2 4PS J80 21
6 823 0,75 Range solenoid valve J80 5 tion 1 2 3
7 821 0,75 Differential solenoid valve J80 7 TCE lift high position

1
A1 857 0,6 J136 A1 857 858 A
8 871 0,75 Forward drive indicator light J137 8 A
Neutral light A2 — — —

3
9 884 0,75 J137 9 888
A3 858 0,6 + Rear PTO stop (wing) J67 B3 817 887 8018 B
10 872 0,75 Reverse drive indicator light J137 10 B
11 862 0,75 Buzzer P20 21
12 824 0,75 Rear PTO solenoid valve J80 8 B1 817 0,75 Rear PTO stop (wing) J1 7
B2 887 0,6 +APC trip computer TCE J134 B2
13 873 0,75 Drive sol. valve earth J68 B7 B3 888 0,6 Trip computer radar speed J134 A3
14 8022 0,75 Neutral J80 2 B3 8018* 0,5 Radar speed J207 3
Without ISO socket
15 832 0,75 Forward drive - SV return J80 10 1 2 3
16 874 0,75 Reverse drive - SV return J80 30 * Version with ISO socket only.
17 — — — 857 858 A
18 808 0,75 Forward speed J136 B1 817 887 888 B
19 864 0,75 Rear PTO speed (IP) P20 19 604msm1j
604hsm65
20 801 0,75 Speed 1 light J137 1
21 802 0,75 Speed 2 light J137 2
22 803 0,75 Speed 3 light J137 3 Wire
23 804 0,75 Speed 5 light J137 4 identifica
2 J49 Ending
1 2 3 4 5
24 850 0,75 4 wheel drive light J137 11 tion A 883 811 812
890
8003 8004
25 M8G 1,5 DRIVETRONIC earth J68 B1 A1 883 0,6 Reverser declutching ctrl P119 13 B 829 841 853 M8M
26 M8H 1,5 DRIVETRONIC earth J68 B2 A2 811 0,75 Control + Ranges J1 15
27 839 1,5 + AVC DRIVETRONIC P119 15 A2 8003 0,6 Control + Ranges J137 16
28 805 0,75 Crawler range light J137 5 A3 — — —
29 856 0,75 Transm. oil temp. light. . P20 20 A4 812 0,75 Control - Ranges J1 16
30 852 0,75 Diagnostic indicator P20 18 A4 8004 0,6 Control - Ranges J137 17

1
+ APC DRIVETRONIC A

2
31 813 1,5 J67 A1 A5 890 0,6 Neutral P20 1
32 837 1,5 + APC DRIVETRONIC J67 B7

4
B
33 878 1,5 +APC solenoid valve supply P119 12 +APC range change

5
B1 829 0,6 J67 A2
34 851 0,75 Differential indicator J137 12 B2 841 0,6 Range change J80 2
35 806 0,75 Rapid range light J137 6 B3 853 0,6 +APC +/- range control J67 B1
36 807 0,75 Rear PTO light P20 15 B4 — — —
B5 M8M 0,6 Declutching ctrl earth J68 B5 604msm2j

Wire
identifica
2 J45 Ending
tion
2 4 6 8
2

1 814 0,75 4-wheel drive control J1 7


4
6

2 — — —
8

3 — — — 814 846
847
4 — — —
1 3 5 7
5 846 0,6 +APC 4-wheel drive control J67 A3
6 — — —
604msm8i
7 — — —
8 — — —

Wire
identifica
2 J46 Ending
tion
2 4 6 8
2

1 815 0,75 Differential control J1 6


4
6

2 — — —
8

3 — — — 815 847
4 — — — 1 3 5 7
5 847 0,6 +APC differential control J67 A5
6 — — —
7 — — — 604msm9i
8 — — —

F2.54 Ares 806 – 09.2004 – GB


8a - GTA 103 / 202 - GPA 40 transmission control harness Wire
identifica
2 J80 Ending
Wire tion
identifica
2 J67 Ending
1 2 3 4 5 6 7 4 842 833 8022 820 1
1 820 0,75 Range J1 32
tion A
2 8022 0,75 Neutral J2 14
9 843 824 821 825 823 5

A1 813 1,5 + APC DRIVETRONIC J2 31 B


3 833 0,6 Diode 131 15 M8L 827 M8N 830 831 832 10
A2 829 0,6 +APC range change J49 B1 604msm3A 4 842 0,6 Oil filter P20 B1 22 826 822 836 835 80428008804016
A2 8010 0,6 +APC accelerator pot J176 B 5 823 0,75 Range solenoid valve J2 2
A3 846 0,6 APC 4WD controls J45 5
Without ISO socket 6 825 0,75 4-wheel drive solenoid valve J2 3 28 8041 868 867 894 8043 854 23

A4 — — — 1 2 3 4 5 6 7 7 821 0,75 Differential solenoid valve J2 7 33 893 8021M8E 874 889 29


A5 847 0,6 +APC differential control J46 5 829 8 824 0,75 Rear PTO solenoid valve J2 12
A 813 846 847 848 849
A6 848 1 +APC clutch control J47 1 8010 9 843 0,75 RR PTO brake solenoid V. ctrl 53 37 891 M8F M8Q M8I 34

A7 849 0,6 +APC ECO PTO 42 B 853 855 858 859 879 895 837 10 832 0,75 Forward drive - SV return J2 15
11 831 0,75 + Engine speed sensor J1 27
B1 853 0,6 +APC +/- range control J49 B3 With ISO socket 12 830 0,75 + Forward speed sensor J1 28
B2 855 1,5 +APC P119 14 13 M8N 0,75 Solenoid valve return rear PTO J88 B6
1 2 3 4 5 6 7
B3 858 0,6 +APC rear PTO stop (wing) J48 A3 14 827 0,6 + Rear PTO speed sensor J1 30
829
B4 859 0,6 +APC crawler speed 47
A 813 846
8010
847 848 849 15 M8L 0,75 Frequency earth J1 31
B4 8011* 0,5 +APC ISO unit J207 1 16 8040 1 Park Lock OFF (sol. valve) J80 16
B 853 855 858 859 879 895 837 17 8008 0,75 Steering angle J1 23
B5 879 0,6 + APC 4 PS automatic controls J137 19 8011
B6 895 0,6 +APC 1000 rpm PTO 54 18 8042 0,6 Park Lock use J237 35
B7 837 1,5 + APC DRIVETRONIC J2 32 19 835 0,75 Transmission oil temperature J1 26
20 836 0,75 Transm. oil temp. signal J1 25
* Version with ISO socket only. 21 822 0,75 EV 2PS - EV 2 4PS J2 5
22 826 0,75 EV 1 4PS J2 4

1
2
A 23 854 0,6 Fuel level P20 17

3
24 8043 0,6 Park Lock disengaged J237 20
25 894 0,6 Oil pressure switch P20 11

5
B

6
26 867 0,75 Forward drive solenoid valve J2 1

7
27 868 0,75 Forward drive solenoid valve J2 2
28 8041 1 Park Lock IN (sol. valve) J237 7
29 889 0,75 + Reverser module speed J1 29
604msm3j 30 874 0,75 Reverse drive - SV return J2 16
31 M8E 1,5 Solenoid valve earth J68 A6 604hsm66
32 8021 1 Air brake solenoid valve P999 1
33 893 0,6 Potentiometer (REF-) J136 B5
34 M8I 0,6 Fuel level earth P119 1
Wire Air brake solenoid valve earth
identifica
2 J68 Ending
1 2 3 4 5 6 7
35
36
M8Q
M8F
1
1 Solenoid valve earth
P999
J68
2
A7
tion 37 891 0,6 Potentiometer (REF+) J136 A5
A
A1 M8A 2 Transmission control earth E6A B
A2 M8B 0,75 Display earth J137 24 604msm3A
A3 M8C 0,6 Accelerator potentiometer earth J176 A Wire
A4 — — — Without ISO socket 2
A5 M8R 1 Auto 5 earth J237 28 1 2 3 4 5 6 7 identifica J134 Ending
A6 M8E 1,5 Solenoid valve earth J80 31 M8D tion 1 2 3
A 857 M8A M8E

1
A7 M8F 1 Solenoid valve earth J80 36 M8B
A1 838 0,6 Trip computer tractor speed J136 B2 838 888 A A
B 863 864

3
M8J M8H M8G M8F A2 — — —
B1 M8G 1,5 DRIVETRONIC earth J2 25 A3 888 0,6 Trip computer radar speed J48 B3 886 887 M8K B B
B2 M8H 1,5 DRIVETRONIC earth J2 26 With ISO socket
B3 M8J 1 DRIVETRONIC unit earth 184 1 2 3 4 5 6 7 Trip computer lift up position
B4 M8K 0,6 On-board computer earth J134 B3 B1 886 0,6 J136 A3 604msm7j
B5 M8M 0,6 Revers. declutching ctrl earth J49 B5 A M8A M8B M8C M8R M8E M8F TCE
B6 M8N 0,75 Rear PTO earth (SV return) J80 13 B2 887 0,6 +APC trip computer TCE J48 B2
B M8G M8H M8J M8K M8M M8N M8O B3 M8K 0,6 Trip computer earth J68 B4
B7 M8O* 1 ISO unit earth J207 2 M8S

* Version with ISO socket only


1
2

A
3

B
6
7

604msm4J

Ares 806 – 09.2004 – GB F2.55


8a - GTA 103 / 202 - GPA 40 transmission control harness Wire
identifica
2 J176 Ending
Wire tion
identifica
2 J136 Ending
1 2 3 4 5 6 7 C B A
A M8C 0,6 Accelerator potentiometer earth J68 A3 892 8010 M8C
tion A B 8010 0,6 +APC accelerator pot J67 A2
A1 857 0,6 Up position TCE J48 A1 C 892 0,75 Accelerator potent. cursor J1 24 CB
B A
A2 885 0,75 Up position TCE J1 10 604msm1C
604msm0K
A3 886 0,6 Trip computer up position TCE J134 B1
A3 8019* 0,5 TCE lift high position J207 10 With ISO socket
A4 — — — 1 2 3 4 5 6 7
Wire
A5 891 0,6 REF potentiometer J80 37 886
A 857 885 8019 891 845 875
identifica
2 J207 Ending
1 2 3 4 5 6
A6 845 0,6 REF potentiometer P20 6 8011 M8O 8012 8013 8014 8015
A7 875 0,75 REF potentiometer J1 1 B 808 838 828 893 844 866 tion
8013
8020 M8P 8019 8018 8017 8016
B1 808 0,75 Tractor speed J2 18 1 8011 0,5 +APC ISO unit J67 B4
B2 838 0,6 Trip computer tractor speed J134 A1 Without ISO socket 2 M8O 0,5 ISO unit earth J68 B7 12 11 10 9 8 7
B2 8013* 0,5 Tractor speed J207 4 1 2 3 4 5 6 7 3 8012 0,5 Rear PTO speed P20 A2
B3 828 0,6 Instrument panel tractor speed P20 14 3 8012 0,5 Rear PTO speed P20 19
B4 — — —
A 857 885 886 891 845 875 4 8013 0,5 Tractor speed J136 B2
B5 893 0,6 REF potentiometer J80 33 B 808 838 828
5 8014 0,5 ISO rear PTO speed J208 3
893 844 866
B6 844 0,6 REF potentiometer P20 9 6 8015 0,5 ISO up position TCE J208 4
B7 866 0,75 REF potentiometer J1 3
7 8016 0,5 ISO radar speed J208 1 1
* Version with ISO socket only. 8 8017 0,5 ISO tractor speed J208 2 12 2
11 3
9 8018 0,5 Radar speed J48 B3 10 4
9 5
10 8019 0,5 TCE lift high position J136 A3 6

1
8

2
7
A 11 M8P 0,5 ISO socket earth J208 7

3
12 8020 0,5 ISO socket supply J208 6 604msm2K

5
B

6
7
Wire
identifica
2 J208 Ending
5 4 3 2 1
604msm8j
tion 8015 8014 8017 8016

1 8016 0,5 ISO radar speed J207 7 M8P 8020


2 8017 0,5 ISO forward speed J207 8
9 8 7 6
Wire 3 8014 0,5 ISO rear PTO speed J207 5
identifica
2 J137 Ending
5 9 13 17 21 25 29
4 8015 0,5 ISO up position TCE J207 6
1 801 805 884 8036 8004 809 33 5 — — —
tion 1
6 8020 0,5 ISO socket supply J207 12 2
3
2 802 806 872 899 8035 34
1 801 0,75 Speed 1 light J2 20 7 M8P 0,5 ISO socket earth J207 11 4
5
2 802 0,75 Speed 2 light J2 21 3 803 860 850 879 898 35 8 — — —
3 803 0,75 Speed 3 light J2 22 9 — — —
4 804 0,75 Speed 4 light J2 23 4 804 871 851 8003 897 M8B 36
5 805 0,75 Crawler range light J2 28
6 806 0,75 Rapid range light J2 35 8 12 16 20 24 28 32 604msm3K
7 860 0,6 Crawler speed light 47
8 871 0,75 Forward drive indicator light J2 8
9 884 0,75 Neutral light J2 9
Wire
10
11
872
850
0,75
0,75
Reverse drive indicator light
4 wheel drive light
J2
J2
10
24 identifica
2 J231 Ending
12 851 0,75 Differential indicator J2 34 tion
13 898 0,6 ECO power take-off light 42
14 899 0,6 PTO light 1000 rpm 54 1 880 0,6 CAN-high IP P133 2
15 — — — 4
2 881 0,6 CAN-low IP P133 1
16 8003 0,6 Control + Ranges J49 A2 5

17 8004 0,6 Control - Ranges J49 A4 3 9


13
6
18 — — — 10 17
2
19 879 0,6 + APC 4 PS automatic controls J67 B5 7 14 21

20 897 0,75 PS automatic controls level 1 J1 14 1 11 18 25


29
604hsm0K
22
21 809 0,75 PS automatic controls level 2 J1 21 8 15
19 26 33
12
22 — — — 16 23 30
23 — — — 20 27 34 1 881
24 M8B 0,75 Display earth J67 A2 24 31
35
25 — — —
28 2 880
32
26 — — — 36

27 — — — 604msm9j
28 — — —
29 — — —
604hsm69
30 — — —
31 — — —
32 — — —
33 — — —

F2.56 Ares 806 – 09.2004 – GB


8a - GTA 103 / 202 - GPA 40 transmission control harness Wire
2 28
identifica J237 Ending 14 42
tion M8R
8028

Wire 1 — — —
identifica
2 J232 Ending 1 8006
2 — — —
13 41
3 — — —
tion 2 8005
4 — — — 12 8023 40
5 — — —
1 8006 0,6 CAN-Low TCE P189 1 6 — — — 11 8036 8024 39
2 8005 0,6 CAN-high TCE P189 2 7 8014 0,5 ISO rear PTO speed J208 3
8 8040 1 Park Lock OFF (sol. valve) J80 16 10 8035 38
9 — — —
604hsm70 10 8035 0,6 Park Lock IN light J137 22 9 37
11 8036 0,6 Park Lock use light J137 13
12 — — — 8 8040 36
13 — — —
Wire 14 — — — 7 8041 8042 35
identifica
2 J233 Ending 1 8026
15 — — — 8043
16 — — — 6 8034 34
tion 2 8025 17 — — —
18 — — — 5 33
1 8026 0,6 CAN-Low J235 1 19 — — —
2 8025 0,6 CAN-High J235 2 20 8043 0,6 Park Lock disengaged J80 24 4 32
21 — — —
22 — — — 3 31
604hsm71 23 — — —
24 — — — 2 30
25 — — —
26 — — — 8029
Wire 27 — — —
identifica
2 J234 Ending 28 M8R 1 Auto 5 earth J68 A5 1
15
29
29 8029 1 +AVC auto 5 P119 15
tion 30 — — —
1 8001 0,75 CAN-Low J1 35 31 — — —
32 — — —
2 8000 0,75 CAN-High J1 34 33 — — —
34 8034 0,6 Park lock control P119 4
35 8042 0,6 Park Lock IN light J137 22
36 — — —
37 — — —
604hsm0K 38 — — —
39 8024 0,6 CAN-Low J236 1
40 8023 0,6 CAN-High J236 2
1 8001 41 — — —
42 8028 1 +APC auto 5 E8C
2 8000
604hsm75

Wire
604hsm72
identifica
2 P20 Ending
4 7 10 13 16
tion 1 890
876
870 865 810 863 8012 19
864
Wire 1 890 0,6 Neutral control J49 A5 2 877 869 894 828 854 856 20
identifica
2 J235 Ending 1 8026 1 876 0,75 Neutral control J1 13
2 — — — 3 842 845 844 816 807 852 862 21
tion 2 8025 3 842 0,6 Transmission oil filter J80 4 6 9 12 15 18
4 — — —
1 8026 0,6 CAN-Low TCE J233 1 5 877 0,75 Clutched position J1 20
2 8025 0,6 CAN-high TCE J233 2 6 845 0,6 Potentiometer (REF+) J136 A6
7 870 0,75 Reverse drive control J1 12
604hsm73
8 869 0,75 Forward drive control J1 11
9 844 0,6 Potentiometer (REF-) J136 B6 19
10 865 0,75 PDT sensor clutch J1 4 16
13
11 894 0,6 Pressure manometer J80 25 10
12 816 0,75 DRIVETRONIC RH brake light J1 19 7
Wire DRIVETRONIC LH brake light
identifica
2 J236 Ending 1 8024
13
14
810
828
0,75
0,6 Instrument panel tractor speed
J1
J136
9
B3
4
1

tion 15 807 0,75 Rear PTO light J2 36


2 8023 16 863 0,6 Hydraulic pressure 131
1 8024 0,6 CAN-Low J237 39 17 854 0,6 Fuel level J80 23
2 8023 0,6 CAN-High J237 40 18 852 0,75 Diagnostic indicator J2 30
19 8012 0,5 Rear PTO speed J207 3
19 864 0,75 Rear PTO speed (IP) J2 19
604hsm74 20 856 0,75 Transmission oil temperature J2 29
21 862 0,75 Outside buzzer J2 11 604hsm67

Ares 806 – 09.2004 – GB F2.57


8a - GTA 103 / 202 - GPA 40 transmission control harness 8b - FPS transmission control harness

Wire
Wire
2 identifica
2 J1 Ending
25 36
identifica P119 Ending
tion 4 7 10 13 tion 839 813 M8H 805 806 807 829 881
1 M8I 8034 883 24 13
1 M8I 0,6 Fuel level J80 34 1 867 0,75 Transmission display data J137 B2 804 833 862 M8J 808 880
2 — — — 2 855 14 2 868 0,75 Transmission display clock J137 B4
3 — — — 3 — — — 867 868 802 840 836 815 837 830 8023 882
4 8034 0,6 Park lock control J237 34 3 878 8029 4 802 0,75 Park lock relay P119 5
5 — — — 839 1 12
6 9 12 15
5 840 0,75 Transmission oil filter P20 6
6 — — — 3 6 836 0,75 Transmission oil temperature P20 11
7 — — — 6
7 — — —
8 — — —
9 — — —
12
15
8 815 0,75 Differential control J46 1
10 — — —
604hsm68 9 837 0,75 +APC seat safety J67 B7
11 — — — 10 830 0,75 + Tractor speed sensor J80 12
12 878 1,5 +APC solenoid valve supply J2 33 11 8023 0,6 +APC EVP P119 12
13 883 0,6 Controls declutch ISC J49 A1 12 882 0,75 CAN - J188 A5
14 855 1,5 +APC J67 B2
15 839 1,5 + AVC DRIVETRONIC III J2 27 13 880 0,75 CAN-High J188 A1
15 8029 1 +AVC auto V J237 29 14 — — —
15 808* 0,75 Tractor speed J136 B1
15 808 0,75 Rear PTO light P20 15
16 M8J 1 Electronic unit earth J68 B4
Wire 17 — — —
identifica
2 P133 Ending 4
18 — — —
604hsm78
19 — — —
tion 20 862 0,75 Buzzer (LED) 134
2
1 881 0,6 CAN-Low (Instrument panel) J231 1 880 21 833 0,75 Hydraulic pressure P20 4
2 880 0,6 CAN-High (Instrument panel) J231 2 3
881
22 804 0,75 Park lock light P119 7
3 — — — 23 — — —
1 24 — — —
4 — — — 604hsm76

25 839 1,5 +AVC electronic unit J119 15


26 813 1,5 +APC electronic unit J67 A1
27 M8H 1 Electronic unit J68 B6
Wire Starting relay
identifica
2 P189 Ending
28
29
805
806
0,75
0,75 Gearbox engaged
P119
P119
8
9
4 30 807 0,75 Rear PTO light P20 15
tion
2 31 — — —
1 8006 0,6 CAN-Low (TCE) J232 1 8005 32 — — —
2 8005 0,6 CAN-High (TCE) J232 2 3 33 — — —
3 — — — 8006 34 829 0,75 Tractor speed sensor J80 13
4 — — — 1 35 — — —
604hsm77 36 881 0,75 CAN-Low J188 B7
* Version without ISO socket only.

Wire
identifica
2 P999 Ending
tion 1 2 1
2

8021 M8Q
1 8021 1 Air brake solenoid valve J80 32
2 M8Q 1 Air brake solenoid valve earth J80 35 604msm7K

F2.58 Ares 806 – 09.2004 – GB


8b - FPS transmission control harness Wire
identifica
2 J47 Ending
tion 1 2 1

2
848
Wire + APC rear PTO clutch engaged
identifica
2 J2 Ending
25 36 1 848 1
controls
J67 A6
604msm0j
tion 801 884 811 843 810 M8G 821 824 865 2 — — —

1 876 0,75 Neutral control P20 1 24 870 819 812 887 814 877 822 825 875 13
2 869 0,75 Forward motion control P20 8
Rear PTO stop 876 869 817 818 863 816 809 823 826 866
3 817 0,75 J48 B1 Wire With ISO socket
4 818 0,75 RR PTO clutch ctrl 53
1 12 identifica
2 J48 Ending 1 2 3
5 863 0,75 Up position TCE J136 B6
6 816 0,75 RH brake light P20 12 tion 857 858 A
7 809 0,75 Declutching information P20 21 A1 857* 0,6 TCE lift high position J136 B5 856
817 842 8018 B
8 — — —
9 823 0,75 - Turbo J80 19 A1 857 0,6 TCE lift high position J68 A1
10 — — — A2 — — — Without ISO socket
11 826 0,75 - Steering angle J80 22 A3 858 0,6 + Rear PTO stop (wing) J67 B3
12 866 0,75 Potentiometer (REF-) P20 20
B1 817 0,75 Rear PTO stop (wing) J2 3

1
13 875 0,75 Potentiometer (REF+) P20 19
B2 842 0,6 +APC trip computer TCE J134 B2 A
14 825 0,75 + Steering angle J80 21

3
B3 856 0,6 Trip computer radar speed J134 A3 1 2 3
15 — — — B
16 822 0,75 + Turbo J80 18 B3 8018* 0,5 Radar speed J207 9 857 858 A
17 — — — * Version with ISO socket only. 817 842 856 B
18 — — — 604hsm80
19 877 0,75 Clutched position P20 5
604hsm79
20 814 0,75 4-wheel drive control J45 1
21 887 0,75 Functional fault P119 13 Wire
22 812 0,75 - control (speed) J49 A4 identifica
2 J49 Ending
1 2 3 4 5
23 819 0,75 Handbrake P20 16 tion A 811 812
890 891
24 870 0,75 Reversing control P20 9
A1 — — — B 883 884 853
892
25 801 0,75 Park lock control P119 4 A2 811 0,75 Control + Ranges J2 27
26 884 0,75 Power ratio J49 B2 A2 890 0,75 + control (speed) J137 A1
27 811 0,75 + control (speed) J49 A2 A3 — — —
Rear PTO brake solenoid valve A4 812 0,75 Control - Ranges J2 22
28 843 0,75 53
control A4 891 0,75 - control (speed) J137 A5

1
A

2
29 810 0,75 LH stop P20 13 A5 — — —
30 M8G* 1 Electronic unit J68 B6

4
B
Electronic unit +APC fork ratio control

5
30 M8G 1 J68 B7 B1 883 0,6 J67 B6
31 — — — B2 884 0,75 Fork ratio J2 26
32 — — — B2 892 0,75 Fork ratio J137 B1
33 821 0,75 Signal (turbo) J80 17 B3 853 0,6 +APC +/- range control J67 B1
34 — — — B4 — — — 604hsm81
35 824 0,75 Steering angle signal J80 20 B5 — — —
36 865 0,75 Clutch cursor pot P20 10
* Version without ISO socket only.

Wire
identifica
2 J67 Ending
1 2 3 4 5 6 7
Wire
identifica
2 J45 Ending tion A

tion A1 813 1,5 +APC electronic unit J1 26 B


2 4 6 8 604msm3A
A2 893 0,75 +APC +/- control (speed) J137 B5
2

1 814 0,75 4-wheel drive control J2 20 Without ISO socket


4

A3 846 0,6 +APC 4-wheel drive control J45 5


2 — — —
6

A4 — — — 1 2 3 4 5 6 7
8

3 — — — 814 846
847 A5 847 0,6 +APC differential control J46 5 A 813 893 846 847 848 849
4 — — —
1 3 5 7 A6 848 1 +APC clutch control J47 1
5 846 0,6 +APC 4-wheel drive control J67 A3
A7 849 0,6 Transmission display J137 A2 B 853 855 858 879 883 837
6 — — —
604msm8i
7 — — — With ISO socket
B1 853 0,6 +APC +/- control (speed) J49 B3
8 — — —
B2 855 1,5 +APC P119 14 1 2 3 4 5 6 7
B3 858 0,6 +APC rear PTO stop (wing) J48 A3
A 813 893 846 847 848 849
B4 8011* 0,5 +APC ISO unit J207 1
B5 879 1,5 +APC TCE harness J80 25 B 853 855 858 8011 879 883 837
Wire B6 883 0,6 +APC fork ratio control J49 B1
identifica
2 J46 Ending B7 837 0,75 +APC seat safety J1 9
tion * Version with ISO socket only.
2 4 6 8
2

1 815 0,75 Differential control J1 8

1
4

2
6

2 — — — A

3
8

3 — — — 815 847

5
4 — — — B

6
1 3 5 7
+APC differential control

7
5 847 0,6 J67 A5
6 — — —
7 — — — 604msm9i
8 — — —
604hsm0E

Ares 806 – 09.2004 – GB F2.59


8b - FPS transmission control harness Wire
identifica
2 J80 Ending
tion
4 1
1 — — —
Wire
identifica
2 J68 Ending
1 2 3 4 5 6 7 2 — — —
9 5

3 — — — 15 803 861 829 830 835 832 10


tion A
4 — — — 22 826 825 824 823 822 821 845 16
A1 857 0,6 Up position TCE J48 A1 B 5 — — —
6 — — — 28 874 879 878 854 23
A1 M8A* 2 Transmission control E6A 604msm3A
A2 M8B* 0,6 Transmission display earth J137 B3 Without ISO socket 7 — — — 33 8021M8E 29
A3 — — — 1 2 3 4 5 6 7 8 — — —
9 — — — 37 M8F M8Q M8I 34
A4 — — — M8D
A 857 M8A M8E
A5 M8D* 0,6 Crawler control earth 47 M8B 10 832 0,6 CAN-High (TCE) J188 B1
A5 M8A 2 Transmission ctrl earth E6A B 863 864 M8J M8H M8G M8F 11 835 0,6 CAN-Low (TCE) J188 A7
A6 M8E* 1,5 TCE earth J80 31 12 830 0,75 + Forward speed sensor J1 10
A6 M8B 0,6 Display earth J137 B3 With ISO socket 13 829 0,75 Tractor speed sensor J1 34
A6 M8D 0,6 Crawler control earth 47 14 861 0,6 Crawler speed control 47
A7 M8F* 1,5 TCE earth J80 36 A M8A M8B M8D M8E M8F 15 803 0,6 Park lock control P119 6
A7 M8E 1,5 TCE earth J80 31 16 845 0,6 Rear PTO speed P20 6
B M8K M8J M8H M8G
17 821 0,75 Signal J2 33
B1 863 0,75 Up position TCE (unit) J2 5 18 822 0,75 + Turbo J2 16
B2 864 0,6 Up position TCE (OBC) J134 B1 19 823 0,75 - Turbo J2 9
B3 M8K* 1 Solenoid valve unit earth J207 2 20 824 0,75 Steering angle signal J2 35
B4 M8J 1 Solenoid valve unit earth J1 16 21 825 0,75 + Steering angle J2 14
- Steering angle

1
B5 M8H 1 Solenoid valve unit earth J1 27 22 826 0,75 J2 11

2
A 23 854 0,6 Fuel level P20 17

3
B6 M8H* 1 Solenoid valve unit earth J1 27
B6 M8G 1 Solenoid valve unit earth J2 30 24 878 1,5 +APC solenoid valve supply P119 12

5
B
25 879 1,5 +APC TCE harness J67 B5

6
B7 M8G* 1 Solenoid valve unit earth J2 30

7
26 — — —
* Version with ISO socket only. 27 — — —
28 874 0,6 CAN - (TCE) J188 B5
604hsm0H 29 — — —
30 — — —
31 M8E 1,5 TCE earth J68 A6 604hsm83
32 8021 1 Air brake solenoid valve P999 1
33 — — —
34 M8I 0,6 Fuel level earth P119 1
35 M8Q 1 Air brake solenoid valve earth P999 2
36 M8F 1,5 TCE earth J68 A7
37 — — —

Wire
identifica
2 J134 Ending
tion 1 2 3

1
A1 838 0,6 Trip computer tractor speed J136 B2 838 856 A A

3
A2 — — —
A3 856 0,6 Trip computer radar speed J48 B3 864 842 M8C B B

B1 864 0,6 Up position TCE (trip computer) J136 B7


604hsm84
B2 842 0,6 +APC trip computer TCE J48 B2
B3 M8C 0,6 Trip computer earth P119 3

F2.60 Ares 806 – 09.2004 – GB


8b - FPS transmission control harness Wire
identifica
2 J207 Ending
1 2 3 4 5 6
8011 M8K 8012 8013 8014 8015
tion
8020 M8L 8019 8018 8017 8016
Wire 1 8011 0,5 +APC ISO unit J67 B4
identifica
2 J136 Ending
1 2 3 4 5 6 7 2 M8K 0,5 ISO unit earth J68 B3 12 11 10 9 8 7
3 8012 0,5 Rear PTO speed P20 6
tion A 4 8013 0,5 Tractor speed J136 B2
A1 — — — 5 8014 0,5 ISO rear PTO speed J208 3
B
A2 — — — 604msm1C 6 8015 0,5 ISO up position TCE J208 4
A3 — — — With ISO socket 7 8016 0,5 ISO radar speed J208 1
A4 — — — 1 2 3 4 5 6 7
A5 — — — 8 8017 0,5 ISO tractor speed J208 2 1

A6 — — — A 9 8018 0,5 Radar speed J48 B3 12 2


11 3
A7 — — — 838 828 8019 857 863 864 10 8019 0,5 TCE lift high position J136 B4 10 4
5
B 808 8013 9
11 M8L 0,5 ISO socket earth J208 7 8 6
7
Tractor speed 12 8020 0,5 ISO socket supply J208 6
B1 808 0,75 J1 15 Without ISO socket
B2 8013* 0,5 Tractor speed J207 4 604hsm88
1 2 3 4 5 6 7
B2 838 0,6 Tractor speed (OBC) J134 A1
B3 828 0,6 Tractor speed (IP) P20 14 A
B4 8019* 0,5 Up position TCE J207 10 B 808 838 828 Wire
B5
B6
857*
863*
0,6
0,75
High position
Up position TCE
J48
J2
A1
5 identifica
2 J208 Ending
5 4 3 2 1

B7 864* 0,6 Up position TCE (trip computer) J134 B1 tion 8015 8014 8017 8016

* Version with ISO socket only 1 8016 0,5 ISO radar speed J207 7 M8L 8020
ISO forward speed

1
2 8017 0,5 J207 8

2
9 8 7 6
A 3 8014 0,5 ISO RR power take off speed J207 5

3
4 8015 0,5 ISO up position TCE J207 6

5
B 5 — — —

6
1

7
6 8020 0,5 ISO socket supply J207 12 2
3
7 M8L 0,5 ISO socket earth J207 11 4
5
8 — — —
9 — — —
604hsm85

604hsm89
Wire
identifica
2 J137 Ending
1 2 3 4 5
A 890 849 827 891
tion
Wire
A1 890 0,75 + control (speed) J49 A2
B 892 867 M8B 868 893
identifica
2 P20 Ending
4 7 10 13 16
A2 849 0,6 +APC transmission display J67 A7 tion 1 876 833 870 865 810 819 875 19
A3 — — —
A4 827 0,6 Side light indicator P20 9 1 876 0,75 Neutral control J2 1 2 877 869 836 828 854 866 20
A5 891 0,75 - control (speed) J49 A4 2 — — —
3 840 845 827 816 807 888 809 21
1

A 3 840 0,75 Transmission oil filter J1 5


2

8012
4 833 0,75 Hydraulic pressure J1 21
B1 892 0,75 Fork ratio J49 B2 Clutched position
6 9 12 15 18
4

B 5 877 0,75 J2 19
Transmission display data
5

B2 867 0,75 J1 1 6 8012* 0,5 Rear PTO speed J207 3


B3 M8B* 0,6 Transmission display J68 A2 6 845 0,6 Rear PTO speed (IP) J80 16
B3 M8B 0,6 Transmission display J68 A6 7 870 0,75 Reverse drive control J2 24
B4 868 0,75 Transmission display clock J1 2 8 869 0,75 Forward drive control J2 2
B5 893 0,75 +APC +/- control (speed) J67 A2 604hsm86 9 827 0,6 Side light indicator J137 A4 19
10 865 0,75 PDT sensor clutch J2 36 16
13
* Version with ISO socket only 11 836 0,75 Transmission oil temperature J1 6 10
12 816 0,75 DRIVETRONIC RH brake light J2 6 7
13 810 0,75 DRIVETRONIC LH brake light J2 29 4
Wire 14 828 0,6 Instrument panel tractor speed J136 B3 1

identifica
2 J188 Ending
1 2 3 4 5 6 7 15 807 0,75 Rear PTO light J1 30
16 819 0,75 Handbrake J2 23
tion A 17 854 0,6 Fuel level J80 23
18 888 0,75 Buzzer 134
A1 880 0,75 CAN-High J1 13 B 19 875 0,75 Potentiometer (REF+) J2 13
A2 831 0,6 CAN-High (IP) P133 2 604msm1C 20 866 0,75 Potentiometer (REF-) J2 12
A3 — — — 21 809 0,75 Disengaged info J2 7
A4 — — — 1 2 3 4 5 6 7
A5 882 0,75 CAN - J1 12 A 880 831 882 834 835 * Version with ISO socket only 604hsm0J

A6 834 0,6 CAN-Low (IP) P133 1


A7 835 0,6 CAN-Low (TCE) P80 11 B 832 8005 8007 873 874 8006 881

B1 832 0,6 CAN-High (TCE) J80 10


B2 8005 0,6 CAN-High (TCE) P189 2
B3 8007 0,6 CAN - (TCE) P189 3
CAN - (Network socket)
1

B4 873 0,6 J133 3


2

B5 874 0,6 CAN - (TCE) J80 28 A


3

B6 8006 0,6 CAN-Low (TCE) P189 1


5

B7 881 0,75 CAN-Low J1 36 B


6
7

604hsm87

Ares 806 – 09.2004 – GB F2.61


8b - FPS transmission control harness 8/1 - ISO socket harness

Wire
Wire
2 4 7 10 13 identifica
2 J219 Ending
identifica P119 Ending
tion 1 M8I 801 804 887 tion 3 4
JA OR
1 M8I 0,6 Fuel level J80 34 2 802 805 855 14 1 BR 0,5 ISO radar speed P208 1
2 — — — 2 VI 0,5 ISO forward speed P208 2 5

On board computer 3 M8C 803 806 8023 839 2 VI NO 5


3 M8C 0,6 J134 B3 878 3 YL 0,5 ISO rear PTO speed P208 3 6
4

4 801 0,75 Park lock control J2 25 6 9 12 15 4 OR 0,5 ISO lift up position TCE P208 4 MA RG
5 802 0,75 Park lock relay J1 4 5 — — — 1 3

6 803 0,6 Park lock solenoid valve control J80 15 6 RD 0,5 ISO socket supply P208 6
1 6 2

7 804 0,75 Park lock light J1 22 — BK 0,5 ISO socket earth P208 7
8 805 0,75 Starting relay J1 28 3 604msm8K
9 806 0,75 Gearbox engaged J1 29 6
10 — — — 12
11 — — — 15
604hsm91
12 8023 0,6 +APC EVP J1 11 Wire
12 878 1,5 +APC solenoid valve supply J80 24
identifica
2 P208 Ending
1
2
3
13 887 0,75 Functional fault J2 21 5 4 3 2 1 4
14 855 1,5 +APC J67 B2 tion OR JA VI MA
5
15 839 1,5 + AVC DRIVETRONIC III J1 25
1 BR 0,5 ISO radar speed J219 1 NO RG
2 VI 0,5 ISO forward speed J219 2
3 YL 0,5 ISO rear PTO speed J219 3 9 8 7 6
4 OR 0,5 ISO lift up position TCE J219 4 604msm9K
Wire
identifica
2 P133 Ending
5 — — —
4 6 RD 0,5 ISO socket supply J219 6
tion 7 BK 0,5 ISO socket earth J219
2
873 831
8 — — —
1 834 0,6 CAN-Low (Instrument panel) J188 A6 9 — — —
2 831 0,6 CAN-High (Instrument panel) J188 A2 3
834
3 873 0,6 CAN - (Instrument panel) J188 B4 Colour legend
1
4 — — — 604hsm92 YL Yellow
BR Brown
BK Black
Wire OR Orange
identifica
2 P189 Ending VI Purple
4
tion RD Red
2
1 8006 0,6 CAN-low (TCE) J188 B6 8007 8005
2 8005 0,6 CAN-high (TCE) J188 B2 3
3 8007 0,6 CAN - (TCE) J188 B3 8006
4 — — — 1
604msm6K

Wire
identifica
2 P999 Ending
tion 1 2 1
2

8021 M8Q
1 8021 1 Air brake solenoid valve J80 32
2 M8Q 1 Air brake solenoid valve earth J80 35 604msm7K

F2.62 Ares 806 – 09.2004 – GB


8/2 - Display harness Wire Level 2
identifica
2 J195 Ending
tion
2 4 6 8
Level 1 1 8120 0,6 4 PS automatic control light J195 10

2
Wire
2

4
1 8128 0,6 4PS controls Diode
identifica J150 Ending 1 5 9 13 17 21

6
2 — — —

8
8120
tion 8101 8105 8109 8114 3 — — — 8128
8127

1 8101 0,6 Speed 1 light P137 1 8102 8106 8110 8134 8133
4 — — — 1 3 5 7

2 8102 0,6 Speed 2 light P137 2 5 8127 0,6 4PS controls (+) J206 8
3 8103 0,6 Speed 3 light P137 3 8103 8107 8111 8115 6 — — — 604msm3L
4 8104 0,6 Speed 4 light P137 4 7 — — —
8104 8108 8112 M8Y 8 — — —
5 8105 0,6 Crawler range light P137 5
6 8106 0,6 Rapid range light P137 6 4 8 12 16 20 24 9 M8Y 0,6 Display earth J150 24 9 10
9
9 M8Z 0,6 4 PS auto light earth P137 24 M8Y
7 8107 0,6 Crawler speed light P137 7 Level 2 8120

1
M8Z

0
8 8108 0,6 Forward drive indicator light P137 8 10 8120 0,6 4 PS automatic control light J195 1
1 5 9 13 17 21
9 8109 0,6 Neutral light P137 9
604msm4L
10 8110 0,6 Reverse drive indicator light P137 10 8101 8105 8109 8114 8131
11 8111 0,6 4 wheel drive light P137 11
12 8112 0,6 Differential indicator P137 12 8102 8106 8110 8113 8134 8133
Wire
13
14
8114
8134
0,6
0,6
PTO light 1000 rpm
Park Lock use light
P137
P137
14
13
8103 8107 8111 8115
identifica
2 J206 Ending
14 8113 0,6 PTO ECO light E8B 8104 8108 8112 8121 M8Y tion 2 4 6 8
15 8115 0,6 PTO drive light P137 15

2
4 8 12 16 20 24
4PS Power control Diode

4
16 — — — 1 8130 0,6 8124 8119 8125 8127

6
17 — — — 1 8131 0,6 4 PS auto Power light J150 21

8
8130
8126
18 — — — 2 8124 0,6 + APC 4 PS auto Power E8A 8131
19 — — — 1 3 8126 0,6 + APC 4 PS auto Power E8A 1 3 5 7
20 8121* 0,6 ECO 4 PS auto light J206 5
2 4 8119 0,6 4PS auto controls P137 21
3
21 8131* 0,6 4 PS auto Power light J206 1 5 8121* 0,6 ECO 4 PS auto light J150 20
4 604msm94
22 8133 0,6 Park Lock IN light P137 22 6 8125 0,6 +APC ECO E8A
23 — — — 7 — — —
24 M8Y 0,6 4PS auto. level 1 light earth J195 9 8 8127 0,6 4PS controls J195 5
604hsm93
* Level 2 only * Level 2 only.

Wire FPS Wire Level 1


2 identifica
2 P137 Ending
identifica J150 Ending 5 9 13 17 21 25 29

tion 1 2 3
tion 1 8101 8105 8109 8134 8117 33

Speed 1 light
1
A1 8100 0,6 +APC display P137 A2 A 8100 8101 A 1 8101 0,6 J150 1 2 8102 8106 8110 8114 8133 34
A2 — — — 2 8102 0,6 Speed 2 light J150 2
3
B
A3 8101 0,6 Display lamps P137 A4 B 8103 M8Z 8102 3 8103 0,6 Speed 3 light J150 3 3 8103 8107 8111 8132 8100 8113 35
B1 8103 0,6 Display data P137 B2 4 8104 0,6 Speed 4 light J150 4
4 8104 8108 8112 8116 8118 M8Z 36
B2 M8Z 0,6 Display earth P137 B3 5 8105 0,6 Crawler range light J150 5
604hsm0F
B3 8102 0,6 Display clock P137 B4 6 8106 0,6 Rapid range light J150 6 8 12 16 20 24 28 32
7 8107 0,6 Crawler speed light J150 7
8 8108 0,6 Forward drive indicator light J150 8 Level 2
9 8109 0,6 Neutral light J150 9 5 9 13 17 21 25 29
10 8110 0,6 Reverse drive indicator light J150 10
Wire Level 1
identifica
2 J195 Ending
11 8111 0,6 4 wheel drive light J150 11 1 8101 8105 8109 8134 8117 8119 33
12 8112 0,6 Differential indicator J150 12
2 8102 8106 8110 8114 8133 34
tion 13 8134 0,6 Park Lock use light J150 13
2 4 6 8 14 8114 0,6 PTO light 1000 rpm J150 14 3 8103 8107 8111 8132 8100 8113 35
1 8120 0,6 4 PS automatic control light J195 10 PTO drive light
2

15 8132 0,6 E8B


4

1 8118 0,6 4PS auto controls P137 20 16 8116 0,6 Control + Ranges 220A 4 8104 8108 8112 8116 8118 M8Z 36
6

2 — — — Control - Ranges
8

8120 8100 17 8117 0,6 220B


3 — — — 8118 8122 8 12 16 20 24 28 32
18 — — —
4 — — — 1 3 5 7 19 8100* 0,6 +APC E8A
5 8100 0,6 + APC Control 4PS P137 19 19 8100 0,6 +APC J195 5
5 8122 0,6 +APC +/- range control 220A 604msm1L 20 8118 0,6 4PS auto controls Diode
6 — — — 21 8119* 0,6 4PS auto controls J206 4
7 — — — 22 8133 0,6 Park Lock IN light J150 22 4
9 10
8 — — — 9 23 8113 0,6 PTO ECO light E8B 5
9
Display earth
3
9 M8Y 0,6 J150 24 M8Y 24 M8Z 0,6 4 PS auto light earth J195 9
1

6 13
8120
0

9 M8Z 0,6 4 PS auto light earth P137 24 M8Z 25 — — — 2


7
10
14
17
21
10 8120 0,6 4 PS automatic control light J195 1 604msm2L 26 — — — 1 11 18 25
29
15 22
8
27 — — — 12 19 26 33
30
28 — — — 16
20
23
27 34
29 — — — 24 31
35
30 — — — 28
32
31 — — — 36

32 — — — 604hsm95
33 — — —
34 — — —
35 — — —
36 — — —
* Level 2 only.

Ares 806 – 09.2004 – GB F2.63


8/2 - Display harness Notes

Wire FPS
identifica
2 P137 Ending 1 2 3 4 5
tion A 8105 8100 8101 8104
A1 8105 0,6 Range + control 220A B 8106 8103 M8Z 8102 8107
A2 8100 0,6 +APC display J150 A2
A3 — — —
A4 8101 0,6 Display lamps J150 A3
A5 8104 0,6 Range - control 220B
B1 8106 0,6 Furrow gear 220C
B2 8103 0,6 Display data J150 B1 A

1
2
B3 M8Z 0,6 Display earth J150 B2

3
B
Display clock

4
B4 8102 0,6 J150 B3

5
B5 8107 0,6 +APC range control 220A

604hsm0G

F2.64 Ares 806 – 09.2004 – GB


Notes Notes

Ares 806 – 09.2004 – GB F2.65


9a - TCE 15/25/35 Control harness 9a - TCE 15/25/35 Control harness

Connectors Designation
J69 TCE 15/25/35 harness connection
J70 Shunt receptacle (white)
J71 Lift central unit (TCE)
J87* Shunt receptacle (white)
J189 Transmission control harness connection
J190* Electrohydraulic spool valve (DEH) control harness connection
J191* Electrohydraulic spool valve (DEH) control harness connection
P42 Rear harness connection

J71
P125** Implement socket
P192 TCE programming socket

P42

E6A
* Version with electrohydraulic spool valves only.
** Version TCE 35 only.

J190
P192

J191
J70

J87
J189 E9A

P125
J69
J71

P42
M9I

606msm16

F2.66 Ares 806 – 09.2004 – GB


9a - TCE 15/25/35 Control harness Wire
identifica
2 J70 Ending
1 2 3 4 5 6 7

tion A

Wire TCE 15/25 with EH spool valves A1 904 1,4 +AVC REH J71 30 B
identifica
2 J69 Ending A2 917* 2 +AVC REH P42 B1 604msm2A
A3 905 0,6 +APC TCE lighting J71 7
tion
A4 — — —
TCE 15/25/35
+APC REH 1 2 3 4 5 6 7
1 906 0,6 V REF. rear position J71 15 4 912 933 907 906 1 A5 923 0,6 J71 34
2 907 0,6 Rear position signal J71 23 9 913 914 934 909 908 5 A6 902 1 +APC (RH+ relayed) P42 A1 A 904 917 905 923 902 903
3 933 0,6 V - rear position J71 19 A7 903 0,6 +APC TCE (RH+ relayed) J71 47
15 915 935 911 910 10 B
4 912 0,75 V - lowering valve J71 6 932 916 925
5 908 0,6 V REF. LH draft J71 16 22 M9G 924 955 16 B1 917 2 +AVC REH P42 B1
6 909 0,6 LH draft signal J71 51 28 948 952 23 B2 932 1,4 +AVC REH J71 31 TCE 35 with EH spool valves
7 934 0,6 V - LH rear draft J71 20 33 947 951 960 956 29
B3 — — — 1 2 3 4 5 6 7
8 914 0,75 V + lowering valve J71 2 B4 916 0,6 +APC REH P42 A6
9 913 0,75 V + raising valve J71 5 37 M9H 34 B5 945* 0,6 +APC front ext. control J69 26 A 904 905 923 902 903
10 910 0,6 + V REF RH draft J71 17 B6 — — —
B 917 932 916 945 925
11 911 0,6 RH draft signal J71 24 B7 925*** 0,6 +APC radar (RH+ relayed) J69 16
12 935 0,6 V - RH rear draft J71 21 B7 925** 0,6 +APC radar (RH+ relayed) J87 A3
13 938*** 0,6 Front lower outside ctrl J71 35 TCE 15/25 without EH spool valves
14 915 0,75 V + raising valve J71 29 * TCE 35 with electrohydraulic spool valves only.
15 926** 0,75 V - down valve 1/2 J71 33 ** TCE 15/25/35 with electrohydraulic spool valves.
16 925**** 0,6 +APC radar (RH + relayed) J70 B7 *** TCE 15/25/35 without electrohydraulic spool valves.

1
+APC radar (RH + relayed) 4 912 933 907 906 1

2
16 955* 0,6 J87 A5 A

3
17 924 0,6 Radar signal P42 B3 9 913 914 934 909 908 5
18 M9G 0,6 Radar earth E9A

5
15 915 935 911 910 10 B

6
19 937*** 0,6 Front rise outside ctrl J71 36

7
20 928** 0,75 V + lowering valve 1/2 J71 1 22 M9G 924 925 16

21 929** 0,75 V + raising valve 1/2 J71 28 28 23


22 927** 0,75 V - up valve 1/2 J71 32 33 29
23 942*** 0,6 VREF front position J71 18 604hsm96
24 943*** 0,6 Front position signal J71 26 37 34

25 944*** 0,6 V - forward position J71 22


26 945*** 0,6 +APC front ext. control J70 B5
27 952* 0,6 CAN-Low LH DEH J87 B6
28 948* 0,6 CAN-high LH DEH J87 B2 TCE 35 with EH spool valves
29 956* 1 +APC LH and RH DEH J87 B5
30 — — —
31 960* 1 Safety solenoid valve ctrl J191 1
32 951* 0,6 CAN-Low RH DEH J87 A6 4 912 933 907 906 1

33 947* 0,6 CAN-High RH DEH J87 A2 9 913 914 934 909 908 5
34 — — — 15 926 915 938 935 911 910 10
35 — — —
36 — — — 22 927 929 928 937 M9G 924 955 16

37 M9H* 1 LH and RH DEH earth E9A 28 948 952 945 944 943 942 23

33 947 951 960 956 29


* TCE 15/25/35 with electrohydraulic spool valves.
** TCE 35 only. 37 M9H 34

*** TCE 35 with electrohydraulic spool valves.


**** TCE 15/25/35 without electrohydraulic spool valves.

TCE 35 without EH spool valves

4 912 933 907 906 1

9 913 914 934 909 908 5

15 926 915 935 911 910 10

22 927 929 928 M9G 924 925 16

28 23

33 29

37 34

604msm7L

Ares 806 – 09.2004 – GB F2.67


9a - TCE 15/25/35 Control harness Wire
identifica
2 J87 Ending 1 2 3 4 5 6 7
tion
A
Wire A1 946 0,6 CAN-high transmission control J189 2
identifica
2 J71 Ending
A B C
A2 947 0,6 CAN-High RH DEH J69 33 B
27 55 27 55 27 55 A3 925 1 +APC radar - DEH J70 B7 604msm2A
tion
A4 — — — 1 2 3 4 5 6 7
54 54 54
1 928** 0,75 V + lowering valve 1/2 J69 20 26 943 26 26 A5 955 0,6 +APC radar J69 16
CAN-Low RH DEH A 946 947 925 955 951 950
2 914 0,75 V + lowering valve J69 8 A6 951 0,6 J69 32
25 53 25 53 25 53
3 M9E 1,4 TCE earth E9A A7 950 0,6 CAN-low transmission control J189 1 B 949 948 957 956 952 953
4 M9F 1,4 TCE earth E9A 24 911 930 24 911 930 24 911
5 913 0,75 V + raising valve J69 9 52 52 52 B1 949 0,6 CAN-high DEH control J190 2
6 912 0,75 V - lowering valve J69 4 B2 948 0,6 CAN-high LH DEH J69 28
23 907 909 51 23 907 909 51 23 907 909 51
7 905 0,6 +APC TCE lighting J70 A3 B3 — — —
8 — — — 50 50 50
B4 957 1 +APC DEH control J191 3
22 944 22 22
+APC RH and LH DEH

1
9 — — — B5 956 1 J69 29

2
10 — — — B6 952 0,6 CAN-Low LH DEH J69 27 A

3
21 935 936 49 21 935 936 49 21 935 49
11 — — — B7 953 0,6 CAN-low DEH control J190 1

5
12 921 0,6 CAN-High return P42 A5 B

6
20 934 48 20 934 48 20 934 48
CAN-Low return

7
13 922 0,6 P42 B5
14 — — — 19 933 903 47 19 933 903 47 19 933 903 47
15 906 0,6 + V REF rear position J69 1
16 908 0,6 + V REF LH draft J69 5 18 942 46 18 46 18 46
17 910 0,6 + V REF RH draft J69 10 604msm0M
18 942* 0,6 VREF front position J69 23 17 910 931 45 17 910 931 45 17 910 45
19 933 0,6 V - rear position J69 3
16 908 16 908 16 908 Wire
V - LH rear draft
20
21
934
935
0,6
0,6 V - RH rear draft
J69
J69
7
12
44 44 44
identifica
2 J189 Ending
22 944* 0,6 V - forward position J69 25 15 906 43 15 906 43 15 906 43 4
tion
23 907 0,6 Rear position signal J69 2 2
14 14 14
24 911 0,6 RH draft signal J69 11 920 42 920 42 920 42 1 950 0,6 CAN-low transmission control J87 A7 954 946
25 — — — 2 946 0,6 CAN-high transmission control J87 A1 3
13 922 919 13 922 919 13 922 919 950
26 943* 0,6 Front position signal J69 24 41 41 41 3 954 0,6 CAN - J190 3
27 — — — 4 — — — 1
12 921 918 40 12 921 918 40 12 921 918 40
28 929** 0,75 V + raising valve 1/2 J69 21 604msm1M
29 915 0,75 V + raising valve J69 14 11 11 11
39 39 39
30 904 1,4 +AVC REH J70 A1
31 932 1,4 +AVC REH J70 B2 10 10 10
900 900 900 Wire
32 927** 0,75 V - up valve 1/2 J69 22
38 38 38
identifica
2 J190 Ending
33 926** 0,75 V - down valve 1/2 J69 15 9 901 37 9 901 37 9 901 37 4
34 923 0,6 +APC REH J70 A5 tion
35 938* 0,6 Front lower outside ctrl J69 13 8 937 36 8 36 8 36 2
36 937* 0,6 Front rise outside ctrl J69 19 1 953 0,6 CAN-low DEH control J87 B7 954 949
37 901 0,6 Rear lowering ext ctrl P42 A3 7 905 938 7 905 7 905 2 949 0,6 CAN-high DEH control J87 B1 3
35 35 35 953
38 900 0,6 Rear raising ext ctrl P42 A2 3 954 0,6 CAN - J189 3
39 — — — 6 912 923 34 6 912 923 34 6 912 923 34 4 — — — 1
40 918 0,6 CAN-High network P42 B2 604msm2M
41 919 0,6 CAN-Low network P42 B4 5 913 926 33 5 913 926 33 5 913 33
42 920 0,6 REH lift up position P42 B6
43 — — — 4 M9F 927 4 M9F 927 4 M9F
32 32 32 Wire
44 — — — identifica
2 J191 Ending
3 M9E 932 3 M9E 932 3 M9E 932 1 2
45 931** 0,6 Implement position VREF P125 PE4 31 31 31
tion 1
46 — — — 960 957
2 914 904 2 914 904 2 914 904

2
47 903 0,6 +APC (RH+ relayed) J70 A7 30 30 30
1 960 1 Safety solenoid valve ctrl J69 31
48 — — — 2 957 1 +APC DEH control J87 B4 M9J
1 928 29 1 928 29 1 29
49 936** 0,6 P125 V2 915 915 915
3 M9J 1 DEH control earth E9A 3
50 — — — 28 28 28 604msm3M
929 929
51 909 0,6 LH draft signal J69 6
52 930** 0,6 Implement position signal P125 U1
53 — — —
54 — — —
55 — — —
* TCE 35 with electrohydraulic spool valves only.
** TCE 35 only.

Parts list —>


A TCE 35 with EH spool valves
B TCE 35 without EH spool valves
C TCE 15/25

604msm9L

F2.68 Ares 806 – 09.2004 – GB


9a - TCE 15/25/35 Control harness Notes

Wire
identifica
2 P42 Ending
1 2 5 36 4
7
A 902 900 901 921 916
tion 959
B 917 918 924 919 922 920
A1 902 1 +APC TCE (D+) J70 A6 958
A2 900 0,6 Ext. TCE up control J71 38
A3 901 0,6 Ext. TCE down control J71 37
A4 — — —
A5 921 0,6 CAN-High return J71 12
A5 959 0,6 CAN-High REH programming P192 2
+APC REH A

1
A6 916 0,6 J70 B4

2
A7 — — —

3
B

4
5
B1 917 2 +AVC REH J70 B1

6
+AVC REH

7
B1 917* 2 J70 A2
B2 918 0,6 CAN-High network J71 40
B3 924 0,6 Radar signal J69 17 604msm4M
B4 919 0,6 CAN-Low network J71 41
B5 922 0,6 CAN-Low return J71 13
B5 958 0,6 CAN-Low REH programming P192 1
B6 920 0,6 TCE lift high position J71 42
B7 — — —
TCE with electrohydraulic spool valves only.

Wire
identifica
2 P125 Ending
tion
U1 930 0,6 Implement position signal J71 52 U1 PE4
V2 936 0,6 V - implement position J71 49 930 931
PE4 931 0,6 Implement position VREF J71 45
W3 — — — 936
V2 W3
TCE 35 only.

604msm5M

Wire
identifica
2 P192 Ending 4
tion 2
959
1 958 0,6 Programming CAN-Low P42 B5 3
2 959 0,6 Programming CAN-High P42 A5 958
3 — — — 1
604msm6M
4 — — —

Ares 806 – 09.2004 – GB F2.69


9b - TCE 15T Control harness 9b - TCE 15T Control harness

Connectors Designation
J69 TCE harness connection
J70 Shunt receptacle (grey)
J71 Electronic linkage control unit (TCE)
J186 Lift central unit (TCE)
J187 Shunt receptacle (grey)
J189 Transmission control harness connection
J190* Electrohydraulic spool valve (DEH) control harness connection
Electrohydraulic spool valve (DEH) control harness connection

J71
J191*
J192* Shunt receptacle (white)

J186
P42 Rear harness connection

* Version with electrohydraulic spool valves

P42

E6A
J190

J191
J187

J70
J192
J189

J69
J186

J42
J71

606msm17

F2.70 Ares 806 – 09.2004 – GB


9b - TCE 15T Control harness
Wire 2 J70 Ending
1 2 3 4 5 6 7
markers
A
TCE 15T without EH spool valves A1 918 1 V + down valve - light J71 14
Wire 2 J69 Ending A2 919 0,6 Lower valve indicator J186 8
B
604msm1C
markers A3 914 1 V + lowering valve J69 8
A4 — — — 1 2 3 4 5 6 7
4 912 933 907 906 1
1 906 0,6 + V REF rear position J70 B5 A5 937 0,6 Return - V lift /Lower valves J71 6
A 918 919 914 937 912 913
2 907 0,6 Rear position signal J71 19 9 913 914 934 909 908 5 A6 912 1 V - lowering valve J69 4
3 933 0,6 V - rear position J187 B5 15 915 935 911 910 10 A7 913 1 V + raising valve J69 7 B 921 922 915 932 906 908 910
4 912 1 V - lowering valve J70 A6 22 16
5 908 0,6 + V REF LH draft J70 B6 B1 921 1 V + upwards valve - light J71 2
6 909 0,6 LH draft signal J71 17 28 23 B2 922 0,6 Up valve indicator J186 19
7 934 0,6 V - LH rear draft J187 B6 33 29 B3 915 1 V + upwards valve - light J69 14
8 914 1 V + lowering valve J70 A3 B4 932 0,6 + V REF RH & LH posit./load J71 13
37 34

1
9 913 1 V + raising valve J70 A7 B5 906 0,6 + V REF position J69 1

2
+ V REF RH draft B6 908 0,6 + V REF LH draft J69 5 A

3
10 910 0,6 J70 B7
11 911 0,6 RH draft signal J71 18 B7 910 0,6 + V REF RH draft J69 10

5
B
12 935 0,6 V - RH rear draft J187 B7

6
TCE 15T with EH spool valves

7
13 — — —
14 915 1 V + raising valve J70 B3
15 — — —
16 — — —
17 — — — 4 912 933 907 906 1 604msm8M
18 — — — 9 913 914 934 909 908 5
19 — — —
20 — — —
15 915 935 911 910 10
TCE 15T without EH spool valves
21 — — — 22 16 Wire 2 J71 Ending 13 12 11 10 9 8 7 6 5 4 3 2 1
22 — — — 28 942 946 23 markers
932 905 924 900 929 928 917 937 902 926 904 921 M9E
23 — — — 33 941 945 952 950 29
24 — — — 1 M9E 1 REH ctrl elec. unit earth J187 A2 903 938 930 931 901 907 911 909 927 936 918
25 — — — 37 M9H 34 2 921 1 V + upwards valve - light J70 B1 25 24 23 22 21 20 19 18 17 16 15 14
26 — — — 3 904 0,6 V REF 1,6 V J186 1
27 946* 0,6 CAN-Low LH DEH J192 B6 4 926 0,6 Mixed check control J186 2 TCE 15T with EH spool valves
28 942* 0,6 + CAN-High LH DEH J192 A6 5 949* 0,6 + APC (D+ relayé) J192 A5 13 12 11 10 9 8 7 6 5 4 3 2 1
29 950* 1 APC LH & RH DEH J192 B5 5 902** 1 + APC (D+ relayé) P42 A1 932 905 924 900 929 928 917 937 949 926 904 921 M9E
30 — — — 6 937 0,6 Return - V lift /Lower valves J70 A5
31 952* 1 Safety solenoid valve ctrl J191 1 7 917 0,6 Line L P42 B7 903 938 930 931 901 907 911 909 927 936 918
32 945* 0,6 CAN-Low RH DEH J192 A6 8 928 0,6 Mode selector J186 5
33 941* 0,6 CAN-High RH DEH J192 A2 9 929 0,6 Diagnostic indicator J186 7 25 24 23 22 21 20 19 18 17 16 15 14
34 — — — 10 900 0,6 Rise - lift ctrl P42 A2
35 — — — 11 924 0,6 Transport light - Line K J187 A5
36 — — — 12 905 0,6 V REF 9,5 V J187 B1
37 M9H* 1 LH and RH DEH earth J187 A3 13 932 0,6 + V REF RH & LH posit./load J70 B4 25
24
23
* With electrohydraulic spool valves only 14 918 1 V + down valve - light J70 A1
22
21
20
15 936 0,6 + V REF RH & LH posit./load J187 B4 19
18
17
16 927 0,6 Depth control J186 4 16
15
604msm7M 14
17 909 0,6 LH draft signal J69 6
18 911 0,6 RH draft signal J69 11
19 907 0,6 Position signal J69 2
20 901 0,6 Lower - lift ctrl P42 A3
21 931 0,6 Transport mode ctrl J186 18
22 930 0,6 Position ctrl (upper stop) J186 3
23 — — —
24 938 0,6 Lower speed control J186 15 604msm9M
25 903 1 +APC lift unit P42 A6
* TCE 15T with electrohydraulic spool valves
** TCE 15T without electrohydraulic spool valves

Ares 806 – 09.2004 – GB F2.71


9b - TCE 15T Control harness
Wire 2 J189 Ending
markers 4
2
1 944 0,6 CAN-low transmission control J192 A7
Wire 2 J186 Ending
13 12 11 10 9 8 7 6
919 929 920 928 927 930 926 904
5 4 3 2 1
2 940 0,6 CAN-high transmission control J192 A1 3
948 940
markers 3 948 0,6 CAN - J190 3 944
922 931 925 M9F 938 923
4 — — — 1
25 24 23 22 21 20 19 18 17 16 15 14
1 904 0,6 V REF 1,6 V J71 3 604msm2N
2 926 0,6 Mixed check control J71 4
3 930 0,6 Position ctrl J71 22
4 927 0,6 Depth control J71 16 25

2
24
23

Mode selector Wire


22
5 928 0,6 J71 8 21

6 920 0,6 Lift up position P42 B6


20
19
18
17
16
15
markers
J190 Ending 4
7 929 0,6 Diagnostic indicator J71 9 14

2
8 919 0,6 Down valve indicator J70 A2
1 947 0,6 CAN-low DEH control J192 B7 948 943
9 — — —
2 943 0,6 CAN-high DEH control J192 B1 3
947
10 — — —
3 948 0,6 CAN - J189 3
11 — — — 1
604msm0N 4 — — —
12 — — — 604msm3N
13 — — —

14 923 0,6 V REF 9,5 V J187 B2


15 938 0,6 Lower speed control J71 24
16 M9F 1 Unit earth J187 A2 Wire 2 J191 Ending 1 2
17 925 0,6 Transport mode indicator J187 A6 markers 1
18 931 0,6 Transport mode ctrl J71 21 952 951

2
19 922 0,6 Up valve indicator J70 B2 1 952 1 Safety solenoid valve ctrl J69 31 M9G
20 — — — 2 951 1 +APC DEH control J192 B4
21 — — — 3 M9G 1 DEH control earth J187 A3 3
22 — — — 604msm4N
23 — — —
24 — — —
25 — — —
Wire 2 J192 Ending
1 2 3 4 5 6 7
markers
A

Wire 2 J187 Ending


1 2 3 4 5 6 7 A1 940 0,6 CAN-high transmission control J189 2 B

markers A2 941 0,6 CAN-High RH DEH J69 33 604msm2A


A A3 902* 1 + APC (D+ relayé) P42 A1 1 2 3 4 5 6 7
A4 — — —
A1 M9A 0,6 Earth E6A B A5 949** 0,6 +APC (RH+ relayed) J71 5
A 940 941 902 949 945 944
A2 M9E 1 REH ctrl elec. unit earth J71 1 604msm1C A6 945 0,6 CAN-Low RH DEH J69 32 B 943 942 951 950 946 947
A2 M9F* 1 REH ctrl elec. unit earth REH J186 16 A7 944 0,6 CAN-low transmission control J189 1
A3 M9G 1 DEH control earth J191 3 TCE 15T with EH spool valves
A3 M9H* 1 LH and RH DEH earth J69 37 1
2 3 4 5 6 7 B1 943 0,6 CAN-high DEH control J190 2
A4 — — — M9E M9G B2 942 0,6 CAN-high LH DEH J69 28
A5 924 0,6 Transport light - Line K J71 11 A M9A
M9F M9H
924 925 916
B3 — — —

1
A6 925 0,6 Transport mode indicator J186 17 +APC DEH control

2
B 905 923 939 936 933 934 935 B4 951 1 J191 2 A

3
A7 916 0,6 Line K P42 A7 B5 950 1 +APC LH and RH DEH J69 29

5
B6 946 0,6 CAN-Low LH DEH J69 27 B
TCE 15T without EH spool valves

6
B1 905 0,6 V REF 9,5 V J71 12 CAN-Low DEH

7
B7 947 0,6 J190 1
B2 923 0,6 V REF 9,5 V J186 14 1 2 3 4 5 6 7
B3 939 0,6 V REF 9,5 V outside TCE ctrl P42 B2 * Without electrohydraulic spool valves only **
B4 936 0,6 - V REF position J71 15 A M9A M9E M9F 924 925 916
With electrohydraulic spool valves only 604msm5N
B5 933 0,6 - V REF position J69 3
B 905 923 939 936 933 934 935
B6 934 0,6 - V REF LH load J69 7
B7 935 0,6 - V REF RH draft J69 12
* With electrohydraulic spool valves only Wire 2 P42 Ending
1 2 3 4 5 6 7
markers A 902 900 901 903 916
1
2

A B 939 920 917


3

A1 902 1 + APC (D+ relayé) J192 A3


A1* 902 1 + APC (D+ relayé) J71 5
5

B
A2 900 0,6 TCE up control J71 10
6
7

A3 901 0,6 TCE down control J71 20


A4 — — —
A5 — — —
A6 903 1 +APC REH J71 25 A

1
2
604msm1N A7 916 0,6 Line K J187 A7

3
B

4
5
B1 — — —

6
B2 939 0,6 VREF 9,5 V outs. ctrl TCE J187 B3

7
B3 — — —
B4 — — — 604msm6N
B5 — — —
B6 920 0,6 TCE lift high position J186 6
B7 917 0,6 Line L J71 7

F2.72 Ares 806 – 09.2004 – GB


Notes Notes

Ares 806 – 09.2004 – GB F2.73


9/1a - TCE 15/25/35 Harness 9/1a - TCE 15/25/35 Harness

Connectors Designation
J72 DOWN solenoid valve
J73 Position sensor
J74 Right force sensor
J75 Left force sensor
J76 UP solenoid valve
J77** DOWN solenoid valve (semi-mounted)
P20
P42

J78** UP solenoid valve (semi-mounted)


J79 Radar
J173*** Front lift harness connection
J193* RH electrohydraulic spool valve
J194* LH electrohydraulic spool valve
J204* Safety solenoid valve
P69 TCE control harness connection
J204

* TCE 15/25/35 with electrohydraulic spool valves


** TCE 35 only
J173

J79
*** TCE 35 with electrohydraulic spool valves
P69

J73
J78
J77
J2

J74
J1

J193
J72

J194
J76

J75

606msm18

F2.74 Ares 806 – 09.2004 – GB


9/1a - TCE 15/25/35 Harness TCE 15/25/35 with EH spool valves
Wire 2 J75 Ending
markers

TCE 15/25/35 with EH spool valves 1 983 0,6 V - LH rear draft P69 7 1 2 3
Wire 2 J72 Ending 2 972 0,6 LH draft signal P69 6 983 972 973
markers 3 973 0,6 + V REF LH draft P69 5

1
2
1 966 0,75 V - lowering valve P69 4 1 2 604msm3O

3
2 976 0,75 V + lowering valve P69 8 966 976

TCE 15/25/35 without EH spool valves

1
Wire 2

2
604msm7N
markers
J75 Ending

V - LH rear draft 1 2 3
TCE 15/25/35 without EH spool valves 1 978 0,6 P69 7
Wire 2 J72 Ending
2 967 0,6 LH draft signal P69 6 978 967 968
markers 3 968 0,6 + V REF LH draft P69 5

1
2
V - lowering valve 1 2

3
1 961 0,75 P69 4 604msm4O
2 971 0,75 V + lowering valve P69 8 961 971

TCE 15/25/35 with EH spool valves

1
Wire 2 J76

2
604msm8N Ending
markers

V + raising valve 1 2
TCE 15/25/35 with EH spool valves 1 965 0,75 P69 9
Wire 2 J73 Ending
2 967 0,75 V + raising valve P69 14 965 967
markers

1
V - rear position

2
A 981 0,6 P69 3 A B C 604msm5O
B 974 0,6 + V REF rear position P69 1 981 974 975
C 975 0,6 Rear position signal P69 2

A
TCE 15/25/35 without EH spool valves
2

B
Wire
J76 Ending

C
604hsm97
markers

TCE 15/25/35 without EH spool valves 1 960 0,75 V + raising valve P69 9 1 2
Wire 2 J73 Ending 2 962 0,75 V + raising valve P69 14 960 962
markers

1
V - rear position 1 2 3

2
A 976 0,6 P69 3 604msm6O
B 969 0,6 + V REF rear position P69 1 982 970 971
C 970 0,6 Rear position signal P69 2
1

TCE 15/25/35 with EH spool valves


2

Wire 2
3

604msm1O
markers
J77 Ending

1 2
TCE 15/25/35 with EH spool valves 1 977 0,75 V - down valve 1/2 P69 15
Wire 2 J74 Ending 2 979 0,75 V + lowering valve 1/2 P69 20 977 979
markers

1
V - RH rear draft A B C

2
1 982 0,6 P69 12 604msm7O
2 970 0,6 RH draft signal P69 11 976 969 970
3 971 0,6 + V REF RH draft P69 10
A

TCE 15/25/35 without EH spool valves


B

Wire 2
C

604hsm98
markers
J77 Ending

TCE 15/25/35 without EH spool valves 1 972 0,75 V - down valve 1/2 P69 15 1 2
Wire 2 J74 Ending 2 974 0,75 V + lowering valve 1/2 P69 20 972 974
markers

1
1 977 0,6 V - RH rear draft P69 12 1 2 3

2
604msm8O
2 965 0,6 RH draft signal P69 11 977 965 966
3 966 0,6 + V REF RH draft P69 10
1

TCE 15/25/35 with EH spool valves


2

Wire 2
3

604msm2O
markers
J78 Ending

1 978 0,75 V - up valve 1/2 P69 22 1 2


2 980 0,75 V + raising valve 1/2 P69 21 978 980

1
2
604msm9O

Ares 806 – 09.2004 – GB F2.75


9/1a - TCE 15/25/35 Harness TCE 35 with EH spool valves
Wire 2 P69 Ending
markers
4 966 981 975 974 1
TCE 15/25/35 without EH spool valves 1 974 0,6 + V REF rear position J73 B
Wire 2 J78 Ending 2 975 0,6 Rear position signal J73 C
9 965 976 983 972 973 5

markers 3 981 0,6 V - rear position J73 A 15 977 967 984 982 970 971 10

4 966 0,75 V - lowering valve J72 1 22 978 980 979 985 M9M 969 968 16

1 973 0,75 V - up valve 1/2 P69 22 1 2 5 973 0,6 + V REF LH draft J75 3 28 993 992 989 988 987 986 23
2 975 0,75 V + raising valve 1/2 P69 21 6 972 0,6 LH draft signal J75 2
973 975 33 991 990 997 994 29
7 983 0,6 V - LH rear draft J75 1
8 976 0,75 V + lowering valve J72 2 37 M9O 34

1
9 965 0,75 V + raising valve J76 1

2
604msm0P 10 971 0,6 + V REF RH draft J74 3
11 970 0,6 RH draft signal J74 2
12 982 0,6 V - RH rear draft J74 1 TCE 15/25 with EH spool valves
TCE 15/25/35 with EH spool valves 13 984* 1 Front lower outside ctrl J173 A
Wire 2 J79 Ending 1 2 3 4 14 967 0,75 V + raising valve J76 2
markers 15 977* 0,75 V + lowering valve 1/2 J77 1
M9M 969 968 4 966 981 975 974 1
16 968 0,6 +APC radar (D+) J79 3
1 M9M 0,6 Radar earth P69 18 17 969 0,6 Radar signal J79 2 9 965 976 983 972 973 5

2 969* 0,6 Radar signal P69 17 TCE 15/25/35 without EH spool valves 18 M9M 0,6 Radar earth J79 1 15 967 982 970 971 10
2 964** 0,6 Radar signal P69 17 19 985* 0,6 Front rise outside ctrl J173 B 22 M9M 969 968 16
3 968* 0,6 +APC radar (RH + relayed) P69 16 20 979* 0,75 V + lowering valve 1/2 J77 2
1 2 3 4 28 993 992
3 963** 0,6 +APC radar (RH + relayed) P69 16 21 980* 0,75 V + raising valve 1/2 J78 2 23

4 — — — M9M 964 963 22 978* 0,75 V - up valve 1/2 J78 1 33 991 990 997 994 29

23 986* 1 + V REF front position J173 C 37 M9O 34


* Version with electrohydraulic spool valves ** 24 987* 1 Front position signal J173 D
Version without electrohydraulic spool valves 25 988* 1 V - forward position J173 E
604hsm99
26 989* 1 +APC front ext. control J173 F
27 992 0,6 CAN-Low LH DEH J194 2
28 993 0,6 CAN-high LH DEH J194 3
29 994 1 +APC LH and RH DEH E9B
Wire 2 J173 Ending 30 — — —
markers 31 997 0,75 Safety solenoid valve ctrl J204 1
32 990 0,6 CAN-Low RH DEH J193 2
A 984 1 Front lower outside ctrl P69 13 H G F E 33 991 0,6 CAN-High RH DEH J193 3
B 985 0,6 Front rise outside ctrl P69 19 989 988 34 — — —

H
C 986 1 + V REF front position P69 23 35 — — —

G
Front position signal 984 985 986 987 36 — — —

F
D 987 1 P69 24 604msm6P
E 988 1 V - forward position P69 25 A B C D 37 M9O 1 LH and RH DEH earth E9C
F 989 1 +APC front ext. control P69 26
* TCE 35 only
G — — —
H — — — 604msm2P

Wire 2 J193 Ending


markers
1 2 3 4
1 995 0,6 +APC RH DEH E9B
2 990 0,6 CAN-Low RH DEH P69 32 995 990 991 M9P
1

3 991 0,6 CAN-High RH DEH P69 33


2

4 M9P 0,6 RH DEH earth E9C


3

604msm3P
4

Wire 2 J194 Ending


markers
1 2 3 4
1 996 0,6 +APC LH DEH E9B
2 992 0,6 CAN-Low LH DEH P69 27 996 992 993 M9Q
1

3 993 0,6 CAN-high LH DEH P69 28


2

4 M9Q 0,6 LH DEH earth E9C


3
4

604msm4P

Wire 2 J204 Ending


markers
1 2
1 997 0,75 Safety solenoid valve ctrl P69 31
2 M9R 0,6 Safety solenoid valve earth E9C 997 M9R
1
2

604msm5P

F2.76 Ares 806 – 09.2004 – GB


9/1a - TCE 15/25/35 Harness Notes

TCE 35 without EH spool valves


Wire 2 P69 Ending
markers
4 961 976 970 969 1
1 969 0,6 + V REF rear position J73 B 9 960 971 978 967 968 5
2 970 0,6 Rear position signal J73 C
15 972 962 977 965 966 10
3 976 0,6 V - rear position J79 A
4 961 0,75 V - lowering valve J72 1 22 973 975 974 M9M 964 963 16
5 968 0,6 + V REF LH draft J75 3 28 23
6 967 0,6 LH draft signal J75 2
33 29
7 978 0,6 V - LH rear draft J74 1
8 971 0,75 V + lowering valve J72 2 37 34
9 960 0,75 V + raising valve J76 1
10 966 0,6 + V REF RH draft J74 3
11 965 0,6 RH draft signal J74 2
12 977 0,6 V - RH rear draft J74 1 TCE 15/25 without EH spool valves
13 — — —
14 962 0,75 V + raising valve J76 2
15 972* 0,75 V + lowering valve 1/2 J77 1
16 963 0,6 +APC radar (RH + relayed) J79 3 4 961 976 970 969 1

17 964 0,6 Radar signal J79 2 9 960 971 978 967 968 5
18 M9M 0,6 Radar earth J79 1
15 962 977 965 966 10
19 — — —
20 974* 0,75 V + lowering valve 1/2 J77 2 22 M9M 964 963 16
21 975* 0,75 V + raising valve 1/2 J78 2 28 23
22 973* 0,75 V - up valve 1/2 J78 1 33 29
23 — — —
24 — — — 37 34
25 — — —
26 — — —
27 — — —
28 — — —
29 — — —
30 — — —
31 — — —
32 — — —
33 — — —
34 — — —
35 — — —
36 — — —
37 — — — 604msm7P
* TCE 35 only

Ares 806 – 09.2004 – GB F2.77


9/1b - TCE 15T Harness 9/1b - TCE 15T Harness

Connectors Designation
J72 DOWN solenoid valve
J73 Position sensor
J74 Right force sensor
J75 Left force sensor
J76 UP solenoid valve
J79 Radar
J193* RH electrohydraulic spool valve
P20
P42

J194* LH electrohydraulic spool valve


J204* Safety solenoid valve
P69 TCE controls harness version

* Version with electrohydraulic spool valves

J204

J173

J79
P69

J73
J78
J77
J2

J74
J1

J193
J72

J194
J76

J75

606msm18

F2.78 Ares 806 – 09.2004 – GB


9/1b - TCE 15T Harness TCE 15T with EH spool valves
Wire 2 J75 Ending
markers

TCE 15T with EH spool valves 1 M9L 0,6 V - LH rear draft P69 7 1 2 3
Wire 2 J72 Ending 2 967 0,6 LH draft signal P69 6 M9L 967 968
markers 3 968 0,6 + V REF LH draft P69 5

1
2
1 961 0,75 V - lowering valve P69 4 1 2

3
604msm4Q
2 971 0,75 V + lowering valve P69 8 961 971

TCE 15T without EH spool valves


2

1
Wire
J75 Ending

2
604msm8P markers

1 M9L 0,6 V - LH rear draft P69 7 1 2 3


TCE 15T without EH spool valves
Wire 2 J72 Ending
2 947 0,6 LH draft signal P69 6 M9L 947 948
3 948 0,6 + V REF LH draft P69 5

1
markers

2
3
1 2 604msm5Q
1 941 1 V - lowering valve P69 4
2 951 1 V + lowering valve P69 8 941 951
TCE 15T with EH spool valves
2

1
Wire
J76 Ending

2
604msm9P markers

1 960 0,75 V + raising valve P69 9 1 2


TCE 15T with EH spool valves
Wire 2 J73 Ending
2 962 0,75 V + raising valve P69 14 960 962
markers

1
2
A B C 604msm6Q
A M9N 0,6 V - rear position P69 3
B 969 0,6 + V REF rear position P69 1 M9N 969 970
C 970 0,6 Rear position signal P69 2

A
TCE 15T without EH spool valves
2

B
Wire
J76 Ending

C
604hsm0A markers

1 940 1 V + raising valve P69 9 1 2


TCE 15T without EH spool valves
Wire 2 J73 Ending
2 942 1 V + raising valve P69 14 940 942
markers

1
V - rear position

2
A M9N 0,6 P69 3 A B C 604msm7Q
B 949 0,6 + V REF rear position P69 1 M9N 949 950
C 950 0,6 Rear position signal P69 2
A

TCE 15T with EH spool valves


2
B

Wire
J79 Ending
C

604hsm0B markers
1 2 3 4
TCE 15T with EH spool valves 1 M9M 0,6 Radar earth P69 18
Wire 2 J74 Ending
2 964 0,6 Radar signal P69 17 M9M 964 963

markers 3 963 0,6 +APC radar P69 16


4 — — — 604msm9Q
1 M9K 0,6 V - RH rear draft P69 12 1 2 3
2 965 0,6 RH draft signal P69 11 M9K 956 966
3 966 0,6 + V REF RH draft P69 10
1

TCE 15T with EH spool valves


2
2

Wire
604msm2Q J79 Ending
3

markers
1 2 3 4
1 M9M 0,6 Radar earth P69 18
TCE 15T without EH spool valves
Wire 2 J74 Ending
2 944 0,6 Radar signal P69 17 M9M 944 943

markers 3 943 0,6 +APC radar P69 16


4 — — — 604msm0R

1 M9K 0,6 V - RH rear draft P69 12 1 2 3


2 945 0,6 RH draft signal P69 11 M9K 945 946
3 946 0,6 + V REF RH draft P69 10
1

Wire 2
2

markers
J193 Ending
3

604msm3Q

1 977 0,6 +APC RH DEH E9B 1 2 3 4


2 972 0,6 CAN-Low RH DEH P69 32 977 972 973 M9P

1
3 973 0,6 CAN-High RH DEH P69 33

2
4 M9P 0,6 RH DEH earth E9C

3
4
604msm1R

Ares 806 – 09.2004 – GB F2.79


9/1b - TCE 15T Harness TCE 15T without EH spool valves
Wire 2 P69 Ending
markers
4 941 M9N 950 949 1
1 949 0,6 + V REF rear position J73 B
Wire 2 J194 Ending
2 950 0,6 Rear position signal J73 C 9 940 951 M9L 947 948 5

markers 3 M9N 0,6 V - rear position J73 A 15 942 M9K 945 946 10
4 941 1 V - lowering valve J72 1 22 M9M 944 943 16
5 948 0,6 + V REF LH draft J75 3
1 978 0,6 +APC LH DEH E9B 1 2 3 4
6 947 0,6 LH draft signal J75 2 28 23
2 974 0,6 CAN-Low LH DEH P69 27 978 974 975 M9Q 7 M9L 0,6 V - LH rear draft J75 1 33 29

1
3 975 0,6 CAN-high LH DEH P69 28 8 951 1 V + lowering valve J72 2

2
4 M9Q 0,6 LH DEH earth E9C 9 940 1 V + raising valve J76 1
37 34

3
10 946 0,6 + V REF RH draft J74 3

4
604msm2R
11 945 0,6 RH draft signal J74 2
12 M9K 0,6 V - RH rear draft J74 1
13 — — —
14 942 1 V + raising valve J76 2
Wire 2 J204 Ending 15 — — —
markers 16 943 0,6 APC radar J79 3
1 2 17 944 0,6 Radar signal J79 2
1 979 0,75 Safety solenoid valve ctrl P69 31 979 M9R 18 M9M 0,6 Radar earth J79 1
2 M9R 0,6 Safety solenoid valve earth E9C 19 — — —
20 — — —

1
21 — — —

2
604msm3R
22 — — —
23 — — — 604msm5R
24 — — —
TCE 15T with EH spool valves
Wire 2 P69 Ending
25
26






markers 27 — — —
4 961 M9N 970 969 1
28 — — —
1 969 0,6 + V REF rear position J73 B 29 — — —
2 970 0,6 Rear position signal J73 C 9 960 971 M9L 967 968 5 30 — — —
3 M9N 0,6 V - rear position J73 A 15 962 M9K 965 966 10 31 — — —
4 961 0,75 V - lowering valve J72 1 22 M9M 964 963 16
32 — — —
5 968 0,6 + V REF LH draft J75 3 33 — — —
6 967 0,6 LH draft signal J75 2 28 975 974 23 34 — — —
7 M9L 0,6 V - LH rear draft J75 1 33 973 972 979 976 29 35 — — —
8 971 0,75 V + lowering valve J72 2 36 — — —
37 M9O 34
9 960 0,75 V + raising valve J76 1 37 — — —
10 966 0,6 + V REF RH draft J74 3
11 965 0,6 RH draft signal J74 2
12 M9K 0,6 V - RH rear draft J74 1
13 — — —
14 962 0,75 V + raising valve J76 2
15 — — —
16 963 0,6 APC radar J79 3
17 964 0,6 Radar signal J79 2
18 M9M 0,6 Radar earth J79 1
19 — — —
20 — — —
21 — — —
22 — — — 604msm4R
23 — — —
24 — — —
25 — — —
26 — — —
27 974 0,6 CAN-Low LH DEH J194 2
28 975 0,6 CAN-high LH DEH J194 3
29 976 1 +APC LH and RH DEH E9B
30 — — —
31 979 0,75 Safety solenoid valve ctrl J204 1
32 972 0,6 CAN-Low RH DEH J193 2
33 973 0,6 CAN-High RH DEH J193 3
34 — — —
35 — — —
36 — — —
37 M9O 1 LH and RH DEH earth E9C

F2.80 Ares 806 – 09.2004 – GB


Notes Notes

Ares 806 – 09.2004 – GB F2.81


9/2a - Cross control harness with Electropilot 9/2b - Cross control harness

240

J198

J127

J129
J128 J128 J129
EP2
P197
E90A EP1

J199 F-5A

J67

E6A

J126 E90B

J126
P20

J205
606msm19 606msm20

Connectors Designation Connectors Designation


J126 Front loader socket J126 Front loader and lift socket
J128 A solenoid valve relay J127 Control connection
J129 B solenoid valve relay J128 A solenoid valve relay
J205 Front lift socket J129 B solenoid valve relay
P197 Electrohydraulic spool valve (DEH) control harness connection

F2.82 Ares 806 – 09.2004 – GB


9/2a - Cross control harness with Electropilot 9/2b - Cross control harness

Wire 2 J126 Ending Wire 2


markers markers
J126 Ending
4 4
1 9108 0,75 EV1 Controls J128 5 2 M90E 1 RD/WH 1 + Solenoid valve A J128 5 2 NO/BU
2 9109 0,75 EV2 Controls J129 5 9109 M90D 2 RD/BL 1 + Solenoid valve B J129 5 RG/BU NO/BC
3 M90D 0,75 EV1 Earth E90B 3 3 BK/WH 1 Solenoid valve A EP2 3
9108
4 M90E 0,75 EV2 Earth E90B 1 4 BK/BL 1 Solenoid valve B EP2 RG/BC
1

604msm6R 604msm1S

Wire 2 J128 Ending


3 Wire 2
markers 9106 markers
J127 Ending
1 2 3
Relay controls R1 4

1
1 9100 0,6 P197 A1 3
A1 BL 1 Relay control A J128 1 A
2 A BU
2 M90B 0,6 Relay earth R1 E90B 2 M90B 4 A2 — — —
JA

3
9100 1
3 9106 0,75 + APC relay R1 E90A 1
A3 YL 1 Relay control B J129 1 B RG/OR B
5
4 — — — 9108
5 9108 0,75 EV1 Controls J126 1 B1 — — —
5 604msm7R
B2 RD/OR 1 +APC common, cross control EP1 604msm2S
B3 — — —

Wire 2 J129 Ending


3
markers 9107
Wire 2 J128 Ending
3
1 9102 0,6 Relay controls R2 P197 A5 4 3 markers RG/VE
2
2 M90c 0,6 Relay earth R2 E90B 2 M90C 9102 1 4
RG/VI

3 9107 0,75 + APC relay R2 E90A 1 1 BL 1 A relay control J127 A1 4 3


5
4 — — — 9109 2 BK/GN 1 A relay earth EP2 2
NO/VE 4
5 9109 0,75 EV2 Controls J126 2 604msm8R 2 BK/VI 1 B relay earth J129 2 2 NO/VI
BU 1 1
5
3 RD/VI 1 +APC J129 3 RG/BC
5
3 RD/GN 1 +APC EP1
4 — — — 5 604msm3S
5 RD/WH 1 + Solenoid valve A J126 1
Wire 2 J205 Ending
markers
4
1 9110 1 +APC front lift E90A
2 M90F 0,75 Front lift E90B
2 9104
Wire 2 J129 Ending
3
M90F 9103 markers
3 9103 0,6 Lift outside ctrl return P197 B1 3 RG/VI
4 9104 0,6 Lower outside ctrl return P197 B5 9110
1 4
1 YL 1 B relay control J127 A3 3
2
2 BK/VI 1 B relay earth J128 2 2 4
NO/VI JA 1
604msm9R 3 RD/VI 1 +APC J128 3 1
5
4 — — — RG/BU
5 RD/BL 1 + Solenoid valve B J126 1 604msm4S
5

Wire 2 P197 Ending


1 2 3 4 5
markers A 9100 9101 M90A 9102

B 9103 9104
A1 9100 0,6 Relay control A1 J128 1
A2 9101 3 +APC electric control F
A3 — — —
A4 M90A 1 Loader / front lift E90B
A5 9102 0,6 Relay control A2 J129 1
A
Lift outside ctrl return
1

B1 9103 0,6 J205 3


2

B2 — — —
3

B
4

B3 — — —
5

B4 — — —
B5 9104 0,6 Lower outside ctrl return J205 4
604msm0S

Ares 806 – 09.2004 – GB F2.83


9/3 - Electrohydraulic spool valve control harness 9/3 - Electrohydraulic spool valve control harness

10 - On-board computer harness Connectors Designation


J197 Towards control harness in a cross with Électropilot
J198 Electrohydraulic spool valve control unit
J199 Joystick harness connection
P190 TCE control harness connection
P191 TCE control harness connection

10 - On-board computer harness


Connectors Designation
J147 Outside air temperature probe
J148 On board computer
J198 P134 Transmission control harness connection

E1

J134
J197
J148

140

P190
J199

P191
J147

J199

140

J80
J148

P134
J198

P20
J147

606msm21

F2.84 Ares 806 – 09.2004 – GB


9/3 - Electrohydraulic spool valve control harness
Wire 2 P190 Ending 4
markers
2
9005
1 9004 0,6 CAN-low DEH control J199 10
Wire 2 J197 Ending
1 2 3 4 5
2 9005 0,6 CAN-high DEH control J199 6
3
9004
markers A 9015 9001 M9Y 9016 3 — — — 1
4 — — — 604msm8S
B 9008 9009
A1 9015 0,6 Relay output 1 J199 14
A2 9001 0,6 +APC cross control J198 2
A3 — — —
A4 M9Y 0,6 Cross control earth J198 18
A5 9016 0,6 Relay output 2 J199 15 Wire 2 P191 Ending

1
A markers 1 2

2
B1 9008 0,6 Lift outside ctrl return J198 14 9003 9000 1

4
B2 — — — B 1 9003 1 Safety solenoid valve ctrl J198 12

2
5
B3 — — — 2 9000 1 +APC DEH control J198 1 M9Z
B4 — — — 3 M9Z 1 DEH control earth J198 17 3
B5 9009 0,6 Lower outside ctrl return J198 15
604msm5S 604msm9S

Wire 2 J198 Ending


1 5 9 13 17
markers 9000 9011 9006 9013 M9Z

1 9000 1 +APC DEH control module P191 2 9001 9012 9007 9008 M9Y
2 9001 0,6 +APC cross control J197 A2 9002 9010 9017 9009 M9X
3 9002 0,6 +APC joystick J199 3
4 — — — 9018 9003 9014
5 9011 0,6 Joystick on/off control J199 8
6 9012 0,6 LED output on / off J199 9 4 8 12 16 20
7 9010 0,6 Hydraul. motor ctrl (on) J199 7
8 9018 0,6 Hydraul. motor ctrl (off) J199 16
9 9006 0,6 Pot. X J199 1
10 9007 0,6 Pot. Y J199 2
11 9017 0,6 Safety SV (on) J199 5
12 9003 1 Safety SV (off) P191 1 4
13 9013 0,6 Raise extension command J199 11 5
9
Lift outside ctrl return
3
14 9008 0,6 J197 B1 6 13

15 9009 0,6 Lower outside ctrl return J197 B5 2


7
10
14
17

16 9014 0,6 Raise extension command J199 12 1 11 18

17 M9Z 1 Electro./ dist. ctrl module earth P191 3 8


12
15
19
18 M9Y 0,6 Cross control earth J197 A4 16

Joystick earth
20
19 M9X 0,6 J199 13 604msm6S
20 — — —

Wire 2 J199 Ending


7

markers 1
3
9010
11
15
9002 9013
9006 9011 9016
1 9006 0,6 Pot. X J198 9 9014

2 9007 0,6 Pot. Y J198 10 9007


9017
9012
M9X
9018

3 9002 0,6 +APC joystick J198 3 2 9004 16


9005 9015
4 — — — 10
5 9017 0,6 Safety SV (on) J198 11 6 14

6 9005 0,6 CAN-High P190 2


7 9010 0,6 Hydraul. motor ctrl (on) J198 7
8 9011 0,6 Joystick on/off control J198 5
9 9012 0,6 LED output on / off J198 6
10 9004 0,6 CAN-Low P190 1
11 9013 0,6 Raise extension command J198 13
12 9014 0,6 Raise extension command J198 16
13 M9X 0,6 Joystick earth J198 19
14 9015 0,6 Relay output 1 J197 A1 604msm7S
15 9016 0,6 Relay output 2 J197 A5
16 9018 0,6 Hydraul. motor ctrl (off) J198 8

Ares 806 – 09.2004 – GB F2.85


10 - On-board computer harness Notes

Wire 2 J147 Ending


markers
B A
A BR 0,6 Ext. air temperature probe J148 5 NO2 MA B
B NO2 0,6 Ext. air temp. probe earth E1 A

604msm0T

Wire 2 J148 Ending


14 13 12 11 10 9 8 7 6 5 4 3 2 1
markers RG2 NO4 RG1 BC VE MA BU VI

1 VI 0,6 Trip computer tractor speed P134 A1


2 BL 0,6 Counter 140
3 — — —

14
13
4 — — —

12
11
5 BR 0,6 Outside air temp. probe J147 A

10
9
Trip computer lift up position

8
6 GN 0,6 P134 B1

7
TCE

6
5
7 WH 0,6 Trip computer radar speed P134 A3

4
3
8 RG1 0,6 +APC trip computer TCE P134 B2

2
1
9 — — —
10 NO4 0,6 On-board computer earth E1
11 RG2 0,6 +APC trip computer TCE P134 B2 604msm1T
12 — — —
13 — — —

Wire 2 P134 Ending


markers
1 2 3
A1 VI 0,6 Trip computer tractor speed J148 1

1
A VI BC A
A2 — — —

2
RG1

3
A3 WH 0,6 Trip computer radar speed J148 7 B VE
RG2
NO1 B

Trip computer lift up position


B1 GN 0,6 J148 6 604msm2T
TCE
B2 RG1 0,6 +APC trip computer TCE J148 8
B2 RG2 0,6 +APC trip computer TCE J148 11
B3 NO1 0,6 On-board computer earth E1

Colour legend
BL White
BL Blue
YL Yellow
BR Brown
BK Black
OR Orange
GN Green
VI Purple
RD Red

F2.86 Ares 806 – 09.2004 – GB


Electricity tools

60 05 006 703 6703 60 05 006 704 6704

Crimping pliers Pin extractor

60 05 006 707 6707 60 05 006 744 6744

TOOLS

Clamp-on ammeter (AC and DC) 0 to 2 A - 0 to 200 A Multifunction multimeter (except temperature)

60 05 006 758 6758 77 00 065 236 5236

Extractor to unlock clips and tabs of MIC type Extractor to unlock clips and tabs of MIC type

Ares 806 – 09.2004 – GB


G1 – INSTRUMENT PANEL

Ares 806 – 09.2004 – GB


Operating principles

Description of panel

11 10 9 8 7 6 5 4 3 2 1

12 21

13 20

14 19
18
15

17
16

C B
584hsm00 Fig. 1

Parts list
1 Maintenance. 9 Trailer "2" turn-signal indicator. 17 Engine temperature.
2 Oil filter. 10 Trailer "1" turn-signal indicator. 18 Transmission oil temperature.
3 Air filter. 11 Tractor direction indicator. 19 Preheating.
4 Hydraulic pressure. 12 Front power take-off. 20 Battery voltage.
5 Oil pressure. 13 Rear power take-off. 21 Diesel level low.
6 Stop. 14 Headlights. B Small digital display.
7 Battery charge. 15 Brake fluid level. C Rev counter dial.
8 Handbrake. 16 Trailer brake pressure. D Large digital display.

G1.2 Ares 806 – 09.2004 – GB


Operating principles

Allocation of light bulbs to indicator lights

1 2 3 4 5 6 7* 8 9 10 11

A B
12 13 14 15 16 17 18 19 20 21

23

22

584hsm08 Fig. 2

Indicator lights
1 Maintenance. 10 Trailer 1 turn-signal indicator. 19 Headlights.
2 Oil filter. 11 Tractor direction indicator. 20 Rear power take-off.
3 Air filter. 12 Diesel level low. 21 Front power take-off.
4 Hydraulic pressure. 13 Battery voltage. 22 Cluster lighting.
5 Oil pressure. 14 Preheating. 23 Cluster lighting.
6 Stop. 15 Transmission oil temperature. A 15-channel socket "JX1".
7 Battery charge. 16 Engine temperature. B 30-channel socket "JX2".
8 Handbrake. 17 Trailer brake pressure.
9 Trailer "2" turn-signal indicator. 18 Brake fluid level.
* Indicator (7) is on a green support, 12 V – 2 A. All of the others are on a blue support, 12 V – 1,2 A.

Ares 806 – 09.2004 – GB G1.3


Characteristics

Indicator operation
Dial and display unit
A signal emitted by the alternator fulfils the following four
functions.
– Analogue rev counter (dial).
– Digital rev counter.
– Front PTO rev counter.
– General hour counter.
At the alternator output, the signal from terminal "W"
or "R" (depending on the type of alternator) has the
following waveform (Fig. 4). The frequency is 0,1 Hz “JX2”
per rpm.
f = 200 Hz at 2 000 rpm.
f = 100 Hz at 1 000 rpm.
– Use tool n° 60 05 006 744 (frequency indicator
function). 584hsm09 Fig. 3
– Check that the signal reaches terminal "21" of
connector "JX2" on the cluster (see diagram of
display).

Hour counter

The fixed symbol is selected. The counter increases U


by one hour when the engine has been running (v)
consecutively for 4 x 1/4 hour.

Daily hour counter

The flashing symbol is selected: The operating time is


recorded by the counter increasing by one hour when the f (Hz)
engine has been running consecutively for 4 x 1/4 hour.

584hsm10 Fig. 4

584hsm11 Fig. 5

G1.4 Ares 806 – 09.2004 – GB


Characteristics

Analogue rev counter (dial)


This is a stepping motor which receives a series of pulses
according to the frequency emitted by the alternator.

Digital rev counter (small display)

When the engine is started and the display selected,


the engine speed is displayed over 300 rpm. Front PTO
speed

After selecting the symbol and activating the front


PTO switch.
The displayed speed is the result of a calculation.

Rear power take-off speed


This indication is not the result of a calculation relating to
the frequency emitted by the alternator. It is a sensor 584hsm12 Fig. 6
which generates a signal to the Drivetronic ECU which is
then transmitted to the dashboard.

When the symbol is selected, the indicated speed is


a measured speed.

Large display
This indicates the theoretical forward speed in km/h or the
actual speed if equipped with radar.

584hsm13 Fig. 7

584hsm14 Fig. 8

Ares 806 – 09.2004 – GB G1.5


Characteristics

Engine temperature
A thermistor (a temperature-sensitive resistor) sends a variable DC voltage to the ECU.
Liquid crystal segments appear from the bottom up according to the engine coolant temperature.
– 9 segments for a scale of 40 to 120°C.
– 106°C is the alarm threshold.

1 2

9
70 Ω 120
8
106 Ω 106
7
155 Ω 97
6
205 Ω 90
5
230 Ω 80
4
405 Ω 70
3
575 Ω 60
2
885 Ω 50
1
1 130 Ω 40

17 JX2 Ω*

584hsm15 Fig. 9

Parts list
1 Resistance is ohms measured on the probe. 2 Temperature corresponding to the segments.

* Measure with an ohmmeter with the ignition switched off.

G1.6 Ares 806 – 09.2004 – GB


Characteristics

Fuel gauge
A rotary potentiometer sends a variable DC voltage to the ECU. The liquid crystal segments go out as the level drops.
Note: A level is not necessarily representative of the volume of diesel left in the tank (this depends on the shape
of the tank).

1/1 7Ω
9

8
3/4 45 Ω
7

6
1
1/2 93 Ω
5
1 16 JX2 Ω*
4
1/4 185 Ω
3

2 2 3
0 270 Ω
1
320 → 340 Ω

584hsm16 Fig. 10

Parts list
1 Resistance in ohms of the fuel gauge.
2 Fuel gauge.
3 Dashboard connector (beware not to damage the contacts on measuring).

* Measure with an ohmmeter with the ignition switched off.

Ares 806 – 09.2004 – GB G1.7


Characteristics

46,4
104,7
335,2
1/1
1/14 Ω
262

469,7
3/4
35/55 Ω

522,8
1/2
78,5/106,5 Ω

563,1
1/4
166,3/201,3 Ω

0 246,3/286,3 Ω

0
320/340 Ω
Absolu

584hsm17 Fig. 11

G1.8 Ares 806 – 09.2004 – GB


Characteristics

Warning lights (red)


Should one of these lights come on, the STOP light (9) will light up and the internal buzzer will be activated automatically.

1 2 3 4

5 6 7 8

584hsm18 Fig. 12

1. Parking brake applied 6. Trailer brake fluid pressure


– Lights up with the STOP light + buzzer when the Check:
engine is running and a gear engaged. – Brake pressure
– Lights up alone when the engine is switched off. – Pressure switch.

2. Alternator charge 7. Engine temperature


Check: Check:
– Alternator (belt, excitation, regulator). – Coolant level.
– Battery condition. – Fan operation.
– Blockage in radiator core.
3. Engine oil pressure – Temperature sensor.
Check:
– Engine oil level. 8. Transmission oil temperature
– Pressure switch. Check:
– Oil pump. – Oil level.
– Fan operation.
4. Hydraulic oil pressure – Blockage in radiator core.
Check: – Temperature switch.
– Transmission oil level. – Oil pump.
– Pressure switch. – Hydraulic system (throttling).
– Oil pump.

5. Brake fluid level in the master cylinder


Check:
– Brake fluid level.
– Ignition.

Ares 806 – 09.2004 – GB G1.9


Characteristics

Secondary warning lights (orange)


10. Air filter blocked
Replace the filter cartridge.

11. Oil filter blocked 10 11 12


Replace the oil filters.

12. Scheduled service


Full service due. 13 14 15
13. Preheating indicator
Lights up for the required time then goes out. This light is
controlled by the engine ECU.

14. Battery voltage below 10,5 Volts or


electrical problem
Check: 584hsm19 Fig. 13

– Alternator charge.
– State of the battery.
– Drivetronic ECU.
– Engine ECU.

16 17 18
Other indicator lights
15. Fuel reserve level reached
19 20 21
Check with the gauge, if the tank has been topped up.

16. Tractor turn-signal indicators


Green light.

17. First trailer turn-signal indicators


Green light.

18. Second trailer turn-signal indicators 584hsm20 Fig. 14

Green light.

19. Front PTO engaged


Orange light.

20. Rear PTO engaged


Orange light.

21. Headlights
Blue light.

G1.10 Ares 806 – 09.2004 – GB


Characteristics

Input/output by function

1 5*

2 6

7*

21 22 23 24 25 20 18 JX2

584hsm21 Fig. 15

Parts list
1 Rear power take-off speed. 5 Actual speed radar signal*.
2 Alternator signal (engine speed). 6 Speed calibration control.
3 Dashboard electronic control unit. 7 Front PTO signal*.
4 Theoretical speed sensor signal. 8 Display selection control.

Nature of signal or electrical level


1, 2, 4, 5* : AC signal measured on frequency indicator.
6, 8 : Earth contact.
7* : 12 V DC voltage if front PTO control engaged.

* Option depending on model.

Ares 806 – 09.2004 – GB G1.11


Characteristics

Input/output by function (gauge and temperature)

16 1 2 17 JX2

584hsm22 Fig. 16

Parts list
1 Fuel gauge. 3 Dashboard electronic control unit.
2 Temperature sensor.

Nature of signal or electrical level


1, 2 : Variable resistance (measured on ohmmeter).

G1.12 Ares 806 – 09.2004 – GB


Characteristics

Inputs/outputs relating to red lights

3 2 1 4 5

6 7 8 5 10 JX1

5 15 17 2 19 JX2

6 7 8 9

584hsm23 Fig. 17

Parts list
1 Alternator regulator, charge D+. 6 Parking brake switch.
2 Engine oil pressure switch. 7 Not used.
3 Transmission oil pressure switch. 8 Engine temperature thermistor.
4 Transmission oil temperature. 9 Gearbox engaged.
5 Brake fluid level switch. 10 Dashboard electronic control unit.

Nature of the signal or electrical level when lit


1 : Voltage below 12 V.
2, 3, 5, 6 : Earthing.
4, 7 : 12 V.
8 : 106 ohm.
9 : Earth .

Ares 806 – 09.2004 – GB G1.13


Characteristics

Inputs/outputs relating to other lights

1 9

2 4

3 2

4 3

12

26 20 14 13 12 11 10 JX2

5 6 7 8 9 10 11

584hsm24 Fig. 18

Parts list
1 Battery voltage. Electrical fault. 7 Tractor turn-signal indicators.
2 Air filter blocked. 8 Rear power take-off.
3 Oil filter blocked. 9 Trailer "1" turn-signal indicators.
4 Preheating. 10 Headlights.
5 Side lights. 11 Trailer "2" turn-signal indicators.
6 Front power take-off. 12 Dashboard electronic control unit.

Nature of signal or electrical level


1 : Voltage below 10 V.
2, 3 : Earthing.
4, 5, 6, 8, 11 : 12 V.
7, 9, 10 : Square-pulse signal 12 V – 0 V.

G1.14 Ares 806 – 09.2004 – GB


Characteristics

Connection and functions of the wires of the single connector "JX1"

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

584hsm25 Fig. 19

Electrical level
Pin N° Wire N° Function
Nature of the signal

1 — Not used. —
2 062 Transmission oil filter. —
3 007 Preheating indicator. —
4 111 Engine oil filter (blockage). Earth
5 063 Transmission oil temperature. —
064
6 Hydraulic pressure. Earth
125*
7 106 Engine oil pressure. Earth
8 108 Alternator charge. "+"
9 173 Fault warning light. "+"
10 136 Brake fluid level. Earth
11 065 Diagnostic link line "L". Logical level
12 066 Diagnostic link line "K". Logical level
13 067 CAN "-". Logical level
14 068 CAN "+". Logical level
15 — Not used. —
* Full Powershift.

Ares 806 – 09.2004 – GB G1.15


Characteristics

Connection and functions of the wires of the double connector "JX2"

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16

584hsm26 Fig. 20

G1.16 Ares 806 – 09.2004 – GB


Characteristics

Electrical level
Pin N° Wire N° Function
Nature of the signal

1 MOA Fuel gauge earth. Earth


2 MOT Engine temperature thermistor earth. Earth
3 — Not used. —
4 113 External buzzer. "+"
5 059 Parking brake switch. Earth
6 104 CAN "+" return. —
7 105 CAN "-" return. —
8 — Not used. —
9 — Not used. —
10 044 Trailer "2" turn-signal indicator.
11 019 Headlights. "+"
12 043 Trailer "1" turn-signal indicator.
13 083 Rear PTO light. "+"
14 042 Tractor turn-signal indicator.
15 — Not used. —
16 060 Fuel gauge signal. "+"
17 110 Engine temperature thermistor signal. "+"
18 054 Dashboard display selector. Earth
19 186 Gearbox engaged. Earth
20 091 Front PTO warning light. "+"
21 109 Engine speed alternator signal.
22 069 Rear power take-off speed. —
23 070 Theoretical speed.
24 071 Radar speed.
25 072 Speed calibration switch. Earth
26 022 Instrument panel light. "+"
27 — Not used. "+"
28 074 "+" APC (ignition), dashboard. "+"
29 075 "+" AVC (constant), dashboard. "+"
30 MOM Earth . Earth

Ares 806 – 09.2004 – GB G1.17


Characteristics

Transmission oil pressure sensor (17


bar)
It is open when there is no pressure. The dashboard
indicator lights up 500 ms after the fault appears. The
Drivetronic on the other hand waits 4 seconds. When
pressure reaches 16 bar, the contact closes. It opens
when the pressure drops below 13 bar. 8

13

Blockage indicator
It is open when there is no pressure.

Engine oil pressure sensor (Fig. 22)


Fig. 21
It is closed when there is no pressure. 584hsm27

Transmission oil temperature sensor


(Fig. 23)
It is composed of a material whose electrical resistance
(ohms) varies with temperature.
Measuring range – 40 to + 150°C.
Tolerance between – 15 and 0°C ± 1,5°C.
Maximum consumption 250 mA. 0,4 0,75

584hsm28 Fig. 22


50

40

30

20

10
5
0
– 50 0 50 100 T

584hsm29 Fig. 23

G1.18 Ares 806 – 09.2004 – GB


Characteristics

Speed sensors
They consist of a magnetic core and a coil. The teeth of a
pinion travelling in front of the core create a variation in
magnetic flux, generating an induced current. This will be
an alternating current identical in frequency to the
passage of the teeth.
1 2
Test
– Resistance 450 ± 20 ohm at 20°C.
– AC output signal.
– Air gap 1 mm ± 0,5 ohm.

On fitting, make sure that the sensor is 3


not screwed between 2 teeth.

Parts list
584hsm30 Fig. 24
1 Permanent magnet.
2 Coil.
3 Output .

Ares 806 – 09.2004 – GB G1.19


Removal/refitting

Connectors "JX1" and "JX2"


Disconnection
– Insert tool n° 77 00 034 484 or n° 77 00 034 485 into
1
the connection socket to push out the locking tabs (1)
and (2).
– Remove the plug squarely.

Connection
– Push the plug firmly home until the tabs (1) and (2) lock
into place.

Replace 2
This type of connector (harness side) is not removable. If
there are contact faults on a pin, the full plug must be
replaced.
“JX1” : 15 channels, red/blue connector n°
60 05 014 522. 584hsm31 Fig. 25

“JX2” : 15 channels, white/blue connector n°


60 05 014 523. 15 channels, black/blue connector n°
60 05 014 524.
The plugs are supplied wired to 350 mm of cable with
crimped insulating sleeves.

How to change
1. Identify the wires in relation to the pin address on the
connector.
2. Cut the harness.
3. Thread the insulating sleeves onto each wire.
4. Strip each wire.
5. Connect each wire to the new connector and crimp.
6. Slide the insulating sleeves along to the crimping point.
N.B.: Connector "JX2" consists of 2 connectors, a
blue/white one labelled from 1 to 15 and a blue/black
one labelled from 16 to 30. These connectors are 584hsm32 Fig. 26
assembled by "dovetailing" with the female part on
the black connector and male part on the white
connector.

Disassembly
– Place your index fingers in front of the blue part of the
black connector.
– Push the whire connector with your thumbs (wire side).
Proceed in reverse order to refit until a clip noise is heard.

584hsm33 Fig. 27

G1.20 Ares 806 – 09.2004 – GB


Calibration

Calibration over 100 metres


Procedure
– Place 2 markers 100 metres apart on a flat, straight,
dry tarmac road.
4
– Position the tractor approximately 15 to 20 metres in
front of the first marker.
– Now remove the trim from under the dashboard where
the calibration switch (4) is located.
– Press this switch for at least 5 seconds until 2 static
horizontal lines appear on the digital display (1): this
indicates that the ECU is in calibration mode.
– Select a forward speed to reach an average speed 601msn10 Fig. 28
of 7 km/h.
– Use the clutch and accelerator manually to keep to a
stable forward speed.
– Press the switch (4) on passing the first marker. The
two horizontal lines start flashing (calibration in
progress).
– Press the switch (4) again on passing the second
marker.
– To validate the calibration, switch off the ignition then
remove the two fuses (7) and (21) for at least 30
seconds.
– Refit these two fuses. The ECU is calibrated in relation
to the new set of tyres.
601hsn17 Fig. 29
Note: If the calibration phase lasts for more than 2
minutes, the time between the two presses on the
switch, (4) appears on the digital display. Return to
normal mode by pressing lever (3), and the previous
calibration is saved. If "Er" appears on the display
during calibration (e.g. you travel 300 metres instead
of 100 metres), return to normal mode by pressing the
lever (3).
Important: This procedure is also to be implemented
when the dashboard is changed.

3
601hsn15 Fig. 30

2 1

100 m

001hsn01 Fig. 31

Ares 806 – 09.2004 – GB G1.21


Calibration

Other operations
For operations such as parameter setting, the error log,
etc. refer to chapter "G7".

G1.22 Ares 806 – 09.2004 – GB


G2 – TCE 15/25 AND TCE 15 T
ELECTRONIC LIFT

Ares 806 – 09.2004 – GB


Description

TCE 15/TCE 25

2 1 3

STO
P

10

11 6 7 8 9

382hsm00 Fig. 1

Parts list
1 5-position mode switch (transport, high position, stop, working 6 Damping key for transport.
position and dropping). 7 Key to adjust top limit.
2 Position display adjustment keys (working depth adjustment). 8 Keys to adjust lowering rate.
3 Power sensitivity control adjustment keys. 9 Adjustment keys "+" (increase) and "–" (decrease).
4 Display. 10 Key to activate wheel slip management*.
5 Safety warning light. 11 Instant wheel slip display key*.
– Light out: System operational.
– Light flashing: Fault detected (Win Métadiag© is required to
determine the origin of the fault).
– Light on steady: System in safety mode.
* TCE 25 only.

G2.2 Ares 806 – 09.2004 – GB


Description

Access to the installed software


version (TCE 15 or TCE 25) 1

To obtain the information:


– Switch on the ignition.
– Press keys (3) simultaneously.
The software will be divided into 2 stages. e.g. 0/12. The
display scrolls between these two digits constantly.

3
Lift operating conditions
If the safety warning light is lit when the tractor is started
up, several actions must be carried out to reset the lift.
– Move the switch (1) to the "working" position then,
immediately afterwards, to the "stop" position.
– Wait for 2 seconds for the CPU to unlock. 382hsm01 Fig. 2

Error codes
System faults appear as an error code. This is indicated
on the screen by "ER" and the code number.
CC = short circuit - CO = circuit open
N.B.: To diagnose the fault corresponding to the error
code, use Win Métadiag© and consult chapter "G7"
(lift application).

Ares 806 – 09.2004 – GB G2.3


Description

TCE 15 T

2
8

3
7

6
5
4

10

382hsn19 Fig. 3

Parts list
1 5-position mode switch (transport, high position, stop, working 7 Key to adjust top limit.
position and dropping). 8 Keys to adjust sensitivity of draft/position control.
2 Position adjustment control (work depth adjustment). 9 Damping mode key for transport.
3 Lift movement indicators (up / down). 10 Mechanical stop identifying the "low limit" position.
4 Travel lock key.
5 Key to adjust rate of descent.
6 Safety warning light. This light will be lit or start flashing if the
safety function or alarm is activated on the TCE unit. It can be
activated in three different ways.
– Light flashing slowly or quickly: Operating fault. The flashing
rate defines the nature of the fault. The lift can still be used
(Win Métadiag© is required to determine the origin of the fault).
– Light on steady: System in safety mode. To reset the unit,
carry out the lift setup procedure.

G2.4 Ares 806 – 09.2004 – GB


Description

Lift operating conditions


1
When the tractor is started up, if the safety warning
light (6) is lit, several actions need to be carried out to
reset the lift.
– Deactivate draft control by turning the adjustment
knob (2) to the left.
– Move the switch (1) to the "stop" position the,
immediately after, to the "working" position.
– Seek the actual position of the arms with the position
setting knob until the safety warning light (6) goes out.

6
Error codes
2
System faults appear as an error code. This is indicated
by the safety warning light (6) flashing.
382hsm03 Fig. 4
N.B.: To diagnose the fault corresponding to the error
code, use Win Métadiag© and consult chapter "G7"
(lift application).

Ares 806 – 09.2004 – GB G2.5


Checks and adjustments

Connections to TCE 15/TCE 25 units


54-pin connector (J71)

1 Not used
2 Down valve value
3 TCE earth
4 TCE earth
5 Up valve return
6 Down valve return
7 +APC
8 Not used
9 Not used
10 Not used
11 Not used
12 CAN-High return
13 CAN-Low return
14 Not used
15 + Rear position reference value
16 + LH draft reference value
17 + RH draft reference value 382hsm04 Fig. 5
18 Not used
19 Value "–" rear position
20 Value "–" LH draft
21 Value "–" RH draft
22 Not used
23 Position signal
24 RH draft signal
25 Not used
26 Not used
27 Not used
28 Not used
29 Value "+" up valve
30 +AVC TCE
31 +AVC TCE
32 Not used
33 Not used
34 +APC TCE
35 Not used
36 Not used
37 External down control
38 External up control
39 Not used
40 CAN-High network 382hsm05 Fig. 6

41 CAN-Low network
42 High position to "Drivetronic"
43 Not used
44 Not used
45 Not used
46 Not used
47 +APC TCE (D + relayed)
48 Not used
49 Not used
50 Not used
51 LH draft signal
52 Not used
53 Not used
54 Not used

G2.6 Ares 806 – 09.2004 – GB


Checks and adjustments

Connections to TCE 15 T units


25-pin connector (J186) on control unit

1 Reference value 1,6 V


2 Mixed check control
3 Position control (upper stop)
4 Depth control
5 Mode selector
6 High position lift to "Drivetronic".
7 Diagnostic indicator
8 Down valve indicator
9 Not used
10 Not used
11 Not used
12 Not used
13 Not used
14 Reference value 9,5 V
15 Lowering speed control
16 Unit earth
17 Transport mode indicator 382hsm06 Fig. 7
18 Transport mode control
19 Up valve indicator
20 Not used
21 Not used
22 Not used
23 Not used
24 Not used
25 Not used

J186

J71
382hsm07 Fig. 8

Ares 806 – 09.2004 – GB G2.7


Checks and adjustments

25-pin connector (J71) on electronic


control unit
(Located under the RH console near to the auxiliary valve
control levers).

1 TCE earth
2 Value "+" up valve "–" indicator
3 Reference value 1,6 V
4 Mixed check control
5 +APC (D + relayed)
6 Return "–" up/down valves value
7 Low line
8 Mode selector
9 Diagnostic indicator
10 TCE lift control "–" up
11 Transport indicator "–" line K
12 Reference value 9,5 V
13 "+" RH and LH draft/position reference value
14 Value "+" down valve "–" indicator
15 "–" RH and LH draft/position reference value
16 Depth control 382hsm06 Fig. 9

17 LH draft signal
18 RH draft signal
19 Position signal
20 Lift control "–" down
21 Transport mode control
22 Position control
23 Not used
24 Lowering speed control
25 +APC Unit

J186

J71
382hsm07 Fig. 10

G2.8 Ares 806 – 09.2004 – GB


Checks and adjustments

Position sensor on GPA 30 axle


The position sensor (A) must be adjusted so that the travel
required for lift operation is within the mechanical stroke of
the sensor.
– Use test harness n° 60 05 005 734 connected between
the sensor and the tractor harness (engine off).
A
– Start the engine.
– Bring the arms to the stop limit on the housing
(maximum high position).
– Using multimeter n° 60 05 006 744, measure the
voltages between terminals "1" and "3": Supply
voltage, between "1" and "2": Signal voltage. The
measured signal (terminal "1" and "2") must be equal
to 75% of the measured supply voltage. If this is 10 V,
the signal voltage will be equal to 7,5 V.
– Screw the sensor in or out to obtain this value.
382hsm08 Fig. 11

3
S 2
1
U

382hsm09 Fig. 12

Ares 806 – 09.2004 – GB G2.9


Checks and adjustments

Position sensor on GPA 40 axle


The rear lift position sensor (1) is located on the RH lift
arm.
Important: The lift must not be loaded when setting.
– Make sure that the chamfer of the pin (A) is opposite
the flat part of the sensor stem (B).
– Position the sensor with the flat part facing up.
– Preset by placing the screws in the centre of the slots.
– With the engine switched off, connect harness
n° 60 05 005 577 and multimeter n° 60 05 006 744 1
(Fig. 16).
– Switch on the ignition.
– Bring the arms to the upper stop limit (maximum high
position).
N.B.: The supply voltage between terminals "1" and
"2" must be 10 V. 382hsm10 Fig. 13

– Adjust the sensor position to obtain a signal voltage


of 7,2 V ± 0,01 between terminals "1" and "3".
– Tighten the sensor mounting screws (C) moderately.

382hsm11 Fig. 14

1
0V

2
UB
3
2 Out
1
UB 0V

3
Out

382hsm12 Fig. 15

G2.10 Ares 806 – 09.2004 – GB


Checks and adjustments

V 7,2 V

3
2,5 V

APC

60 05 005577

2
B B B B
3
C C C C 1
1 A A
A A

382hsm13 Fig. 16

Parts list
1 Position information from sensor. 3 Values measured on a tractor.
2 Position sensor mounted on RH lift arm.

N.B.: For position sensor calibration, refer to chapter


"G7" (lift application).

Ares 806 – 09.2004 – GB G2.11


Checks and adjustments

Draft sensor on GPA 30 and GPA 40 axles


The rear lift draft sensors (1) are located between the lift drawbar and the rear axle with GPA 30 axles (Fig. 17) and
GPA 40 axles (Fig. 18).

5
1

2
4
3 Frenbloc (270)
7,5 ± 1 daN.m

382hsm14 Fig. 17

Parts list
1 Load sensors. 4 Bush.
2 Sensor mounting plate. 5 Sensor protection.
3 Sensor mounting screw.

G2.12 Ares 806 – 09.2004 – GB


Checks and adjustments

3 Frenbloc (270)
7,5 ± 1 daN.m

4 2

382hsm15 Fig. 18

Important: The lift must not be loaded when setting.


– Use test harness n° 60 05 005 734 connected between
the sensor and the tractor harness.
– Using multimeter n° 60 05 006 744, measure the
voltages between terminals "1" and "3": Supply
voltage, between "1" and "2": Signal voltage. The
measured signal (terminal "1" and "2") must be equal 3
to 50% of the supply voltage (Terminals "1" and "3").
Example: If the measured supply voltage is 10 V, the 2
signal voltage must be equal to 5 V. 1

382hsm16 Fig. 19

Ares 806 – 09.2004 – GB G2.13


Checks and adjustments

Theoretical forward speed sensor on


GPA 30 and GPA 40 axles
The theoretical speed sensor (1) is located under the cab,
above the rear axle ring gear.
N.B.: Racoretanch (577) must be used on refitting the
sensor (1).
– Without overtightening, screw the speed sensor fully
on until it is in contact with the differential ring gear. 1
– Unscrew the sensor by 3/4 of a turn to obtain 1 mm of
clearance between the sensor and the ring gear.
– Tighten the nut (2) moderately.
– Connect the sensor harness.
N.B.: To test the state of the sensor, check that its
resistance is 450 ± 20 ohm.

382hsm17 Fig. 20

1
1 ± 0,5

382hsm18 Fig. 21

G2.14 Ares 806 – 09.2004 – GB


Checks and adjustments

Radar (TCE 25 only)


The radar is mounted on the right-hand side of the
transmission.
Important: Do not look directly at the transducer to
avoid eye damage from the microwaves emitted by
this radar when connected.
N.B.: See chapter "F" to check the radar electrical
power supply.

Lift spool valve solenoid


valves
The solenoid valve resistance of the lift spool valve (A)
is 1,8 ohm.
382hsm19 Fig. 22

1,8 Ω

382hsm20 Fig. 23

Ares 806 – 09.2004 – GB G2.15


Notes

G2.16 Ares 806 – 09.2004 – GB


G3 – TRANSMISSION/AXLE CONTROL

Ares 806 – 09.2004 – GB


Drivetronic III

17
13

6
5
11
10
8
9
1
2

12

3
4
14
16
18

15

583hsm19 Fig. 1

G3.2 Ares 806 – 09.2004 – GB


Drivetronic III

Location of the LS 100 l/min components and sensors


Parts list
1 Power take-off speed sensor. 10 Differential locking solenoid valve.
2 Displacement speed sensor. 11 Four-wheel-drive solenoid valve.
3 Quadrishift front brake solenoid valve. 12 Field/road range solenoid valve.
4 Quadrishift rear brake solenoid valve. 13 REVERSHIFT output speed sensor.
5 Forward gear clutch solenoid valve. 14 Transmission temperature sensor.
6 Reverse gear clutch solenoid valve. 15 Engine speed sensor.
7 Control pressure switch. 16 Range switch.
8 Rear power take-off clutch solenoid valve. 17 Steering filter blockage pressure switch.
9 Rear power take-off brake solenoid valve. 18 Strainer blockage pressure switch.

Ares 806 – 09.2004 – GB G3.3


Drivetronic III

Location of the LS 110 l/min components and sensors

2
7 1

9
13
10

17

11

16
18
15 14
12
4
3
6
5
583hsm20 Fig. 2

Parts list
1 Power take-off speed sensor. 11 Four-wheel-drive solenoid valve.
2 Displacement speed sensor. 12 Field/road range solenoid valve.
3 Quadrishift front brake solenoid valve. 13 REVERSHIFT output speed sensor.
4 Quadrishift rear brake solenoid valve. 14 Transmission temperature sensor.
5 Forward gear clutch solenoid valve. 15 Engine speed sensor.
6 Reverse gear clutch solenoid valve. 16 Range switch.
7 Control pressure switch. 17 Filter blockage pressure switch.
8 Rear power take-off clutch solenoid valve. 18 Rear axle lubrication and boost pressure switch.
9 Rear power take-off brake solenoid valve.
10 Differential locking solenoid valve.

G3.4 Ares 806 – 09.2004 – GB


Drivetronic III

TOC, BOC switches and angle detector

1
2

583hsm01 Fig. 3

Parts list
1 TOC switch (pedal upwards contact). 3 Angle detector.
2 BOC switch (pedal downwards contact).

Drivetronic electronic unit


Located behind the seat under the horizontal cab trim.

Ares 806 – 09.2004 – GB G3.5


Drivetronic III

Shuttle reverser lever characteristics


(illustrated in neutral)
188

AV N

AR
R

D2 D1

B3 A2 A4 B2 B5 B4 B1

583hsm21 Fig. 4

Position A2 (front) A4 (rear) B2 (neutral) B4 (+ solenoid valve)


Neutral 0 0 + 12 V 0
Forward gear + 12 V 0 0 + 12 V
Reverse gear 0 + 12 V 0 + 12 V
Declutched 0 + 12 V + 12 V + 12 V

B1 and "B3" = + 12 V
"B5" = Earth

Range and declutching control


+APC
Parts list
63 ISC declutching +/- range control.
184 Electronic control unit.
188 Hydraulic shuttle reverser control. B3 63
220 Range switch. 220b 220a
+

– + –

B1 B2 A2 A4 A1 A5 B5

J1.32 J1.16 B3 J1.13


188 184
J1.15
184

583hsm22 Fig. 5

G3.6 Ares 806 – 09.2004 – GB


Drivetronic III

Clutch pedal switches

55a

2 + APC
3
J1.20

55b

2
J2.33
1

187
1 A

3 C

2 B

55a

55b

187
1 A

3 C

2 B

583hsm23 Fig. 6

Parts list
55a TOC switch. 187 Angle detector.
55b BOC switch. Pins "A" and "B" = 12 V supply.
Pin "C" = output voltage (4,5 V: 0,5 V).

Switch Position J1.20 J2.33

Clutch engaged 12 V –
55a
Clutch released 0V –
Clutch engaged – 0 V if 188 in neutral, if not + 12 V
55b
Clutch released – 0V

Ares 806 – 09.2004 – GB G3.7


Drivetronic III
Quadrishift II (244) and Quadractiv (245) control switches
Parts list
244 Quadrishift II control.
245 Quadractiv control.

245

2
2
1 0

2 J1.21
+ 12 V
6

8
3

L2 L3

244 J1.14
9

L1
10

1 1

0
5

583hsm24 Fig. 7

Switch Position J1.14 J1.21 Indicator L1 Indicator L2 Indicator L3

0 0 0 Out — —
244
1 12 V — Lit — —
12 V Lit
0 0 Out Out
(if 244 in 1) (if 244 in 1)
245
1 0 12 V Out Lit Out
2 12 V 12 V Out Out Lit

G3.8 Ares 806 – 09.2004 – GB


Drivetronic III

Solenoid valves

192 193 126 125

583hsm25 Fig. 8

Parts list
125 Quadrishift solenoid valve "EV2". 192 Quadrishift solenoid valve "EVP1" (forward gear).
126 Quadrishift solenoid valve "EV1". 193 Quadrishift solenoid valve "EVP2" (reverse gear).

Solenoid Resistance
Maximum current Forward gear Reverse gear Gear 1 Gear 2 Gear 3 Gear 4
valve (power off)

125 – – 0 12 V 12 V 0
126 – – 12 V 12 V 0 0
10 W 1,2 A
192 Active 0 – – – –
193 0 Active – – – –

N.B.: Coil resistance for the other solenoid valves is 10 ohm.

Ares 806 – 09.2004 – GB G3.9


Drivetronic III

Solenoid valve current setpoint for forward motion

1 5
2
3
4

B
583hsm26 Fig. 9

Parts list
A Current setpoint. B Time.

Phase Duration Start of setpoint PWM* End of setpoint PWM*

1 32 ms Maximum current
2 272 ms Calibrated current
3 As long as clutch speed = 0 Slope = + 3 bar/s
4 As long as clutch speed differs from engine speed. Speed loop on clutch output.
5 Until declutching requested or change of direction. 100 %
* Pulse width modulation.

G3.10 Ares 806 – 09.2004 – GB


Drivetronic III

Control pressure switch


– Operating pressure = maximum 30 bar.
– Engine off (0 bar), contacts "1", "2" open.
– Engine running (17 bar), contacts "1", "2" closed.
– If pressure drops, contacts "1", "2" open.

1
Lubrication/boost pressure switch, P
2
3 bar (Fig. 11)
– Operating pressure = maximum 30 bar.
– Engine off (0 bar), contacts "1", "2" closed.
– Engine running (3 bar), contacts "1", "2" open.
– If pressure drops, contacts "1", "2" closed.

583hsm27 Fig. 10

Blockage indicator (Fig. 12)


– Mounted in parallel to the filter, if "∆P" between
chambers "A" and "B" greater than or equal to 2,4 bar

1
P
2

583hsm28 Fig. 11

2
B A

583hsm29 Fig. 12

Ares 806 – 09.2004 – GB G3.11


Drivetronic III

Speed sensors
Resistance: 460 ± 10 ohm.
Output signal: AC.
Air gap: 1 ± 0,5 mm.

On fitting, make sure that the sensor is


not screwed between 2 teeth.

Temperature sensor (Fig. 14)


Measuring capacity: – 40 to + 150°C.
Tolerance between – 15 and 0°C: ± 1,5°C.

583hsm30 Fig. 13

50

40

30

20

10
5
0
– 50 0 50 100 ˚C

583hsm31 Fig. 14

G3.12 Ares 806 – 09.2004 – GB


Drivetronic III

Adjustment of TOC, BOC and angle detector switches

mm
2,5
=

6 3

80 m
=

0 mm
15

4
1,5
mm

16,4 mm
1

583msm04 Fig. 15

Ares 806 – 09.2004 – GB G3.13


Drivetronic III

1. Adjust the pedal low position.


– Obtain the 16,4 mm dimension.
2. Adjust the pedal high position.
– Obtain a total pedal stroke of 150 mm.
3. Adjust the "engaged pedal" travel.
– Insert a 2,5 mm shim between the TOC switch and the pedal.
4. Adjust the "pedal clutch released" travel.
– Insert a 1,5 mm shim between the BOC switch and the pedal.
5. Adjust the rod to 80 mm in centreline distance ball points.
6. Position the angle detector so that the adjustment lights are half-way.
N.B.: These adjustments are possible with Métadiag - see electrical tests.

Static calibration of clutches


Independent Win Métadiag© procedure, applicable from version B8-B9.
Purpose: Owing to mechanical, hydraulic and electrical differences, load pressure varies from one tractor to another. This
pressure must be measured to ensure good gradual engagement.

1. Calibration input procedure


1. Warm up the tractor to obtain an oil temperature of approximately 50°C (+ 50°C) - see the temperature display*.
2. Position the tractor on a smooth flat surface.
3. Start up the tractor and apply the hand brake.
4. Place the gearbox in neutral.
5. Place the lever (reverser control) either in forward or in reverse.
6. Place the tractor in low range (tortoise).
7. Run the engine at 1 500 rpm (manually).
8. Engage the Quadrishift in as low a gear as possible.
9. Contact simultaneously the range and the differential switch for at least 4 seconds (this is now in high range).
Calibration begins, the front and rear indicators flash alternately plus the neutral indicator, and the buzzer is activated during
the 4 phases of calibration.

2. Calibrating the clutches


The clutches are calibrated automatically (duration about 5 minutes).

3. End of calibration
The operator is informed of the end of calibration when the 4 Quadrishift indicators stay on for 3 seconds. After 3 secondes,
the forward or rear arrow flashes. To cancel the flashing, press and release the clutch pedal. The tractor can then function.

* Temperature information is available on Win Métadiag© or according to the transmission temperature indication procedure.

G3.14 Ares 806 – 09.2004 – GB


Drivetronic III

Transmission temperature
indication
– Tractor running
– Shuttle reverser lever in neutral.
1
– Contact the range and differential switches
simultaneously for at least 4 seconds.
– The 4 indicators of the quadrupler signal the
transmission temperature.
Calibration can begin if 3 indicators are lit + 1 flashing (1).
Optimum calibration = 4 indicators lit solid.
To exit this mode, switch off the ignition or start the
calibration procedure.

583hsm32 Fig. 16

Ares 806 – 09.2004 – GB G3.15


Drivetronic III

Adjusting the calibration procedures


If the tractor acceptance criteria are not fulfilled or if the user would like a faster or slower shuttle reverser reaction, the
procedure described below can be used to optimise the calibration parameters.

Phases Actions Observations Remarks

1. Mode entry Stop the tractor. — —


conditions Switch on the ignition. Wait until the range and quadrupler —
indicators have gone out. Clutch pedal
released.
2. Entering the mode Hold the shuttle reverser The 4 quadrupler indicators light up after 4 —
lever in the raised seconds.
position and contact the
differential switch for 4
seconds.
3. Selecting the clutch Position the shuttle The two front and rear indicators of the It is possible to change as long as
to change the offset reverser lever forward or shuttle reverser light up after 4 seconds. the direction has not been selected.
back (front and rear
clutches respectively).
4. Choice of raising or Press the differential On pressing, just one of the two shuttle If the lever position is changed:
lowering the offset switch several times. reverser indicators stays lit and alternates Return to phase "2".
Note: The increment each time the switch is pressed.
selected does not depend Forward: tractor faster (harder).
on the number of presses Reverse: Tractor slower (softer).
on the switch, it depends
solely on the indicator
selected.
5. Validation Put the shuttle reverser After 4 seconds, the ECU is reset causing If the lever returns to the neutral
lever into the raise all the indicators to go out and one of the position before the 4 seconds are up:
position for 4 seconds. quadrupler indicators to light up. Return to phase "1".
Adjustment accepted. Front or rear: Return to phase "2".

N.B.: If at any point in this procedure the lever is returned to neutral or if ignition is switched off: Return to
phase "1". This adjustment procedure can be repeated 5 times in the same direction for the same clutch. The credit
is reset when the transmission is calibrated. If, during phase "4", the choice is not permitted, this means that this
operation has already been carried out more than 5 times.

G3.16 Ares 806 – 09.2004 – GB


Drivetronic III

Inputs/outputs by functions
and automatic systems 188
AV N
Activation – Deactivation of the ECU
AR
The ECU is activated by the ignition source. The R

automatic systems are activated by engine speed D2 D1


and 17 bar pressure, except for the hydraulic shuttle B5 B4 B1
reverser function which is activated by engine speed + AVC
or 17 bar pressure.
55b
The automatic systems are deactivated when the
following condition is true: 2
1
No hydraulic pressure for 4 seconds and engine speed
< 200 rpm for 6 seconds.
OR
Loss of ignition source (+APC) AND engine speed + AVC + AVC
< 200 rpm for 60 seconds.
AND
Wheel speed < 2 km/h for 60 seconds.

"Drivetronic" power supply J2.27 J2.31 J2.32

Parts list J2.33

38 Engine speed sensor.


55b Pedal switch. 184
J2.25
115 Oil pressure switch.
184 Transmission electronic control unit. J2.26
J1.27 J1.31 J1.33
188 Hydraulic shuttle reverser control.

2 1

38 115
P

583hsm33 Fig. 17

Ares 806 – 09.2004 – GB G3.17


Drivetronic III

Front axle engagement control


• Solenoid valve control logic:
– Control = battery voltage = front axle disengaged.
• On activation, the manual control is in the status saved when the automatic system was deactivated.
• The front axle is engaged permanently if:
– The control is pressed and forward speed > 14 km/h.
– The control is pressed > 2 seconds and forward speed is < 14 km/h.
• The front axle is disengaged if:
– The control is pressed.
• The front axle is engaged temporarily if:
– Speed zero (< 0,3 km/h) (indicator out).
– The control is pressed < 2 seconds and forward speed is < 14 km/h.
– Differential locking.
– Both brakes are applied simultaneously.
– Oil pressure fault (no action on indicator).
– Engine speed fault.
– Battery voltage > 16 V (indicator out).
• The front axle is disengaged temporarily if:
– Speed > 14 km/h (the manual control still has priority), unless permanent engagement has been requested by pressing
the manual control > 2 seconds.
• On oil pressure fault:
– The front axle is engaged; when the fault has been cleared, the function is reactivated.

G3.18 Ares 806 – 09.2004 – GB


Drivetronic III

+ APC

+ APC

234

2
1

J1.17 J2.3 101


203b 203a

J1.9

184
J1.19
J2.24

J1.27 J1.31 J1.28 J1.33

2 1

38 37 115
P

583hsm34 Fig. 18

Parts list
37 Displacement speed sensor. 184 Transmission electronic central unit.
38 Engine speed sensor. 203 Brake pedal switches.
101 4-wheel drive solenoid valve. 234 4-wheel drive switch.
115 Oil pressure switch.

Ares 806 – 09.2004 – GB G3.19


Drivetronic III

Differential locking control


Solenoid valve control logic: Control = battery voltage = differential locked.
The differential can be in one of the following three modes:
– Off.
– Auto.
– Push.
When the tractor is started up, the differential is always off. Regardless of which mode is active, if the speed
exceeds 14 km/h, the differential is switched off.
– Pressing the control for longer than 2 s at less than 14 km/h will switch it to push mode regardless of which mode
is active.
– Pressing the control briefly switches the differential off regardless of which mode is active.
– If off, pressing the control briefly at less than 14 km/h switches it to auto mode.
In auto mode, pressing at least one brake switches the differential off if it was not previously disengaged by one of the auto
mode conditions.

Off mode
– The differential is not controlled.
– The indicator is out.

Auto mode
The differential is controlled according to conditions governing the steering angle, speed and lift selector position:
If speed < 10 km/h:
– The differential is disengaged at 15°C.
– The differential can be re-engaged at 13°C.
If speed is lower than or equal to 10 km/h:
– The differential is disengaged at 5°C.
– The differential can be re-engaged at 3°C.
If lift raising is requested, the differential is disengaged. The differential is effectively re-engaged when the disengaging
conditions are no longer fulfilled. The indicator is lit when the differential is engaged and out when disengaged.

Push mode
The differential is controlled.
The indicator is flashing (lit 95% of the time).
All PLC changes are locked on an engine speed fault. When the fault is cleared, the system switches to "permanently
unlocked" mode.

Steering angle calibration


Refer to chapter "G7".

G3.20 Ares 806 – 09.2004 – GB


Drivetronic III

+ APC

TCE 15/25 TCE 15 T


+ APC

J186.6
J71.42
232

1 2

J1.6 J1.10 J2.7 102


203b 203a
J1.9

184
J1.19
J2.34
A
401 J1.23
C B J1.27 J1.31 J1.28 J1.33
+ APC

38 37 115
P

583hsm35 Fig. 19

Parts list
37 Displacement speed sensor. 184 Transmission electronic control unit.
38 Engine speed sensor. 203 Brake pedal switches.
102 Differential lock solenoid valve. 232 Differential switch.
115 Oil pressure switch. 401 Steering angle.

Ares 806 – 09.2004 – GB G3.21


Drivetronic III

Quadrupler control
Solenoid valve control logic:

Ratio 1 2 3 4

EV1 Active Active — —


EV2 — Active Active —

On activation, the system returns automatically to the gear ratio stored in memory on deactivation.
To maintain driver comfort and ensure optimum reliability of the transmission, there is a time lag of 1 to 2 seconds
between 2 successive gear changes.
Monitoring of the engine speed on gear changes
"Slower" request: If engine speed > set values, the request is not carried out (stored) and the engaged gear indicator
flashes.
"Faster" request: If the engine speed dropped by more than 12% on the last gear change and the speed has not picked up
again, the request is not carried out (stored) and the engaged gear indicator flashes.
If the "declutched" switch is active and if the speed exceeds 1 km/h or the selected direction of operation has only been
selected for one second, then the gear change requests are not carried out (stored, protection against simultaneous main
gearbox and quadrupler shifting).
• Electronic injection control
The accelerator sensor, which was used for quadrupler automation, is also used to send the engine speed setpoint to the
electronic injection ECU. Engine speed is no longer calculated by "Drivetronic III" but received by the CAN from the injection
ECU.
If the engine speed is not received, its value is not refreshed. After a period of 1,6 seconds, it is set to 0: "Drivetronic III"
then manages this fault.
Should a fault occur, the electronic injection ECU sends a message over the CAN network and "Drivetronic III" will light the
diagnostic indicator if the fault is serious enough.
The diagnostic indicator will be lit for the following faults (refer to chapter "G7" for the meaning of the codes):
SPN = 29, 91, 158, 627, 629, 632, 636, 637, 1076, 1078, 1079, 1080, 1485.
SPN = 110 with FMI = 3 or 4.
SPN = 174 with FMI = 31.
SPN = 1077.
• Speed governor (Quadrishift Overdrive)
When there is a quadrupler gear change, a mechanical gear change or a simultaneous change of both types of gear ratio
in the automatic system, the engine speed setpoint is changed instantly. Its value is defined by the position of the
accelerator pedal but this position can be bridled according to the speed limit, the total transmission ratio and the type of
transmission.
Note: When the engine speed setpoint is changed, it is not done suddenly as this would cause a loss of injection
in certain cases.
For example, if the quadrupler moves up a gear automatically in "Power" mode, the engine speed setpoint should change
from 2 100 rpm to approximately 1 700 rpm. This is done gradually (– 4 rpm every 16 ms) to ensure a smooth transition.

G3.22 Ares 806 – 09.2004 – GB


Drivetronic III

Maximum engine speed setpoints in road range for tractors limited to 40 km/h.

Tractor type III – 4 IV – 1 IV – 2 IV – 3 IV – 4

Ares 816 (plate shaft) — — — 2 100 1 840


Ares 816 (smooth shaft) 826/836 (30 km/h) — — — 2 200 1 990
Ares 836 (40 km/h gearbox) — — — — —

• Excessively low temperature control (only on activation)


If temperature < 0°C: Indicators "1" and "4" flash simultaneously.
If forward speed > maximum permitted speed x (28/30): The engaged gear indicator flashes.
If forward speed > maximum permitted speed, the 4 indicators "1", "2", "3", "4" flash simultaneously.
If forward speed > maximum permitted speed x (33/30) and gear "3" selected: Downshift from "3" to "2".
If forward speed > maximum permitted speed x (32/30) and gear "4" selected: Downshift from "4" to "3".
• Oil pressure fault
Shifted to gear "4". When the fault is cleared, the function is activated.
• Engine speed fault
System frozen. When the fault is cleared, the function is activated.
• Battery voltage > 16 V
Shifted to gear "4" and indicator out. When the fault is cleared, the function is activated.

Use of tractor is downgraded mode


Defect on the tractor's forward speed sensor
Irrespective of the mechanical gear and the quadrupler gear engaged, the engine speed setpoint is 1 800 rpm for a tractor
limited to 40 km/h. This fault is detected by the gearbox sensor in neutral and by the speed sensor measuring the speed of
the ISC module.
• CAN fault
If the setpoint transmitted to the engine ECU by the transmission ECU is incorrect or if there is no setpoint, the engine speed
is limited to 1 400 rpm. (Default value in engine ECU).

Ares 806 – 09.2004 – GB G3.23


Drivetronic III

63

B3
+ –
A4

A2 197
C B
+ APC

1 2
+ APC
126

220b 220a
2
1

– + 125

J1.15 J1.16 J1.24 J2.4 J2.5


J2.23

245
J2.22
2 1

4 J2.21
J1.21 184
2
+ APC J2.20
6
185
8 JX1.5
3 J1.14 J2.29
J1.27 J1.31 J1.28 J1.33
1
5

2 1
244 9

38 37 115
10 P

583hsm36 Fig. 20

Parts list
37 Displacement speed sensor. 184 Transmission electronic control unit.
38 Engine speed sensor. 197 Accelerator potentiometer.
63 Range +/- controls. 220 Range switches.
125 Solenoid valve "EV2". 244 Automatic "Quadrishift" control.
126 Solenoid valve "EV1". 245 "Quadrishift Eco/Power" control.

G3.24 Ares 806 – 09.2004 – GB


Drivetronic III

Range change control – Crawl range – The switch from field range to road range is made at a
• Solenoid valve control logic: control = battery voltage = forward speed of less than 10 km/h.
high range. • Oil pressure fault: Status frozen.
• On activation: Initialisation in status stored on • Engine speed fault: Status frozen.
deactivation. • Battery voltage > 16 V
• Range change authorisation – Solenoid valve and indicators cut out.
– The switch from road range to field range is made at a – On clearance of the fault, initialisation in the status
forward speed of less than 8 km/h. stored on deactivation.

63
+

B1 B2

+ APC

48

J2.14 J1.32
J2.35

97 J2.6 J2.28
1

2
184

47

J1.5 + APC

J1.27 J1.31 J1.28 J1.33

2 1

38 37 115
P

583hsm37 Fig. 21

Parts list
37 Displacement speed sensor. 63 Range +/- controls.
38 Engine speed sensor. 97 High / crawler range solenoid valve.
47 Crawler speed contact. 115 Oil pressure switch.
48 High / crawler range contact. 184 Transmission electronic control unit.

Ares 806 – 09.2004 – GB G3.25


Drivetronic III

Hydraulic shuttle reverser (ISC)


• On activation • Engine speed fault: Operation maintained.
– Shuttle reverser locked until pedal bottom switch is • Battery voltage > 16 V.
activated. The system then matches up to the lever – Indicators out. When the fault has been cleared, the
position automatically. indicators are reactivated according to the shuttle
• Oil pressure fault: Operation maintained. reverser status.

B5
63 A1

188 55b 55a


A1 B3
N
AV
B3
+ APC
+ – AR R

D2 D1 1 2 3 2

A2 A4 B2 B5 B4 B1
+ APC

+ APC

J1.11 J1.13 J2.33 J1.20


J1.12 J2.8

192 J2.1 J2.9


1

2 J2.10
184
J2.15
193 1 J2.2 JX1.9
J2.30

2 185
J2.16 JX2.4
J2.11
J1.27 J1.31 J1.28 J1.29

38 37 27

583hsm38 Fig. 22

Parts list
27 Reverser module speed sensor. 184 Transmission electronic control unit.
37 Displacement speed sensor. 185 Instrument panel .
38 Engine speed sensor. 188 Hydraulic shuttle reverser control.
55a Clutch pedal contact (TOC). 192 Forward drive solenoid valve.
55b Clutch pedal contact (BOC). 193 Reverse drive solenoid valve.
63 Range +/- controls.

G3.26 Ares 806 – 09.2004 – GB


Drivetronic III

Rear PTO controls (proportional solenoid valve)


Gradual engagement adapted to the implement
Gradual engagement is managed in 5 phases.

Phases Duration Start of setpoint PWM End of setpoint PWM

1 400 ms 80% 80%


2 As long as number of pulses < 5 or no PTO speed. 33% —
3 As long as number of pulses < 2 rotations. 30% + 0,025%/16 ms
4 As long as PTO clutch speed < 98% of engine speed. Speed loop on clutch output.
5 Until PTO shutdown is requested. 100%

• Protection against major drops in engine speed: If, during the "filling" and "speed up" phase, the engine speed drops
by > 50%, the system switches to safety, the solenoid valve is cut out and the indicator switches to "fault" status.
• Protection against clutch slippage: From the start of the "speed up" phase to the next PTO shutdown, the sum of clutch
slippage is recorded. If this term exceeds a threshold limit, the system switches to safety, the solenoid valve is cut out
and the indicator switches to "fault" status.
• In "economic" mode for an engine speed > 1 900 rpm: Switched to safety, the solenoid valve is cut out and the indicator
switches to "fault" status.
• On activation
– The solenoid valve is cut out. If the cab control or one of the emergency stop controls is active, the indicator signals a
fault.
• Oil pressure fault
– The solenoid valve and indicator are cut out. When the fault is cleared, the indicator signals a fault (flashing).
• Engine speed fault
– The solenoid valve and indicator are cut out. When the fault is cleared, the indicator signals a fault (flashing).
• Battery voltage > 16 V
– The solenoid valve and indicator are cut out. When the fault is cleared, the indicator signals a fault (flashing).
• Drive-proportional power take-off safety
– If the tractor has a drive-proportional power take-off, a safety feature is provided. The indicator flashes if the proportional
PTO is engaged.
– If the speed exceeds 20 km/h and the proportional PTO is still engaged, an audible alarm sounds to warn the user.

Ares 806 – 09.2004 – GB G3.27


Drivetronic III

44b 44a
53 A B B A
+ APC
J

1 42
+ APC
C2

104 1 J1.22 J1.7 J1.8 54

2 J1.18

103 1
J2.12

184
2

J2.19 JX2.22

J1.33 185
J2.36 JX2.13

J1.27 J1.31 J1.28 J1.30

1 2

115 38 37 39
P

583hsm39 Fig. 23

Parts list
37 Displacement speed sensor. 54 Rear PTO selection contact.
38 Engine speed sensor. 103 Rear PTO clutch solenoid valve.
39 Rear power take-off speed sensor. 104 Rear PTO brake solenoid valve.
42 "Eco" rear PTO switch. 115 Oil pressure switch.
44 Emergency stops. 184 Transmission electronic control unit.
53 Rear PTO clutch switch. 185 Instrument panel .

G3.28 Ares 806 – 09.2004 – GB


Drivetronic III

Safety features
• Transmission oil pressure
Detection by a pressure switch on the transmission hydraulic circuit and information sent directly to the dashboard (pressure
established = earth contact closed).
The various functions are switched to safety 4 seconds after the fault appears (see paragraphs on front axle, differential,
doubler, quadrupler, shuttle reverser and power take-off).
• Transmission oil temperature
Measured by a probe on the transmission hydraulic circuit, an excessive oil temperature lights up an indicator on the
dashboard (temperature over 90°C = battery voltage output).
Control of the quadrupler safety function (see paragraph on the quadrupler).

Ares 806 – 09.2004 – GB G3.29


Drivetronic III

General schematic diagram

J2.27 12 V
J1.27
J2.31 J2.32 12 V
J1.28 J2.25 J2.26

J2.18
J1.29
J2.19
J1.30
J1.34
J1.31
J1.35
J1.33
J1.2
12 V J1.18 12 V
J2.33
J1.22
J2.36
J1.8
J2.29
J1.7
J2.11
J1.9 J2.30

J1.19
J2.20
J1.6
J2.21
J1.10 J2.22
J2.23

J1.17 J2.8
J2.9
J2.10
J1.5
J2.35
J2.28
J1.32

J2.14 J2.34
- J1.16
+ J2.24
J1.15
J2.4
J1.20
Quadrishift
J2.5
J1.14

J1.21 J2.6

J1.13
J2.7
J1.11

J1.12 J2.3

J1.25
J2.12
J1.26

J1.1 J2.13

J1.4
J2.1
J1.3 J2.15
+ 12 V
J2.2
J1.24 J2.16

+ 12 V

J1.23

583hsm40 Fig. 24

G3.30 Ares 806 – 09.2004 – GB


Drivetronic III

Pin Types Allocation

J1.1 Output + 5 Volts power supply


J1.2 Analog input Drive-proportional PTO
J1.3 Output – 12 Volts power supply
J1.4 Analog input Clutch pedal setpoint
J1.5 Logical input Crawler speeds
J1.6 Logical input Differential locking
J1.7 Logical input Power take-off stop
J1.8 Logical input Economy power take-off
J1.9 Logical input Left brake
J1.10 Logical input Lift up position
J1.11 Logical input Forward gear
J1.12 Logical input Reverse gear
J1.13 Logical input Neutral
J1.14 Logical input Quadractiv level selection
J1.15 Logical input + Quick
J1.16 Logical input – Quick
J1.17 Logical input Front axle engagement
J1.18 Logical input PTO, 1000 rpm
J1.19 Logical input Right brake
J1.20 Logical input Clutch upwards
J1.21 Logical input "Quadractiv" level selection
J1.22 Logical input Power take-off forward
J1.23 Analog input Steering angle
J1.24 Analog input Accelerator pedal input
J1.25 Analog input Temperature signal
J1.26 Earth Temperature
J1.27 Frequency input Engine speed
J1.28 Frequency input Theoretical speed
J1.29 Frequency input Clutch output speed
J1.30 Frequency input Power take-off speed
J1.31 Common earth Sensors ground
J1.32 Logical input Range changes
J1.33 Logical input Pressure switch, 17 bar
J1.34 CAN H CAN link
J1.35 CAN L CAN link
J1.36 CAN Gnd CAN network earth

Ares 806 – 09.2004 – GB G3.31


Drivetronic III

Pin Types Allocation

J2.1 Output Front solenoid valve


J2.2 Output Rear solenoid valve
J2.3 Output Front axle solenoid valve
J2.4 Output "Quadrishift" solenoid valve 1
J2.5 Output "Quadrishift" solenoid valve 2
J2.6 Output Range solenoid valve
J2.7 Output Differential solenoid valve
J2.8 Output Forward drive indicator light
J2.9 Output Neutral light
J2.10 Output Reverse drive indicator light
J2.11 Output Buzzer
J2.12 Output Power take-off solenoid valve
J2.13 — Proportional solenoid valve earth
J2.14 Logical input Gearbox in neutral
J2.15 Output Front solenoid valve return
J2.16 Output Rear solenoid valve return
J2.17 — —
J2.18 Frequency output Theoretical speed
J2.19 Frequency output Power take-off speed
J2.20 Output Indicator 1
J2.21 Output Indicator 2
J2.22 Output Indicator 3
J2.23 Output Indicator 4
J2.24 Output Front axle indicator light
J2.25 Power supply Earth
J2.26 Power supply Earth
J2.27 Power supply + 12 volt constant source
J2.28 Output Crawler (tortoise) range indicator
J2.29 Output Temperature indicator
J2.30 Output Diagnostic indicator
J2.31 Power supply + 12 volt switched
J2.32 Power supply + 12 volt switched
J2.33 Power supply "Drivers" power supply (BOC 1)
J2.34 Output Differential indicator
J2.35 Output Road range indicator
J2.36 Output Power take-off indicator

G3.32 Ares 806 – 09.2004 – GB


Drivetronic V

Inputs/outputs and automatic systems


Emergency brake released position

+ AVC + APC

29 42
180
S3 10 V1

34
+ APC
11 V2

Drivetronic 5
35
39 CAN Hi
E
40 CAN Lo

20
S2
S1

7 8 28

1
E2
2

1
E1
2

17 bar

583hsm41 Fig. 25

Ares 806 – 09.2004 – GB G3.33


Drivetronic V

Emergency brake engaged position

+ AVC + APC

29 42
180
S3 10 V1

34
+ APC
11 V2

Drivetronic 5
35
39 CAN Hi
E
40 CAN Lo

20
S2
S1

7 8 28

1
E2
2

1
E1
2

17 bar

583hsm42 Fig. 26

Parts list
S1 Switch (released position). E1 Filling solenoid valve.
S2 Switch (worn brake position). E2 Solenoid-operated drain valve.
S3 Impulse switch (emrgency brake engagement/release). V1 Brake engaged indicator.
E Information conveyed via the CAN: V2 Brake worn or failure indicator.
– Forward speed . 180 Display.
– Engine speed .
– Transmission status (forward/neutral/reverse).

G3.34 Ares 806 – 09.2004 – GB


Drivetronic V

When the tractor is started up, the emergency brake attempts to engage which enables the working order of the system to
be checked (built-in test on the two indicators which stay lit for 1 second after start-up). Then they indicate the emergency
brake status.

Emergency Emergency
Conditions E1 E2 S1 S2 V1 V2 brake brake
released engaged

Engine cut out + forward 1 For 3 s


0 0 0 — — 0 1
speed < 1 km/h then 0.
Engine running, "Revershift"
lever moved forward or back 1 0 1 0 — — 1 0
or "S3" pressed
Flashes slowly
If forward speed between 1
(engagement
and 5 km/h and "Revershift 0 0 0 0 — 0 1
request in
lever in neutral, press "S3"
memory).
If forward speed < 1 km/h
1 For 3 s
and "Revershift lever in 0 0 0 Lit solid — 0 1
then 0
neutral
If emergency brake
1 For 3 s
requested and mechanism 0 0 1 Lit solid Lit solid 0 1
then 0
worn

Any request made other than in neutral or at a speed of over 5 km/h is not accepted or memorised. When emergency brake
engagement has been requested, the request is cancelled if:
– The speed goes back above 5 km/h.
or
– "S3" is pressed again.
or
– The lever is in forward or reverse gear.
The system is deactivated when the emergency brake is engaged, the ignition is switched off and "Drivetronic III" has not
emitted a message over the CAN for 30 seconds.

Ares 806 – 09.2004 – GB G3.35


Drivetronic V

Switch and solenoid valve


check
Resistance "E1" and "E2" = 10 ohm.
S1 = 0 ohm if brake released otherwise + oo.
S2 = 0 ohm if brake worn otherwise + oo E1

Error codes
Refer to chapter "G7".
S1

S2 E2

583hsm43 Fig. 27

G3.36 Ares 806 – 09.2004 – GB


Full Powershift

Location of components and


sensors PSD

The Full Powershift transmission comprises 2 control


units:
– One called Transmission Controller (TC).
– And another called Renault Cabine Controller (RCC).
Information is displayed on the Powershift Display (PSD).

TC
The TC is located on the right-hand side of the gearbox RCC
behind a protective cover (Fig. 29). It is linked to the RCC
and to the transmission by 5 connectors labelled "A", "B",
"C", "D" and "E".
TC
RCC
The RCC is located at the back of the cab in the
583hsm44 Fig. 28
crossmember under the hinged panel (Fig. 30).

A D E

B
1

583hsm45 Fig. 29

583hsm46 Fig. 30

Ares 806 – 09.2004 – GB G3.37


Full Powershift

Parts list
1 Engine speed sensor. 8 Clutch "L" proportional solenoid valve.
2 Clutch "C" proportional solenoid valve. 9 Gearbox low pressure circuit pressure switch (9 bar).
3 Clutch calibration sensor. 10 Clutch "A" proportional solenoid valve.
4 Clutch "B" proportional solenoid valve. 11 Clutch "2" proportional solenoid valve.
5 Clutch "R" proportional solenoid valve. 12 Displacement speed sensor (gearbox output).
6 Clutch "1" proportional solenoid valve. 13 Clutch "H" proportional solenoid valve.
7 Temperature sensor. 14 Clutch "M" proportional solenoid valve.

G3.38 Ares 806 – 09.2004 – GB


Full Powershift

14
11

13
10

12
Y

5th
4th

9
3rd

1st

6th
W

W
2nd

7th

Grolleau le technicien

12345x
Teddy
Y
1
2
3
Z

8
5

7
6

583hsm47 Fig. 31

Ares 806 – 09.2004 – GB G3.39


Full Powershift

Layout on the rear axle

2 1 12

10

3 11

583hsm48 Fig. 32

Parts list
1 Theoretical displacement speed sensor. 7 Front/rear differential lock control solenoid valve.
2 Rear power take off speed sensor (clutch output). 8 Front axle control solenoid valve.
3 Rear power take off shaft speed sensor (instrument panel). 9 Park lock control solenoid valve.
4 Rear axle low pressure circuit pressure switch (9 bar). 10 Rear axle lubrication circuit pressure switch (9 bar).
5 Rear power take off clutch proportional solenoid valve. 11 Blocked filter indicator (differential pressure: 2,4 bar).
6 Rear power take off brake control solenoid valve. 12 Engine speed sensor.

G3.40 Ares 806 – 09.2004 – GB


Full Powershift

Features/settings
Shuttle reverser lever characteristics
(See page G3.6)

Range +/- and manouevring gear control

+ APC

63 B2

220c + 220a 220b

– + –

B1 B3 A1 A3

J2.26 J2.27 J2.22


184

583hsm49 Fig. 33

Parts list
63 Range +/- and manouevring gear control. 220b Range switch.
184 Electronic control unit. 220c Manouevring gear switch.
220a Range switch.

Ares 806 – 09.2004 – GB G3.41


Full Powershift

Clutch pedal switches

55a

2 + APC
3
J2.19

55b

2
+ APC
3
J2.7
1
188.B1

187
1 A

3 C

2 B

55a

55b

3
1

187
1 A

3 C

2 B

583hsm56 Fig. 34

Parts list
55a TOC switch. 187 Angle detector.
55b BOC switch. Pins "A" and "B" = 12 V supply.
Pin "C" = output voltage (4,5 V: 0,5 V).

Switch Position J2.19 188.B1 J2.7

Clutch engaged 12 V — —
55a
Clutch released 0V — —
Clutch engaged — 12 V 0V
55b
Clutch released — 0V 12 V

G3.42 Ares 806 – 09.2004 – GB


Full Powershift

Solenoid valves and sensors

4 3 2 1 6 7

5 8 9
583hsm50 Fig. 35

Current Solenoid valve Solenoid valve


Clutches Solenoid valves Maximum
Gears selected measured per resistance tightening
engaged excited current
solenoid valve* (power off) torque

F1 1-A-L 4-6-5
F2 2-A-L 7-6-5
F3 1-B-L 4-2-5
F4 1-A-M 4-6-9
F5 2-B-L 7-2-5
F6 2-A-M 7-6-9
F7 1-C-L 4-1-5
F8 1-B-M 4-2-9
F9 2-C-L 7-1-5
F10 2-B-M 7-2-9
F11 1-A-H 4-6-8
F12 1-C-M 4-1-9 Coil retaining nut:
F13 2-A-H 7-6-8 2,2 ± 0,6 N.m
0,66 A 0,9 A 10 Spool on the
F14 2-C-M 7-1-9 housing:
F15 1-B-H 4-2-8 17,5 ± 2,5 N.m
F16 2-B-H 7-2-8
F17 1-C-H 4-1-8
F18 2-C-H 7-1-8
R1 R-A-L 3-6-5
R2 R-B-L 3-2-5
R3 R-A-M 3-6-9
R4 R-C-L 3-1-5
R5 R-B-M 3-2-9
R6 R-A-H 3-6-8
R7 R-C-M 3-1-9
R8 R-B-H 3-2-8
* Important: Even in neutral, the solenoid valve receives a 0,10 A current.

Ares 806 – 09.2004 – GB G3.43


Full Powershift

1 12

6
2
7
3
8

10

11

583hsm51 Fig. 36

G3.44 Ares 806 – 09.2004 – GB


Full Powershift

Ref Component Type Resistance

1 Theoretical forward speed sensor.


Inductive sensor. 450 W ± 10 %
2 Rear power take off speed sensor.
Between sensor pin 1 and 2: +oo W
Between 2 and 3: +oo W
Between 1 and 3: 14,3 M ohm
3 Rear power take off shaft speed sensor. Hall-effect sensor.
N.B.: For the last two measurements,
wire "–" of the multimeter must be on
pin 3.
If pressure < 9 bar ± 1: +oo W
4 Rear axle low pressure circuit pressure switch. Normally open.
If pressure > 9 bar ± 1: 0 W
Proportional solenoid
5 Rear power take-off clutch solenoid valve.
valve.
6 Rear power take off brake control solenoid valve. 10 W
7 Front/rear differential lock control solenoid valve.
On/off solenoid valve.
8 Front axle control solenoid valve.
9 Park lock control solenoid valve. 17 W
If pressure < 1,5 bar ± 0,2: 0 W
10 Rear axle lubrication circuit pressure switch. Normally closed.
If pressure > 1,5 bar ± 0,2: +oo W
If "∆P" > 2,4 bar ± 0,3: 0 W
11 Blocked filter indicator. Normally open.
If "∆P" < 2,4 bar ± 0,3: +oo W
12 Engine speed sensor. Inductive sensor. 450 W ± 10 %

Ref Adjustment Tightening torque Power supply


1 Bring the sensor into contact with the pinion and Tighten the checknut to

2 unscrew by 1/2 to 3/4 of a turn. 1,4 daN.

3 12 V
0,7 daN.
4 —
5
6 Coil retaining nut:
0,25 daN.
7 Not adjustable. 12 V
Spool on the housing:
8 2 daN.
9
10
2 ± 0,5 daN. —
11
Bring the sensor into contact with the pinion and Tighten the checknut to
12 —
unscrew by ½ to ¾ of a turn. 1,4 daN.

Ares 806 – 09.2004 – GB G3.45


Full Powershift

2 1

3 4

583hsm52 Fig. 37

Ref Component Type Resistance Adjustment Tightening torque

1 Engine speed sensor.


Inductive sensor. 500 W ± 10 % 14 N.m
2 Clutch calibration sensor.
25°C = 2 820 W ± 5 % Not
3 Temperature sensor. — 100°C = 180 W ± 2,5 % adjustable. —
125°C = 89 W ± 3 %
4 Displacement speed sensor. Inductive sensor 500 W ± 10 % 14 N.m

Turbocharger pressure sensors


Operating range: 0,5 to 2,5 bar.
Maximum voltage delivered (signal): 5 ± 0,5 volts.
Measured current: Less than or equal to 10 mA.
A
Parts list A
A Sensor "–". B
B Signal . B
C Sensor "+". C
C

583hsm53 Fig. 38

G3.46 Ares 806 – 09.2004 – GB


Full Powershift

Steering angle calibration


Transmission calibration
Turbo sensor calibration
PTO torque adjustment
Refer to chapter "G7".

Adjustment of TOC, BOC and angle detector switches


Refer to page G3.13.

Ares 806 – 09.2004 – GB G3.47


Full Powershift

Schematic diagram of TC/RCC (190, 184)

60
+AVC
63 188 55b 55a
B3 187
AV N +APC
A B R4
+

AR R
– C
D2 D1 1 3 2 3 2

B1 B3 A1 A3 B2 A2 A4 B2 B5 B4 B1
32

+APC +APC +APC

185
J2.22 J2.2 J2.1 J1.11 J2.7 J2.19 J2.36 J1.28
J2.27 J2.24
J1.29 JX2.19
J2.26
J1.21 JX1.6
BB J1.5 JX1.2
Can H J1.15 JX2.23
DA J1.13
DK J1.20 JX2.4
190 J1.36
J1.30 JX2.13
Can L
JX2.5

204
J2.23
B1 J1.1
B2 184 203a
J1.2
A2
+ J2.29
A1
B3
+ APC
203b
J2.6 +APC
401
1
B J2.33 J2.11
J2.35 2
Capteur turbo C J2.16 J2.14 3
A J2.9 232
J1.8

J71.42 J2.5 234


TCE 15/25
J2.30
J2.20
J1.27
J1.25 J1.26 J1.16 J2.4 J2.28 J2.3 J1.34 J1.10

A 44b

+AVC +APC
B
53 B 44a 37
J

1 A

C2

+APC

583hsm54 Fig. 39

N.B.: The Park lock function is illustrated on the TC schematic diagram (190).

G3.48 Ares 806 – 09.2004 – GB


Full Powershift

Parts list
32 Starter. 187 Clutch potentiometer.
37 Tractor speed sensor. 188 Hydraulic shuttle reverser control.
42 "Eco" rear PTO switch. 190 "TC" unit.
44a RH rear PTO emergency stop. 203a LH brake pedal switch.
44b LH rear PTO emergency stop. 203b RH brake pedal switch.
53 Rear PTO clutch switch. 204 Handbrake switch.
54 Rear PTO selection contact. 232 Differential switch.
55a Clutch pedal contact (TOC). 234 4-wheel drive switch.
55b Clutch pedal contact (BOC). 401 Steering angle.
60 Starting switch. R4 Starter relay.
63 Speed +/- control, manoeuvring gear.
184 "RCC" unit.
185 Instrument panel .
JX 2.19: Gearbox engaged.
JX 1.6: Hydraulic pressure.
JX 1.2: Transmission oil filter.
JX 2.23: Theoretical speed.
JX 2.4: Buzzer.
JX 2.13: Rear PTO light.
JX 2.5: Hand brake contact.

Ares 806 – 09.2004 – GB G3.49


Full Powershift

Pin n° on connector "J1" Designation

1 Serial link RCC = PSD


2 Serial link RCC = PSD
3 Not used
4 Park Lock relay
5 Transmission oil filter blockage indicator
6 Transmission oil temperature
7 Not used
8 Differential control
9 +APC seat safety (not used)
10 Tractor speed sensor
11 +APC proportional solenoid valve
12 Not used
13 CAN-High
14 Not used
15 Tractor speed
16 Electronic unit earth
17 Not used
18 Not used
19 Not used
20 Buzzer
21 Hydraulic pressure
22 "Park Lock" indicator
23 Not used
24 Not used
25 +APC RCC
26 +APC RCC
27 RCC earth
28 Starting relay
29 Gearbox engaged
30 Rear PTO light
31 Not used
32 Not used
33 Not used
34 Tractor speed sensor
35 Not used
36 CAN-Low

G3.50 Ares 806 – 09.2004 – GB


Full Powershift

Pin n° on connector "J2" Designation

1 "Neutral position" shuttle reverser control


2 "Forward gear position" shuttle reverser control
3 Rear PTO stop
4 Rear PTO clutch control
5 “TCE” High position
6 RH brake pedal switch
7 Declutching information (BOC)
8 Not used
9 “–” Turbocharger sensor
10 Not used
11 “–” Steering angle sensor
12 Not used
13 Not used
14 “+” Steering angle sensor
15 Not used
16 “+” Turbocharger sensor
17 Not used
18 Not used
19 Clutched position (TOC)
20 4-wheel drive switch
21 Functional fault (information to ECU "DE10")
22 Speed "–" control
23 Handbrake
24 "Reverse gear position" shuttle reverser control
25 Park Lock switch
26 Manoeuvring gear switch
27 Speed "+" control
28 Rear PTO brake solenoid valve switch
29 LH brake pedal switch
30 RCC earth
31 Not used
32 Not used
33 Turbocharger sensor signal
34 Not used
35 Steering angle signal
36 Clutch pedal angle detector signal

Ares 806 – 09.2004 – GB G3.51


Full Powershift

Parts list
1 Clutch solenoid valve "1". 133 Tractor forward speed sensor.
2 Clutch solenoid valve "2". 184 "RCC" unit.
29 Rear PTO shaft sensor. 185 Instrument panel .
37 Engine speed sensor. JX 2.22: PTO speed.
39 Rear PTO sensor. 190 "TC" unit.
47 Crawler speed contact. 194 Park lock solenoid valve.
68 Park Lock switch. 195 Park Lock switch.
101 4-wheel drive solenoid valve. 199 Rear axle lubrication pressure switch.
102 Differential lock solenoid valve. A Clutch solenoid valve "A".
103 Rear PTO clutch solenoid valve. B Clutch solenoid valve "B".
104 Rear PTO brake solenoid valve. C Clutch solenoid valve "C".
114 Transmission oil temperature sensor. H Clutch solenoid valve "H".
115 Rear axle oil pressure switch. L Clutch solenoid valve "L".
127 Hydraulic filter blockage pressure switch. M Clutch solenoid valve "M".
128 Gearbox pressure sensor. R Clutch solenoid valve "R".
130 Diodes. R3 Park Lock relay.
132 Intermediate speed sensor. V1 "Park Lock" indicator.

G3.52 Ares 806 – 09.2004 – GB


583hsm55
68

+APC
A C R 2 1 M L H 101 B 104 102 103 194 J2.25
J1.11 J1.22 V1

J1.13
184 R3
J1.4
J1.36 +AVC
14 16a J1.6
N G

2 22 1 21 10 29 9 28 8 24 7 27 6 26 5 25 4 3 23 13 20 18 30 17
BE N BL N VI N V N S N M N RO N R N J B N B N BL N V
16b G

Can L
Can H
130

16 G
47

35 J
34 M 114
36 Ro

10 9 8 7 6 33 35 32b 36

K
J
K
G

F
F

H
G
J
195
1 5

A
E
A

B
D
B
C
D
E

C
31
2 34 18
A D
38
20 37
13 A 44
F E 14 K
17 43
G D 45 B J
4 B R01
H C 190 C H
AC11 16 E 42a
J B D G
M13 41
K A PS1 39 E F
M12 40 185
JX2.22

Ares 806 – 09.2004 – GB


24 23 22 F
C

C
B

D
A

E
21
25

G
H
J

F
Full Powershift

26 27 28 29 30
+ APC

39 M +APC

39a M 44 37 38
40 41 AC12 42 R01 43
B BE Ro
R 39b J G RV N BL

R03 R05 R02 R04


N N N N

132 39 37 133 29 127 199 115 128

G3.53
Fig. 40
Full Powershift

Pin n° on connector "A" Designation

A Clutch solenoid valve "C".


B Clutch solenoid valve "A".
C Clutch solenoid valve "B".
D Differential lock solenoid valve "102".
E Clutch solenoid valve "H".
F Clutch solenoid valve "I".
G Clutch solenoid valve "M".
H Clutch solenoid valve "1".
J Clutch solenoid valve "2".
K Clutch solenoid valve "R".

Pin n° on connector "B" Designation

A Earth .
B + APC Solenoid valve supply.
C Diode.
D PTO clutch solenoid valve "103".
E PTO brake solenoid valve "104".
F PTO brake solenoid valve "104".
G PTO clutch solenoid valve "103".
H Front axle solenoid valve "101".
J + APC.
K Earth .

Pin n° on connector "C" Designation

A Clutch solenoid valve "C".


B Clutch solenoid valve "A".
C Clutch solenoid valve "B".
D Clutch solenoid valve "1".
E Clutch solenoid valve "H".
F Clutch solenoid valve "L".
G Clutch solenoid valve "M".
H Clutch solenoid valve "2".
J Earth .
K Earth .

Pin n° on connector "D" Designation


A CAN-High.
B Not used.
C Not used.
D Not used.
E Not used.
F Park lock switch, "195".
G Transmission oil temperature sensor "114".
H Not used.
J Transmission oil temperature sensor "114".
K CAN-Low.

G3.54 Ares 806 – 09.2004 – GB


G4 – ENGINE MANAGEMENT

Ares 806 – 09.2004 – GB


DE 10 Pump

Location of components and sensors

582msm01 Fig. 1

G4.2 Ares 806 – 09.2004 – GB


DE 10 Pump

Parts list
1 Manifold air temperature sensor. 5 Pump control solenoid.
2 Engine coolant temperature sensor. 6 Calculator.
3 Fuel temperature sensor. 7 Accelerator pedal angle detector.
4 Crankshaft position sensor.

Ares 806 – 09.2004 – GB G4.3


DE 10 Pump

Characteristics of the components


Manifold air temperature sensor
Tightness torque = 10 N.m.
CTN type sensor (the resistance reduces in proportion to the increase in temperature).
Role: Informs the air temperature calculator so as to have the correct quantity of fuel in normal mode and at the end of cold
starting up.

Measurement of the voltage of probe f (t°) on Win Métadiag©

Temperature (in °C) V ± 0,4 %

– 20 4,914
– 10 4,850
0 4,748
10 4,595 UCE
20 4,378
30 4,089
40 3,730 5V
50 3,313
60 2,867
70 2,422
80 2,004
90 1,632
100 1,315
110 1,053
582msm02 Fig. 2
120 0,841

˚t B B
A A

D1 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm03 Fig. 3

Parts list
D1 Temperature input. 1 Engine control unit.
D3 Sensor earth. 2 Manifold air temperature sensor.

G4.4 Ares 806 – 09.2004 – GB


DE 10 Pump

Engine coolant temperature sensor


Tightness torque = 10 N.m.
CTN type sensor.
Role: Informs the calculator of the amount of fuel to supply for starting up.
Determines the idling speed.
Engine protection.

Measurement of sensor resistance f (t°)

16°C : 4,2 kΩ ± 10%


60°C : 134 Ω ± 10%
90°C : 51,2 Ω ± 10%
100°C : 38,5 Ω ± 10%

˚t B B
A A

B1 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm04 Fig. 4

Parts list
B1 Temperature input. 1 Engine control unit.
D3 Sensor earth. 2 Engine coolant temperature sensor.

Ares 806 – 09.2004 – GB G4.5


DE 10 Pump

Fuel temperature sensor


Tightness torque = 13 to 18 N.m.
CTN type sensor.
Role: Informs the calculator of the correct quantity of fuel to supply.
Measurement of the voltage of probe f (t°) on Win Métadiag©.
Same characteristics as the air collector temperature probe.

˚t B B
A A

C3 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm05 Fig. 5

Parts list
C3 Temperature input. 1 Engine control unit.
D3 Sensor earth. 2 Fuel temperature sensor.

G4.6 Ares 806 – 09.2004 – GB


DE 10 Pump

Crankshaft position sensor


Tightness torque = 14 N.m.
Inductive sensor.
Role: Informs the calculator of the engine speed.
Resistance measurement.
Resistance: 3 kΩ ± 10%

B B
A A

B2 D2

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm06 Fig. 6

Parts list
B2 Crankshaft position input. 1 Engine control unit.
D2 Sensor return. 2 Crankshaft position sensor.

The shim wheel is composed of 46 teeth uniformly spaced and of 2 missing teeth which determine the high neutral position.

Ares 806 – 09.2004 – GB G4.7


DE 10 Pump

Pump control solenoid


Role: Depending on whether the calculator controls authorise or not the fuel to reach the injection pressure.
Resistance measurement.
Resistance: 0,3 = 0,4 ohm at 18°C.

A1 A2 A3

B1 B2 B3
2
C1 C2 C3
D1 D2 D3

A3 E1 E2 E3
B B
1
A A K2
F1 F2 F3

G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3

582msm07 Fig. 7

Parts list
A3 Solenoid valve return. 1 Engine control unit.
K2 Solenoid valve feed. 2 Pump control solenoid.

The shim wheel is composed of 46 teeth uniformly spaced and of 2 missing teeth which determine the high neutral position.

Calculator
Role: The calculator notes the different information necessary to manage the quantity and moment of fuel to inject.
The calculator controls the preheating from – 5 °C.

Fuel temperature Preheating time Indicator light time

– 5 to – 15 °C 15 seconds
– 15 to – 25 °C 20 seconds 30 seconds
– 30 °C 20 seconds

G4.8 Ares 806 – 09.2004 – GB


DE 10 Pump

It checks the diagnostic system and informs Win Métadiag© of the various fault codes (see Diagnostic Win Métadiag©).
It acts on the engine by applying the following conditions:

Idling speed control


If fuel temperature < 15°C:
Engine speed = 1 050 rpm.
– 15°C < Fuel temperature < 40°C:
850 850 rpm < Engine speed < 1 050 rpm.
Fuel temperature > 40°C:
Engine speed = 850 rpm.
Fuel temperature sensor fault:
Engine speed = 1 050 rpm for 3 min.

Fuel temperature
If fuel temperature < 40°C:
Power increased by 2% per 10°C less.
40°C < Fuel temperature < 60°C no action on power.
Fuel temperature > 60°C.
Power decreased by 2% per 10°C more.

Coolant temperature
When this is:
– 113°C reduction in power of 40% per minute up to 60% of its maximum power.
– 118°C reduction in power of 60% per minute up to 40% of its maximum power.

A1 A2 A3
B1 B2 B3
C1 C2 C3 1
D1 D2 D3
E1 E2 E3

F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3

582msm08 Fig. 8

Ares 806 – 09.2004 – GB G4.9


DE 10 Pump

Schematic diagram (QUADRISHIFT transmission)

12 V

12 V

197
A

B 406 B 201 B 405 25


t t t A
139
A A A B 3 1 2
B
C A B

C3 B1 D3 D1 D2 B2 K2 A3 A2 K1 B3 J1.24

24 184
CAN L CAN H
K3 J1 J2 F1 G1 J1.34 J1.35

226 120 Ω

34

3/JX1
185

263
1 2

582hsm15 Fig. 9

Parts list
24 Engine ECU. 197 Accelerator pedal angle detector.
25 Pump control solenoid. 201 Coolant temperature sensor.
34 Preheating resistance. 226 Preheating spark plug relay.
139 Crankshaft position sensor. 263 Diagnostic plug.
184 DRIVETRONIC. 405 Engine air temperature sensor.
185 Instrument panel . 406 Fuel temperature sensor.

G4.10 Ares 806 – 09.2004 – GB


DE 10 Pump

Schematic diagram (Full Powershift)

12 V

12 V

197
A

B 406 B 201 B 405 25


t t t A
139
A A A B 3 1 2
B
C A B

C3 B1 D3 D1 D2 B2 K2 A3 A2 K1 B3

24
CAN L CAN H
K3 J1 J2 F1 G1

226 120 Ω

34

3/JX1
185

263*
1 2

582hsm16 Fig. 10

Parts list
24 Engine ECU. 201 Coolant temperature sensor.
25 Pump control solenoid. 226 Preheating spark plug relay.
34 Preheating sparking plugs. 263*Diagnostic socket specific to DE 10.
139 Crankshaft position sensor. 405 Engine air temperature sensor.
185 Instrument panel . 406 Fuel temperature sensor.
197 Accelerator pedal angle detector.

Ares 806 – 09.2004 – GB G4.11


DE 10 Pump

Adjusting the accelerator detector


Hall effect detector.
Output voltage measurement: Master switch on.
Using the wiring n° 60 05 005 577 measure the voltage of the "cursor".

V
2

0,5 V < U < 0,9 V 0,85 V

3,1 V < U < 4,5 V 3,47 V

APC

60 05 005 577

2
B B B B
184 J1.24
3
C C C C
24 B3
1 A A
A A

582hsm17 Fig. 11

Parts list
1 Accelerator detector. 3 Transmission (184) or engine (24) control unit.
2 Values measured on a tractor.

Diagnostic harness
If the engine cannot be started, the engine control unit can at 1 050 rpm. With this test, mechanical problems can be
be powered directly with the aid of the diagnostic harness separated from electrical problems and the tractor can be
(Fig. 12). This locally manufactured wiring is connected to moved if necessary. To produce this harness, the
the crankshaft position sensor, the pump control solenoid, connectors and clips are available from the spare parts
the battery "+" and "–" terminals and the engine control store (see parts list). Wire with a section of 1 mm² must be
unit. If the various connected components are good, the used.
engine will start and run at 1 100 rpm and then settle

G4.12 Ares 806 – 09.2004 – GB


DE 10 Pump

K1 1
A2 B2 D2 J2 K2 2
3
A3

A2 K1 J2 A3 K2 B2 D2
5
50 cm

ABCDEFGHJK
100 cm

B A

A B

3
250 cm

+ –

582hsm18 Fig. 12

Parts list
1 Engine control unit connector ref. n° 77 00 063 507. 3 Crankshaft position sensor connector ref. n° 77 00 067 744.
Clips ref. n° 77 00 063 509 (quantity: 7). Clips ref. n° 77 00 067 745 (quantity: 2).
2 Pump control solenoid ref. n° 77 00 065 917. 4 Battery.
Clips ref. n° 77 00 065 919 (quantity: 2). 5 Grid markers on connector (1).

N.B.: Connector (1) is shown from a rear view.

Ares 806 – 09.2004 – GB G4.13


VP 44 Pump

Location of components and sensors

1
2

6
5
4
3

582hsm19 Fig. 13

Parts list
1 Manifold air temperature sensor. 5 Engine control unit (pump).
2 Electric transfer pump. 6 Coolant temperature sensor (thermostat housing).
3 Pump position sensor. 7 Accelerator pedal angle detector.
4 Crankshaft position sensor.

G4.14 Ares 806 – 09.2004 – GB


VP 44 Pump

Characteristics of the components


Manifold air temperature sensor
Tightening torque = 1,5 daN.m.
CTN type sensor (the resistance reduces in proportion to the increase in temperature).
Resistance at 16°C: 4,2 kΩ.
Role: Informs the ECU of the air temperature in order to have the correct quantity of fuel to be supplied.

2
˚t B B
A A

50 24

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm01 Fig. 14

Parts list
1 Engine control unit connector. 24 Manifold air temperature earth.
2 Manifold air temperature sensor. 50 Manifold air temperature input.

Ares 806 – 09.2004 – GB G4.15


VP 44 Pump

Coolant temperature sensor


Tightening torque = 1,5 daN.m.
CTN type sensor.
Resistance at 16°C: 4,2 kΩ
Role: Informs the ECU of the coolant temperature in order to modulate the quantity of fuel injected. Determines the idling
speed.

˚t B B
A A

6 24

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm20 Fig. 15

Parts list
1 Engine control unit connector. 6 Engine coolant temperature input.
2 Engine coolant temperature sensor. 24 Engine coolant temperature earth.

G4.16 Ares 806 – 09.2004 – GB


VP 44 Pump

Pump position sensor


Tightening torque = 1,4 daN.m.
Inductive type of sensor.
Resistance: 3 kΩ.
Frequency at 1 000 rpm = 280 Hz.
Role: Informs the ECU of the engine speed and the dead centre of each cylinder in order to supply the quantity of fuel to
be injected at the appropriate time.

B B
A A

10 36

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm21 Fig. 16

Parts list
1 Engine control unit connector. 10 Pump position input signal.
2 Pump position sensor. 36 Pump position return.

The pinion of the injection pump consists of 12 evenly spaced slots and an additional offset notch indicating the approach
of the top dead centre of cylinder n° 1 to the engine control unit.

Ares 806 – 09.2004 – GB G4.17


VP 44 Pump

Crankshaft position sensor


Tightening torque = 1,4 daN.m.
Inductive type of sensor.
Resistance: 3 kΩ.
Frequency at 1 000 rpm = approx. 800 Hz.
Role: Informs the ECU of the engine speed and exact position of the piston in relation to the injection order.

B B
A A

9 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm07 Fig. 17

Parts list
1 Engine control unit connector. 9 Crankshaft position input signal.
2 Crankshaft position sensor. 34 Crankshaft position return.

The crankshaft timing wheel is composed of 48 evenly spaced teeth and 2 missing teeth. These spaces enable the engine
control unit to determine the top dead centre.

G4.18 Ares 806 – 09.2004 – GB


VP 44 Pump

Fuel transfer pump


Resistance: 0,9 Ω.
Role: To maintain constant fuel pressure and bleed the air in the circuit.

B B
A A

22 67

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm22 Fig. 18

Parts list
1 Engine control unit connector. 22 Transfer pump supply.
2 Fuel transfer pump. 67 Transfer pump supply.

Each time the ignition is switched on, the engine ECU powers the diesel pump for 40 seconds. If the engine fails to start
within this period, the electrical supply to the pump is cut out.

Ares 806 – 09.2004 – GB G4.19


VP 44 Pump

ECUs
Preheating
When the diesel temperature is lower than 0°C, the engine ECU powers the preheating relay and corresponding indicator.
Preheating is interrupted when the engine is started. The preheating relay is not activated if the battery voltage is lower
than 6 V.

Fuel temperature Preheating time Indicator light time

– 5 to – 15 °C 15 seconds
– 15 to – 25 °C 20 seconds 30 seconds
– 30 °C 20 seconds

Idling speed control


If fuel temperature < 15°C:
Engine speed = 1 050 rpm.
– 15 °C < Fuel temperature < 40°C:
850 850 rpm < Engine speed < 1 050 rpm.
Fuel temperature > 40°C:
Engine speed = 850 rpm.
Fuel temperature sensor fault (located inside the injection pump):
Engine speed = 1 080 rpm for 3 min then drops gradually to 850 rpm.

Power correction according to fuel temperature


The normal working temperature is 40 to 60°C. Outside this range, the power is modified by approximately 2% per 10°C
variation; power is reduced for a temperature over 60°C and vice-versa for a temperature below 40°C.

Power reduction
See chapter "G7" to identify the various fault codes read on Win Métadiag©. .
Manifold air temperature > 100°C:
Power reduced by 2% per minute up to 80% of its maximum power.
Coolant temperature > 118°C:
Power reduced by 60% per minute up to 40% of its maximum power.
Coolant temperature > 108°C:
Power reduced by 2% per minute up to 95% of its maximum power.
Coolant temperature > 113°C:
Power reduced by 40% per minute up to 60% of its maximum power.
Fuel temperature > 73°C:
Power reduced by 75% per minute up to 25% of its maximum power.

G4.20 Ares 806 – 09.2004 – GB


VP 44 Pump

Crankshaft position sensor


Power reduced by 20% per minute up to 50% of its maximum power.

Protection requested by the injection pump ECU


High fuel temperature, high pressure solenoid valve constantly excited or jammed, faulty internal speed sensor:
Power reduced by 20% per minute up to 50% of its maximum power.

Schematic diagram

12 V

12 V

J214.7
241
405 201 407 139 137
J214.5
J214.8 410
B B CAN L
J214.1
A A
CAN H J214.4
J214.2 J214.6
A A B B CAN - J214.3

197

50 24 6 36 10 34 9 67 19 23 62 35 18 17 59 58 60
22 68

24 184
CAN L CAN H 3 1 2
63 66 1 21 44 42 J1.34 J1.35 J1.24
C A B
226 120 Ω

34

3/JX1
185

263
1 2 3

582hsm23 Fig. 19

Parts list
24 Engine ECU. 201 Engine water temperature thermistor.
34 Preheating resistance. 226 Preheating relay.
137 Diesel electric pump. 241 Safety relay.
139 Crankshaft position sensor. 263 Diagnostic plug.
184 DRIVETRONIC. 407 Pump position sensor.
185 Instrument panel . 410 Engine ECU (pump).
197 Accelerator pedal angle detector.

Ares 806 – 09.2004 – GB G4.21


VP 44 Pump

Details of injection pump

3 4
B
A

A B

410

J214.8
J214.7

J214.5

J214.1

J214.2

J214.3
J214.4
J214.6
CAN L

CAN H

5 CAN –

241

+ 12 V

62 35 18 17 59 58 60

24

582hsm24 Fig. 20

Parts list
1 Fuel temperature sensor. 5 Injection pump.
2 Injection pump speed sensor. 24 Engine ECU.
3 High-pressure solenoid valve. 241 Safety relay.
4 Advance solenoid valve. 410 Engine ECU (pump).

G4.22 Ares 806 – 09.2004 – GB


VP 44 Pump

Allocate pins on engine and injection pump ECU connectors

Pin n° on connector 24 Designation

1 Earth
2 to 5 Not used
6 Coolant temperature sensor
6 to 8 Not used
9 Engine speed sensor
10 Pump speed sensor
11 to 16 Not used.
17 Pump ECU engine speed output
18 Fuel cut-out to pump ECU
19 +APC
20 Not used
21 CAN CAN-Low
22 Feed pump supply
23 +AVC (constant source)
24 Sensors return
25 to 30 Not used
31 Accelerator sensor signal
32 to 33 Not used
34 Engine speed sensor
35 Injection pump supply
36 Pump speed sensor
37 to 41 Not used
42 CAN Shielding CAN
43 Not used
44 to 49 Not used
50 Air temperature sensor
51 to 57 Not used
58 CAN CAN-High (injection bus)
59 CAN CAN-Low (injection bus)
60 CAN Shielding CAN (injection bus)
61 Not used
62 Safety relay control
63 Preheating relay control
64 to 65 Not used
66 Preheating indicator control
67 Feed pump supply
68 +AVC (constant source)

Ares 806 – 09.2004 – GB G4.23


VP 44 Pump

Pin n° on connector 410 Designation

1 CAN-Low bus
2 CAN-High bus
3 Shielding
4 Earth
5 Fuel feed cut-out
6 Earth
7 Injection pump supply
8 Engine speed output

G4.24 Ares 806 – 09.2004 – GB


VP 44 Pump

Adjusting the accelerator detector


Hall effect detector.
Output voltage measurement: Master switch on.
Using the wiring n° 60 05 005 577 measure the voltage of the "cursor".

V
3

0,5 V < U < 0,9 V 0,85 V

3,1 V < U < 4,5 V 3,47 V

APC

25 26 27 28 29 30 31 32 33 34 35 36
13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12
60 05 005577

8
7
2
B B B B
J1.24

6
3
C C C C

5
1 A A
A A

2 4
3
2
1

582msm10 Fig. 21

Parts list
1 Engine control unit. 3 Values measured on a tractor.
2 Accelerator detector.

Ares 806 – 09.2004 – GB G4.25


VP 44 Pump

Diagnostic harness
If the engine cannot be started, the injection pump control at 750 rpm. With this test, mechanical problems can be
unit can be powered directly with the aid of the separated from electrical problems and the tractor can be
diagnostic harness (Fig. 22). This locally manufactured moved if necessary. To produce this harness, the
wiring is connected to the injection pump and the connector and clips are available from the spare parts
battery "+" and "-" terminals. If the various connected store (see parts list). Wire with a section of 1 mm² must be
components are good, the engine will start and run used.

G4.26 Ares 806 – 09.2004 – GB


VP 44 Pump

4 6

7 4 6
250 cm

+ –

582hsm25 Fig. 22

Parts list
1 Injection pump control unit connector ref. n° 77 00 064 574. 2 Battery.
Clips ref. n° 77 00 064 684 (quantity: 3).

N.B.: Connector (1) is shown from a rear view.

Ares 806 – 09.2004 – GB G4.27


Notes

G4.28 Ares 806 – 09.2004 – GB


G5 – INFOTRAC AND ISO SOCKET

Ares 806 – 09.2004 – GB


Description

Functions of the on-board computer


It provides the user with information on the following – Area worked.
functions: – Time worked.
– Events counter. – Area worked per hour.
– Distance travelled. – Outside temperature.

Operating principles

6
2

581hsn01 Fig. 1

G5.2 Ares 806 – 09.2004 – GB


Description

Designation of symbols

Partial event counter


1. Digital display unit
Permanent event counter

Partial travelled distance


2. Total counter symbol
Total travelled distance

Partial worked surface


3. Partial counter symbol
Total worked surface

Partial worked time


4. Selected function index
Total worked time

5. Symbols of the various functions (see opposite) Instantaneous surface worked per hour

6. Calibration mode selection index Outside temperature

Work width programming

Ares 806 – 09.2004 – GB G5.3


Description

Button (A)

Counter resetting.
Key "–" programming implement width.

Button (B)

Counter "on/off" key.


"+" button for implement width programming.
A B C

Fig. 2
Button (C) 581hsn02

Display mode selection and function scroll


key: Total or partial.

Location of the connections to the event


counter tools
Event counter connector
This connector (1) is located beside the right console,
close to plug 25 A.

Use
Refer to the user manual. 601hsn52 Fig. 3

G5.4 Ares 806 – 09.2004 – GB


Description

Summary of functions and measurement ranges

Events Distance Area worked Outside Implement


Area worked Hour counter
counter travelled per hour temperature width

0,1 hour and 1


Unit No unit m and km Hectare Hectare/hour °C Metre
hour
0 to 999 m
Measurement 0 to 99,9
0 to 9999 1 to 99,9 km 0 to 99,9 0 to 50 – 40 to + 60 0 to 99,9
range 100 to 999
100 to 999 km
Stop
— — Lift condition* — — — —
conditions
* Function valid for TCE 15 and 25 lifts.

Ares 806 – 09.2004 – GB G5.5


Removal/refitting and electrical checks

A C
C

A D

581hsm00 Fig. 4 581hsm01 Fig. 5

Removing the unit and changing


the bulbs
A
Right side
Two screws (A).

Left side
Two screws (A).
Two clips (B).
B
Removing the bulbs
– Remove the unit by pressing the clips (C).
– Remove the bulbs (D).

581hsm02 Fig. 6

G5.6 Ares 806 – 09.2004 – GB


Removal/refitting and electrical checks

ISO socket
Two screws retain the plug socket.

ISO unit
N.B.: This unit requires no programming or parameter
setting. Its purpose is to make the signals received for
an implement usable.
Change the unit in the event of a fault.
The ISO unit is located on the rear panel. It is held
by 2 screws.

External temperature probe


581hsm03 Fig. 7
It is located under the roof in a line with the left-hand
centre pillar of the cab.

Ares 806 – 09.2004 – GB G5.7


Removal/refitting and electrical checks

581hsm04 Fig. 8

Parts list
1 Temperature sensor. 3 ISO unit.
2 Unit fasteners.

G5.8 Ares 806 – 09.2004 – GB


Removal/refitting and electrical checks

Schematic diagram

1 T˚
A B 2

12

JX2 22 24 J148 6 1 7 8 11 10 2 5

+ APC
J71
11 42
4
R10

J186
10 6

J1
B+ W D+
9 15

J1
10
+ –

8 J2
18

19

6
J207 J207
6 10
5
4 3
5 3
7 5 NO 2 8 4

6 1 7 9

11 2

12 1 + APC

581hsm05 Fig. 9

Parts list
1 On board computer. 7 ISO socket (front view).
2 External temperature probe. 8 Drivetronic unit.
3 Events counter. 9 "RCC" unit.
4 Relay "R10" on fuse plate. 10 TCE 15 lift unit.
5 Alternator. 11 TCE 15/25 lift unit.
6 ISO unit. 12 Instrument panel .

Ares 806 – 09.2004 – GB G5.9


Removal/refitting and electrical checks

Functions of connector wires


14-pin connector – On board computer (J148)

Pin n° Wire marking Function Nature of the signal

1 VI Theoretical speed
2 BL Events counter
3 Not used
4 Not used
5 BR Outside air temperature probe
6 GN TCE lift high position +
7 WH Radar speed
8 RD1 +APC +
9 Not used
10 BK4 On-board computer earth –
11 RD2 +APC +
12 Not used
13 Not used
14 Not used

12-pin connector – ISO unit (J207)

Pin n° Wire marking Function Nature of the signal

1 8011 +APC ISO unit +


2 MBO Unit earth –
3 8012 Rear power take-off speed – Input
4 8013 Theoretical speed – Input
5 8014 Rear power take-off speed – Output
6 8015 TCE lift high position – Output +
7 8016 Radar speed – Output
8 8017 Theoretical speed – Output
9 8018 Radar speed – Input
10* 8019 TCE lift high position – Input +
11 M8P ISO socket earth –
12 8020 +APC ISO socket +
* The TCE 15/25 lift unit output voltage values are: Low position = 8 V maximum. High position = 10 V minimum.

N.B.:
• The radar signal is ignored below a theoretical speed of 1 km/h.
• If the actual speed does not exceed the theoretical speed by more than 5%, the actual speed is taken into account.
• If the actual speed exceeds the theoretical speed by more than 5%, the theoretical speed is taken into account.

G5.10 Ares 806 – 09.2004 – GB


Removal/refitting and electrical checks

Electrical check on the ISO socket

Ref Wire colour Function

1 BR ISO radar speed


2 VI ISO forward speed
3 YL ISO RR power take off speed
4 OR TCE ISO high position
5 — Not used
6 RD +APC ISO socket
N0 BK ISO socket earth

Check with multimeter CA 5220


Voltage: Multimeter in voltmeter position, engine
running.
ISO socket supply
Between terminal "6" and "N0": 13,5 V. 581hsm06 Fig. 10

TCE lift high position output


Between terminal "4" and "N0": 12,5 V.
Signals: Multimeter in frequency indicator position.
To have a stable value, a 10 µF capacitor will need to be
added in series with the multimeter.

Forward speed

Radar frequency (Hz) Theoretical speed frequency (Hz)


Instrument panel speed
(Terminals 1 and N0) (Terminals 2 and N0)

5 135 55
10 278 135
15 425 165
20 540 220

Rear power take-off speed

Frequency displayed (Hz)


Instrument panel speed PTO position
(Terminals 3 and N0)

540 540 54
1 000 1 000 100

Ares 806 – 09.2004 – GB G5.11


Removal/refitting and electrical checks

Outside air temperature sensor


It is composed of a material whose electrical resistance varies with the temperature.
Measuring range – 40°C to + 70°C.
Resistance tolerance: ± 1%.

R (kΩ)

350

300

250

200

150

100

50


0
– 50 – 40 – 30 – 20 – 10 0 10 20 30 40 50 60 70
581hsm07 Fig. 11

G5.12 Ares 806 – 09.2004 – GB


Removal/refitting and electrical checks

Forward speed calibration


Refer to the user manual.

Maintenance function
The computer must enable the technician to change the speed calibration parameters without running the calibration
procedure, or to display the installed software version. The procedure to be carried out is as follows:
The user turns the unit on, by starting up the engine, at the same time holding down the function selection key for at
least 4 seconds after turning the unit on.
• While the key is depressed all the segments are lit up.
• When the function menu key is released, all the segments on the display are lit for 3 seconds, then the indication "P1"
appears for 3 seconds and the calibration parameter of the "theoretical speed" is displayed and becomes accessible.
• The calibration parameter of the theoretical speed flashes if its value is modifed by pressing the +/-keys, the parameter
is validated after a short press on the function selection key.
• A second short press on the function selection key enables you to go to the calibration parameter of the "real speed"
after the display of the identification "P2" for 3 seconds, the real speed parameter is then displayed.
• The real speed calibration parameter flashes if its value is modified by pressing the +/- keys, the parameter is validated
after a short press on the functions key.
• A third short press on the function selection key takes you to parameter "P3".
N.B.: Parameter available from units of references n° 77 000 63 688 and n° 77 000 70 600.
• Parameter "d – on" appears by pressing +/ "d – off" appears and flashes.
• "d – on" = configuration to operate with "D+" from the alternator.
• "d – off" = configuration to operate with an ignition source (+APC).
• A fourth short press on the function scroll key takes you to the "software version" display.
• If the function scroll key is held down for 4 seconds, then the onboard computer returns to the implement width function.

Ares 806 – 09.2004 – GB G5.13


Notes

G5.14 Ares 806 – 09.2004 – GB


G6 – ELECTROPILOT

Ares 806 – 09.2004 – GB


Description

Controls
Parts list
1 On/Off pulse button.
2 Warning light (see chapter "G7"). 3 2
3 Flow rate control of spool valve (8).
4 Flow rate control of spool valve (9).
5 DC power switch of spool valve (9). 1
6 Pulse buttons (see following paragraph).
7 Floating position pulse button.
8 Mechanical backup control spool valve.
4 5
9 Mechanical backup control spool valve.
10 Safety solenoid valve (enables or disables spool valve
operation).
X Control shaft of spool valve (9).
Y Control shaft of spool valve (8).

Pulse buttons (6)


391hsn05 Fig. 1
N.B.: The pulse buttons (6) are used to control the
relays that control an (on-off) solenoid selector valve
for an elevator or a gripper on a loader. The socket
connecting the relays is ready under the right console
(it is identical to the holding socket of the mechanical
cross control). This control is not processed by the X
electronics of the joystick.
Important: The relays must be fitted with a free-wheel 7 Y
diode to neutralise the high-voltage surge.

Backup control (Fig. 3)


The Electropilot system includes manual controls (8), (9)
for moving an implement in the event of electrical system
failure. Activate the control of the spool valve concerned. 6
An upward action supplies the red pressure take-off. The
yellow pressure take-off is then in return.
Adownward action supplies the yellow pressure take-off.
The red pressure take-off is then in return.
391hsn06 Fig. 2
Important: The use of the manual controls should be
exceptional when the joystick is non-operational.
This actuation must be carried out inside the cab,
making sure there is nobody near the implement.
10

9 8

391hsm69 Fig. 3

G6.2 Ares 806 – 09.2004 – GB


Description

Joystick connections (Fig. 4)


1 Potentiometer "X" (axis "X")
2 Potentiometer "Y" (axis "Y")
3 "+" ignition source for joystick
4 Not used
5 Safety solenoid valve (on)
6 CAN-High
7 Hydraulic motor control (on)
8 Joystick on / off control
9 LED output on / off
10 CAN-Low
11 Lift external control
12 Lower external control
13 Joystick earth
14 Relay output 1 391hsm70 Fig. 4
15 Relay output 2
16 Hydraulic motor control (off)
5 4 3 2 1

DC power switch connections (Fig. 5)


1 Yellow wire (switch terminal 2)
2 Green wire (switch terminal 6)
3 Blue wire (switch terminal 8)
4 Yellow/red wire (switch terminal 9)
5 White wire (switch terminal 10)
6 Module 20-pin connector

391hsm71 Fig. 5

Ares 806 – 09.2004 – GB G6.3


Description

Connections on module
"+" ignition source for electrohydraulic spool valve
1
control module
2 "+" ignition source for cross-control 4 3 2 1
3 "+" ignition source for joystick
8 7 6 5
4 Not used
5 Joystick on / off control 10 9
12 11
6 Diode on/off output
7 Hydraulic motor control (on) 16 15 14 13
8 Hydraulic motor control (off)
9 Potentiometer "X" 20 19 18 17

10 Potentiometer "Y"
11 Safety solenoid valve (on)
12 Safety solenoid valve (off)
13 Lift external control
391hsm72 Fig. 6
14 Lift external control return
15 Lower external control return
16 Lower external control
17 Electrohydraulic spool valve control module earth
18 Cross control earth
19 Joystick earth
20 Not used

G6.4 Ares 806 – 09.2004 – GB


Description

Electrohydraulic spool valve ("DEH")

10 11

14
1
9

8 7 6 4 3
391hsm73 Fig. 7

Parts list
1 Electrohydraulic spool valve ("DEH"). 8 Spool displacement sensor. 14 Connector ("1" "+" ignition source, "2"
2 Spool. 9 Control electronic system. CAN-Low, "3" CAN-High, "4" earth).
3 Pressure balance. 10 System fault display. LS Signal .
4 Check valve. 11 Control valve. P Power supply .
5 Safety solenoid valve. 12 Control return. Pil Control.
6 Neutral return spring. 13 Control valve supply. R Return .
7 Spool control piston.

10 11

5 12

14
13

1
2 2
3 4

8 7 6

391hsm74 Fig. 8 391hsm75 Fig. 9

Ares 806 – 09.2004 – GB G6.5


Removal/refitting

Electrohydraulic spool valve ("DEH")


To remove/refit the spool valves, consult the procedure
described in chapter "E1".
Important: One electrohydraulic spool valve (1) is 3
equipped with ball bearings (3) and must be
1
positioned between the other electrohydraulic spool
valve (2) and the mechanical spool valves.

391hsm76 Fig. 10

Control handle
The metal support of the electric cross control (joystick) of Important: Imperatively fit the screws recommended
the distributors is secured on the plastic part of the arm by CLAAS.
rest by four screws.

0,35 daN.m

0,35 daN.m

0,55 daN.m
0,35 daN.m

391hsm77 Fig. 11

G6.6 Ares 806 – 09.2004 – GB


Measurement and checking points

Should the safety warning light flash on the module, consult chapter "G7".

Checking the safety solenoid valve


– If the two electrohydraulic spool valves fail to work, it is – When the control is activated, the voltage must
possible that the fault originates from the safety be 12 V.
solenoid valve. This cuts out the control pressure in – With the power off, connect cable n° 60 05 005 734
case of failure. only to the solenoid valve and to a multimeter
– With power on, connect test harness n° 60 05 005 734 (ohmmeter function).
between the solenoid valve and the power supply – The resistance should be 5,3 ohms.
harness. Connect multimeter n° 60 05 006 744 – If the voltage and resistance values are correct,
(voltmeter function). remove the solenoid valve and check the hydraulic
– When the control is in neutral, the voltage must be 0 V. components of the valve (Fig. 13).


60 05 005 734

390hsm50 Fig. 12

Ares 806 – 09.2004 – GB G6.7


Measurement and checking points
Test conditions:
– Engine at nominal speed.
– Oil temperature at 60°C.

Checking the control pressures


– Connect pressure gauge n° 60 05 705 076 with – Activate the control, the pressure must
a 12 x 150 coupling in place of the plug (5). be 22,5 ± 1,5 bar.

4
1 2

T LS P X Tx

5
3

4
2

391hsm78 Fig. 13

G6.8 Ares 806 – 09.2004 – GB


"Inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:

Tractor type.............................................................................................................................................................................
The serial number...................................................................................................................................................................
Total operating hours..............................................................................................................................................................
Date of operation ....................................................................................................................................................................

Checking the safety solenoid valve

Test conditions with power on Voltage (volt) Measured value

Control in neutral 0
Control activated 12

Test condition with power off Resistance (Ohm) Measured value

Coil 5,3

Checking the control pressure

Test conditions
Oil temperature at 60°C Pressure (bar) Measured value
Engine at nominal speed

Control activated 22,5 ± 1,5

Ares 806 – 09.2004 – GB G6.9


Notes

G6.10 Ares 806 – 09.2004 – GB


TOOLS

Instrument panel – TCE 15/25 and TCE 15 T electronic lift –


Transmission/axle control – Engine management – Infotrac and
ISO socket – Electropilot

Ares 806 – 09.2004 – GB


Instrument panel – TCE 15/25 and TCE 15 T electronic lift – Transmission/axle control –
Engine management – Infotrac and ISO socket – Electropilot

60 05 005 577 60 05 005 734

Test harness Test harness

60 05 006 703 60 05 006 707

Crimping pliers Clamp-on ammeter (AC and DC) 0 to 2 A - 0 to 200 A

60 05 006 744 60 05 014 522

Multimeter 15 pin (red, white)

G6.12 Ares 806 – 09.2004 – GB


Instrument panel – TCE 15/25 and TCE 15 T electronic lift – Transmission/axle control –
Engine management – Infotrac and ISO socket – Electropilot

60 05 014 523 60 05 014 524

A A

15 pin (blue, white) 15 pin (blue, black)

60 05 705 076 77 00 034 484

Pressure gauge kit Plug extractor "JX1" (15 pin)

77 00 034 485

Plug extractor "JX2" (2 x 15 pin)

Ares 806 – 09.2004 – GB G6.13


Notes

G6.14 Ares 806 – 09.2004 – GB


G7 WIN METADIAG© MANUAL
ARES 806

Chapter G7

Ares 806 60 05 030 557 – 09.2004 publication


CONTENTS

G7 – WIN METADIAG© ARES 806 MANUAL

CONNECTING WIN METADIAG©


ENGINE APPLICATION ................................................................................................................................................. G7.2
TRANSMISSION, REAR AXLE AND ELECTROPILOT APPLICATIONS ...................................................................... G7.2
TCE 15T APPLICATION – INSTRUMENT PANEL ....................................................................................................... G7.2
TCE 15/25 APPLICATION.............................................................................................................................................. G7.3

ENGINE APPLICATION
WIN METADIAG© ENGINE APPLICATION ................................................................................................................... G7.4
SPN AND FMI CODES................................................................................................................................................... G7.5
ENGINE WITH PUMP DE 10 ......................................................................................................................................... G7.6
ENGINE WITH PUMP VP 44........................................................................................................................................ G7.40

TRANSMISSION APPLICATION
TRANSMISSION APPLICATION................................................................................................................................ G7.104
DRIVETRONIC ........................................................................................................................................................... G7.104
FULL POWERSHIFT .................................................................................................................................................. G7.118
RCC AND TC FAULT HISTORY ................................................................................................................................ G7.124

REAR AXLE APPLICATION


GPA 41/42/43 ............................................................................................................................................................. G7.134

REAR LIFT APPLICATION


TCE 15/25................................................................................................................................................................... G7.137
TCE 15 T .................................................................................................................................................................... G7.141

DASHBOARD APPLICATION
DASHBOARD APPLICATION .................................................................................................................................... G7.144

ELECTROPILOT APPLICATION
ELECTROPILOT APPLICATION................................................................................................................................ G7.147

Ares 806 – 09.2004 – GB


G7
WIN MÉTADIAG© MANUAL
ARES 806

Ares 806 – 09.2004 – GB


Connecting Win Métadiag©

Engine application (Fig. 1)


Remove the blank under the steering wheel and connect
as shown.

Transmission, rear axle and


Electropilot applications (Fig. 2) 60 05 006 748

60 05 006 760 60 05 006 747


TCE 15 T application - Instrument
panel (Fig. 3)

ARES 826 FULL

582hsm12 Fig. 1

60 05 006 748

60 05 006 760 60 05 006 747

582hsm13 Fig. 2

60 05 006 739

60 05 006 730

60 05 006 721

CERES
ARES

CERES
ARES
60 05 006 721

585hsm00 Fig. 3

G7.2 Ares 806 – 09.2004 – GB


Connecting Win Métadiag©

TCE 15, 25 application (Fig. 4)


Remove the contactor panel (front axle switch and front
and rear axle differential locking switch).

60 05 006 747

60 05 006 748

60 05 006 764

585hsm01 Fig. 4

Ares 806 – 09.2004 – GB G7.3


Engine application
Win Métadiag© engine application
- Switch on the ignition.
- Run the Win Métadiag© program and select application Ares (2).

583msm11 Fig. 5

Parts list
1 Choice of language. 3 Keyboard shortcut. 5 Version.
2 Choice of type of tractor. 4 Help. 6 Exit.

3 4 5 6 7
582msm12 Fig. 6

Parts list
1 Overview. 4 Help. 6 Return to previous mask.
2 Fault history. 5 Version. 7 Exit.
3 Keyboard shortcut.

G7.4 Ares 806 – 09.2004 – GB


Engine application
SPN and FMI codes
The SPN FMI codes are codes in 3 parts in conforrmity with the standard SAE J1939.
The first part is the suspect parameter number (SPN). It generally contains 2 to 4 figures. The SPN identifies the affected
system or component. For example: SPN 110 indicates a failure in the engine coolant temperature circuit.
The second part of the code is the failure mode identifier (FMI). The FMI contains 2 figures. The FMI identifies the type of
failure produced. For example: FMI 3 indicates a value above the standard. For the failure to be precisely identified, the
SPN and the FMI are both required. The combination of SPN 110 and FMI 3 signals a high engine coolant temperature
input voltag.
The third part is the occurrence. It is the appearance number of the code concerned.
The engine control unit (UCE) transmits the SPN/FMI codes on the CAN network. This enables Win Métadiag© to display
the active and memorised anomaly diagnostic codes. The following SPN FMI codes are classified in increasing order.

SPN : 110 FMI : 0 OC : 1

1 2 3

582msm13 Fig. 7

Parts list
1 System or component affected. 2 Type of failure. 3 Appearance number.

Ares 806 – 09.2004 – GB G7.5


Engine application
Engine with pump DE 10

586hsm60 Fig. 8

Parts list
1 Percentage of engine charge at a given 2 Signifies an error on the fuel temperature 3 Error code relating to point (2). Double-
speed. function. click it to access the corresponding
sheet.

586hsm07 Fig. 9

Parts list
1 Double-click the error code to access the sheet. 3 Deletion of passive errors.
2 Case of intermittent breakdowns for example. 4 Return to previous mask.

G7.6 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 105 FMI 3
High manifold air temperature input voltage

°t B
B
A A

D1 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm16 Fig. 10

Parts list
D1 Manifold air temperature input. 1 Engine control unit.
D3 Sensor earth. 2 Manifold air temperature sensor.

Code SPN 105 FMI 3 is declared if


– The manifold air temperature input voltage exceeds the sensor's maximum threshold. The voltage is higher than physically possible for the collector
air.
– The maximum input voltage threshold of the temperature probe is 4,9 volts.
This is what happens if the SPN 105 FMI 3 code is in force
The engine control unit uses a collector air temperature default value of 60 °C (104 °F) to turn the engine over.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit, the collector Go to 2.
air temperature sensor connection and all the connectors that
Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– The sensor earth circuit is open.
– The input circuit is open or short-circuited at 12 V.
– The air sensor is faulty.
– The engine control unit is defective.

Ares 806 – 09.2004 – GB G7.7


Engine application
Anomaly code SPN 105 FMI 4
Low manifold air temperature input voltage

°t B
B
A A

D1 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm16 Fig. 11

Parts list
D1 Manifold air temperature input. 1 Engine control unit.
D3 Sensor earth. 2 Manifold air temperature sensor.

Code SPN 105 FMI 4 is declared if


– The manifold air temperature input voltage is lower than the sensor's minimum threshold. The voltage is lower than what is physically possible for the
collector air temperature.
– The minimum input voltage threshold of the manifold air temperature probe is 0,1 V.
This is what happens if the SPN 105 FMI 4 code is in force
The engine control unit uses a collector air temperature default value of 60 °C (104 °F) to turn the engine over.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit, the collector Go to 2.
air temperature sensor connection and all the connectors that
Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– The input circuit is short-circuited at the earth.
– The air sensor is faulty.
– The control unit connector is defective.
– The engine control unit is defective.

G7.8 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 105 FMI 16
Moderately high manifold air temperature input voltage

°t B
B
A A

D1 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm16 Fig. 12

Parts list
D1 Manifold air temperature input. 1 Engine control unit.
D3 Sensor earth. 2 Manifold air temperature sensor.

Code SPN 105 FMI 16 is declared if


The engine control unit detects a manifold air temperature higher than 120°C.
This is what happens if the SPN 105 FMI 16 code is in force
The engine control unit uses a collector air temperature default value of 60 °C (104 °F) to turn the engine over.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit, the collector Go to 2.
air temperature sensor connection and all the connectors that Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– The air sensor is faulty.
– The control unit connector is defective.
– The engine control unit is defective.

Ares 806 – 09.2004 – GB G7.9


Engine application
Anomaly code SPN 110 FMI 0
Extreme coolant over-heating

°t B
B
A A

B1 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm17 Fig. 13

Parts list
B1 Engine coolant temperature input. 1 Engine control unit.
D3 Engine coolant temperature earth. 2 Engine coolant temperature sensor.

Code SPN 110 FMI 0 is declared if


The engine control unit detects a coolant temperature higher than 118°C (244 °F).
This is what happens if the SPN 110 FMI 0 code is in force
The engine protection function is activated. The engine reduces its power by 60 % a minute until it reaches 40 % of its maximal power.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit, the collector Go to 2.
air temperature sensor connection and all the connectors that Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Engine overheating (see chapter A).
– Integrity of input and earth circuits (open or short-circuited).
– The air sensor is faulty.

G7.10 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 110 FMI 3
Engine coolant temperature input voltage high

°t B
B
A A

B1 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm17 Fig. 14

Parts list
B1 Engine coolant temperature input. 1 Engine control unit.
D3 Engine coolant temperature earth. 2 Engine coolant temperature sensor.

Code SPN 110 FMI 3 is declared if


– The coolant temperature input voltage exceeds the sensor's maximum threshold. This voltage corresponds to a temperature lower than what is
physically possible for the engine coolant.
– The maximum coolant temperature input voltage threshold is 4,9 V.
This is what happens if the SPN 110 FMI 4 code is in force
– In start-up mode, the engine control unit defines the engine coolant temperature at the default value of –30°C (–22 °F).
– In running mode, the engine control unit defines the engine coolant temperature at the default value of 93°C (194 °F).

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit, the collector Go to 2.
air temperature sensor connection and all the connectors that Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

Possible causes
– The sensor connector is defective.
– The temperature sensor is faulty.
– The circuit is open at the input.
– The circuit is open at the sensor earth.
– The control unit connector is defective.
– The engine control unit is defective.

Ares 806 – 09.2004 – GB G7.11


Engine application
Anomaly code SPN 110 FMI 4
Engine coolant temperature input voltage low

°t B
B
A A

B1 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm17 Fig. 15

Parts list
B1 Engine coolant temperature input. 1 Engine control unit.
D3 Engine coolant temperature earth. 2 Engine coolant temperature sensor.

Code SPN 110 FMI 4 is declared if


– The coolant temperature input voltage falls below the sensor's minimum threshold. This voltage corresponds to a temperature higher than what is
physically possible for the engine coolant.
– The minimum coolant temperature input voltage threshold is 0,1 V.
This is what happens if the SPN 110 FMI 4 code is in force
– In start-up mode, the engine control unit defines the engine coolant temperature at the default value of –30°C (–22 °F).
– In running mode, the engine control unit defines the engine coolant temperature at the default value of 93°C (194 °F).

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit, the collector Go to 2.
air temperature sensor connection and all the connectors that
Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Short circuit at the earth at the sensor input.
– The temperature sensor is faulty.
– The control unit is faulty.

G7.12 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 110 FMI 15
Slight over-heating of the engine coolant

°t B
B
A A

B1 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm17 Fig. 16

Parts list
B1 Engine coolant temperature input. 1 Engine control unit.
D3 Engine coolant temperature earth. 2 Engine coolant temperature sensor.

Code SPN 110 FMI 15 is declared if


The engine control unit detects a coolant temperature higher than 108°C.
This is what happens if the SPN 110 FMI 15 code is in force
The engine protection function is activated. The engine reduces its power by 2 % a minute until it reaches 95 % of its maximal power.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit, the collector Go to 2.
air temperature sensor connection and all the connectors that Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Engine overheating (see chapter A).
– The temperature sensor is faulty.
– The engine control unit is defective.

Ares 806 – 09.2004 – GB G7.13


Engine application
Anomaly code SPN 110 FMI 16
Moderate over-heating of the engine coolant

°t B
B
A A

B1 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm17 Fig. 17

Parts list
B1 Engine coolant temperature input. 1 Engine control unit.
D3 Engine coolant temperature earth. 2 Engine coolant temperature sensor.

Code SPN 110 FMI 16 is declared if


The engine control unit detects a coolant temperature higher than 113°C.
This is what happens if the SPN 110 FMI 16 code is in force
The engine protection function is activated. The engine reduces its power by 40 % a minute until it reaches 60 % of its maximal power.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit, the collector Go to 2.
air temperature sensor connection and all the connectors that Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Engine overheating (see chapter A).
– The temperature sensor is faulty.
– The engine control unit is defective.

G7.14 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 158 FMI 17
Feed stop error of the engine control unit

K1 A2

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm18 Fig. 18

Parts list
A2 Positive after contact. 1 Engine control unit.
K1 More before contact. 2 Starter connector.

Code SPN 158 FMI 17 is declared if


The engine control unit detects the presence of voltage on input A2.
This is what happens if the SPN 158 FMI 17 code is in force
The vehicle battery risks being decharged if the engine control unit is still switched on.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit, the collector Go to 2.
air temperature sensor connection and all the connectors that Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– The ignition switch is faulty.
– The input circuit is open or short-circuited at 12 V.
– The switch circuit is faulty.
– The control unit connector is defective.
– The engine control unit is defective.

Ares 806 – 09.2004 – GB G7.15


Engine application
Anomaly code SPN 174 FMI 3
Fuel temperature input voltage high

˚t B B
A A

C3 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm05 Fig. 19

Parts list
C3 Fuel temperature input. 1 Engine control unit.
D3 Sensor earth. 2 Fuel temperature sensor.

Code SPN 174 FMI 3 is declared if


– The fuel temperature input voltage exceeds the sensor?s maximum threshold. This voltage corresponds to a temperature lower than what is
physically possible for the fuel.
– The maximum fuel temperature input voltage is 4,9 V.
This is what happens if the SPN 174 FMI 3 code is in force
– The engine control unit will use a default "return to workshop" value with a fuel temperature of –20 °C (–4 °F) during start-up and of 40 °C (104 °F)
when running.
– The engine power is slightly reduced.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit, the collector Go to 2.
air temperature sensor connection and all the connectors that
Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– The sensor connector is defective.
– The temperature sensor is faulty.
– The circuit is open on the sensor input.
– The circuit is open at the sensor earth.
– The control unit connector is defective.
– The engine control unit is defective.

G7.16 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 174 FMI 4
Fuel temperature input voltage low

˚t B B
A A

C3 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm05 Fig. 20

Parts list
C3 Fuel temperature input. 1 Engine control unit.
D3 Sensor earth. 2 Fuel temperature sensor.

Code SPN 174 FMI 4 is declared if


– The fuel temperature input voltage exceeds the sensor?s maximum threshold. This voltage corresponds to a temperature lower than what is
physically possible for the fuel.
– The maximum fuel temperature input voltage is 0,1 V.
This is what happens if the SPN 174 FMI 4 code is in force
– The engine control unit will use a default "return to workshop" value with a fuel temperature of –20 °C (–4 °F) during start-up and of 40 °C (104 °F)
when running.
– The engine power is slightly reduced.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit, the collector Go to 2.
air temperature sensor connection and all the connectors that
Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Short circuit at the earth at the sensor input.
– The temperature sensor is faulty.
– The engine control unit is defective.

Ares 806 – 09.2004 – GB G7.17


Engine application
Anomaly code SPN 174 FMI 16
Fuel temperature moderately high

˚t B B
A A

C3 D3

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm05 Fig. 21

Parts list
C3 Fuel temperature input. 1 Engine control unit.
D3 Sensor earth. 2 Fuel temperature sensor.

Code SPN 174 FMI 16 is declared if


The engine control unit detects a fuel temperature higher than 120 °C (248 °F).
This is what happens if the SPN 174 FMI 16 code is in force
– The engine protection function is activated.
– The engine reduces its power by 2 % a minute until it reaches 80 % of its maximal power.

1. Preliminary check No problem detected


Before starting this diagnosis procedure: Go to 2.
– Make sure that the fuel level in the tank is not too low.
Problem
– Make sure that the fuel cooler is clean.
Repair and carry out the test again.

2. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit, the collector Go to 3.
air temperature sensor connection and all the connectors that Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

3. Check the fuel feed pressure Fuel pressure compliant with specifications
Determine the fuel feed pressure. See check the fuel feed Go to 4.
pressure chapter A.
Fuel pressure lower than specifications
Determine the cause of the lack of fuel feed pressure.

4. Look for obstruction in the fuel return pipes Fuel return pipes not blocked
Check if the fuel pipes are blocked between the fuel tank and: Fuel cooler faulty.
– The overflow valve on the injection pump. or
– The fuel feed pipe to the injectors. Injection pump faulty.
Obstruction in a fuel return pipe
Determine the cause of the obstruction. Repair and carry out the
test again.

G7.18 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 190 FMI 0
Extreme engine overspeed

B B
A A

B2 D2

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm06 Fig. 22

Parts list
B2 Crankshaft position sensor input. 1 Engine control unit.
D2 Crankshaft position sensor return. 2 Fuel temperature sensor.

Code SPN 190 FMI 0 is declared if


The engine control unit detects that the engine speed exceeds 3 400 rpm.
This is what happens if the SPN 190 FMI 0 code is in force
The engine control unit cuts off the fuel feed until the engine runs at less than 2 800 rpm.

1. The electronic management system may be affected


Using WIN Métadiag©, watch whether other codes appear and
look at their diagnostic procedure.

2. In the absence of other memorised or active codes, clear


the SPN 190 FMI 0 code and monitor the codes to see if they
are repeated.

Ares 806 – 09.2004 – GB G7.19


Engine application
Anomaly code SPN 190 FMI 16
Moderate engine overspeed

B B
A A

B2 D2

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm06 Fig. 23

Parts list
B2 Crankshaft position sensor input. 1 Engine control unit.
D2 Crankshaft position sensor return. 2 Fuel temperature sensor.

Code SPN 190 FMI 16 is declared if


The engine control unit detects that the engine speed exceeds 3 000 rpm.
This is what happens if the SPN 190 FMI 16 code is in force
The engine control unit cuts off the fuel feed until the engine runs at less than 2 800 rpm.

1. The electronic management system may be affected


Using WIN Métadiag©, watch whether other codes appear and
look at their diagnostic procedure.

2. In the absence of other memorised or active codes, clear


the SPN 190 FMI 16 code and monitor the codes to see if
they are repeated.

G7.20 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 620 FMI 3
Sensor feed voltage high
Sensor feed voltage
The engine control unit feeds voltage to different sensors depending on the application. It monitors the drop in voltage
caused by the sensor and compares it with the values pre-programmed in its memory in order to determine the value of the
parameter measured by the sensor. Moreover, the control unit checks the exact voltage of the feed circuit of 5 V to ensure
that the records are accurate.
Code SPN 620 FMI 3 is declared if
The engine control unit detects a voltage higher than 5,5 V on its feed circuit.
This is what happens if the SPN 620 FMI 3 code is in force
The engine control unit uses default values for the sensors supplied by the input feed voltage.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit connector. Go to 2.
Find any dirty, worn or badly positioned terminals.
Defective connection(s)
Repair the defective connection(s).

2. Possible causes
– The input circuit is open or short-circuited at +12 V.
– The temperature sensor is faulty.
– The engine control unit is defective.

Ares 806 – 09.2004 – GB G7.21


Engine application
Anomaly code SPN 620 FMI 4
Sensor feed voltage low
Sensor feed voltage
The engine control unit feeds voltage to different sensors depending on the application. It monitors the drop in voltage
caused by the sensor and compares it with the values pre-programmed in its memory in order to determine the value of the
parameter measured by the sensor. Moreover, the control unit checks the exact voltage of the feed circuit of 5 V to ensure
that the records are accurate.
Code SPN 620 FMI 4 is declared if
The engine control unit detects a voltage lower than 4,44 V on its sensor feed circuit of 5 V.
This is what happens if the SPN 620 FMI 4 code is in force
The engine control unit uses default values for the sensors supplied by the input feed voltage.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit connector. Go to 2.
Find any dirty, worn or badly positioned terminals.
Defective connection(s)
Repair the defective connection(s).

2. Possible causes
– Short circuit at the earth at the sensor input.
– The temperature sensor is faulty.
– The engine control unit is defective.

G7.22 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 629 FMI 13
Engine control unit error
Code SPN 629 FMI 13 is declared if
The engine control unit detects an internal problem.
This is what happens if the SPN 629 FMI 13 code is in force
The engine does not start or won't go.
1. Possible causes
– Intermittent problem: Check the electrical wiring.
– The engine control unit is defective.

Ares 806 – 09.2004 – GB G7.23


Engine application
Anomaly code SPN 637 FMI 2
Crankshaft position input noise

B B
A A

B2 D2

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm06 Fig. 24

Parts list
B2 Crankshaft position sensor input. 1 Engine control unit.
D2 Crankshaft position sensor return. 2 Crankshaft position sensor.

Code SPN 637 FMI 2 is declared if


The engine control unit detects an excessive noise (too many pulses) at the crankshaft position input.
This is what happens if the SPN 637 FMI 2 code is in force
The engine will probably not work.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit connector, the Go to 2.
crankshaft position sensor connector and all the connectors that
Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
1 The SPN 637 FMI 2 code probably comes from the radiation
or "noise conduction" emanating from some component of the
machine. This problem may come from earthed electrical
connections or badly connected supply on the machine.
Check:
– All electrical wiring connectors.
– Alternator switches.
– Earth connections on chassis and battery earth connections.
– Corrosion, dirt or paint likely to cause breaks in connection or
interference.
– Look for open circuits or short circuits in the wires, in particular those
of the crankshaft sensor.
– Make sure of the correct positioning of the crankshaft sensor wiring
terminals and the control unit connectors.

G7.24 Ares 806 – 09.2004 – GB


Engine application
2 Other possible causes of the SPN 637 FMI 2 code:
– Electromagnetic interference caused by poorly installed radio
transceiver.
– Interference from some radar source.
– Teeth possibly broken on the crankshaft synchronisation ring.

Ares 806 – 09.2004 – GB G7.25


Engine application
Anomaly code SPN 637 FMI 10
Crankshaft position input configuration error

B B
A A

B2 D2

A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

582msm06 Fig. 25

Parts list
B2 Crankshaft position sensor input. 1 Engine control unit.
D2 Crankshaft position sensor return. 2 Crankshaft position sensor.

Code SPN 637 FMI 10 is declared if


The engine control unit detects that the crankshaft position input does not have the correct configuration.
This is what happens if the SPN 637 FMI 10 code is in force
The engine will probably not work.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit connector, the Go to 2.
crankshaft position sensor connector and all the connectors that Defective connection(s)
link them up. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Crankshaft position sensor test Between 2 500 and 3 500 ohms


1 Master switch off. Go to 3.
2 Disconnect the crankshaft position sensor switch.
Less than 2 500 ohms or more than 3 500 ohms
3 Measure with the multimeter the resistance between the
2 terminals of the crankshaft position sensor. Crankshaft position sensor defective.

3. Find the opening to the crankshaft sensor input and The 2 recorded of 5 ohms or less
return Go to 4.
1 Master switch off.
A record of more than 5 ohms
2 Disconnect the crankshaft position sensor switch.
3 Disconnect the engine control unit switch. Open circuit.
or
4 With a multimeter, measure the resistance between:
Possible inversion of the terminals A and B.
– The terminal A on the front wiring side of the crankshaft position
sensor and terminal B2 of the engine control unit switch.
– The terminal B on the front wiring side of the crankshaft position
sensor and terminal D2 of the engine control unit switch.

G7.26 Ares 806 – 09.2004 – GB


Engine application
4. Check the crankshaft sensor input wiring All the records of more than 2 000 ohms
1 Master switch off. Go to 5.
2 Crankshaft position sensor switch and engine control unit
A record of more than 2 000 ohms
switch still disconnected.
Wires of the crankshaft position sensor input defective.
3 Measure with the multimeter the resistance between the
terminal B2 on the front wiring side and:
4 A good earth.
5 All the other terminals of the two (2) control unit connectors.

5. Check the crankshaft sensor return wiring All the records of more than 2 000 ohms
1 Master switch off. Go to 6.
2 Crankshaft position sensor switch and engine control unit A record of more than 2000 ohms
switch still disconnected.
Wires of the crankshaft position sensor input defective.
3 Measure with the multimeter the resistance between the
connector terminal D2 and:
4 A good earth.
5 All the other terminals of the two (2) control unit connectors.

6 Check the crankshaft sensor return wiring All the components in good condition
1 Remove the crankshaft position sensor from the injection Go to 7.
pump.
A defective component
2 Inspect the sensor and its tip to find any cracks, traces of
corrosion or any other foreign body. Repair or replace the component if required.
3 See if the crankshaft shim wheel notches have any flashes or
chips.

6. Check the distribution by pinions All the pinions wedged


1 Master switch off. Crankshaft position sensor connector defective
2 Remove the timing cover. or
3 Check the shim of the camshaft pinions, the crankshaft and Control unit connector faulty
the injection pump (see chapter A). or
Engine control unit faulty.
One or more pinions offset
Make all the adjustments necessary to ensure a correct shim.

Ares 806 – 09.2004 – GB G7.27


Engine application
Anomaly code SPN 898 FMI 09
Invalid engine speed or torque message

A1 A2 A3
CAN L F1
B1 B2 B3
CAN H G1 C1 C2 C3
D1 D2 D3
E1 E2 E3

F1 F2 F3
G1 G2 G3
1 2 3 J1.35 J1.34 J1.36 H1 H2 H3
J1 J2 J3
3 K1 K2 K3
25 26 27 28 29 30 31 32 33 34 35 36
3 4 2 13 14 15 16 17 18 19 20 21 22 23 24 2
1
1 2 3 4 5 6 7 8 9 10 11 12
1

582msm19 Fig. 26

Parts list
1 Engine control unit. 3 Diagnostic plug.
2 Transmission control unit (Drivetronic).

Code SPN 898 FMI 09 is declared if


The engine control unit does not receive the engine speed or torque message on the CAN or the message is invalid.
This is what happens if the SPN 898 FMI 09 code is in force
The engine control unit defines the idling speed as the default engine speed.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine and Go to 2.
transmission UCE connectors of the digital accelerator
Defective connection(s)
connector and of all the connectors linking them. Find any dirty,
Repair the defective connection(s).
worn or badly positioned terminals.

2. Possible causes
– The accelerator is badly adjusted or defective.
– The control unit connector is defective.
– The engine control unit is defective.
– The transmission control unit is defective.

G7.28 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 1076 FMI 0
Pump distributor closure too long

A1 A2 A3

B1 B2 B3
2
C1 C2 C3
D1 D2 D3

A3 E1 E2 E3
B B
1
A A K2
F1 F2 F3

G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3

582msm20 Fig. 27

Parts list
1 Engine control unit. A3 Pump solenoid valve return.
2 Pump solenoid valve. K2 Pump solenoid valve feed.

Code SPN 1076 FMI 0 is declared if


The control unit determines that the pump distributor takes too long to close.
This is what happens if the SPN 1076 FMI 0 code is in force
The engine performances risk being irregular.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit connector, the Go to 2.
pump connector and any other connector. Find any dirty, worn or
Defective connection(s)
badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Pump distributor defective.
– The control unit is faulty.

Ares 806 – 09.2004 – GB G7.29


Engine application
Anomaly code SPN 1076 FMI 1
Pump distributor closure too short

A1 A2 A3

B1 B2 B3
2
C1 C2 C3
D1 D2 D3

A3 E1 E2 E3
B B
1
A A K2
F1 F2 F3

G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3

582msm20 Fig. 28

Parts list
1 Engine control unit. A3 Pump solenoid valve return.
2 Pump solenoid valve. K2 Pump solenoid valve feed.

Code SPN 1076 FMI 1 is declared if


The control unit determines that the distributor closes too quickly.
This is what happens if the SPN 1076 FMI 1 code is in force
The engine performances risk being irregular.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit connector, the Go to 2.
pump connector and any other connector. Find any dirty, worn or
Defective connection(s)
badly positioned terminals.
Repair the defective connection(s).

2. Check the battery voltage Equal or near to the battery voltage


1 Ignition on, engine off. Go to 3.
2 Record the battery voltage. Clearly higher or lower than the battery voltage
Electricity supply defective.

3. Check the injection pump SPN 1076 FMI 1 reappears


1 Remove the injection pump and replace it with a new one. Engine control unit faulty.
See removal and refitting of the injection pump chapter A.
SPN 1076 FMI 1 does not reappear
2 Contact on, engine running.
3 Read the anomaly codes on Win Métadiag©. Problem solved.

G7.30 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 1076 FMI 3
Pumpe solenoid valve intensity high

A1 A2 A3

B1 B2 B3
2
C1 C2 C3
D1 D2 D3

A3 E1 E2 E3
B B
1
A A K2
F1 F2 F3

G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3

582msm20 Fig. 29

Parts list
1 Engine control unit. A3 Pump solenoid valve return.
2 Pump solenoid valve. K2 Pump solenoid valve feed.

Code SPN 1076 FMI 3 is declared if


The control unit determines that the pump solenoid valve intensity exceeds the normal.
This is what happens if the SPN 1076 FMI 3 code is in force
The engine performances risk being irregular.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit connector, the Go to 2.
pump connector and any other connector. Find any dirty, worn or Defective connection(s)
badly positioned terminals.
Repair the defective connection(s).

2. Check the pump solenoid return wire Record of less than 20 000 ohms
1 Master switch off. Go to 3.
2 Disconnect the pump solenoid valve and UCE connectors.
Record of less than 20 000 ohms
3 Measure the resistance between A3 and the other terminals
of the UCE connector.. Short circuit at the pump solenoid valve return wire.

3. Check the supply wire Record of less than 20 000 ohms


1 Master switch off. Go to 4.
2 Disconnect the pump solenoid valve and UCE connectors.
Record of less than 20 000 ohms
3 Measure the resistance between K2 and the other terminals
of the UCE connector.. Short circuit at the pump solenoid valve return wire.

4. Check the injection pump SPN 1076 FMI 3 reappears


1 Remove the injection pump and replace it with a new one (see Engine UCE defective.
chapter A).
SPN 1076 FMI 3 does not reappear
2 Contact on, engine running.
3 Read the anomaly codes on Win Métadiag©. Problem solved.

Ares 806 – 09.2004 – GB G7.31


Engine application
Anomaly code SPN 1076 FMI 5
Pump solenoid valve circuit open

A1 A2 A3

B1 B2 B3
2
C1 C2 C3
D1 D2 D3

A3 E1 E2 E3
B B
1
A A K2
F1 F2 F3

G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3

582msm20 Fig. 30

Parts list
1 Engine control unit. A3 Pump solenoid valve return.
2 Pump solenoid valve. K2 Pump solenoid valve feed.

Code SPN 1076 FMI 5 is declared if


The engine control unit determines that the pump solenoid valve circuit is open.
This is what happens if the SPN 1076 FMI 5 code is in force
The engine cannot run.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit connector, the Go to 2.
pump connector and any other connector. Find any dirty, worn or
Defective connection(s)
badly positioned terminals.
Repair the defective connection(s).

2. Check the engine control unit Record of less than 5 ohms


1 Contact cut, engine stopped. Go to 2.
2 Disconnect the engine control unit switch. Record of 5 ohms or more
3 Measure with the multimeter the resistance between the
Control unit connector faulty.
terminals K2 and A3.
or
Engine control unit faulty.

3. Check the injection pump wiring The 2 recorded of 5 ohms or less


1 Master switch off. Pump connector defective
2 Disconnect the pump solenoid valve and engine control unit or
connectors. Injection pump faulty.
3 With a multimeter, measure the resistance between: A record of more than 5 ohms
– Terminal K2 and terminal A.
Pump connector defective
– Terminal A3 and terminal B.
or
Control unit connector faulty
or
Circuit open in the solenoid valve feed wire
or
Circuit open in the pump solenoid valve return wire.

G7.32 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 1076 FMI 6
Pump solenoid valve circuit short circuited

A1 A2 A3

B1 B2 B3
2
C1 C2 C3
D1 D2 D3

A3 E1 E2 E3
B B
1
A A K2
F1 F2 F3

G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3

582msm20 Fig. 31

Parts list
1 Engine control unit. A3 Pump solenoid valve return.
2 Pump solenoid valve. K2 Pump solenoid valve feed.

Code SPN 1076 FMI 6 is declared if


The engine control unit determines that the pump solenoid valve circuit is short-circuited.
This is what happens if the SPN 1076 FMI 6 code is in force
The control unit immediately cuts off the engine.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit connector, the Go to 2.
pump connector and any other connector. Find any dirty, worn or
Defective connection(s)
badly positioned terminals.
Repair the defective connection(s).

2. Check the engine control unit Record of less than 20 000 ohms
1 Master switch off. Go to 3.
2 Disconnect the pump solenoid valve and engine control unit Record of less than 20 000 ohms
connectors.
Pump solenoid valve feed wire short-circuited.
3 Measure with the multimeter the resistance between the
terminal K2 on the front wiring side and:
4 A good earth.
5 All the other terminals of the control unit connector.

3. Check the pump solenoid valve return circuit Record of less than 20 000 ohms
1 Master switch off. Go to 4.
2 Disconnect the pump solenoid valve and engine control unit Record of less than 20 000 ohms
connectors.
Pump solenoid valve return wire short-circuited.
3 Measure with the multimeter the resistance between the
terminal A3 on the front wiring side and:
4 A good earth.
5 All the other terminals of the control unit connector.

Ares 806 – 09.2004 – GB G7.33


Engine application
4. Check the injection pump SPN 1076 FMI 6 reappears
1 Remove the injection pump and replace it with a new one. Engine control unit faulty.
See removal and refitting of the injection pump chapter A.
SPN 1076 FMI 6 does not reappear
2 Contact on, engine running.
Problem solved.
3 Read the anomaly codes on Win Métadiag©.

G7.34 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 1076 FMI 7
Pump distributor closure not detected

A1 A2 A3

B1 B2 B3
2
C1 C2 C3
D1 D2 D3

A3 E1 E2 E3
B B
1
A A K2
F1 F2 F3

G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3

582msm20 Fig. 32

Parts list
1 Engine control unit. A3 Pump solenoid valve return.
2 Pump solenoid valve. K2 Pump solenoid valve feed.

Code SPN 1076 FMI 7 is declared if


The engine control unit determines that it cannot detect the pump distributor closure.
This is what happens if the SPN 1076 FMI 7 code is in force
The engine performances risk being irregular.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit connector, the Go to 2.
pump connector and any other connector. Find any dirty, worn or
Defective connection(s)
badly positioned terminals.
Repair the defective connection(s).

2. Check the injection pump SPN 1076 FMI 7 reappears


1 Remove the injection pump and replace it with a new one. Engine control unit faulty.
See removal and refitting of the injection pump chapter A. SPN 1076 FMI 7 does not reappear
2 Contact on, engine running.
Problem solved.
3 Read the anomaly codes on Win Métadiag©.

Ares 806 – 09.2004 – GB G7.35


Engine application
Anomaly code SPN 1076 FMI 10
Pump solenoid valve circuit intermittently short-circuited

A1 A2 A3

B1 B2 B3
2
C1 C2 C3
D1 D2 D3

A3 E1 E2 E3
B B
1
A A K2
F1 F2 F3

G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3

582msm20 Fig. 33

Parts list
1 Engine control unit. A3 Pump solenoid valve return.
2 Pump solenoid valve. K2 Pump solenoid valve feed.

Code SPN 1076 FMI 10 is declared if


The pump solenoid valve circuit is short-circuited at the supply.
This is what happens if the SPN 1076 FMI 10 code is in force
The control unit immediately reduces the engine power to 50 % of its maximum power.

1. Check the connection No defective connection


Carry out a preliminary inspection of the UCE unit connector, the Go to 2.
pump connector and any other connector. Find any dirty, worn or
Defective connection(s)
badly positioned terminals.
Repair the defective connection(s).

2. Check the engine control unit Record of less than 20 000 ohms
1 Master switch off. Go to 3.
2 Disconnect the pump solenoid valve and engine control unit Record of less than 20 000 ohms
connectors.
Pump solenoid valve feed wire short-circuited.
3 Measure with the multimeter the resistance between the
terminal K2 of the front wiring assembly:
– A good earth.
– All the other terminals of the control unit connector.

3. Check the pump solenoid valve return circuit Record of less than 20 000 ohms
1 Master switch off. Go to 4.
2 Disconnect the pump solenoid valve and engine control unit Record of less than 20 000 ohms
connectors.
Pump solenoid valve return wire short-circuited.
3 Measure with the multimeter the resistance between the
terminal A3 on the front wire assembly side and:
– A good earth.
– All the other terminals of the control unit connector.

G7.36 Ares 806 – 09.2004 – GB


Engine application

4. Check the injection pump SPN 1076 FMI 10 reappears


1 Remove the injection pump and replace it with a new one. Engine control unit faulty.
See removal and refitting of the injection pump chapter A.
SPN 1076 FMI 10 does not reappear
2 Contact on, engine running.
Problem solved.
3 Read the anomaly codes on Win Métadiag©.

Ares 806 – 09.2004 – GB G7.37


Engine application
Anomaly code SPN 1569 FMI 31
Reduction of fuel input
Code SPN 1569 FMI 31 is declared if
– The engine control unit detects overheating of the engine coolant.
– The engine control unit detects overheating of the fuel.
This is what happens if the SPN 1569 FMI 31 code is in force
The control unit limits the quantity of fuel so as to protect the engine.
The SPN 1569 FMI 31 code appears
If the anomaly code SPN 110 FMI 0 or SPN 174 FMI 16 is active. Refer to their sheet.

G7.38 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 2000 FMI 6
Internal failure of the UCE

A1 A2 A3

B1 B2 B3
2
C1 C2 C3
D1 D2 D3

A3 E1 E2 E3
B B
1
A A K2
F1 F2 F3

G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3

582msm20 Fig. 34

Parts list
1 Engine control unit. A3 Pump solenoid valve return.
2 Pump solenoid valve. K2 Pump solenoid valve feed.

Code SPN 2000 FMI 6 is declared if


The engine control unit has detected an internal short-circuit causing extremely high intensity at the injection pump.
This is what happens if the SPN 2000 FMI 6 code is in force
Replace the UCE.

Ares 806 – 09.2004 – GB G7.39


Engine application
Engine with pump VP 44

586hsm68 Fig. 35

Parts list
1 Percentage of engine charge at a given 2 Indicates an error on the coolant 3 Error code relating to point (2). Double-
speed. temperature function. click it to access the corresponding sheet.

586hsm07 Fig. 36

Parts list
1 Double-click the error code to access the sheet. 3 Deletion of passive errors.
2 Case of intermittent breakdowns for example. 4 Return to previous mask.

G7.40 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 91 FMI 3
High accelerator input voltage (C)

1
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
+ APC

2
2
B B
3 31
C C
1 A
A
1

582hsm08 Fig. 37

Parts list
1 Engine control unit connector. 2 Accelerator pedal sensor.

Code SPN 91 FMI 3 is declared if


– The accelerator input voltage (C) exceeds the sensor's maximum threshold. The voltage exceeds the upper limit of the throttle control lever capacity.
– The maximum analog accelerator input voltage threshold (C) is 4,7 V.
This is what happens if the SPN 91 FMI 3 code is in force
The control unit uses a default "return to workshop" accelerator value which allows the engine to idle only.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the analog accelerator connector and all connectors linking these
Defective connection(s)
components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Sensor connector faulty.
– Short circuit on accelerator input voltage.
– Accelerator sensor faulty.
– Control unit connector faulty.
– Control unit faulty.

Ares 806 – 09.2004 – GB G7.41


Engine application
Anomaly code SPN 91 FMI 4
Low accelerator position input voltage (C)

1
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
+ APC

2
2
B B
3 31
C C
1 A
A
1

582hsm08 Fig. 38

Parts list
1 Engine control unit connector. 2 Accelerator pedal sensor.

Code SPN 91 FMI 4 is declared if


– The accelerator input voltage (C) is lower than the sensor's minimum threshold. The voltage fails to reach the lower limit of the throttle control lever
capacity.
– The minimum analog accelerator input voltage threshold (C) is 0,3 V.
This is what happens if the SPN 91 FMI 4 code is in force
The control unit uses a default "return to workshop" accelerator value which allows the engine to idle only.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the analog accelerator connector and all connectors linking these Defective connection(s)
components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Accelerator maladjusted.
– Open circuit on sensor supply or return.
– The input circuit is shorted to earth or open.
– Sensor faulty.
– Control unit connector faulty.
– Engine control unit faulty.
– Sensor connector faulty.
– Circuit open at accelerator sensor earth.

G7.42 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 105 FMI 3
High manifold air temperature input voltage

2
˚t B B
A A

50 24

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm01 Fig. 39

Parts list
1 Engine control unit connector. 24 Manifold air temperature earth.
2 Manifold air temperature sensor. 50 Manifold air temperature input.

Code SPN 105 FMI 3 is declared if


– The manifold air temperature input voltage exceeds the sensor's maximum threshold. The voltage corresponds to a temperature which is lower than
what is physically possible for the manifold air.
– The maximum input voltage threshold of the temperature probe is 4,9 volts.
This is what happens if the SPN 105 FMI 3 code is in force
The engine control unit will use a default "return to workshop" value corresponding to a manifold air temperature of 60°C.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the air temperature sensor connector, the manifold and all connectors
Defective connection(s)
linking these components. Find any dirty, worn or badly positioned
Repair the defective connection(s).
terminals.

2. Possible causes
– The sensor earth circuit is open.
– The input circuit is open or short-circuited at 12 V.
– The air sensor is faulty.
– Sensor connector faulty.
– Engine control unit connector faulty.
– Engine control unit faulty.

Ares 806 – 09.2004 – GB G7.43


Engine application
Anomaly code SPN 105 FMI 4
Low manifold air temperature input voltage

2
˚t B B
A A

50 24

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm01 Fig. 40

Parts list
1 Engine control unit connector. 24 Manifold air temperature earth.
2 Manifold air temperature sensor. 50 Manifold air temperature input.

Code SPN 105 FMI 4 is declared if


– The manifold air temperature input voltage is lower than the sensor's minimum threshold. The voltage corresponds to a temperature which is higher
than what is physically possible for the manifold air.
– The minimum input voltage threshold of the manifold air temperature probe is 0,1 V.
This is what happens if the SPN 105 FMI 4 code is in force
The engine control unit will use a default "return to workshop" value corresponding to a manifold air temperature of 60°C.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the air temperature sensor connector, the manifold and all connectors
Defective connection(s)
linking these components. Find any dirty, worn or badly positioned
Repair the defective connection(s).
terminals.

2. Possible causes
– The input circuit is short-circuited at the earth.
– The air sensor is faulty.
– Engine control unit connector faulty.
– Engine control unit faulty.
– The sensor connector is defective.

G7.44 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 105 FMI 16
Moderately high manifold air temperature input voltage

2
˚t B B
A A

50 24

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm01 Fig. 41

Parts list
1 Engine control unit connector. 24 Manifold air temperature earth.
2 Manifold air temperature sensor. 50 Manifold air temperature input.

Code SPN 105 FMI 16 is declared if


The engine control unit detects a manifold air temperature higher than 100°C.
This is what happens if the SPN 105 FMI 16 code is in force
The engine control unit reduces engine power by 2% per minute up to a maximum of 20% (code SPN 1569 FMI 31 is also active). When
the air temperature drops back below the maximum temperature setting, the power is increased by 2% per minute up to its maximum
value, unless the maximum temperature setting is again exceeded.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the air temperature sensor connector, the manifold and all connectors
Defective connection(s)
linking these components. Find any dirty, worn or badly positioned
Repair the defective connection(s).
terminals.

2. Possible causes
– Ambient air temperature extremely high.
– Supercharging air cooler blocked, dirty or damaged.
– Cooling fan belt slack.
– Cooling fan malfunctioning
– Intake air pipe blocked or damaged.
– Cooling fan cover damaged.
– The air sensor is faulty.
– Control unit connector faulty.
– Engine control unit faulty.

Ares 806 – 09.2004 – GB G7.45


Engine application
Anomaly code SPN 110 FMI 0
Extreme engine coolant overheating

˚t B B
A A

06 46

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm03 Fig. 42

Parts list
1 Engine control unit connector. 06 Engine coolant temperature input.
2 Engine coolant temperature sensor. 46 Engine coolant temperature earth.

Code SPN 110 FMI 0 is declared if


The engine control unit detects a coolant temperature higher than 118°C (244°F).
This is what happens if the SPN 110 FMI 0 code is in force
The engine protection function is activated.
The engine reduces its power by 60 % a minute until it reaches 40 % of its maximal power.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the coolant temperature connector and all connectors linking these Defective connection(s)
components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Engine overheating (see chapter "A1").
– Integrity of input and earth circuits (open or short-circuited).
– The temperature sensor is faulty.

G7.46 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 110 FMI 3
Engine coolant temperature input voltage high

˚t B B
A A

06 46

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm03 Fig. 43

Parts list
1 Engine control unit connector. 06 Engine coolant temperature input.
2 Engine coolant temperature sensor. 46 Engine coolant temperature earth.

Code SPN 110 FMI 3 is declared if


– The coolant temperature input voltage exceeds the sensor's maximum threshold. This voltage corresponds to a temperature lower than what is
physically possible for the engine coolant.
– The maximum coolant temperature input voltage threshold is 4,9 V.
This is what happens if the SPN 110 FMI 3 code is in force
– In start-up mode, the engine control unit defines the engine coolant temperature at the default value of –30°C (–22°F).
– In running mode, the engine control unit defines the engine coolant temperature at the default value of 90°C (194°F).
The function protecting the engine against high coolant temperature is invalidated.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the coolant temperature connector and all connectors linking these Defective connection(s)
components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Sensor connector faulty.
– The temperature sensor is faulty.
– The circuit is open at the input.
– The circuit is open at the sensor earth.
– Control unit connector faulty.
– The control unit is faulty.

Ares 806 – 09.2004 – GB G7.47


Engine application
Anomaly code SPN 110 FMI 4
Engine coolant temperature input voltage low

˚t B B
A A

06 46

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm03 Fig. 44

Parts list
1 Engine control unit connector. 06 Engine coolant temperature input.
2 Engine coolant temperature sensor. 46 Engine coolant temperature earth.

Code SPN 110 FMI 4 is declared if


– The coolant temperature input voltage falls below the sensor's minimum threshold. This voltage corresponds to a temperature higher than what is
physically possible for the engine coolant.
– The minimum coolant temperature input voltage threshold is 0,25 V.
This is what happens if the SPN 110 FMI 4 code is in force
– In start-up mode, the engine control unit defines the engine coolant temperature at the default value of 30°C
(–22°F).
– In running mode, the engine control unit defines the engine coolant temperature at the default value of 90°C (194°F).
The function protecting the engine against high coolant temperature is invalidated.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the coolant temperature sensor connector and all connectors linking
Defective connection(s)
these components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Short circuit at the earth at the sensor input.
– Sensor faulty.
– The control unit is faulty.

G7.48 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 110 FMI 15
Slight over-heating of the engine coolant

˚t B B
A A

06 46

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm03 Fig. 45

Parts list
1 Engine control unit connector. 06 Engine coolant temperature input.
2 Engine coolant temperature sensor. 46 Engine coolant temperature earth.

Code SPN 110 FMI 15 is declared if


– The engine control unit detects a coolant temperature higher than 108°C.
This is what happens if the SPN 110 FMI 4 code is in force
The engine protection function is activated.
– Reduction in power by 2% per minute up to a maximum of 5% (code SPN 1569 FMI 31 is also active). When the engine coolant temperature drops
below the maximum temperature setting, the power is increased by 2% per minute up to its maximum value, unless the maximum temperature setting is
again exceeded.
– If the engine coolant temperature continues to rise in spite of the reduction in power, code SPN 110 FMI 16 is generated at 113°C (235°F) and the
engine control unit reduces the engine power still further.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the coolant temperature sensor connector and all connectors linking
Defective connection(s)
these components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Engine overheating (see chapter "A1").
– Sensor faulty.
– The control unit is faulty.

Ares 806 – 09.2004 – GB G7.49


Engine application
Anomaly code SPN 110 FMI 16
Moderate over-heating of the engine coolant

˚t B B
A A

06 46

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm03 Fig. 46

Parts list
1 Engine control unit connector. 06 Engine coolant temperature input.
2 Engine coolant temperature sensor. 46 Engine coolant temperature earth.

Code SPN 110 FMI 16 is declared if


The engine control unit detects a coolant temperature higher than 113°C.
This is what happens if the SPN 110 FMI 16 code is in force
The engine protection function is activated.
The engine reduces its power by 40% per minute until it reaches 60% of its maximum power (codes SPN 1569 FMI 31 and SPN 110
FMI 15 are also active). When the engine coolant temperature drops below 113°C (235°F), the power is increased by 40% per minute up
to the maximum value, unless the coolant temperature again increases to over 113°C (235°F).

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the coolant temperature sensor connector and all connectors linking
Defective connection(s)
these components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Engine overheating (see chapter "A1").
– Sensor faulty.
– The control unit is faulty.

G7.50 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 158 FMI 17
Feed stop error of the engine control unit

3
2

68 23 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm05 Fig. 47

Parts list
1 Engine control unit connector. 19 +APC.
2 Battery. 23 +APC.
3 Ignition/starter switch. 68 +APC.

Code SPN 158 FMI 17 is declared if


The engine control unit cannot stop the engine correctly as voltage is detected on one or more inputs.
This is what happens if the SPN 158 FMI 17 code is in force
The vehicle battery risks being decharged if the engine control unit is still switched on.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the ignition supply circuit and all connectors linking these components.
Defective connection(s)
Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– The ignition switch is faulty.
– Short-circuit +12 V.
– The switch circuit is faulty.
– Control unit connector faulty.
– The control unit is faulty.

Ares 806 – 09.2004 – GB G7.51


Engine application
Anomaly code SPN 174 FMI 0
Extreme fuel overheating

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 48

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 174 FMI 0 is declared if


The pump control unit detects that the temperature of the fuel inside the injection pump has exceeded 75°C.
This is what happens if the SPN 174 FMI 0 code is in force
Considerable reduction in engine power (codes SPN 1569 FMI 31, SPN 1109 FMI 31, SPN 174 FMI 15 and 16 may also be active).

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the fuel temperature sensor connector and all connectors linking these Defective connection(s)
components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Fuel pressure check Fuel pressure compliant with specifications


Go to 3.
Fuel pressure lower than specifications
(see chapter "A1").

G7.52 Ares 806 – 09.2004 – GB


Engine application
3. Look for obstruction in the fuel return pipes No obstruction in the fuel return pipes. Possible causes
– Injection pump overflow valve faulty;
– Fuel cooler faulty;
– Injection pump faulty.
Obstruction in a fuel return pipe
Repair and carry out the test again.

Ares 806 – 09.2004 – GB G7.53


Engine application
Anomaly code SPN 174 FMI 15
Slight fuel overheating

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 49

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 174 FMI 15 is declared if


The engine control unit detects that the temperature of the fuel inside the injection pump has exceeded 65°C (149°F).
This is what happens if the SPN 174 FMI 15 code is in force
The control unit does not reduce engine power.

1. Preliminary check No problem detected


Before starting this diagnosis procedure: Go to 2.
– Make sure that the fuel level in the tank is not too low. Problem
– Make sure that the fuel cooler is clean.
Repair and carry out the test again.

2. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 3.
the fuel temperature sensor connector and all connectors linking these
Defective connection(s)
components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

G7.54 Ares 806 – 09.2004 – GB


Engine application
3. Check the fuel feed pressure Fuel pressure compliant with specifications
Determine the fuel feed pressure (cf. Fuel feed pressure check in Go to 4.
chapter "A1").
Fuel pressure lower than specifications
Determine the cause of the lack of fuel feed pressure.

4. Look for obstruction in the fuel return pipes Fuel return pipes not blocked
Check if the fuel pipes are blocked between the fuel tank and: – Injection pump overflow valve faulty.
– The overflow valve on the injection pump. – Fuel cooler faulty
– The fuel feed pipe to the injectors. – Injection pump faulty.
Obstruction in a fuel return pipe
Determine the cause of the obstruction.
Repair and carry out the test again.

Ares 806 – 09.2004 – GB G7.55


Engine application
Anomaly code SPN 174 FMI 16
Fuel temperature moderately high

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 50

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 174 FMI 16 is declared if


The engine control unit detects that the temperature of the fuel inside the injection pump has exceeded 73°C (160°F).
This is what happens if the SPN 174 FMI 16 code is in force
The engine protection function is activated.
Power is reduced by 75% per minute until it reaches 75% of its maximum power.

1. Code SPN 174 FMI 31 is declared if No problem detected


The fuel temperature input voltage is outside the range of what is Go to 2.
physically possible for the fuel temperature.
Problem
This is what happens if the SPN 174 FMI 31 code is in force Repair and carry out the test again.
– The engine control unit will use a default "return to workshop" value with a fuel
temperature of –20 °C (–4 °F) during start-up and of 40 °C (104 °F) when
running.
– The engine power is slightly reduced.

2. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 3.
the fuel temperature sensor connector and all connectors linking these
Defective connection(s)
components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

G7.56 Ares 806 – 09.2004 – GB


Engine application
3. Check the fuel feed pressure Fuel pressure compliant with specifications
Determine the fuel feed pressure. See check the fuel feed pressure Go to 4.
chapter "A1".
Fuel pressure lower than specifications
Determine the cause of the lack of fuel feed pressure.

4. Look for obstruction in the fuel return pipes Fuel return pipes not blocked
Check if the fuel pipes are blocked between the fuel tank and: – Fuel cooler faulty.
– The overflow valve on the injection pump. – Injection pump overflow valve faulty.
– The fuel feed pipe to the injectors. – Injection pump faulty.
Obstruction in a fuel return pipe
Determine the cause of the obstruction.
Repair and carry out the test again.

Ares 806 – 09.2004 – GB G7.57


Engine application
Anomaly code SPN 174 FMI 31
Fuel temperature sensor faulty

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 51

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 174 FMI 31 is declared if


The fuel temperature input voltage is outside the range of what is physically possible for the fuel temperature.
This is what happens if the SPN 174 FMI 16 code is in force
Codes SPN 1077 FMI 31 and SPN 1569 FMI 31 are also active. The protection function is activated. Power is reduced by 20% per
minute until it reaches 50% of its maximum power.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the fuel temperature sensor connector and all connectors linking these
Defective connection(s)
components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
Injection pump faulty.

G7.58 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 189 FMI 31
Engine speed reduction
Code SPN 189 FMI 31 is declared if
The engine control unit detects a condition requiring a reduction in engine speed, a fuel pressure of less than – 0,11 bar when the engine
speed is above the idling speed for more than 30 seconds (code SPN 94 FMI 1 is also active).
This is what happens if the SPN 189 FMI 31 code is in force
The control unit limits the engine speed to protect it.

1. The electronic management system may be affected


Using WIN Métadiag©, watch whether other codes appear and look at
their diagnostic procedure.

Ares 806 – 09.2004 – GB G7.59


Engine application
Anomaly code SPN 190 FMI 0
Extreme engine overspeed

B B
A A

9 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm07 Fig. 52

Parts list
1 Engine control unit connector. 9 Crankshaft position input signal.
2 Crankshaft position sensor. 34 Crankshaft position return.

Code SPN 190 FMI 0 is declared if


The engine control unit detects that the engine speed exceeds 3 400 rpm.
This is what happens if the SPN 190 FMI 0 code is in force
The engine control unit cuts off the fuel feed until the engine runs at less than 2 600 rpm.

1. The electronic management system may be affected No other code appears


Using WIN Métadiag©, watch whether other codes appear. Erase code SPN 190 FMI 0 and watch whether other codes
appear.
Other codes appear
Look at their diagnostic procedure.

G7.60 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 190 FMI 16
Moderate engine overspeed

B B
A A

9 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm07 Fig. 53

Parts list
1 Engine control unit connector. 9 Crankshaft position input signal.
2 Crankshaft position sensor. 34 Crankshaft position return.

Code SPN 190 FMI 16 is declared if


The engine control unit detects that the engine speed exceeds 3 000 rpm.
This is what happens if code SPN 190 FMI 16 is in force
The engine control unit cuts off the fuel feed until the engine runs at less than 2 600 rpm.

1. The electronic management system may be affected No other code appears


Using WIN Métadiag©, watch whether other codes appear. Erase code SPN 190 FMI 0 and watch whether other codes
appear.
Other codes appear
Look at their diagnostic procedure.

Ares 806 – 09.2004 – GB G7.61


Engine application
Anomaly code SPN 627 FMI 4
Control unit supply missing

3
2

68 23 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm05 Fig. 54

Parts list
1 Engine control unit connector. 19 +APC.
2 Battery. 23 +AVC (constant source).
3 Ignition/starter switch. 68 +AVC (constant source).

Code SPN 627 FMI 4 is declared if


The engine control unit does not detect any battery voltage.
This is what happens if the SPN 627 FMI 4 code is in force
The engine does not start or won't go.

1. Check the connection No defective connection


Carry out a preliminary inspection of the connector and all earths of the Go to 2.
engine control unit to locate dirty, damaged or badly positioned
Defective connection(s)
terminals.
Repair the defective connection(s).

2. Possible causes
– Battery faulty.
– Control unit supply fuse faulty.
Or
– Control unit connection faulty.
Or
– Open circuit.
Or
– Short-circuit on control unit supply.

G7.62 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 629 FMI 19
Communication error between the engine control unit and the pump

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 55

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 629 FMI 19 is declared if


The engine control unit receives no CAN message from the injection pump.
This is what happens if the SPN 629 FMI 19 code is in force
In the absence of other codes, the engine control unit leaves the pump running at low speed. If other codes are active, the engine control
unit may switch off the engine.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector. Go to 2.
Look for dirty, damaged or badly positioned terminals on all connectors.
Defective connection(s)
Repair the defective connection(s).

2. Unplug the injection pump connector Over or equal to 12 V


Check the voltage between terminal (7) and the chassis earth. Go to 3
Considerably under
Circuit open - Wiring faulty.

Ares 806 – 09.2004 – GB G7.63


Engine application
3. Unplug the engine control unit and injection pump connectors Over 5 Ω
– Check for continuity between (1) and (59). Wiring faulty.
– Check for continuity between (2) and (58). Under 5 Ω
Go to 4.

4. The 2 connectors unplugged Over 20 kΩ


Measure the resistance between terminal (58) and: Injection pump connector or injection pump faulty.
A good earth; Under 20 kΩ
All other terminals of the connector; Short-circuit to earth in the CAN-high wire or another wire in
Of the engine control unit. the harness.

G7.64 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 632 FMI 2
Fuel cutout error

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 56

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 632 FMI 2 is declared if


The pump control unit detects a fuel cutout voltage which does not correspond to the information communicated on the CAN.
This is what happens if the SPN 632 FMI 2 code is in force
The engine cuts out and cannot be restarted.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector Go to 2.
and the injection pump connector. Find any dirty, worn or badly Defective connection(s)
positioned terminals.
Repair the defective connection(s).

2. Check the injection pump voltage Battery voltage present


1. Master switch off. Go to 3.
2. Unplug the injection pump connector.
Battery voltage zero
3. Ignition on, engine off.
4. With a multimeter, measure the voltage between a good chassis earth Injection pump connector faulty.
Or
and terminal (5) of the injection pump connector.
Injection pump faulty.

Ares 806 – 09.2004 – GB G7.65


Engine application
3. Search for a short-circuit Over 20 kΩ
1. Master switch off. Engine control unit connector faulty.
2. With a multimeter, measure the resistance between terminal (18) of Or
the engine control unit connector and the rest of the connector's Engine control unit faulty.
terminals. Under 20 kΩ
Short-circuit to voltage in the fuel cutout wire.

G7.66 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 632 FMI 5
Fuel cutout non-operational

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 57

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 632 FMI 5 is declared if


The engine control unit fails to detect any change to the engine speed following a long engine shutdown.
This is what happens if the SPN 632 FMI 5 code is in force
No change to engine performance is detected.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector Go to 2.
and the injection pump connector. Find any dirty, worn or badly Defective connection(s)
positioned terminals.
Repair the defective connection(s).

2. Check continuity of fuel cutout wire Under 5 Ω


1. Master switch off. Go to 3.
2. Unplug the injection pump connector and the engine control unit
Over 5 Ω
connector.
3. Ignition on, engine off. Circuit open in the fuel cutout wire.
4. With a multimeter, measure the resistance between terminal (18) of
the engine control unit connector and terminal (5) of the injection pump
connector.

Ares 806 – 09.2004 – GB G7.67


Engine application
3. Search for a short-circuit Over 20 kΩ
1. Master switch off. Engine control unit connector faulty.
2. With a multimeter, measure the resistance between terminal (18) of Or
the engine control unit connector and a good chassis earth. Engine control unit faulty.
Under 20 kΩ
Short-circuit to earth in the fuel cutout wire.

G7.68 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 636 FMI 2
Pump position input noise

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 58

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 636 FMI 2 is declared if


The engine control unit detects excessive noise (too many pulses) on pump position input.
This is what happens if the SPN 636 FMI 2 code is in force
If a crankshaft position sensor anomaly code appears at the same time as code SPN 636 FMI 2, the engine stalls and cannot be restarted
until one of these 2 codes has been eliminated. The engine control unit will base itself only on the crankshaft position sensor input in
determining the piston position. At the precise moment when the anomaly code is declared, the engine might shudder or stall but it should
restart. The engine may take longer to activate before starting.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector Go to 2.
and the pump position sensor connector. Find any dirty, worn or badly Defective connection(s)
positioned terminals.
Repair the defective connection(s).

Ares 806 – 09.2004 – GB G7.69


Engine application
2. Possible causes
1 The SPN 636 FMI 2 code probably comes from the radiation or "noise
conduction" emanating from some component of the machine. This
problem may come from earthed electrical connections or badly
connected supply on the machine. Check:
– All connectors;
– Alternator connections;
– Earth connections on chassis and battery earth connections;
– Corrosion, dirt or paint likely to cause breaks in connection or interference;
– Look for open circuits or short circuits in the wires, in particular those of the
crankshaft sensor;
– Make sure of the correct positioning of the crankshaft sensor wiring terminals
and the control unit connectors.
2 Other possible causes of the SPN 636 FMI 2 code:
– Electromagnetic interference caused by poorly installed radio transceiver;
– Interference from some radar source;
– Teeth possibly broken on the crankshaft synchronisation ring.

G7.70 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 636 FMI 8
Pump position missing

B B
A A

9 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm07 Fig. 59

Parts list
1 Engine control unit connector. 9 Crankshaft position input signal.
2 Crankshaft position sensor. 34 Crankshaft position return.

Code SPN 636 FMI 8 is declared if


The engine control unit fails to detect a pump position input.
This is what happens if the SPN 636 FMI 8 code is in force
If a crankshaft position sensor anomaly code appears at the same time as code SPN 636 FMI 8, the engine stalls and cannot be restarted
until one of these 2 codes has been eliminated. The engine control unit will base itself only on the crankshaft position sensor input in
determining the piston position. At the precise moment when the anomaly code is declared, the engine might shudder or stall but it should
restart. The engine may take longer to activate before starting.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector Go to 2.
and the pump position sensor connector. Find any dirty, worn or badly
Defective connection(s)
positioned terminals.
Repair the defective connection(s).

2. Test the pump position sensor From 2 500 to 3 500 Ω


1 Master switch off. Go to 3.
2 Unplug the pump position sensor connector.
Less than 2 500 Ω or more than 3 500 Ω
3 With a multimeter, measure the resistance between the 2 terminals of
the pump position sensor connector on the engine wiring harness. Pump position sensor faulty.

3. Check the pump position sensor input wiring 2 measurements of 5 Ω or less


1 Master switch off. Go to 4.
2 Unplug the pump position sensor connector.
Any measurement of over 5 Ω
3 Disconnect the engine control unit switch.
4 With a multimeter, measure the resistance between: Circuit open in the pump position sensor input wire
OR
– Terminal (A) of the pump position sensor connector and terminal (10) of the
Circuit open in the pump position sensor return wire.
engine control unit connector on the engine harness.
– Terminal (B) of the pump position sensor connector and terminal (36) of the OR
Possible reversal of terminals (A) and (B) of the pump
engine control unit connector on the engine harness.
position sensor harness connector.

Ares 806 – 09.2004 – GB G7.71


Engine application
4. Check the pump position sensor wiring All measurements over 2 kΩ
1 Master switch off. Go to 5.
2 Pump position sensor connector and engine control unit connector still
Any measurement under 2 kΩ
unplugged.
Short circuit on the pump position input wire with the low
3 With a multimeter, measure the resistance between terminal (10) of
the engine control unit connector on the engine wiring harness and: resistance wire.
– A good earth on the chassis;
– All other terminals of the engine control unit connector.

5. Check the pump position sensor return wiring All measurements over 2 kΩ
1 Master switch off. Pump position sensor connector faulty
2 Pump position sensor connector and engine control unit connector still Or
unplugged. Pump position sensor damaged.
3 With a multimeter, measure the resistance between terminal (36) of Or
the engine control unit connector on the engine wiring harness and: Engine control unit connector faulty.
– A good earth on the chassis; Or
– All other terminals of the engine control unit connector. Engine control unit faulty.
Any measurement under 2 kΩ
Pump position sensor return wiring harness faulty.

G7.72 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 636 FMI 10
Pump position input configuration error

B B
A A

9 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm07 Fig. 60

Parts list
1 Engine control unit connector. 9 Crankshaft position input signal.
2 Crankshaft position sensor. 34 Crankshaft position return.

Code SPN 636 FMI 10 is declared if


The engine control unit detects that the pump position input configuration is incorrect.
This is what happens if the SPN 636 FMI 10 code is in force
If a crankshaft position sensor anomaly code appears at the same time as code SPN 636 FMI 10, the engine stalls and cannot be
restarted until one of these 2 codes has been eliminated. The engine control unit will base itself only on the crankshaft position sensor
input in determining the piston position. At the precise moment when the anomaly code is declared, the engine might shudder or stall but
it should restart. The engine may take longer to activate before starting.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the pump position sensor connector and all connectors linking these
Defective connection(s)
components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Test the pump position sensor 2 measurements 5 Ω or less


1 Master switch off. Go to 3.
2 Unplug the pump position sensor and engine control unit connectors.
All measurements over 5 Ω
3 With a multimeter, measure the resistance between the 2 terminals of
the pump position sensor connector on the engine wiring harness. Circuit open on the pump position sensor input wire or circuit
open on the pump position sensor return wire or possible
reversal of terminals (A) and (B) of the pump position sensor
harness connector.

3. Check the pump position sensor input wiring All measurements over 2 Ω
1 Master switch off. Go to 4.
2 Pump position sensor connector and engine control unit connector still
Any measurement under 2 kΩ
unplugged.
Pump position sensor input wiring harness faulty.
3 With a multimeter, measure the resistance between terminal (10) of
the engine control unit connector on the engine wiring harness and:
– A good earth on the chassis;
– All other terminals of the engine control unit connector.

Ares 806 – 09.2004 – GB G7.73


Engine application
4. Check the pump position sensor return wiring All measurements over 2 kΩ
1 Master switch off. Go to 5.
2 Pump position sensor connector and engine control unit connector still
Any measurement under 2kΩ
unplugged.
Pump position sensor return wire faulty.
3 With a multimeter, measure the resistance between terminal (36) of
the engine control unit connector on the engine wiring harness and:
– A good earth on the chassis;
– All other terminals of the engine control unit connector.

5. Check the pump setting wheel and position sensor All the components in good condition
1 Remove the pump position sensor from the injection pump. Inspect Go to 6.
the sensor and its tip to find any cracks, traces of corrosion or any other A defective component
foreign body.
Repair or replace the component if required.
2 Check whether there are any burrs or chips in the slots in the pump
setting wheel.

6. Check crankshaft and camshaft synchronisation All pinions are set


1 Master switch off. Pump position sensor connector or engine control unit
2 Remove the timing cover. connector or control unit faulty.
3 Check the shim of the camshaft pinions, the crankshaft and the
One or more pinions offset
injection pump.
Make all the adjustments necessary to ensure a correct
shim.

G7.74 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 637 FMI 2
Crankshaft position input noise

B B
A A

9 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm07 Fig. 61

Parts list
1 Engine control unit connector. 9 Crankshaft position input signal.
2 Crankshaft position sensor. 34 Crankshaft position return.

Code SPN 637 FMI 2 is declared if


The engine control unit detects an excessive noise (too many pulses) at the crankshaft position input.
This is what happens if the SPN 637 FMI 2 code is in force
– The engine protection function is activated and the engine reduces its power by 20% per minute until it reaches 50% of its maximum power.
– If a pump position sensor anomaly code appears as the same time as code SPN 637 FMI 02, the engine stalls and cannot be restarted until one of
these 2 codes has been eliminated.
– The engine control unit will base itself only on the pump position sensor input in determining the piston position.
– At the precise moment when the anomaly code is declared, the engine might shudder or stall but it should restart.
– The engine may take longer to activate before starting.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the crankshaft position sensor connector and all connectors linking Defective connection(s)
these components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

Ares 806 – 09.2004 – GB G7.75


Engine application
2. Crankshaft signal noise test
1 Code SPN 637 FMI 2 probably comes from the electric "noise"
conduction or radiation emanating from some component of the
machine. This problem may come from badly connected earthed or
supply connections on the tractor. Check:
– All harness connectors;
– Alternator connections;
– Earth connections on chassis and battery earth connections;
– Corrosion, dirt or paint likely to cause breaks in connection or interference;
– Search for open circuits or intermittent short circuits in the wires, especially
the crankshaft position sensor wires;
– Ensure that the crankshaft position sensor wiring pins and the control unit
connectors are correctly positioned.
2 Other possible causes of the SPN 637 FMI 2 code:
– Electromagnetic interference caused by poorly installed radio transceiver;
– Interference from some radar source;
– Teeth possibly broken on the crankshaft synchronisation ring.

G7.76 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 637 FMI 8
No crankshaft position input

B B
A A

9 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm07 Fig. 62

Parts list
1 Engine control unit connector. 9 Crankshaft position input signal.
2 Crankshaft position sensor. 34 Crankshaft position return.

Code SPN 637 FMI 8 is declared if


The engine control unit fails to detect a crankshaft position input.
This is what happens if the SPN 637 FMI 8 code is in force
The engine reduces its power by 20% per minute until it reaches 50% of its maximum power. If a pump position sensor anomaly code
appears as the same time as code SPN 637 FMI 8, the engine stalls and cannot be restarted until one of these 2 codes has been
eliminated. The engine control unit will base itself only on the pump position sensor input in determining the piston position. At the precise
moment when the anomaly code is declared, the engine might shudder or stall but it should restart. The engine may take longer to
activate before starting.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the crankshaft position sensor connector and all connectors linking
Defective connection(s)
these components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Check the crankshaft position sensor No signs of damage


1 Master switch off. Go to 3.
2 Remove the crankshaft position sensor from the timing cover and look Sensor damaged
for signs of damage, such as cracks or debris on the sensor tip.
Determine the cause of the damage to the sensor. Replace
the sensor and test again.

3. Crankshaft position sensor test From 2 500 to 3 500 Ω


1 Master switch off. Go to 4.
2 Disconnect the crankshaft position sensor switch. Less than 2 500 Ω or more than 3 500 Ω
3 Measure with the multimeter the resistance between the 2 terminals of
Crankshaft position sensor defective.
the crankshaft position sensor.

Ares 806 – 09.2004 – GB G7.77


Engine application
4. Find the opening to the crankshaft sensor input and return 2 measurements 5 Ω or less
1 Master switch off. Go to 5.
2 Disconnect the crankshaft position sensor switch.
Any measurement of over 5 Ω
3 Disconnect the engine control unit switch.
Open circuit.
4 With a multimeter, measure the resistance between:
– The terminal (A) on the front wiring side of the crankshaft position sensor and Or
Possible inversion of the terminals (A) and (B).
terminal (9) of the engine control unit switch.
– The terminal (B) on the front wiring side of the crankshaft position sensor and
terminal (34) of the engine control unit switch.

5. Check the crankshaft sensor input wiring All measurements over 2 000 Ω
1 Master switch off. Go to 5.
2 Crankshaft position sensor switch and engine control unit switch still
Any measurement over 2 000 Ω
disconnected.
Wires of the crankshaft position sensor input defective.
3 Measure with the multimeter the resistance between the terminal (9)
on the front wiring side and:
– A good earth.
– All the other terminals of the two (2) control unit connectors.

6. Check the crankshaft sensor return wiring All measurements over 2 000 Ω
1 Master switch off. Crankshaft position sensor connector faulty or damaged
2 Crankshaft position sensor switch and engine control unit switch still Or
disconnected. Engine control unit connector faulty.
3 Measure with the multimeter the resistance between the connector Or
terminal (34) and: Engine control unit faulty.
– A good earth.
Any measurement over 2 000 Ω
– All the other terminals of the two (2) control unit connectors.
Crankshaft position sensor return wiring harness faulty.

G7.78 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 637 FMI 10
Crankshaft position input error

B B
A A

9 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

582hsm07 Fig. 63

Parts list
1 Engine control unit connector. 9 Crankshaft position input signal.
2 Crankshaft position sensor. 34 Crankshaft position return.

Code SPN 637 FMI 10 is declared if


The engine control unit detects that the crankshaft position input configuration is incorrect.
This is what happens if the SPN 637 FMI 10 code is in force
The engine reduces its power by 20% per minute until it reaches 50% of its maximum power. If a pump position sensor anomaly code
appears as the same time as code SPN 637 FMI 10, the engine stalls and cannot be restarted until one of these 2 codes has been
eliminated. The engine control unit will base itself only on the pump position sensor input in determining the piston position. At the precise
moment when the anomaly code is declared, the engine might shudder or stall but it should restart. The engine may take longer to
activate before starting.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the crankshaft position sensor connector and all connectors linking
Defective connection(s)
these components. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Crankshaft position sensor test From 2 500 to 3 500 Ω


1 Master switch off. Go to 3.
2 Disconnect the crankshaft position sensor switch. Less than 2 500 Ω or more than 3 500 Ω
3 Measure with the multimeter the resistance between the 2 terminals of
Crankshaft position sensor defective.
the crankshaft position sensor.

3. Find the opening to the crankshaft sensor input and return 2 measurements 5 Ω or less
1 Master switch off. Go to 4.
2 Disconnect the crankshaft position sensor switch. Any measurement of over 5 Ω
3 Disconnect the engine control unit switch.
Open circuit.
4 With a multimeter, measure the resistance between:
Or
– The terminal (A) on the front wiring side of the crankshaft position sensor and
terminal (9) of the engine control unit switch. Possible inversion of the terminals (A) and (B).
– The terminal (B) on the front wiring side of the crankshaft position sensor and
terminal (34) of the engine control unit switch.

Ares 806 – 09.2004 – GB G7.79


Engine application
4. Check the crankshaft sensor input wiring All measurements over 2 000 Ω
1 Master switch off. Go to 5.
2 Crankshaft position sensor switch and engine control unit switch still
Any measurement over 2 000 Ω
disconnected.
Wires of the crankshaft position sensor input defective.
3 Measure with the multimeter the resistance between the terminal (9)
on the front wiring side and:
– A good earth.
– All the other terminals of the two (2) control unit connectors.

5. Check the crankshaft sensor return wiring All measurements over 2 000 Ω
1 Master switch off. Go to 6.
2 Crankshaft position sensor switch and engine control unit switch still Any measurement over 2 000 Ω
disconnected.
Wires of the crankshaft position sensor input defective.
3 Measure with the multimeter the resistance between the connector
terminal (34) and:
– A good earth.
– All the other terminals of the two (2) control unit connectors.

6. Check the crankshaft sensor return wiring All the components in good condition
1 Remove the crankshaft position sensor from the injection pump. Go to 7.
2 Inspect the sensor and its tip to find any cracks, traces of corrosion or A defective component
any other foreign body.
Repair or replace the component.
3 See if the crankshaft shim wheel notches have any flashes or chips.

7. Check the timing synchronisation All the pinions wedged


1 Master switch off. Crankshaft position sensor connector defective.
2 Remove the timing cover. Or
3 Check the shim of the camshaft pinions, the crankshaft and the Control unit connector faulty.
injection pump (see chapter "A1"). Or
Engine control unit faulty.
One or more pinions offset
Make all the adjustments necessary to ensure a correct
shim.

G7.80 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 898 FMI 9
Engine speed or torque message missing or invalid

CAN L 44
CAN H 21

1
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
42

1 2 3
J1.35 J1.34 J1.36
3
25 26 27 28 29 30 31 32 33 34 35 36
3 4 2 13 14 15 16 17 18 19 20 21 22 23 24 2
1 2 3 4 5 6 7 8 9 10 11 12
1

1
582hsm09 Fig. 64

Parts list
1 Engine control unit. 3 Diagnostic plug.
2 Transmission control unit (Drivetronic).

Code SPN 898 FMI 9 is declared if


The engine control unit does not receive the engine speed or torque message on the CAN or the message is invalid.
This is what happens if code SPN 898 FMI 9 is in force
The engine control unit defines the idling speed as the default engine speed.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine and transmission UCE Go to 2.
connectors of the digital accelerator connector and of all the connectors
Defective connection(s)
linking them. Find any dirty, worn or badly positioned terminals.
Repair the defective connection(s).

2. Check the connection


– The accelerator is badly adjusted or defective.
– The control unit connector is defective.
– The engine control unit is defective.
– The transmission control unit is defective.

Ares 806 – 09.2004 – GB G7.81


Engine application
Anomaly code SPN 1076 FMI 2
Fault detected by the pump

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 65

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 1076 FMI 2 is declared if


The engine control unit detects that the high-pressure solenoid valve located inside the pump is constantly energised or incapable of
detecting solenoid valve closure. The pump's internal speed sensor is broken.
This is what happens if code SPN 1076 FMI 2 is in force
If the code is declared while the engine is not running, it is possible that the engine is failing to start. Codes SPN 1077 FMI 31 and
SPN 1569 FMI 31 are also in force.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the pump connector and any other connector. Find any dirty, worn or
Defective connection(s)
badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Pump connector defective.
– Injection pump faulty.

G7.82 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 1077 FMI 7
Fuel supply attempt without a command

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 66

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 1077 FMI 7 is declared if


When the engine control unit asks the pump control unit to stop supplying fuel, the latter indicates that the high-pressure solenoid valve is
closed.
This is what happens if code SPN 1077 FMI 7 is in force
The engine control unit does not reduce engine power.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector, Go to 2.
the pump connector and any other connector. Find any dirty, worn or Defective connection(s)
badly positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Injection pump connector faulty.
– Injection pump faulty.

Ares 806 – 09.2004 – GB G7.83


Engine application
Anomaly code SPN 1077 FMI 11
Pump supply attempt out of range

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 67

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 1077 FMI 11 is declared if


The pump control unit detects an abnormal battery voltage.
This is what happens if code SPN 1077 FMI 11 is in force
The engine might not be running.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit, the pump Go to 2.
connector and any other connector. Find any dirty, worn or badly
Defective connection(s)
positioned terminals.
Repair the defective connection(s).

2. Check the injection pump Much higher or lower than the battery voltage
1 Master switch off. Go to 3.
2 Unplug the injection pump connector.
Close to the battery voltage
3 Ignition on, engine off.
Injection pump connector faulty.
4 With a multimeter, measure the voltage between terminal (7) of the
injection pump connector - wiring side - and a good earth on the chassis. Or
Injection pump faulty.

G7.84 Ares 806 – 09.2004 – GB


Engine application
3. Check the pump control unit wire between the relay and the Close to the battery voltage
battery Go to 4.
1 Master switch off.
Much higher or lower than the battery voltage
2 Unplug the connector from the pump control unit relay.
Pump control unit supply circuit faulty between pump relay
3 With a multimeter, measure the voltage between terminal (30) of the
pump control unit relay connector and a good earth on the chassis. and battery.

4. Search for a short circuit in the pump control unit wire Over 2 kΩ
1 Master switch off. Go to 5.
2 Unplug the engine control unit connector while leaving the injection
Under 2 kΩ
pump connector and the connector at the pump control unit relay
Short circuit to earth on the pump control unit supply with
unplugged.
3 With a multimeter, measure the resistance between terminal (35) of another wire in the harness.
the engine control unit connector and:
– A good earth ;
– All other terminals of the engine control unit connector.

5. Search for continuity in the control unit wire Under 5 Ω


1 Master switch off. Rotary pump relay connector faulty.
2 With a multimeter, measure the resistance between terminal (35) of Or
the engine control unit connector and: Rotary pump relay faulty.
– Terminal (7) of the injection pump connector ;
Over 5 kΩ
– Terminal (30) of the pump control unit relay.
Harness cut.

Ares 806 – 09.2004 – GB G7.85


Engine application
Anomaly code SPN 1077 FMI 12
Pump self-diagnostic error

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 68

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 1077 FMI 12 is declared if


The pump control unit determines that the pump's internal components are not working properly.
This is what happens if code SPN 1077 FMI 12 is in force
This leads to a reduction in power of 20% per minute until it reaches 50% of its maximum power.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector Go to 2.
and the injection pump connector to locate any dirty, damaged or badly
Defective connection(s)
positioned terminals.
Repair the defective connection(s).

2. Possible causes
– Injection pump connector faulty.
– Injection pump faulty.

G7.86 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 1077 FMI 19
Communication error detected by the pump

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 69

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 1077 FMI 19 is declared if


The pump receives no input from the engine control unit on the CAN whereas a speed is detected on the crankshaft speed output wire.
This is what happens if code SPN 1077 FMI 19 is in force
If the code is declared while the engine is not running, it is possible that the engine is failing to start.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector Go to 2.
and the injection pump connector to locate any dirty, damaged or badly
Defective connection(s)
positioned terminals.
Repair the defective connection(s).

2. Check the pump CAN wiring 2 measurements 5 Ω or less


1 Master switch off. Go to 3.
2 Unplug the engine control unit and injection pump connectors. Any measurement of over 5 Ω
3 With a multimeter, measure the resistance between: CAN bus wiring faulty between the injection pump and the
– Terminal (1) of the injection pump connector and terminal (59) of the engine engine control unit.
control unit connector.
– Terminal (2) of the injection pump connector and terminal (58) of the engine
control unit connector.

Ares 806 – 09.2004 – GB G7.87


Engine application
3. Search for a short circuit on the pump CAN wire 2 measurements over 20 kΩ
1 Master switch off. Engine control unit connector faulty.
2 Engine control unit connector still unplugged. Or
3 With a multimeter, measure the resistance between a good earth on Engine control unit faulty.
the chassis and: One measurement under 20 kΩ
– Terminal (1) of the injection pump connector. Short circuit to earth in the CAN bus wiring between the
– Terminal (2) of the injection pump connector. pump and the engine control unit.

G7.88 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 1077 FMI 31
Code SPN 1077 FMI 31 is declared if
– The pump control unit detects an extremely high fuel temperature.
– The fuel temperature input voltage received by the pump control unit is outside the range of what is physically possible for the fuel temperature.
– The pump control unit detects that the high-pressure solenoid valve is constantly energised and is incapable of detecting the closure of the high-
pressure solenoid valve, or the pump's internal speed sensor is broken.
– The pump control unit detects that the components located inside the pump are not working properly.
– The pump control unit detects a crankshaft signal sent by the engine control unit and out of range in relation to the pump's internal timing.
This is what happens if code SPN 1077 FMI 31 is in force
If the code is declared while the engine is not running, it is possible that the engine is failing to start. The engine protection function is
activated. The engine reduces its power by 20% per minute until it reaches 50% of its maximum power.

One of the following codes is active Refer to the anomaly code.


SPN 174 FMI 0, SPN 174 FMI 31, SPN 1076 FMI 2, 1077 FMI 12,
SPN 1078 FMI 7, SPN 1078 FMI 31.

Ares 806 – 09.2004 – GB G7.89


Engine application
Anomaly code SPN 1078 FMI 7
Engine control unit – Pump timing slightly out of synchronisation

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 70

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 1078 FMI 7 is declared if


The pump control unit detects a crankshaft signal sent by the engine control unit and slightly out of range in relation to the pump's internal
timing.
This is what happens if code SPN 1078 FMI 7 is in force
– If the code is declared while the engine is not running, it is possible that the engine is failing to start.
– One of the following codes is active: SPN 1077 FMI 31, SPN 1569 FMI 31.
– The engine protection function is activated.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector Go to 2.
and the injection pump connector to locate any dirty, damaged or badly
Defective connection(s)
positioned terminals.
Repair the defective connection(s).

2. Check the crankshaft and pump sensors None of the mentioned points defective
– Poor electrical connections. Go to 3.
– Pump or crankshaft position sensor damaged. One of the mentioned points defective
– Crankshaft or injection pump pinion timing wheels damaged. Repair or change.
– Electromagnetic disurbance originating from other electronic devices around
the vehicle.

G7.90 Ares 806 – 09.2004 – GB


Engine application
3. Search for a short circuit on the crankshaft speed output wire All measurements over 2 kΩ
1 Unplug the injection pump and engine control unit connectors. Go to 4.
2 With a multimeter, measure the resistance between terminal (17) of
Any measurement under 2 kΩ
the engine control unit connector and all other terminals of this
Short circuit on the crankshaft speed output wire.
connector.

4. Search for an opening on the crankshaft speed wire 5 Ω or less


1 Leave the injection pump and engine control unit connectors Injection pump incorrectly fitted.
unplugged. Or
2 With a multimeter, measure the resistance between terminal (17) of Injection pump faulty.
the engine control unit connector and terminal (8) of the injection pump
Over 5 Ω
connector on the engine wiring harness.
Circuit open on crankshaft speed output wire.

Ares 806 – 09.2004 – GB G7.91


Engine application
Anomaly code SPN 1078 FMI 11
Engine control unit - Pump motor speed out of synchronisation

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 71

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 1078 FMI 11 is declared if


The engine control unit detcts that the pump's internal timing does not correspond to the engine speed.
This is what happens if code SPN 1078 FMI 11 is in force
– The engine may be running irregularly.
– The engine may be difficult to start.
N.B.: If codes SPN 636 or 637 appear at the same time as code SPN 1078 FMI 11, diagnose these codes first of all.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector Go to 2.
and the injection pump connector to locate any dirty, damaged or badly
Defective connection(s)
positioned terminals.
Repair the defective connection(s).

2. Check the crankshaft and pump sensors None of the mentioned points defective
– Poor electrical connection. Go to 3.
– Pump or crankshaft position sensor damaged. One of the mentioned points defective
– Crankshaft or injection pump pinion timing wheels damaged. Repair or change.
– Electromagnetic disurbance originating from other electronic devices around
the vehicle.

G7.92 Ares 806 – 09.2004 – GB


Engine application
3. Search for a short circuit on the crankshaft speed output wire All measurements over 2 kΩ
1 Unplug the injection pump and engine control unit connectors. Go to 4.
2 With a multimeter, measure the resistance between terminal (17) of
All measurements over 2 Ω
the engine control unit connector and all other terminals of this
Short circuit on the crankshaft speed output wire.
connector.

4. Search for an opening on the crankshaft speed wire 5 Ω or less


1 Leave the injection pump and engine control unit connectors Injection pump incorrectly fitted.
unplugged. Or
2 With a multimeter, measure the resistance between terminal (17) of Injection pump faulty.
the engine control unit connector and terminal (8) of the injection pump
Over 5 Ω
connector.
Circuit open on crankshaft speed output wire.

Ares 806 – 09.2004 – GB G7.93


Engine application
Anomaly code SPN 1078 FMI 31
Engine control unit - Pump timing considerably out of synchronisation

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 72

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 1078 FMI 31 is declared if


The pump control unit detects a crankshaft signal sent by the engine control unit and considerably out of range in relation to the pump's
internal timing.
This is what happens if code SPN 1078 FMI 31 is in force
– If the code is declared while the engine is not running, it is possible that the engine is failing to start.
– One of the following codes is active: SPN 1077 FMI 31, SPN 1569 FMI 31.
– The engine protection function is activated.
N.B.: If codes SPN 636 or 637 appear at the same time as code SPN 1078 FMI 31, diagnose these codes first of all.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector Go to 2.
and the injection pump connector to locate any dirty, damaged or badly
Defective connection(s)
positioned terminals.
Repair the defective connection(s).

G7.94 Ares 806 – 09.2004 – GB


Engine application
2. Check the crankshaft and pump sensors None of the mentioned points defective
Search for faults liable to cause these problems: Go to 3.
– Poor electrical connections. One of the mentioned points defective
– Pump or crankshaft position sensor damaged. Repair or change.
– Crankshaft or injection pump pinion timing wheels damaged.
– Electromagnetic disurbance originating from other electronic devices around
the vehicle.

3. Search for a short circuit on the crankshaft speed output wire All measurements over 2 kΩ
1 Unplug the injection pump and engine control unit connectors. Go to 4.
2 With a multimeter, measure the resistance between terminal (17) of
Any measurement under 2 kΩ
the engine control unit connector and all other terminals of this
connector on the engine wiring harness. Short circuit on the crankshaft speed output wire.

4. Search for an opening on the crankshaft speed wire 5 Ω or less


1 Leave the injection pump and engine control unit connectors Injection pump incorrectly fitted.
unplugged. Or
2 With a multimeter, measure the resistance between terminal (17) of Injection pump faulty.
the engine control unit connector and terminal (8) of the injection pump
Over 5 Ω
connector on the engine wiring harness.
Circuit open on crankshaft speed output wire.

Ares 806 – 09.2004 – GB G7.95


Engine application
Anomaly code SPN 1079 FMI 3
Sensor supply voltage (1) high
Code SPN 1079 FMI 3 is declared if
The engine control unit detects a voltage in excess of 5,5 V on its 5 V sensor supply circuit (1) (terminal 03).
This is what happens if code SPN 1079 FMI 3 is in force
The engine control unit uses default values for the sensors powered by the input supply voltage (1).

G7.96 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 1079 FMI 4
Sensor supply voltage (1) low
Code SPN 1079 FMI 4 is declared if
The engine control unit detects a voltage of less than 4,44 V on its 5 V sensor supply circuit (1) (terminal 03).
This is what happens if code SPN 1079 FMI 4 is in force
The engine control unit uses default values for the sensors powered by the input supply voltage (1).

Ares 806 – 09.2004 – GB G7.97


Engine application
Anomaly code SPN 1080 FMI 3
Sensor supply voltage (2) high
Code SPN 1080 FMI 3 is declared if
The engine control unit detects a voltage in excess of 5,5 V on its 5 V sensor supply circuit (2) (terminal 53).
This is what happens if code SPN 1080 FMI 3 is in force
The engine control unit uses default values for the sensors powered by the input supply voltage (2).

G7.98 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 1080 FMI 4
Sensor supply voltage (2) low
Code SPN 1080 FMI 4 is declared if
The engine control unit detects a voltage of less than 4,4 V on its 5 V sensor supply circuit (2) (terminal 53).
This is what happens if code SPN 1080 FMI 4 is in force
The engine control unit uses default values for the sensors powered by the input supply voltage (2).

Ares 806 – 09.2004 – GB G7.99


Engine application
Anomaly code SPN 1485 FMI 2
Pump supply relay fault

1 59

1
6

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
2 58

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 60
5

5
4 1
4

4
5 18

8 17
3

3
7 35
2

2
6 1

5 4

62

86 30

3
2
85 87

582hsm06 Fig. 73

Parts list
1 Engine control unit connector. 4 Pump connector. 58 CAN-high.
2 Battery. 5 Rotary injection pump. 59 CAN-low.
3 Rotary pump relay. 17 Crankshaft speed output. 60 CAN shielding.
18 Fuel cutout.

Code SPN 1485 FMI 2 is declared if


The engine control unit detects that the voltage at terminal (62) does not correspond to the voltage at terminal (35).
This is what happens if code SPN 1485 FMI 2 is in force
The engine may fail to start.

1. Check the connection No defective connection


Carry out a preliminary inspection of the engine control unit connector Go to 2.
and the injection pump connector to locate any dirty, damaged or badly
Defective connection(s)
positioned terminals.
Repair the defective connection(s).

2. Check the battery voltage before the rotary pump relay Close to the battery voltage
1 Unplug the rotary pump relay connector. Go to 3.
2 With a multimeter, measure the voltage between terminal (30) of the Considerably less than the battery voltage
rotary pump relay connector and a good earth on the chassis. Fuse(s) blown.
Or
Short circuit to earth in the supply wire.
Or
Circuit open in the pump control unit relay supply wire.

G7.100 Ares 806 – 09.2004 – GB


Engine application
3. Search for a cut in the rotary pump earth wire Close to the battery voltage
1 Ignition on, engine off. Go to 4.
2 With a multimeter, measure the voltage between terminal (30) and
Much lower than the battery voltage
terminal (85) of the rotary pump relay connector.
Circuit open on the rotary pump relay earth wire.

4. Check the relay control voltage Close to the battery voltage


1 Ignition on, engine off. Go to 5.
2 With a multimeter, measure the voltage between terminal (86) of the Much lower than the battery voltage
rotary pump relay connector on the engine wiring harness and a good Go to 6.
earth on the chassis.

5. Check the resistance of the pump control unit supply wire Under 5 Ω
1 Master switch off. Pump relay connector faulty.
2 Unplug the injection pump connector. Or
3 With a multimeter, measure the resistance between terminal (7) of the Pump relay faulty.
injection pump connector and terminal (30) of the rotary pump relay
Over 5 Ω
connector.
Pump control unit supply wire faulty.

6. Check the resistance of the pump control unit activation wire Under 5 Ω
1 Master switch off. Engine control unit connector faulty.
2 Disconnect the engine control unit switch. Or
3 With a multimeter, measure the resistance between terminal (62) of Engine control unit faulty.
the engine control unit connector and terminal (86) of the pump relay
Over 5 Ω
connector.
Pump control unit activation wire faulty.

7. Check the voltage of the pump control unit wire at the injection Close to the battery voltage with ignition on and off
pump Go to 9.
1 Master switch off.
Voltage zero with ignition off and close to the battery
2 Unplug the injection pump connector.
voltage with ignition on
3 With a multimeter, measure the voltage between terminal (7) of the
injection pump connector and a good earth on the chassis. Go to 8.
4 Ignition on, engine off.
5 Measure the voltage at the same point.

8. Search for a short circuit on powering the pump control unit Much lower than the battery voltage
supply wire Pump relay faulty.
1 Master switch off.
Close to the battery voltage
2 Unplug the rotary pump relay connector.
Short circuit on supply to the pump control unit supply wire.
3 Ignition on, engine off.
4 With a multimeter, measure the voltage between terminal (30) of the
pump relay connector and a good earth on the chassis.

9. Search for a opening on the pump control unit supply wire Under 5 Ω
1 Master switch off. Engine control unit connector faulty.
2 Unplug the engine control unit connector and the rotary pump relay Or
connector. Engine control unit faulty.
3 With a multimeter, measure the resistance between terminal (35) of
Over 5 Ω
the engine control unit connector and terminal (30) of the rotary pump
relay connector. Circuit open on the pump control unit supply wire.

Ares 806 – 09.2004 – GB G7.101


Engine application
10. Check the pump control unit activation wire voltage Voltage zero with ignition off and close to the battery
1 Master switch off. voltage with ignition on
2 Disconnect the pump relay connector. Go to 12.
3 With a multimeter, measure the voltage between terminal (86) of the
Close to the battery voltage with ignition on and off
rotary pump relay connector and a good earth on the chassis.
4 Ignition on, engine off. Go to 11.
5 Measure the voltage at the same point.

11. Search for a short circuit on powering the pump control unit Much lower than the battery voltage
activation wire Engine control unit connector faulty.
1 Master switch off. Or
2 Disconnect the engine control unit switch. Engine control unit faulty.
3 Ignition on, engine off.
Close to the battery voltage
4 With a multimeter, measure the voltage between terminal (86) of the
Short circuit on supply to the pump control unit activation
pump relay connector and a good earth on the chassis.
wire.

12. Search for a short circuit on powering the pump control unit Much lower than the battery voltage
supply wire Pump relay faulty.
1 Master switch off.
Close to the battery voltage
2 Unplug the rotary pump relay connector.
Short circuit on supply to the pump control unit supply wire.
3 Ignition on, engine off.
4 With a multimeter, measure the voltage between terminal 30 of the
pump relay connector and a good earth on the chassis.

G7.102 Ares 806 – 09.2004 – GB


Engine application
Anomaly code SPN 1569 FMI 31
Code SPN 1569 FMI 31 is declared if
– The engine control unit detects insufficient oil pressure.
– The engine control unit detects overheating of the manifold air.
– The engine control unit detects overheating of the engine coolant.
– The engine control unit detects that the quantity of water in the fuel exceeds the set threshold over a prolonged period.
– The engine control unit detects a loss of engine coolant.
– The engine control unit detects overheating of the fuel.
– The engine control unit detects a crankshaft synchronisation problem.
– The engine control unit receives a request from another electronic control unit on the vehicle/application.
– The engine control unit receives a signal from the pump control unit for a pump problem.
This is what happens if code SPN 1569 FMI 31 is in force
– The control unit limits the quantity if fuel made available to the engine in an attempt to protect it.
– If several power reductions are active, the greatest power reduction takes priority.

Code SPN 1569 FMI 31 appears. Refer to the corresponding sheets.


If anomaly code SPN 110 FMI 0, SPN 110 FMI 15, SPN 110 FMI 16,
SPN 174 FMI 00, SPN 174 FMI 16, SPN 174 FMI 31, SPN 637 FMI 2,
SPN 637 FMI 8, SPN 637 FMI 10, SPN 1076 FMI 2, SPN 1077 FMI 12,
SPN 1077 FMI 31 and SPN 1078 FMI 31 is active.

Ares 806 – 09.2004 – GB G7.103


Transmission application
Drivetronic 3

3 4 5 6
586hsm00 Fig. 74

Parts list
1 Choice of language. 3 Keyboard shortcut. 5 Version.
2 Choice of type of tractor. 4 Help. 6 Exit.

2 3

6 7 8 9 10
586hsm01 Fig. 75

Parts list
1 Overview. 5 Calibration. 8 Version.
2 Electrical tests. 6 Keyboard shortcut. 9 Return to previous mask.
3 Programming. 7 Help. 10 Exit.
4 Parameter setting.

G7.104 Ares 806 – 09.2004 – GB


Transmission application
Overview

1 2 3 4 5 6 7 8 9

10

11

31 12

13

14
30
15
29

28

27

26 25 24 23 22 21 20 19 18 17 16

586hsm09 Fig. 76

Parts list
1 Oil indicator. 17 +/- speed switch.
2 Low pressure indicator. 18 Clutch switch.
3 Diagnostic indicator. 19 Reverser switch.
4 Theoretical forward speed. 20 Range solenoid valve.
5 Quadrishift switch. 21 Display.
6 Quadrishift II/Quadractiv automatic system switch. 22 QUADRISHIFT solenoid valves.
7 Quadractiv status. 23 Differential locking switch.
8 Accelerator pedal set point. 24 Lift raised position.
9 Software version. 25 Front axle switch.
10 Engine control unit status. 26 Brake switch.
11 Error code. 27 Front axle solenoid valve.
12 Rear power take-off stop control. 28 Front axle solenoid valve.
13 Power take-off control. 29 Steering angle.
14 Rear power take-off economy speed selection. 30 Engine speed .
15 Rear PTO speed selection: 540/1 000 rpm. 31 Alarm.
16 Range change control.

Ares 806 – 09.2004 – GB G7.105


Transmission application
Engine control unit status

State Designations Cause

0 Alarm Pressure cut off for 4 s


1 Alarm wait Pressure cut off and engine speed <200 rpm
2 Work Normal
3 Work wait Loss of pressure
4 PTO alarm Loss of engine speed <200 rpm (transient state)
5 PTO wait state Loss of engine speed <200 rpm (stable state)
6 Standby Sleep
7 Parameter error Incorrect parameter
8 Not used —
9 High voltage Battery voltage over 16 V

Table of error codes


Action to recover
Error Fault
Possible fault Authorised functions all functions
code class
following repair
Short circuit on forward
Switch off tractor
01 1 gear solenoid valve +12 V Revershift locked (1)
(2)
power supply
Short circuit on reverse
Switch off tractor
02 1 gear solenoid valve +12 V Revershift locked (1)
(2)
power supply
Short circuit on forward Shift lever to
03 3 Reverse gear possible with lever and pedal control.
gear solenoid valve earth neutral
Short circuit on reverse Shift lever to
04 3 Forward gear possible with lever and pedal control.
gear solenoid valve earth neutral
Forward gear solenoid Shift lever to
05 3 Reverse gear possible with lever and pedal control
valve circuit open neutral
Reverse gear solenoid Shift lever to
06 3 Forward gear possible with lever and pedal control.
valve circuit open neutral

G7.106 Ares 806 – 09.2004 – GB


Transmission application
Table of error codes (continued)
Action to recover
Error Fault
Possible fault Authorised functions all functions
code class
following repair
Before shifting lever to neutral: Pedal declutching function to
No contact active on Declutch pedal
11 2 change gear. No change in direction. After shifting lever to
steering wheel controls (bottom contact)
neutral: None
Before shifting lever to neutral: Pedal declutching function to
Forward and neutral Declutch pedal
12 2 change gear. No change in direction. After shifting lever to
contact at same time (bottom contact)
neutral: None
Before shifting lever to neutral: Pedal declutching function to
Reverse and neutral Declutch pedal
13 2 change gear. No change in direction. After shifting lever to
contact at same time (bottom contact)
neutral: None
Before shifting lever to neutral: Pedal declutching function to
Forward and reverse Declutch pedal
14 2 change gear. No change in direction. After shifting lever to
contact at same time (bottom contact)
neutral: None
Circuit open or short circuit
All functions are provided but no pedal graduality. (shifting with
15 3 to earth on pedal None
automatic management of pressurisation).
potentiometer
Short circuit to +5 V on All functions are provided but no pedal graduality. (shifting with
16 3 None
pedal potentiometer automatic management of pressurisation).
Short circuit to +5 V on
171 3 All functions authorised. None
pedal potentiometer
Short circuit to +12 V on
18 3 All functions are provided but pedal graduality downgraded. None
bottom contact
Circuit open or short circuit
19 3 All functions authorised. None
to earth
Short circuit to +12 V on All functions are provided but no pedal graduality. (shifting with
20 3 None
top contact automatic management of pressurisation).
Fault on Revershift speed
21 3 All functions authorised. None
sensor
No power supply to
Shift lever to
22 3 proportional solenoid valve None.
neutral
pilots
Parameter table reading
23 2 All functions authorised. None
fault
1. Fault not detected in versions A6, B2 and subsequent versions.

Ares 806 – 09.2004 – GB G7.107


Transmission application
Electrical tests
Supply and safety

1 2 3

586hsm10 Fig. 77

N.B.: JX-X corresponds to the connector channel on the Drivetronic unit.

Parts list
1 Shuttle reverser lever or clutch pedal bottom contact (neutral or 3 Engine speed . The information is sent by the sensor whose
disengaged position). target is the hydraulic pump driving pinion.
2 Low pressure switch (contact open when stopped). N.B.: The dashboard information comes from the alternator.

1 2 3 4

586hsm11 Fig. 78

Parts list
1 Front axle engagement switches. 3 Front axle solenoid valve.
2 Front axle indicator light. 4 Brake pedals.

G7.108 Ares 806 – 09.2004 – GB


Transmission application
Power take-off (PTO)

1 2

586hsm12 Fig. 79

Parts list
1 PTO output speed.
2 Engine speed .
3 PTO slip. Clutch sliding is summoned (from engagement to stoppage of the power take-off). If this value exceeds the limit threshold,
the system switches to safety, the solenoid valve is cut out and the PTO indicator flashes quickly.

Ares 806 – 09.2004 – GB G7.109


Transmission application
REVERSHIFT

1
2 3

586hsm13 Fig. 80

Parts list
1 Clutch pedal setpoint.
2 Clutch pedal top contact.
3 Shuttle reverser lever or clutch pedal bottom contact (neutral or disengaged position).
4 Current in the prportional solenoid valves: 0 to 1,2 A.

G7.110 Ares 806 – 09.2004 – GB


Transmission application
Adjustment of top (TOC), bottom (BOC) and angle detector switches

A1 A A2

J1.20 J1.20

J2.33 J2.33

A1 A5 A3 A2

583msm10 Fig. 81

Position the reverser lever in forward or reverse.

A = Mechanical travel.
B = Electrical travel.
A1 = Pedal clutch engaged.
A2 = Clutch pedal released.
A3 = BOC opening.
A5 = TOC opening.

– Adjustment of the mechanical pedal end stops.

Vn = Numerical value of J1.4 read on Win Métadiag©.

Vn A1 – Vn A2 _> 200

– BOC switch adjustment (J2.33).

Vn A3 – Vn A2 _> 20

– TOC switch adjustment (J1.20).

Vn A1 – Vn A5 _> 20

Ares 806 – 09.2004 – GB G7.111


Transmission application
Quadractive

3 7 2

5
4
6

586hsm14 Fig. 82

Parts list
1 Indicator lights output. 5 Quadrishift II/Quadractiv automatic system switch.
2 Quadrishift solenoid valve (cf. table). 6 Quadractiv switch.
3 Clutch output sensor speed. 7 Quadractiv status.
4 Accelerator pedal setpoint.

Gear 1 2 3 4
EV1 Active Active — —

EV2 — Active Active —

G7.112 Ares 806 – 09.2004 – GB


Transmission application
Ranges

586hsm15 Fig. 83

Parts list
1 Field/road range lever switch. 3 Field lamp output.
2 Neutral logic input (switch on gearbox cover). 4 Range solenoid valve.

Ares 806 – 09.2004 – GB G7.113


Transmission application
Differential locking

1 4

586hsm16 Fig. 84

Parts list
1 Differential locking switch. 5 Lift position input (lift raising instruction). If lift raising is
2 Differential locking lamp output. requested, the differential disengages.
3 Differential lock solenoid valve. 6 Brake switches.
4 Steering angle.
If tractor speed <10 km/h.
ß Differential is triggered at 15°.
ß Differential can re-engage at 13°.
If tractor speed _>10 km/h.
ß Differential is triggered at 5°.
ß Differential can re-engage at 3°.

G7.114 Ares 806 – 09.2004 – GB


Transmission application
Quadrishift

586hsm17 Fig. 85

Parts list
1 "Faster" input. 3 Oil temperature indicator (t° > 90°).
2 "Slower" input. 4 Oil temperature probe information.

Ares 806 – 09.2004 – GB G7.115


Transmission application
Programming

586hsm18 Fig. 86

Parts list
1 Win Métadiag© version to be programmed in the Drivetronic 3 computer.

Parameter setting

3
2

586hsm19 Fig. 87

Parts list
1 Existing parameters in the unit.
2 Parameters selected with Win Métadiag© [validated after setting (3)].

G7.116 Ares 806 – 09.2004 – GB


Transmission application
Calibration

586hsm20 Fig. 88

Steering calibration is necessary after changing the steering angle sensor or the electronic unit.
– Set the wheels straight.
– Read value (1); this must be between 114 and 138.
– Click "OK".
N.B.: Calibration of the forward motion clutches is an independent Win Métadiag© operation - see chapter "G3".

Ares 806 – 09.2004 – GB G7.117


Transmission application
Full Powershift

3 4 5 6
586hsm21 Fig. 89

Parts list
1 Choice of language. 3 Keyboard shortcut. 5 Version.
2 Choice of type of tractor. 4 Help. 6 Exit

1 3
2 4

6 7 8 9 10
586hsm22 fr Fig. 90

Parts list
1 Overview. 5 Calibration. 9 Return to previous mask.
2 Electrical tests. 6 Keyboard shortcut. 10 Exit.
3 Programming. 7 Help.
4 Parameter setting. 8 Version.

G7.118 Ares 806 – 09.2004 – GB


Transmission application
Electric tests on "TC" (Transmission Controler)
Solenoid valves

586hsm23 Fig. 91

N.B.: For example, "AH-CD" means connector "A" of "TC" channel "H" ; Connector "C" of "TC" channel "D".

Parts list
AH – CD Clutch "1" proportional solenoid valve. AK – CJ Clutch "R" proportional solenoid valve.
AJ – CH Clutch "2" proportional solenoid valve. BH Front axle solenoid valve.
AB – CB Clutch "A" proportional solenoid valve. AD – CK Front/rear differential locking solenoid valve.
AC – CC Clutch "B" proportional solenoid valve. BG – BD PTO clutch proportional solenoid valve.
AA – CA Clutch "C" proportional solenoid valve. BF – BE PTO brake solenoid valve.
AF – CF Clutch "L" proportional solenoid valve. BC "Park Lock" control solenoid valve.
AG – CG Clutch "M" proportional solenoid valve. SPEED Gear engaged display.
AE – CE Clutch "H" proportional solenoid valve.

Clutch combinations

Gears Clutches Gears Clutches Gears Clutches


F1 1-A-L F10 2-B-M R1 R-A-L
F2 2-A-L F11 1-A-H R2 R-B-L
F3 1-B-L F12 1-C-M R3 R-B-M
F4 1-A-M F13 2-A-H R4 R-C-L
F5 2-B-L F14 2-C-M R5 R-B-M
F6 2-A-M F15 1-B-H R6 R-A-H
F7 1-C-L F16 2-B-H R7 R-C-M
F8 1-B-M F17 1-C-H R8 R-B-H
F9 2-C-L F18 2-C-H

Ares 806 – 09.2004 – GB G7.119


Transmission application
Sensors

586hsm24 Fig. 92

Parts list
EE – EH Engine speed sensor. EJ Gearbox filter blockage indicator.
EF – EH Gearbox output speed sensor. EK Rear axle lubrication circuit pressure switch.
ED – EH PTO speed sensor (slip calculation). EA Rear axle low pressure switch.
EG PTO speed sensor (dashboard speed). EB Gearbox low pressure switch.
DJ – DG Gearbox oil temperature sensor. EC Crawling range engaged switch.
DF Park Lock safety switch.

N.B.:
Low pressure switches "EA" and "EB".
– Switch open at rest (pressure = 0 bar) lamp lit.
– Switch closed with engine running (pressure = 17 bar) lamp out.
Rear axle lubrication circuit pressure switch "EK".
– Switch closed at rest (pressure = 0 bar) lamp lit.
– Switch open with engine running (pressure = 1,8 bar) lamp out.

G7.120 Ares 806 – 09.2004 – GB


Transmission application
Electric tests on "RCC" (Renault Cabin Controler)
Front axle and differential

586hsm25 Fig. 93

N.B.: For example, "J2-20" means connector "J2" channel "20".

Parts list
J2 – 20 Front axle switch. J2 – 22 "Park Lock" indicator.
J1 – 8 Front/rear differential locking switch. J2 – 23 Handbrake switch.
J2 – 29 LH brake pedal switch. J2 – 5 Raised position "TCE" information
J2 – 6 RH brake pedal switch. (contact closed = raised position).
J2 – 25 Park Lock switch. J2 – 35 Steering angle sensor signal.

Shuttle reverser

586hsm69 Fig. 94

Parts list
J2 – 19 Pedal top switch information (TOC). J2 – 22 Speed gear switch (decelerate).
J2 – 36 Approach pedal potentiometer. J2 – 2 "Forward position" shuttle reverser switch.
J2 – 7 Pedal bottom switch information (BOC). J2 – 1 "Neutral position" shuttle reverser switch.
J2 – 26 Manoeuvring gear switch. J2 – 24 "Reverse position" shuttle reverser switch.
J2 – 27 Speed gear switch (accelerate). J2 – 33 Supercharging signal.

Ares 806 – 09.2004 – GB G7.121


Transmission application
Adjustment of top (TOC), bottom (BOC) and angle
detection switches

– Adjustment of the mechanical pedal end stops


(example of values taken on a tractor).
V = Voltage of J2.36 on Win Métadiag©
V2 – V1 = 4,45 – 0,41 = 4,04 V

– Adjustment of switch BOC (J2.37).


V2 – V3 = 4,45 – 4,17 = 0,28 V

– Adjustment of switch TOC (J2.19).


V4 – V1 = 1,08 – 0,41 = 0,67 V V1

586hsm61 Fig. 95

V4

586hsm62 Fig. 96

V3

586hsm63 Fig. 97

V2

586hsm64 Fig. 98

G7.122 Ares 806 – 09.2004 – GB


Transmission application
Power take-off (PTO)

586hsm26 Fig. 99

N.B.: For example, "J2-20" means connector "J2" channel "20".

Parts list
J2 – 4 Rear PTO clutch control. J1 – 30 Rear PTO light.
J1 – 28 Rear PTO brake switch. J1 – 20 Alarm.
J2 – 3 PTO stop switches on wings.

Ares 806 – 09.2004 – GB G7.123


Transmission application

"RCC" and "TC" fault history

586hsm27 Fig. 100

Parts list
1 Number of transmission hours. 2 Error code.

N.B.: The error codes are also visible in the bottom right-hand corner of the display.

1 2
586hsm28 Fig. 101

Parts list
1 Error code.
2 Special case of transmission oil pressure fault. Whn a loss of oil pressure is recorded on one of the hydraulic circuits, lights up
and an alarm is activated.
tra = Low pressure transmission circuit (rear axle).
bte = Low pressure gearbox circuit.
lub = Lubrication system (rear axle).

G7.124 Ares 806 – 09.2004 – GB


Transmission application
List of "RCC" error codes
Code Cause
121 Excessive battery (regulator) voltage.
122 Insufficient battery (regulator) voltage.
123 Excessive engine oil pressure sensor signal.
124 Insufficient engine oil pressure sensor signal.
125 Excessive engine temperature sensor signal.
126 Insufficient engine temperature sensor signal.
127 Excessive fuel gauge signal.
128 Insufficient fuel gauge signal.
129 Excessive battery voltage.
130 Insufficient battery voltage.
131 Excessive turbo pressure sensor signal.
132 Insufficient turbo pressure sensor signal.
133 Excessive steering angle sensor signal.
134 Insufficient steering angle sensor signal.
139 Excessive approach pedal potentiometer signal.
140 Insufficient approach pedal potentiometer signal.
141 Engine speed out of range.
142 Pedal top switch (TOC) short circuit to + 12 V.
143 Pedal bottom switch (BOC) short circuit to + 12 V.
144 Neutral switch (normally open) short circuit to + 12 V.
145 Neutral switch (normally open) short circuit to + 12 V.
146 Neutral switch (normally closed) short circuit to + 12 V.
147 Neutral switch (normally open) short circuit to earth.
148 Reprogramming attempted with engine running.
149 CAN error.
150 Loss of message on CAN.
151 Transmission output speed out of limit.
152 Engine hourmeter error.
153 "EEPROM" monitoring problem.
154 Communication error between "RCC" and "TC".
156 Top pedal switch (TOC) remained open.
157 No engine speed signal.
158 Transmission speed sensor error.
159 Engine torque too low (Atles only, "EMR" unit).
160 Engine torque too high (Atles only, "EMR" unit).
161 No engine torque information (Atles only, "EMR" unit).
162 Unstable engine torque (Atles only, "EMR" unit).

Ares 806 – 09.2004 – GB G7.125


Transmission application
List of "TC" error codes (from version TC 02.17)
0 Not used.
1 Not used.
2 Current incident on clutch "L" (circuit open or short circuit to earth).
3 Current incident on clutch "L" (short circuit on +12 AC).
4 Current incident on clutch "M" (circuit open or short circuit to earth).
5 Current incident on clutch "M" (short circuit on +12 AC).
6 Current incident on clutch "H" (circuit open or short circuit to earth).
7 Current incident on clutch "H" (short circuit on +12 AC).
8 Current incident on clutch "1" (circuit open or short circuit to earth).
9 Current incident on clutch "1" (short circuit on +12 AC).
10 Current incident on clutch "2" (circuit open or short circuit to earth).
11 Current incident on clutch "2" (short circuit on +12 AC).
12 Current incident on clutch "R" (circuit open or short circuit to earth).
13 Current incident on clutch "R" (short circuit on +12 AC).
14 Current incident on clutch "A" (circuit open or short circuit to earth).
15 Current incident on clutch "A" (short circuit on +12 AC).
16 Current incident on clutch "B" (circuit open or short circuit to earth).
17 Current incident on clutch "B" (short circuit on +12 AC).
18 Current incident on clutch "C" (circuit open or short circuit to earth).
19 Current incident on clutch "C" (short circuit on +12 AC).
20 Engaged gear request by "RCC" incorrect.
21 Transmission oil temperature for calibration less than 50°C.
22 Engine speed above limit for calibration (1 800 rpm).
23 Engine speed below limit for calibration (1 250 rpm).
24 Gearbox output speed above limit for calibration.
25 Use of default calibration values.
26 Incorrect parameter setting for number of pulses per PTO revolution.
27 No calibration speed sensor signal.
28 Forward speed signal of calibration speed sensor incorrect.
29 Reverse speed signal of calibration speed sensor incorrect.
30 Calibration speed sensor signal not falling.
31 Surface pressure over 5,1 bar.
32 Not used.
33 Not used.
34 Not used.
35 Not used.
36 Not used.
37 Not used.
38 Not used.
39 Not used.
40 Not used.

G7.126 Ares 806 – 09.2004 – GB


Transmission application

41 Detection of transmission slip.


42 Not used.
43 Not used.
44 Not used.
45 Excessive alternator regulator voltage (filtered battery signal).
46 Insufficient alternator regulator voltage (filtered battery signal).
47 Not used.
48 Not used.
49 Excessive transmission temperature sensor electric signal.
50 Insufficient transmission temperature sensor electric signal.
51 Not used.
52 Not used.
53 Excessive PTO solenoid valve current value.
54 Insufficient PTO solenoid valve current value.
55 Excessive PTO brake solenoid valve current value.
56 Insufficient PTO brake solenoid valve current value.
57 Excessive clutch "C" solenoid valve current value.
58 Insufficient clutch "C" solenoid valve current value.
59 Excessive clutch "R" solenoid valve current value.
60 Insufficient clutch "R" solenoid valve current value.
61 Excessive clutch "A" solenoid valve current value.
62 Insufficient clutch "A" solenoid valve current value.
63 Excessive clutch "2" solenoid valve current value.
64 Insufficient clutch "2" solenoid valve current value.
65 Excessive clutch "B" solenoid valve current value.
66 Insufficient clutch "B" solenoid valve current value.
67 Excessive clutch "1" solenoid valve current value.
68 Insufficient clutch "1" solenoid valve current value.
69 Excessive differential locking solenoid valve current value.
70 Insufficient differential locking solenoid valve current value.
71 Excessive clutch "M" solenoid valve current value.
72 Insufficient clutch "M" solenoid valve current value.
73 Excessive clutch "H" solenoid valve current value.
74 Insufficient clutch "H" solenoid valve current value.
75 Excessive clutch "L" solenoid valve current value.
76 Insufficient clutch "L" solenoid valve current value.
77 Loss of CAN message.
78 CAN deactivated.
79 No CAN message from "RCC".
80 Minor "Checksum" error on serial "EEPROM" (table of contents).
81 Fatal "Checksum" error on serial "EEPROM" (default values retrieved).
82 Minor incident on transmission hour counting ("TC" internal).

Ares 806 – 09.2004 – GB G7.127


Transmission application

83 Major incident on transmission hour counting ("TC" internal).


84 Minor incident on counting tenths of transmission hours ("TC" internal).
85 Major incident on counting tenths of transmission hours ("TC" internal).
86 Gearbox 17 bar pressure faults.
87 3 bar lubrication pressure switch fault.
88 Reprogramming attempted with engine running.
89 "TC" internal circuit (protection transistor remained open).
90 No electric signal from PTO speed sensor.
91 No electric signal from engine speed sensor.
92 Fall in engine speed and stalling.
93 PTO clutch slip.
94 PTO brake incident.
95 No hydraulic pressure.
96 Short circuit to + 12 AC on PTO clutch solenoid valve.
97 Overvoltage detected on PTO clutch solenoid valve.
98 Park Lock engagement error.
99 Park Lock displacement error.
100 Incident on front axle solenoid valve.
101 Not used.
102 Not used.
103 Not used.
104 Not used.
105 Not used.
106 Not used.
107 Not used.
108 Not used.
109 Not used.
110 "RC" internal circuit (protection transistor remained open).
111 Fault between presumed current and measured current on clutch "1".
112 Fault between presumed current and measured current on clutch "2".
113 Fault between presumed current and measured current on clutch "R".
114 Fault between presumed current and measured current on clutch "A".
115 Fault between presumed current and measured current on clutch "B".
116 Fault between presumed current and measured current on clutch "C".
117 Fault between presumed current and measured current on clutch "L".
118 Fault between presumed current and measured current on clutch "M".
119 Fault between presumed current and measured current on clutch "H".
163 Calibration fault, filling time on clutch "1" too low.
164 Calibration fault, filling time on clutch "2" too low.
165 Calibration fault, filling time on clutch "R" too low.
166 Calibration fault, filling time on clutch "A" too low.

G7.128 Ares 806 – 09.2004 – GB


Transmission application

167 Calibration fault, filling time on clutch "B" too low.


168 Calibration fault, filling time on clutch "C" too low.
169 Calibration fault, filling time on clutch "L" too low.
170 Calibration fault, filling time on clutch "M" too low.
171 Calibration fault, filling time on clutch "H" too low.
172 Calibration fault, filling time on clutch "1" too high.
173 Calibration fault, filling time on clutch "2" too high.
174 Calibration fault, filling time on clutch "R" too high.
175 Calibration fault, filling time on clutch "A" too high.
176 Calibration fault, filling time on clutch "B" too high.
177 Calibration fault, filling time on clutch "C" too high.
178 Calibration fault, filling time on clutch "L" too high.
179 Calibration fault, filling time on clutch "M" too high.
180 Calibration fault, filling time on clutch "H" too high.
181 Calibration fault, surface pressure time on clutch "1" too low.
182 Calibration fault, surface pressure time on clutch "2" too low.
183 Calibration fault, surface pressure time on clutch "R" too low.
184 Calibration fault, surface pressure time on clutch "A" too low.
185 Calibration fault, surface pressure time on clutch "B" too low.
186 Calibration fault, surface pressure time on clutch "C" too low.
187 Calibration fault, surface pressure time on clutch "L" too low.
188 Calibration fault, surface pressure time on clutch "M" too low.
189 Calibration fault, surface pressure time on clutch "H" too low.
190 Calibration fault, surface pressure time on clutch "1" too high.
191 Calibration fault, surface pressure time on clutch "2" too high.
192 Calibration fault, surface pressure time on clutch "R" too high.
193 Calibration fault, surface pressure time on clutch "A" too high.
194 Calibration fault, surface pressure time on clutch "B" too high.
195 Calibration fault, surface pressure time on clutch "C" too high.
196 Calibration fault, surface pressure time on clutch "L" too high.
197 Calibration fault, surface pressure time on clutch "M" too high.
198 Calibration fault, surface pressure time on clutch "H" too high.

Ares 806 – 09.2004 – GB G7.129


Transmission application
Programming

1 2 3
586hsm29 Fig. 102

Parts list
1 "RCC 1" 77 00 054 734. 2 "RCC 1" 77 00 058 272. 3 "TC" 77 00 049 277.

N.B.:
The rear trim needs to be removed to be able to read the "RCC" reference on the unit. The program version is visible on
the display.
– Press the front axle and differential locking engagement switches simultaneously then.
– Switch on the ignition.
– The version of the various programs then appears on the "PSD" in the form of a drop-down menu.

Example: Cab ˘ P30 ˘ r52 ˘ trA ˘ P02 ˘ r17.

Cab = RCC (Renault Controler Cabine) trA = TC (Transmission Controler)


P01 = Phase n° 1 P02 = Phase n° 2
P52 = Revision n° 52 r17 = Revision n° 17

Parameter setting

586hsm30 Fig. 103

Choice to be made in the two "RCC" unit references.

G7.130 Ares 806 – 09.2004 – GB


Transmission application

586hsm31 Fig. 104

Choice of tractor - the Ares 826 RZ TIER II is distinguished by its electronic injection system.

Calibration
Steering calibration
Refer to calibration on page G7.117.

Transmission calibration

586hsm32 Fig. 105

Parts list
1 Tractor value.
2 When the conditions are met, validate the request and "mode normal" (normal mode) changes to "mode étalonnage" (calibration
mode). Calibration is necessary after changing the "TC", "RCC" or proportional solenoid valve, mechanical repair to the clutches. . .

N.B.: Check that the air conditioning is switched off.

Ares 806 – 09.2004 – GB G7.131


Transmission application
Coupling the calibration connector
1 Remove the "TC" protection plate under the cab on the
right-hand side of the transmission. B
2 Unplug connectors (A).
3 Couple connector (A) (brown wire) to standby
connector (B) (red wire).
4 Continue with the procedure described in Win
Métadiag© in "Transmission calibration".
5 Once the calibration has been accepted, remember to A
couple connectors (A) together.
N.B.: Gearbox clutch calibration takes around 8
to 10 minutes during which time each clutch will be
pressurized (briefly) leading to reduced engine
speed. This phenomenon is normal. It is essential that
the tractor is at a standstill with the handbrake
applied.

586hsm33 Fig. 106

Details of the various stages of calibration

0 Calibration of spool currents (approx. 15 s). —


1 R–C
2 Checks correct speed of intermediate shaft. 2–C
3 2–B
4 Calibration of clutch "1" surface pressure. 1–R–C
5 Calibration of clutch "2" surface pressure. 2–R–C
6 Calibration of clutch "R" surface pressure. 2–R–C
7 Calibration of clutch "A" surface pressure. 2–A–C
8 Calibration of clutch "B" surface pressure. B–2–C
9 Calibration of clutch "C" surface pressure. B–2–C
10 Calibration of clutch "L" surface pressure. L–2–C
11 Calibration of clutch "M" surface pressure. M–2–C
12 Calibration of clutch "H" surface pressure. H–2–C
13 Calibration of clutch "1" filling time. H–1–C
14 Calibration of clutch "2" filling time. H–2–C
15 Calibration of clutch "R" filling time. H–R–C
16 Calibration of clutch "A" surface pressure. H–2–A
17 Calibration of clutch "B" surface pressure. H–B–2
18 Calibration of clutch "C" surface pressure. H–2–C
19 Calibration of clutch "L" surface pressure. L–B–2
20 Calibration of clutch "M" surface pressure. M–B–2
21 Calibration of clutch "H" surface pressure. H–B–2

G7.132 Ares 806 – 09.2004 – GB


Transmission application
PTO torque adjustment

586hsm34 Fig. 107

This operation is necessary in case of incorrect gearshifting during use of implements with the PTO. Win Métadiag© will
measure the torque with and without PTO and transmit it to the unit in order to adjust gearshifting.

Turbo sensor calibration

586hsm35 Fig. 108

This operation is necessary on changing:


– Turbo sensor.
– Transmission units.
It is also necessary when the tractor has changed geographical location (difference in atmospheric pressure). This
calibration acts on gearshifting under torque.

Ares 806 – 09.2004 – GB G7.133


Rear axle application
GPA 41-42-43

3 4 5 6
586hsm36 Fig. 109

Parts list
1 Choice of language. 3 Keyboard shortcut. 5 Version.
2 Choice of lift type. 4 Help. 6 Exit.

2 3 4 5 6
586hsm37 Fig. 110

Parts list
1 Overview. 4 Version. 6 Exit.
2 Keyboard shortcut. 5 Return to previous mask. 7 Programming.
3 Help.

G7.134 Ares 806 – 09.2004 – GB


Rear axle application
Overview

2
5

7 4
586hsm38 Fig. 111

Parts list
1 "EV1" and "EV2": Solenoid valves. 4 Error code. 7 Engagement/release switch "S3".
2 "S1" and "S2": Switches. 5 Indicator 1 = red.
3 Software version. 6 Indicator 2 = orange.

Combination

EV1 EV2 Function

1 0 Road
0 1 Automatic brake active
0 0 Memory

Ares 806 – 09.2004 – GB G7.135


Rear axle application
List of error codes

Error code Component Failure Effects

Sticks open: "Brake engaged"


35 information presented Loss of brake engagement/release function.
continuously to the system.
Switch "S1"
Locked shut: "Brake engaged"
36 information never received by Loss of brake engagement/release function.
the system.
Locked shut: "Brake worn"
Lamp "V2" constantly lit, no loss of engagement/
37 Switch "S2" information presented
release function.
continuously to the system.
Locked shut: Brake engagement In normal operation, an engagement request can
Engagement/release switch
38 request impossible due to only be made if the "ISC" lever is in neutral. "V1"
"S3"
management on transition. could indicate that "PL" is about to be engaged.
17 Short-circuit to earth. Loss of brake engagement function.
18 Open circuit. Loss of brake engagement function.
Draining solenoid valve "EV1" Brake engaged as soon as "EV2" power supply is
34 Short circuit to 12 V. switched off. The system continues to operate as
if there is no fault.
Loss of disengagement function: lamp "V1" stays
19 Short-circuit to earth.
lit and lamp "V2" signals the fault.
Loss of disengagement function: lamp "V1" stays
20 Filling solenoid valve "EV2" Open circuit.
lit and lamp "V2" signals the fault.
Brake released as soon as the fault occurs: lamp
21 Short circuit to 12 V.
"V1" is out and lamp "V2" signals the fault.

Programming

586hsm65 Fig. 112

Once programming is complete, the software version is visible in the overviews.

G7.136 Ares 806 – 09.2004 – GB


Rear lift application
TCE 15-25

2
1

3 4 5 6
586hsm39 Fig. 113

Parts list
1 Choice of language. 3 Keyboard shortcut. 5 Version.
2 Choice of lift type. 4 Help. 6 Exit.

4 5 6 7 8

586hsm40 Fig. 114

Parts list
1 Overview. 4 Keyboard shortcut. 7 Return to previous mask.
2 Programming. 5 Help. 8 Exit.
3 Calibration. 6 Version.

Ares 806 – 09.2004 – GB G7.137


Rear lift application
Lift overview

1 2 3 4 5 6 7

18

17

16

15

14 13 12 11 10 9 8
586hsm41 Fig. 115

Parts list
1 Display. 11 Upper limit.
2 Transport shock absorber. 12 Voltage supplied by the position sensor.
3 5-position mode switch indicator. 13 Voltages supplied by the signal from the bars and load
4 Position display. correspondence (from – 6 to + 6 tonnes).
5 Load control sensitivity. 14 Activated solenoid valve indication.
6 Control keys. 15 Current values in the solenoid valves (from 0 to 3,5 A).
7 Exterior control indicator. 16 Active slip control.
8 Theoretical forward speed. 17 Slip rate.
9 Actual forward speed. 18 Warning light.
10 Lowering speed.

G7.138 Ares 806 – 09.2004 – GB


Rear lift application
List of error codes

System faults may appear in the form of an error code: This is displayed on the screen (1) "Er" followed by the code:

Error code Definition Flashing

0 Battery voltage. Fast


2 LH draft sensor. Slow
3 RH draft sensor. Slow
7 "TCE" position output to Drivetronic. Slow
8 5-position selector potentiometer. —
9 Lift position sensor. Fast
10 Short circuit on lift raising valve or circuit open. Fast
11 Short circuit on lift lowering valve or circuit open. Fast
12 Semi-mounted plough sensor. Slow
13 Raising proportional solenoid valve for semi-mounted. Slow
14 Lowering proportional solenoid valve for semi-mounted. Slow
16 Diagnostic lamp in open circuit. —
18 No information on CAN bus. Slow

Ares 806 – 09.2004 – GB G7.139


Rear lift application
Programming
Parts list 1
©
1 Win Métadiag version to be programmed in the computer.

586hsm42 Fig. 116

Calibration

586hsm43 Fig. 117

Select the component to be calibrated and follow the indications mentioned on the Win Métadiag© screen.

G7.140 Ares 806 – 09.2004 – GB


Rear lift application
TCE 15 T

2
1

3 4 5 6
586hsm44 Fig. 118

Parts list
1 Choice of language. 3 Keyboard shortcut. 5 Version.
2 Choice of lift type. 4 Help. 6 Exit.

2 3 4 5 6

586hsm45 Fig. 119

Parts list
1 Overview. 3 Help. 5 Return to previous mask.
2 Keyboard shortcut. 4 Version. 6 Exit.

Ares 806 – 09.2004 – GB G7.141


Rear lift application
Overview

1 2 3 4 5

13

12

11

10

9 8 7 6
586hsm46 Fig. 120

Parts list
1 Load control. 8 Battery condition.
2 Transport shock absorber. 9 Voltages supplied by the load sensor signal.
3 4-position mode switch indicator. 10 Activated solenoid valve indicator and value of transversed
4 Movement indicator. current (from 0 to 3,5 A).
5 Depth setting. 11 Warning light.
6 Exterior control indicators. 12 Upper limit.
7 Voltages supplied by the position sensor signal. 13 Lowering speed.

N.B.:
When a fault is detected, it is signalled under the overview by the symbol.
The electronic unit is equipped with a self-diagnostic function and the user can obtain the error code through the flashing
of the safety indicator lamp.

G7.142 Ares 806 – 09.2004 – GB


Rear lift application
Example of how to read the safety indicator lamp.

Parts list
1 Long pause. 2 Short pause.

The self-diagnostic system signals error code "34".

586hsm47 Fig. 121

List of error codes

Code Component concerned Source of the problem

Serious failures

11 Raising proportional solenoid valve Circuit open on raising solenoid circuit or engine control unit faulty.
12 Lowering proportional solenoid valve Circuit open on lowering solenoid circuit or engine control unit faulty.
Current measured at 6 too high, short circuit between 2 and 6 or 14
13 Short circuit
and 6 or short circuit in proportional solenoid valve.
14 Rear UP button —
15 Rear DOWN button —
16 Supply voltage Supply voltage less than 9,5 V.

Medium severity failures

Circuit open, short circuit or short circuit to earth of the sensor,


22 Position sensor
incorrect setting.
23 Position order potentiometer Short circuit on potentiometer or circuit open.
24 TOP limit potentiometer Short circuit on potentiometer or circuit open.
28 Transport/stop/check selector Short circuit on potentiometer or circuit open.

Minor failures

Circuit open, short circuit or short circuit to earth of the sensor,


32 Load sensor
incorrect setting.
34 DOWN speed potentiometer Short circuit on potentiometer or circuit open.
36 Mixed potentiometer Potentiometer short circuit or open circuit.

Ares 806 – 09.2004 – GB G7.143


Dashboard application

3 4 5 6

586hsm48 Fig. 122

Parts list
1 Choice of language. 3 Keyboard shortcut. 5 Version.
2 Choice of type of tractor. 4 Help. 6 Exit.

3 4 5 6 7

586hsm49 Fig. 123

Parts list
1 Overview. 4 Help. 7 Exit.
2 Parameter setting. 5 Version.
3 Keyboard shortcut. 6 Return to previous mask.

G7.144 Ares 806 – 09.2004 – GB


Dashboard application
Overview

1 2
586hsm50 Fig. 124

Parts list
1 Built-in test. Illustrated indicator lamps lit simultaneously or successively.
2 Software version.

History of faults

3
4

1 2
586hsm51 Fig. 125

Reading of parameters (1) with alarm resetting (2).

Ares 806 – 09.2004 – GB G7.145


Dashboard application
Parameter setting

586hsm52 Fig. 126

Parts list
1 Choice of type of tractor. 2 Speed calibration. 3 Maintenance frequency setting.

"Forward speed" computer calibration procedure

. Cf. Tractor service manual.

G7.146 Ares 806 – 09.2004 – GB


Electropilot application

3 4 5 6

586hsm53 Fig. 127

Parts list
1 Choice of language. 3 Keyboard shortcut. 5 Version.
2 Choice of application. 4 Help. 6 Exit.

4 5 6 7 8

586hsm54 Fig. 128

Parts list
1 Overview. 4 Keyboard shortcut. 7 Return to previous mask.
2 Parameter setting. 5 Help. 8 Exit.
3 Calibration. 6 Version.

N.B.: the Electropilot application is only accessible with the engine running.

Ares 806 – 09.2004 – GB G7.147


Electropilot application
Overview

1 2 3 4 5 6

18
8

17
9

16

15 14 13 12 11 10
586hsm55 Fig. 129

Parts list
1 Warning light status. 7 Spool valve n° 1.
2 ON / OFF switch. 8 Value supplied by the spool position sensor.
3 Percentage of flow required by the joystick. 9 Spool valve n° 2.
4 Status of command sent by the joystick: 10 Error code indication.
11 Square and cross-haired cursor corresponding to the joystick
position.
Floating . 12 Light grey zone corresponding to the floating position.
13 White zone corresponding to the supply and return positions.
Power supply . 14 Spool valve n° 2 continuous operation command.
15 Engine speed (data transmitted by the DRIVETRONIC 3 or
Neutral. "TC" transmission unit).
16 Software version.
17 Position of the flow control knob for axis "B" of spool valve n° 2.
Power supply .
18 Position of the flow control knob for axis "A" of spool valve n° 1.
5 Error code specific to the valve.
6 Temperature at the electrohydraulic spool valve control unit.

G7.148 Ares 806 – 09.2004 – GB


Electropilot application
Error codes

Spool valve n° 1
Spool valve n° 2
Flashing Description of errors
Error code

Joystick Possible causes


Slow
Fast
Off
On

No error

0 X
Actuator not connected.
CAN faulty.
'SETPOINT' message not
17 X X received Solenoid valve number setting incorrect.
Actuator or valve periods incorrectly programmed.
Data transfer rate in CAN incorrect.
Actuator not connected.
CAN faulty.
18 X X 'CONFIGURATION' message Solenoid valve number setting incorrect.
not received
Actuator or valve periods incorrectly programmed.
Data transfer rate in CAN incorrect.
The actuator signals an error on initialisation.
Formatting error in 'SETPOINT'
19 X X message A data byte contains an invalid value 'FF'.
Several simultaneous commands requested.

Formatting error in The actuator signals an error on initialisation.


20 X X
'CONFIGURATION' message A data byte contains an invalid value 'FF'.
EEPROM incorrectly programmed.
22 X X EEPROM incoherent
Faulty EEPROM cell.

23 X X Mandatory return to neutral —


(voltage error)
Battery voltage too low.
33 X X Under-supply Lowest battery voltage value programmed in EEPROM incorrect.
Excessive battery voltage hysteresis programmed in the EEPROM.
Battery voltage too high.
34 X X Over-supply Highest battery voltage value programmed in EEPROM incorrect.
Excessive battery voltage hysteresis programmed in the EEPROM.
Insufficient control pressure due to too many consumers and
insufficient speed of rotation.
Solenoid valve jammed.
35 X Spool movement too short Oil viscosity too high.
Temperature too low.
Position transducer faulty or connector loose.
Insufficient control pressure due to too many consumers and
insufficient speed of rotation.
Solenoid valve jammed.
36 X X Excessive slide movement Oil viscosity too high.
Temperature too low.
Position transducer faulty or connector loose.

Ares 806 – 09.2004 – GB G7.149


Electropilot application

Spool valve n° 1
Spool valve n° 2
Flashing Description of errors
Error code

Joystick
Possible causes
Slow
Fast
Off
On

No error

Insufficient control pressure due to too many consumers and


insufficient speed of rotation.
Solenoid valve jammed.
Impossible to reach the floating
37 X X position Oil viscosity too high.
Temperature too low.
Position transducer faulty or connector loose.
Manual operation or other mechanical action.
38 X X Manual operation
Position transducer faulty or connector loose.
49 X X Voltage < 8 V —
50 X X Voltage > 36 V —
65 X X Excessive voltage (> 48 V) Battery voltage too high caused by voltage spikes.
Printed circuit faulty.
Solenoid of on/off solenoid valve faulty.
66 X X Internal driver output error
Solenoid connector of on/off solenoid valve not plugged in.
Damp in the electronics.
The core of the position transducer is missing or has shifted.
The connector of the position transducer is disconnected or removed.
67 X X Slide position sensor failure
Printed circuit faulty.
Damp in the electronics.
80 X X "EEPROM" incoherent —
81 X X Hall effect sensor failure —
82 X X ADC error —
83 X X Potentiometer error —
On/off switch permanently set
84 X X to 1 —

85 X X No message ’DIAGNOSIS’ —
from the valves
Hydraulic motor switch pressed
86 X X —
on system startup
Exterior control pressed when
87 X X power switched on or pressed —
> 5 seconds
88 X X Temperature error —
89 X X Motor error below parameter —
Normally open and normally
96 X X closed hydraulic motor contacts —
in same logic state
Solenoid valve jammed.
Transducer position error.
129 X X Spool not returning to neutral
Temperature too low.
Oil viscosity too high.
Solenoid valve jammed.

Valve not in neutral when Solenoid valve deactivated following a voltage drop.
130 X X
power switched on Transducer position error.
Oil viscosity too high.

G7.150 Ares 806 – 09.2004 – GB


Electropilot application
Parameter setting

586hsm56 Fig. 130

Select the component for which the parameters are to be set.

Joystick selection

586hsm57 Fig. 131

N.B.: An incorrect choice of (1) will lead to system When used as a charger, this setting enables different
failure. The system is set by default to 100% i.e. an flow rates to be obtained between the two outlets of the
identical flow on both spool valve outlets. spool valve controlled by joystick axis (A). These different
flow rates make it possible to achieve the same raising
Example for a charger, it is possible to alter the ratio
and lowering speed despite the differences in lift arm
between the raising flow and the lowering flow on a single
section.
spool valve: Set from 1 to 100%.
– If set towards 1, the raising flow exceeds the lowering
flow.
– If set towards 100, the lowering flow exceeds the raising
flow.

Ares 806 – 09.2004 – GB G7.151


Electropilot application
Spool valve selection
The spool valve parameters need to be set for them to
react correctly to joystick movements.
Electrovalve (A).
Electrovalve (B).

391hsn14 Fig. 132

393hsn12 Fig. 133

G7.152 Ares 806 – 09.2004 – GB


Electropilot application
Changing a spool valve

586hsm58 Fig. 134

A new spool valve is not allocated to either of the joystick control axes.
It does, however, have a "GENUINE PARTS" identification enabling Win Métadiag© to detect it when it is connected to the
tractor.
The procedure initially consists of setting up both valves on the same axis (Fig. 135). Set both spool valves on axis "Y" (1).

A 1

586hsm66 Fig. 135

Ares 806 – 09.2004 – GB G7.153


Electropilot application
Disconnect spool valve (A). Set the parameters for spool valve (B).

586hsm67 Fig. 136

Calibration

586hsm59 Fig. 137

The procedure consists of sweeping the chequered zone N.B.: Moving the hard spot during calibration
(1) along both axes without going as far as the floating eliminates the floating position.
position. Press OK to validate.

G7.154 Ares 806 – 09.2004 – GB


H1 – CAB LIFT

Ares 806 – 09.2004 – GB


Description

Identification
Type series N°
Plate (A) is located to the rear of the cab, on the right-
hand side (Fig. 1).

Certification
Plate (B) is located to the rear of the cab, on the right-
hand side (Fig. 1).

Safety structure identification N°


Plate (C) is located on the cab left-hand pillar (Fig. 2).

Important: If a safety structure is


damaged (deformed) as a result of an
accident, it must be replaced not A B
repaired.
841hsm70 Fig. 1

841hsm02 Fig. 2

H1.2 Ares 806 – 09.2004 – GB


Description

Right side (location of operations)

3 4 20 8 9 17

5
10
6

19

13

14 11 16 15 2

3 4 20 8 9 17

5
10
6

19

13

14 16 15 2

841hsm00 Fig. 3

Ares 806 – 09.2004 – GB H1.3


Description

Left side (location of operations)

8 4

5
6

19

18 21 12 1

8 4

5
6

19

18 21 12 1

841hsm01 Fig. 4

H1.4 Ares 806 – 09.2004 – GB


Full cab removal
Partial removal of rear section: Operations 1 to 7. – Mark out the working area.
Full removal: Operations 1 to 21. – Use a certified hoist in perfect working order.
– Use certified shackles.
– Use certified slings in perfect working order.
Safety measure – Respect safety instructions. Wear gloves and safety
shoes.
To lift the cab, always use a hoist in perfect working order,
with a sufficient hook height to clear the cab comfortably.
If the cab is partly lifted, it must be propped up.
– Put the tractor on flat and level ground.
Sling specifications
– If the tractor is equipped with a suspended axle, put it – Cab weight: About 850 kg.
in the low position.
Lifting bar reference 77 01 388 907.
– Chock the wheels.
Lifting kit reference 77 11 132 317.

The removal operations presented were performed on the cab of a tractor from the 806 range, closed
centre hydraulics, equipped with air conditioning and air brakes. Special points relating to other
tractors can be found at the end of the chapter. In all cases, the platform must be lifted slowly, making
sure at all times that no element remains attached to the girder and that components such as the master
cylinder at the front of the cab do not interfere with parts remaining on the girder. Raise the cab only with a
lifting bar to avoid any risk of deformation to the lifting points.

Prohibited Lifting bar only

841hsm03 Fig. 5

Ares 806 – 09.2004 – GB H1.5


Removal/refitting

Operation n° 1

– Remove the rear wheels.


– Place the tractor on stands.

Placing on axle stands. Carry out this


operation on a smooth horizontal and
sufficiently firm surface. Check the axle
stands are suitable for the load. 4-wheel-drive
tractor: If the rear axle is on stands, do not start
the engine (risk of moving the tractor). If the
engine has to be started, it is essential to place
the front axle up on axle stands too.

Operation n° 2
841hsm04 Fig. 6
– Disconnect the battery (Fig. 6).

Operation n° 3

– Identify and disconnect the plugs, transmission


harness, lift spool valve supply, position sensor and
load sensor on the same harness (Fig. 7).

Operation n° 4

Preparing the lifting bar


– Use lifting bar reference n° 77 01 388 907 (Fig. 8).
– Equip the lifting bar as follows:
a. Remove the trucks.
Fig. 7
b. Fit the spacers, screws and washers from kit 841hsm69

reference n° 77 11 132 317.

841hsm06 Fig. 8

H1.6 Ares 806 – 09.2004 – GB


Removal/refitting

Installing the lifting bar


– Screw in the lifting screws tightly at the points provided.
– Centre the lifting bar.
– Raise gradually while checking all cables and pipes.

The screws must be screwed tightly into


the lifting supports on the cab. The load
must be pulled vertically. Before lifting,
check the state of the screws, especially the
threads, and check for deformation. If necessary,
replace with screws n° 77 03 001 749 only
(class 8.8 must be used). As a safety measure, it is
also advisable to feed a strap inside the cab and
attach it to the lifting hook.

841hsm07 Fig. 9
Taking the weight of the cab

Operation n° 5 D
F

– Remove the rear shock absorber mounting screws (D).


– Remove the left and right-hand longitudinal bar
mounting screw (E).
– Remove the rear crossbar mounting screw (F).

Operation n° 6

– Disconnect the stabiliser bar mounting screws (G).

E
841hsm08 Fig. 10

841hsm09 Fig. 11

Ares 806 – 09.2004 – GB H1.7


Removal/refitting

841hsm10 Fig. 12 841hsm61 Fig. 13

Operation n° 7

– Disconnect the power take-off selection cable (H)


(Fig. 12).
– If the tractor is equipped with an economy power take-
off, disconnect the selection cable on the right-hand
side of the rear axle.
– If the tractor is equipped with a proportional power
take-off. Disconnect selection cable (X) (Fig. 13).

Operation n° 8

– Remove the front shock absorber upper mounting


screws (Fig. 14).
841hsm11 Fig. 14

Operation n° 9
I
– Disconnect the stabiliser link (I) on the right-hand side
(Fig. 15).

841hsm12 Fig. 15

H1.8 Ares 806 – 09.2004 – GB


Removal/refitting

Operation n° 10

– Remove the side covers.


– Disconnect the front harness plugs and the earth
terminal (Fig. 16).

Operation n° 11

– Remove the gearshift cables. On extra-slow versions,


disconnect the cable just behind the gearshift cable (on
Quadrishift only), (Fig. 17).

Operation n° 12

– If the tractor is equipped with a suspended front axle,


disconnect the supply plug (J) from the unit (Fig. 18). 841hsm13 Fig. 16

841hsm62 Fig. 17

841hsm17 Fig. 18

Ares 806 – 09.2004 – GB H1.9


Removal/refitting

L L

K
L L

M M

841hsm18 Fig. 19 841hsm19 Fig. 20

Operation n° 13

Figures 19 and 20
– Identify and disconnect the spool valve control
junctions.
– Open junction (K).
– Unscrew locknuts (L). X
– Unscrew nut (M) towards the control lever.

Operation n° 14

• Disconnect the handbrake cable (X):


– Quadrishift version (Fig. 21).
– Full Powershift version (Fig. 22). 841hsm20 Fig. 21
• See chapter C4 for adjustment.

841hsm63 Fig. 22

H1.10 Ares 806 – 09.2004 – GB


Removal/refitting

Operation n° 15

– Disconnect the screen washer pipe(s) in the battery


tray.

Operation n° 16

– Disconnect the pressure gauge supply pipe (N)


(Fig. 23), (according to equipment).
N

Operation n° 17

Fig. 24
– Identify and disconnect the 2 power braking hoses (O).
– Identify and disconnect the 2 brake supply hoses (P).
841hsm21 Fig. 23
– Retrieve the brake fluid after unscrewing the reservoir
cap.
– Disconnect the brake valve supply line (Q). P

Operation n° 18
Q
– Disconnect the steering cylinder supply lines (Fig. 25).

841hsm22 Fig. 24

344bsm23 Fig. 25

Ares 806 – 09.2004 – GB H1.11


Removal/refitting

Operation n° 19

– Drain the coolant system (see chapter A2).


– Disconnect the hoses on the left (Fig. 26) and right-
hand side (Fig. 27).

841hsm64 Fig. 26

841hsm65 Fig. 27

H1.12 Ares 806 – 09.2004 – GB


Removal/refitting

S
R

T T

841hsm26 Fig. 28 841hsm66 Fig. 29

Operation n° 20

– Identify and disconnect the hydraulic steering unit


signal, supply and return lines ((R), (S) and (T)
respectively).
– Quadrishift closed centre circuit transmission, R
110 l/min (Fig. 28). S
– Quadrishift closed centre circuit transmission,
100 l/min (Fig. 29).
– Full Powershift transmission (Fig. 30 and 31).

841hsm67 Fig. 30

841hsm68 Fig. 31

Ares 806 – 09.2004 – GB H1.13


Removal/refitting

Operation n° 21

– Retrieve the refrigerant by connecting the recovery


station to the outlet and inlet valves of the
compressor (U).
– Disconnect the hoses under the left-hand step and
remove the flange (CHC M 4 screw).
– Plug the holes in the pipe immediately to prevent the
U
absorption of humidity.
If the cab is to be lifted but not fully removed, the air
conditioning circuit does not need to be drained.

841hsm27 Fig. 32

841hsm28 Fig. 33

H1.14 Ares 806 – 09.2004 – GB


Refitting the cab
Proceed in reverse order to the removal operations.

D
Special points F

On lowering, beware of interference with


the brake master cylinder or air filter.

– Insert the front shock absorbers into their housing


without fitting the screws.
– Lower the cab onto the rear shock absorbers (D).
– Fit the rear shock absorber screws.
– Lift the front of the cab slightly to fit the front shock
absorber upper screws (H) more easily.
– Connect the left and right-hand side longitudinal E
bars (E). 841hsm08 Fig. 34

– Connect the rear crossbar (F).


– Connect the stabiliser bar (G).
– Fit the stabiliser link screw (I) on the right-hand side.

Before clamping the cab, make sure that


no hoses or cables are trapped.

Tightening torques
D 13 daN.m ± 2.
E 9 daN.m ± 2. G
F 13 daN.m ± 2.
G 9 daN.m ± 2.
H 13 daN.m ± 2.
841hsm09 Fig. 35
I 9 daN.m ± 2 (Fig. 37).

841hsm29 Fig. 36

Ares 806 – 09.2004 – GB H1.15


Refitting the cab

Adjustments
I
For the main adjustments, refer to the chapters
corresponding to the components concerned.

841hsm12 Fig. 37

H1.16 Ares 806 – 09.2004 – GB


Removing/refitting the roof

Full removal with the air conditioning


fans
Cab interior
– Remove the right and left-hand brackets to access the
roof mounting screws (Fig. 38).
– Open the trap door and turn the two roof attachment
lugs (J) after unscrewing their attachment screw.

Cab exterior
– Remove the mounting screws above the roof.
– Remove the roof with the air conditioning lines by
sliding it from the front to the rear of the tractor.

Refitting
841hsm30 Fig. 38

Proceed in reverse order to the removal operations.


J

841hsm31 Fig. 39

Ares 806 – 09.2004 – GB H1.17


Notes

H1.18 Ares 806 – 09.2004 – GB


H2 – HEATING/AIR CONDITIONING

Ares 806 – 09.2004 – GB


Description

Characteristics Pressure switch


This has 2 functions:
Heating circuit – Low pressure cut-off: It cuts off compressor
The heating circuit consists of a heating radiator in the operation as soon as the low pressure circuit
cab, a regulating valve and a ventilation unit. drops below 2 ± 0,25 bar.
– High pressure cut-off: It cuts off compressor operation
Circuit capacity: 22 litres.
as soon as the high pressure circuit reaches 27,5 bar.
Coolant volume: It establishes the circuit at 21 ± 2 bar.
ELF GLACEOL RX GF type D. Expansion valve
Protection temperature: – 37°C. This is a preset device which adjusts the fluid inlet rate
according to variations in compressor speed.
Cooling circuit Evaporator
Circuit capacity: 1 650 g.
R134a refrigerant in the liquid state flows through tubes.
Refrigerant type: R134a (HFC 134a). Heat exchange takes place at the fins. The hot air cools
The air conditioning circuit consists of the following and loses its humidity. The R134a turns to gas and is
components: drawn back in by the compressor.
Compressor Electronic thermostat
The compressor comes supplied with 230 ± 20 cm³ of oil. It is used to adjust the air temperature at the evaporator.
On charging the circuit, 40 cm³ of PAG 244 oil must be Trigger threshold:
added (reference n° 60 05 014 466). – Maximum cold: 2°C ± 1.
Condenser – Minimum cold: 5°C ± 1.
The condenser transfers the heat of the compressed
refrigerant gas into the ambient air. The refrigerant gas Maintenance
then condenses to a liquid state. As engine power is required to compress the refrigerant,
Drier it is advisable to check the engine coolant level quite
often. Change the dust filter in the cab frequently when the
This part has a triple role:
tractor is used in very dusty environments. The refrigerant
– To act as a refrigerant liquid buffer tank. circuit must be checked annually. The drier must be
– To filter the fluid flowing through the circuit. changed every 3 years.
– To retain the humidity contained in the circuit. N.B.: It is essential that any faulty components on the
We recommend replacing the drier on each maintenance circuit are changed.
action.
In case of a long maintenance action (over 15 minutes) on
the air conditioning system, plug all orifices on the circuit.

H2.2 Ares 806 – 09.2004 – GB


Description
Safety instructions What to do in case of contact with the refrigerant
– Rinse with clear, cold water for 15 minutes (eyes also).
Maintenance work on the air conditioning – Seek medical advice as soon as possible.
system must be carried out by an What to do when working on the air conditioning
authorised person who has received circuit
relevant training.
– Wear gloves and goggles.
– Work in an extremely clean environment.
Welding and brazing on the air – Respect safety instructions.
conditioning circuit is totally prohibited
– Use the exact quantity of refrigerant when filling the
(ultraviolet rays can filter into the circuit
circuit.
and decompose the refrigerant). Carry out all
maintenance work on the system in a well- R134a is the only refrigerant to be used. Do not use
ventilated room (risk of suffocation). any other.
– Use only the special oil recommended for topping up.
Start up the gas extraction system in the room. As Oil cans must be sealed properly after use.
refrigerants are colourless and odourless and as their
specific weight is higher than that of air, never store them
in shafts, pits, air stacks, etc.

Ares 806 – 09.2004 – GB H2.3


Description

Diagram of operating principle

20 2
10

8 7
22
3 17
4
18

12 19

11
11
18

10

14

19

21 13
15

16
6

2 11

641hsm01 Fig. 1

H2.4 Ares 806 – 09.2004 – GB


Description
Parts list
1 Ambient air. 12 Engine.
2 Outside ambient air. 13 Pressure switch.
3 Cold air. 14 Power take-offs.
4 Cab. 15 Engine cooling radiator.
5 Compressor. 16 Drier reservoir.
6 Condenser. 17 Thermostat.
7 Expansion valve. 18 Low pressure vapour.
8 Evaporator. 19 High pressure vapour.
9 Condensation water flow. 20 Fans.
10 Low pressure liquid. 21 Cooling fan.
11 High pressure liquid. 22 Condensation water flow.

Control panel
A. Front air flow direction selector. E
Air directed to the windscreen (deicing/
demisting).
D
Air directed to the windscreen and
footwell.
C
Air directed to the footwell.

Air directed to the driver.


B

B. Heating control.
C. Fan control. A
D. Mode selector.
641hsm02 Fig. 2
Heating.

Ventilation.

Air conditioning.

E. Thermostat control.

Ares 806 – 09.2004 – GB H2.5


Removal/refitting
Important: In case of a long maintenance action (over
15 minutes) on the circuit, plug all orifices on the
circuit components to prevent internal condensation
and oxidation. This precaution is essential for the
drier cartridge. 3
1

Engine layout
Condenser
– Free the locking screw (3) to pivot the condenser
forward (Fig. 3). 2
– Clean it by blowing compressed air from the inside out
(Fig. 4).
– If necessary, restore the condenser fins with a fin
comb.

641hsm03 Fig. 3
Do not use a high-pressure cleaner.

Fig. 3
1. Input: From compressor.
2. Output : To drier.
3.

641hsm04 Fig. 4

H2.6 Ares 806 – 09.2004 – GB


Removal/refitting
Compressor (Fig. 5)
4. Air intake.
5. Discharge.

Clutch: 12 V, maximum current 2,2 A.


The compressor comes supplied with 230 ± 20 cm³ of oil.
On charging the circuit, 40 cm³ of PAG 244 oil must be
added (reference n° 60 05 014 466).

Drier (Fig. 6)
6. Input: From condenser.
7. Output : To expansion valve.
8. Fluid flow indicator.
9. High and low pressure switch.
Pressure switch
4 5
Low pressure cut-off: < 2 bar ± 0,25.
High pressure cut-off: > 27,5 bar (circuit re-established 641hsm05 Fig. 5
at 21 bar ± 2).

Air filter - Heating (Fig. 7)


Located at the front of the cab. 8
9
– Remove the cover retaining nut. 7
– Extract the cover and the filter.
– Clean the filter carefully (frequent replacement
recommended).
6

641hsm06 Fig. 6

641hsm07 Fig. 7

Ares 806 – 09.2004 – GB H2.7


Removal/refitting

Cab layout
Air filters - Air conditioning
Interior filter (Fig. 8).
Exterior filter (Fig. 9).
– Remove them before cleaning.
– Clean carefully with pulsed air (frequent replacement
recommended).

Evaporator unit - Ventilation (Fig. 10)


– Remove the screws from the air conditioning
compartment.
– Hold and tilt the assembly.
– Unplug the connectors.
– Remove the fan holder (10).
641hsm08 Fig. 8

641hsm09 Fig. 9

10

641hsm10 Fig. 10

H2.8 Ares 806 – 09.2004 – GB


Removal/refitting
Air conditioning fans
– Remove the mounting screws (11) to replace the fan.
Fig. 12
A. Black wire (earth).
11
B. Yellow wire (A1).
C. Red wire (power supply).
D. White wire (A2).

641hsm11 Fig. 11

D C

B A
641hsm12 Fig. 12

Ares 806 – 09.2004 – GB H2.9


Removal/refitting
Evaporator
– Remove the filter/fan assembly.
– Remove the evaporator retaining screws.
– Cut the worklight cable ties.
Fig. 14
12. Evaporator.
13. Expansion valve.
14. Return piping.
15. Intake piping.
16. Electronic thermostat.
17. Probe (to be inserted between the blades).
Note: On refitting the evaporator, beware not to bend
the blades (place a sheet of cardboard between the
evaporator and your hand).
Cleaning
– Clean the fins paying attention to the thermostat probe. 641hsm13 Fig. 13

– If necessary, restore the fins with a fin comb.

17 14

15 16

12 13

641hsm14 Fig. 14

H2.10 Ares 806 – 09.2004 – GB


Removal/refitting
Expansion valve (Fig. 15)
A. Input: From drier.
B. Output : To evaporator.
C. Input: From evaporator.
D. Output : To compressor.

Thermostat

Adjustment Hot Cold

Potentiometer value 10 kΩ 0Ω
Switching threshold: contact closed 21°C 5°C
Switching threshold: contact open 18°C 2°C

C D

B
A

641hsm15 Fig. 15

Ares 806 – 09.2004 – GB H2.11


Removal/refitting

621hsm13 Fig. 16 621hsm02 Fig. 17

Heating radiator unit and fans


– Remove the dashboard side and upper trim.
– Disconnect and remove the fuse and relay box
(Fig. 16).
– Remove the left-hand side cover of the fan
compartment.
– Unscrew the left-hand fan bracket fasteners (Fig. 17).
– Remove the right-hand side cover of the fan
compartment.
– Unscrew the right-hand fan bracket fasteners (Fig. 18).
– Slide the fan via the left-hand side (Fig. 19).

Refitting
– Proceed in reverse order to the removal operations. 621hsm03 Fig. 18

Note: Do not lean on the fan grille (risk of breaking).


Coat the edge of the side covers with sealant
(Loctite 5366). Rewire correctly.

621hsm04 Fig. 19

H2.12 Ares 806 – 09.2004 – GB


Removal/refitting

621hsm05 Fig. 20 621hsm06 Fig. 21

Heating radiator
– Remove the upper and lower side trims.
– Remove the fuse and relay box.
– Remove the fan left-hand side cover.
– Remove the fuse box support plate (Fig. 20).
– Remove the 2 dashboard support screws (Fig. 21).
– Remove the 4 steering column support screws
(Fig. 22).
– Disconnect the radiator piping (Fig. 23).

621hsm07 Fig. 22

621hsm08 Fig. 23

Ares 806 – 09.2004 – GB H2.13


Removal/refitting

621hsm09 Fig. 24 621hsm10 Fig. 25

– Tilt the bracket back (Fig. 24).


– Remove the mounting screws on each side (Fig. 25).
– Remove the radiator by sliding from right to left
(Fig. 26).
– Remove the screws from the valve flange (Fig. 27).

Refitting
Proceed in reverse order to the removal operations.
Note: On tilting the bracket forwards, reposition the
brake pedal rods correctly in the master cylinders.

621hsm11 Fig. 26

621hsm12 Fig. 27

H2.14 Ares 806 – 09.2004 – GB


Removal/refitting
Final steps
– The O-rings must be changed on each removal/
refitting.
18
– To avoid thermal shocks and to ensure correct
operation of the air conditioning system, suitably lag all 18
couplings liable to cause a cooling loss: evaporator,
expansion valve, etc.
– Check the compressor oil level with the air conditioning
station.
– Fill the refrigerant circuit.
– For correct operation of the air conditioning system, the
filter, evaporator and condenser must be as clean as
possible.

Checks - Inspections
Tapping points
They are located on the compressor (18) (Fig. 28). 641hsm16 Fig. 28

Test conditions
– Clean air filter.
Quantity of oil to be
– Engine running at 2 000 rpm. Maintenance on AC circuit
added
– Fan at low speed. Condenser replacement 30 ml
– Thermostat set to maximum. Evaporator replacement 30 ml
– Circuit charged to 1 650 g. Drier reservoir replacement 15 ml
– Operating time prior to testing: 5 to 10 minutes. Pipe replacement 10 ml
– Absence of air bubbles (to be checked on drier
indicator). When replacing the compressor, 40 cm³ of PAG 244 oil
must be added on charging the circuit (reference
Values at ambient temperature of 20°C n° 60 05 014 466).
Low pressure: 0,2 bar ± 0,2.
High pressure: 8 bar ± 1. Diagnostics - Preliminary operations
Pulsed air temperature: 6°C ± 2 (at nozzle outlets). The ambient temperature is important for effective testing.
Where possible, check the air conditioning circuit at an
Values at ambient temperature of 35°C
ambient temperature of 20°C (if necessary, turn on the
Low pressure: 2 bar ± 0,2. heating in the cab in cold weather).
High pressure: 21 bar ± 1.
Pulsed air temperature 9°C ± 2 (at nozzle outlets).
Quantity of oil to be added on a maintenance action
N.B.: Measure the quantity of oil collected on
draining. On refilling, add the same quantity of new oil
plus the amount lost from the replaced component.

Ares 806 – 09.2004 – GB H2.15


Notes

H2.16 Ares 806 – 09.2004 – GB


Troubleshooting Guide

Diagnostics

Cooling malfunction

No cooling Excessive cooling Insufficient cooling

Check the pressure on the cooling circuit :


- Connect the checking device on the
Electric checks
Mechanical and hydraulic checks connection points and check the pressure
in the test conditions.

- Check the fuses on the cab and - Check the thermostat probe
- Check the proper triggering of the - Check the condition and tension
on the instrument panel
thermostat (max temperature) of the compressor belt.
- Check the ventilation switch
- Check the proper operation of the - Check the operation of the
- Check the thermostat
compressor clutch compressor (spindle seizing
- Check the pressure switch
- Check the proper operation of the and clutch).
pressure switch - Repair or change any faulty part.
- Repair or change any faulty part.

No Does the Does the No No Does the


problem persist ? problem persist ? problem persist ? Pressure correct LP and HP too high LP too high LP normal LP too high LP too low
LP and HP too low
and HP normal and HP too high. and HP too low. and HP too high.

Yes Yes
Yes

- Check the continuity of the - Check for proper operation of the Lack of coolant.
electric wiring Lack of coolant. Excess coolant. Pressure regulator Large quantity of air Compressor or clutch Partial restriction
thermostat at the appropriate Pressure regulator
- Check the connections Pressure regulator Pressure regulator blocked open. present on the circuit. malfunction. between the compressor
trigger thresholds. blocked closed.
- Check for proper earthing blocked closed. blocked open. Check and repair.. Check and repair.. Check and repair.. outlet and the pressure
- Change it if it is faulty. Dehydrator saturated.
(cab, compressor) Dehydrator saturated. Bad condenser regulator inlet.
Check and repair. Check and repair.. cooling (motor fan). Check and repair..
Check and repair..

No Does the
No Does the problem persist ?
problem persist ?
Yes
Yes
Visually inspect the coolant circuit :
- Check for the presence of air bubbles
- Check the compressor clutch. on the dehydrator indicator.
- Check for clamped or blocked hoses
(after removing/installing).
- Check for the absence of leaks in the
entire circuit.
- Repair or change any faulty part. Does the No
Does the Yes
problem persist ? problem persist ?

Yes
No

Pressure too low or too high - Change the coolant.


No Does the Yes
in respect to normal pressure - Change the dehydrator filter.
problem persist ? - Change the pressure regulator.
(pressure switch open).
Insulate the unions properly.

END END

641hsn02_fr Fig. 29

Ares 806 – 09.2004 – GB H2.17


H3 – BONDING THE WINDOWS

Ares 806 – 09.2004 – GB


Removal/refitting

Warning!

The bonded glass forms an integral part of the safety structure.


For a fast, quality maintenance action, we recommend using BETA SEAL x 2 500 two-pack sealant for
the windscreen.
This technique minimises the bonding time which is largely unaffected by temperature and air moisture
constraints (unlike one-pack sealants).
It complies with original equipment specifications and CEE and OECD safety approval tests.
All equipment has been selected to meet the quality, safety and service requirements currently in force in the
principal countries.

WE STRONGLY RECOMMEND THESE INVESTMENTS.

The following products block the adhesive polymerisation process.


Avoid all contact with these products:
Thinners
Grease
Oils
Spirits (screen washer)
Chlorinated products
Wash primer (rust inhibitor)
Silicones
Soap or soapy water

H3.2 Ares 806 – 09.2004 – GB


Removal/refitting

List of equipment to use - Special instructions


1. Protective and safety equipment - Safety instructions
• No smoking during this operation. • Wear protective gloves (beware of risk of cuts).
• Carry out this operation as far away as possible from • Wear safety goggles.
areas where grinding, welding, engine testing, etc. is • When fitting a windscreen, use stepladders and get
performed (beware of fire hazards linked to the someone to help you.
chemicals used).

841hsm41 Fig. 1 841hsm40 Fig. 2 841hsm39 Fig. 3 841hsm38 Fig. 4

2. Essential special equipment


• Clean up fragments of glass carefully with a vacuum • Prepare the Betagun two-pack sealant gun.
cleaner. • Have some straps and a spreader ready.
• Cut away the seal with an electric or pneumatic • If the temperature is too low (below 5°C), use a hot air
vibrating knife. fan.
• Take hold of the windscreen with the suction cups and
place it on the support.

841hsm37 Fig. 5 841hsm36 Fig. 6 841hsm35 Fig. 7 841hsm34 Fig. 8

Ares 806 – 09.2004 – GB H3.3


Removal/refitting
3. Consumables
• Clean rag paper. • Degreasing fluid (heptane type).
• Masking tape. • Windscreen bonding kit.

Heptane
Nettoyant de surface
Surface cleaning
er
Oberflachenreing
smiddel
Opperviokle reinging
iale
Detergente superfic
ie
Limpiador de superfic
de limpero de superficie
Producto

841hsm33 Fig. 9 841hsm32 Fig. 10 841hsm15 Fig. 11 841hsm14 Fig. 12

Removal
2 3
Remove:
– The windscreen wiper blade (1).
– The front worklights (2).
– The sun blind (3).
1
Wear cut-resistant protective gloves and
safety goggles.

– Use the specified vibrating knife with the appropriate


blade (shovel blade).
– Sharpen the large vibrating knife blade correctly.
– From the inside, cut away the seal around the
perimeter while dipping the blade frequently into a little
soapy water (makes the job easier). 841hsm44 Fig. 13

Note: While preparing to bond another windscreen,


clean the rebate carefully to remove all traces of soap.

841hsm42 Fig. 14

H3.4 Ares 806 – 09.2004 – GB


Removal/refitting

841hsm43 Fig. 15 841hsm45 Fig. 16

– Strike off the old seal at the last minute, leaving a


residual strip (5) approximately 1 mm thick.
– Do not use a compressed air gun (risk of lubricant
being deposited).
– Degrease the perimeter carefully with a heptane-based
product.

NO SMOKING - Take all standard


precautions to avoid the risk of ignition of
the degreasing fluid.
– Clean the outer surface of the windscreen if necessary.
– Moisten the suction cups.
– Stick the suction cups on the outside of the
windscreen.
– Place the windscreen on the support (inside
uppermost). 841hsm46 Fig. 17

Preparing the windscreen before


applying primer 6

– Apply the activator in the bottle with the yellow cap (6)
to the black edge of the windscreen.
– Do not apply to the glass (wipe off if applied
accidentally, risk of marking the glass).
– Wipe with a clean, lint-free cloth.

841hsm47 Fig. 18

Ares 806 – 09.2004 – GB H3.5


Removal/refitting

Applying primer
– Shake the bottle with the green cap (7) until you hear
the balls rattling and for at least one minute. 7
– Use a round brush to paint the black edge of the
windscreen (where the bead of sealant will be applied).
N.B.: This product is beneficial to sealant adhesion
and protects the metal parts stripped bare on cutting
away the old sealant against rust. It will also protect
the two-pack sealant from the sun's ultraviolet rays.
– Coat the rebate of the cab windscreen frame with the
same product at the points where the paint has been
removed on cutting away the old seal.
– Leave to dry for approximately 15 minutes.
– Dry with a hot air blower if the temperature is too low.
– Stick the cushion pads (P/N 60 05 020 197) to the
frame rebate (Fig. 21). 841hsm48 Fig. 19

841hsm49 Fig. 20

1 2 3

10 4

8 7 6
9 5

841hsm50 Fig. 21

H3.6 Ares 806 – 09.2004 – GB


Removal/refitting

Preparing the two-pack sealant


Check the expiry date!
– If the temperature is low (less than 15°C), warm up the
cartridges to improve fluidity (bain-marie or hot air
blower).
– Release the sealant cartridge holder (red ring).
– Connect to the 220 V mains supply.
– Press the trigger and place the push-rods in the back
position (see the "BETAGUN" manual).
– Place the cartridges in the gun compartments and
close the gun casing.
– Cut the nozzle guide tip in a "vee" and screw the
nozzle onto the gun.
– Press the trigger to feed the two products which are
mixed in the nozzle.
841hsm51 Fig. 22
– Deposit a hazelnut-sized ball of sealant on a piece of
paper (drying indicator).
– Place this sample in the cab.
– Carry out a trial by moving around the windscreen to
check that there are no obstacles preventing the
sealant from being applied in a single, continuous
operation.
– Deposit the sealant in the centre of the black edge,
adjusting the speeds of displacement and extrusion to
obtain a regular, triangular bead as shown.
– A triangular bead simplifies the positioning of the
windscreen.
– Join the beads as shown in the illustration opposite.

841hsm52 Fig. 23
12

841hsm53 Fig. 24

Ares 806 – 09.2004 – GB H3.7


Removal/refitting
– As soon as the perimeter of the windscreen frame is
covered: With the help of another person and
observing rules of safety (gloves, goggles and
stepladder on each side of the engine), bond the
windscreen to the cab starting at the top.
Take care on passing the worklight protectors.
– Align the windscreen vertically and horizontally with the
lower windows.
– Apply the necessary pressure to flatten the seal around
the entire perimeter.
– Strap the suction cup handles to the front worklight
protectors to prevent the windscreen from dropping.
– Strap the windscreen against the cab.
Do not fasten too tightly.
– Stick masking tape at the lower window joints.
– Coat the joint grooves with sealant and smooth off the 841hsm54 Fig. 25
excess with a spreader.
– Refit the removed components.
Tractor standing time after bonding:
30 minutes at an outdoor temperature of 20°C.
If the temperature is very low:
– Start the engine and set the cab heating to the deicing
position.
– If necessary, hear the perimeter of the windscreen with
a hot air blower.
– In all cases, refer to the drying indicator which must not
be tacky.

841hsm55 Fig. 26

841hsm56 Fig. 27

H3.8 Ares 806 – 09.2004 – GB


Removal/refitting

1 2 3

8 4

7 6 5

841hsm57 Fig. 28 841hsm58 Fig. 29

Replacing the ploughing window


• Apply the same instructions as above:
– Cut away the seal.
– Degrease and clean.
– Apply primer to the rebate and glass.
– Drying time.
• Stick the cushion pads (P/N 60 05 020 197) to the
points indicated (Fig. 28).
• Remove the bead of adhesive (Fig. 29).
• Bond the ploughing window.
• Chock underneath (Fig. 30).
• Use adhesive tape to hold the window to the cab.
• Reapply the joint seal between the windscreen and the
ploughing window (see previous page). 841hsm59 Fig. 30

N.B.: For the rear ploughing window, the licence plate


support panel must be removed.

841hsm60 Fig. 31

Ares 806 – 09.2004 – GB H3.9


Notes

H3.10 Ares 806 – 09.2004 – GB


TOOLS

Cab lifting - Heating/air conditioning - Glass


bonding equipment

Ares 806 – 09.2004 – GB


Cab lifting - Heating/air conditioning - Glass bonding equipment

60 05 020 187 60 05 006 744

Suction cups with 2 x 5 metre straps Multimeter

1 Round brush.
60 05 020 189
Two-pack windscreen sealant kit (450 ml) 2 Component "A" cartridge.
3 Nozzle to be cut.

2
5
3

4
6 7

4 Component "B" cartridge. 6 Bottle of degreasing agent (yellow cap).


5 Mixer. 7 Bottle of primer (green cap).

60 05 020 192 60 05 020 197

"Betagun" sealant gun 56 cushion pads

H3.12 Ares 806 – 09.2004 – GB


Cab lifting - Heating/air conditioning - Glass bonding equipment

60 05 020 224 60 05 020 225

Set of long blades (to remove windscreen) Set of short blades (to cut away seal)

60 05 020 330 77 01 388 907

Heptane
e
Nettoyant de surfac
Surface cleaning
r
Oberflachenreinge
ngsmiddel
Opperviokle reingi
ente super ficiale
Deterg
ficie
Limpiador de super
ro de superficie
Producto de limpe

Bottle of heptane Compensation bar (supplied with trolley)

77 11 132 317

Lifting kit

Ares 806 – 09.2004 – GB H3.13


Notes

H3.14 Ares 806 – 09.2004 – GB


J1 – LIFT AND FRONT POWER
TAKE-OFF

Ares 806 – 09.2004 – GB


Front lift

Characteristics
Consult the plate (A) to determine the lift type.

Type MX R28 MX R38 MX R53

Maximum lifting capacity 2 800 daN 3 800 daN 5 300 daN


Linkage (type) Foldable arms
Number of cylinders 2 (double acting) 2 (double acting) + damper 2 (double acting) + damper
Control Auxiliary distributor in cab (double acting)
Isolation valve Yes
Arm travel 781 ± 20 mm
Supply pressure 200 bar

Parts list
1 Front cover. 20 Flexible pin ø 10 x 40.
2 RH side rail. 21 Bolts, HM 18 x 130.
3 LH side rail. 22 Nut M 18.
4 Angle bracket (welded to 826 Full Powershift). 23 Bolts, HM 10 x 45.
5 Top link support. 24 Nut M 10.
6 Top link bar. 25 Bolts, HM 10 x 20.
7 Top link pin. 26 Bolts, HM 20 x 50.
8 Cylinders. 27 Lockwasher.
9 Right arm. 28 Bolts, HM 22 x 70.
10 Left arm. 29 Lockwasher.
11 Ball joint category 3/2. 30 Nut HM 22.
12 Locking pin, ø 30 x 100. 31 Bolts, HM 18 x 50.
13 Cylinder pin. 32 Lockwasher.
14 Pin, ø 40 x 565. 33 Bolts, HM 18 x 70.
15 Compensation bar. 34 Bolts, HM 18 x 60.
16 Wear bush. 35 Thrust bar GTA 3130.
17 Spacer. 36 Thrust bar GTA 1040.
18 Washer. 37 Bolts, HM 14 x 90.
19 Pin 8 x 42. 38 Nut M 14.
39 Bolts, HM 20 x 40.
40 Bolts, HM 16 x 50.

J1.2 Ares 806 – 09.2004 – GB


Front lift

Exploded view

32
31

2
31
32
A
4 34
32
32
3
32
31 34
29
7
5
33
6
9 31
11
28
19
8 27
16 26
14
24
30 25
27
26
15
13
22
25
19
23
18
13
20
21
11
18
10 12
17

26
40
38
37
28
35

38
39
37
28
36

411hsm01 Fig. 1

Ares 806 – 09.2004 – GB J1.3


Front lift

Tightening torques
Front lifts MX R 28, R 38 and R 53.
Important: All the screws must be fitted with Loctite Frenetanch (242).

24 daN.m

24 daN.m
24 daN.m

4 daN.m

24 daN.m

45 daN.m

34 daN.m

34 daN.m

4 daN.m
4 daN.m
24 daN.m

411hsm02 Fig. 2

34 daN.m

17 daN.m

11 daN.m

45 daN.m

34 daN.m

11 daN.m

45 daN.m

411hsm03 Fig. 3

J1.4 Ares 806 – 09.2004 – GB


Measurement and checking points
Test conditions:
– Engine at nominal speed.
– Oil temperature at 60°C.

Checking the cylinder pressure


– Connect tester n° 60 05 705 076 at the level of the isolation valve (1).
– Place the front lift at the high or low end stop position and measure the pressure.
– The measured pressure must be 200 bar.

401msm03 Fig. 4

Ares 806 – 09.2004 – GB J1.5


"Inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:

Tractor type: ...........................................................................................................................................................................

The serial number: .................................................................................................................................................................

Total operating hours: ............................................................................................................................................................

Date of operation: ..................................................................................................................................................................

Checking the cylinder pressure

Test conditions
Pressure Measured value
Oil temperature at 60°C

Engine running at 2 200 rpm 200 bar

J1.6 Ares 806 – 09.2004 – GB


Front power take-off

Characteristics

Front power take-off unit

Power take-off (PTO) (type) Mono-gear


Clutch Dry with hydraulic controls
Control Electrohydraulic with progressivity
Rotation direction Clockwise or counterclockwise
Rotation speed 2 200 rpm (engine) = 1 100 rpm (PTO)
Output shaft 1" 3/8" 6 splines
Transmissible continuous power 88,3 kW (120 ch)
Oil type API GL4 - GIMA M1143 - ISO HV 68
Capacity (reducer) 1,3 L
Unit supply pressure 17 bar

Ares 806 – 09.2004 – GB J1.7


Front power take-off

Exploded view of the front power take-off assembly

Frenetanch (242) 13
5 ± 0,7 daN.m 16
15
Frenetanch (242) 9
4
10
3
17 Frenetanch (242)
2 15 ± 3 daN.m
18
1 14 Frenetanch (242)
5 ± 0,7 daN.m

12 Frenetanch (242)
7 11 15 ± 3 daN.m

6 Frenetanch (242)
26 ± 4 daN.m

22
7
8

21
20
19
421hsm01 Fig. 5

Parts list
1 Unit. 12 Screw.
2 Support. 13 Screw.
3 Screw. 14 Screw.
APPLY: 4 punch marks. 15 Universal joint shaft.
4 Guard. APPLY: 4 points of Loctite Scelbloc (648) on the flanges.
5 Screw. 16 Flange.
6 Screw. APPLY: 4 points of Loctite Scelbloc (648).
7 Grid. 17 Screw.
8 Protector. 18 Hollow key.
9 Screw. 19 Screw.
10 Hydraulic controlled dry clutch. TIGHTENING: See the engine chapter.
11 Flange. 20 Washer.
APPLY: 4 points of Loctite Scelbloc (648). 21 Coupling pulley.
22 Screw.

J1.8 Ares 806 – 09.2004 – GB


Front power take-off

Removal / refitting of the unit


– Remove the plate (24).
– Remove the closing cover (4). 27

Removal of universal joint


– Uncouple the univeral joint shaft (15) on the
engine side using the Stahlwille socket
reference 1054 KKX-03361408 going under
the radiator (Fig. 7).
4
– Uncouple the universal joint shaft (15) on the clutch
side.
25
Removal of clutch 24
– Remove the flange (11), (Fig. 5).
– Loosen the screw (9) locking the front power take-off
unit in rotation. 26
– According to the assembly loosen the 2 screws (6), 421hsm02 Fig. 6
place the housing-support in a sling then remove
the 2 screws (6) at the top.
– Remove the clutch (10) assembled on wedged shaft
(Fig. 8).

Removal of housing
– Take out the pins (25) in order to remove the lift
cylinders (Fig. 6).
– Loosen the screws (26) then remove the bar (27) 15
(Fig. 6).
– Then remove the screws (6) to dismantle the housing-
support unit.
– Take the support housing apart by removing the
screws (3).

Refitting
– Reassemble in the opposite order to the dismantling
operations, observing the instructions given in the list.
421hsm03 Fig. 7

10

421hsm04 Fig. 8

Ares 806 – 09.2004 – GB J1.9


Front power take-off

1 2 3 4 5 11 12 13

11 8

16
3

421msm06 Fig. 9

17
Removing the clutch
– Remove the hub (1) from the housing (15) using a
press.
– Take out the holding spring (6) then remove the lining.
– Identify the piston (8) in relation to the hub (1).
– To replace the seals, take out bearing (12) then remove
the central flexible ring (11) holding the piston (8)
compressed using a press.
– Refit the assembly in reverse order to removal.
Note: To position the flexible ring (11), it is imperative to
place the grooves in alignment and us the press to
compress the springs (Fig. 9). 7 6 8 9 10 14 12 15
Parts list
1 Clutch hub. 421msm02 Fig. 10

2 Return spring.
3 Grooves. 12 15
4 Seal.
5 O-ring.
6 Holding spring. 14
7 Lining. 5 6
8 Piston. 8 9
9 Seal.
2 16
10 Flange.
11 Outer flexible ring.
12 Bearing. 1
13 Shims. 17
14 Inner flexible ring. Frenetanch
15 Clutch housing. (242)
16 Retaining washer.
17 Assembly screw. 10 11 13
4 7
3
421msm03 Fig. 11

J1.10 Ares 806 – 09.2004 – GB


Front power take-off

Exploded view of the unit

1
12 10 Rectijoint (518)
2
3
4
5
8
3

4
11

9
9 2
2 3
3 7
8 8
4
6
3
2
13
9
14
15

3
2
1

421msm04 Fig. 12

Parts list
1 Caps. 6 Input shaft. 11 Breather.
2 Inner circlips. 7 Output shaft. 12 Plug.
3 Bearings. 8 Pinions. 13 Level plug.
4 Hollow keys. 9 Lipped seals. 14 Drain plug.
5 Countershaft. 10 Cover. 15 Casing.

Removal
Take out the seals, remove the circlips then remove the shafts, bearings and pinions.

Ares 806 – 09.2004 – GB J1.11


Measurement and checking points
Test conditions:
– Engine at nominal speed.
– Oil temperature at 60°C.

Checking the clutch feed pressure


– Connect tester n° 60 05 705 076 at the solenoid valve exit.
– Apply the front power take-off clutch.
– The measured pressure must be 17 bar.

a e

d
c

421hsm05 Fig. 13

Parts list
a Supply coming from the filter. d Return from brake boosters.
b Towards accumulator. e Return to the casing.
c To gearbox control.

J1.12 Ares 806 – 09.2004 – GB


"Inspection results" sheet

This sheet is intended to be duplicated and completed for each operation on the tractor. If you have to send it to the
manufacturer's after sales service, it is essential to indicate:

Tractor type: ...........................................................................................................................................................................

The serial number: .................................................................................................................................................................

Total operating hours: ............................................................................................................................................................

Date of operation: ..................................................................................................................................................................

Checking the clutch feed pressure

Test conditions
Pressure Measured value
Oil temperature at 60°C

Engine running at 2 000 rpm 17 bar

Ares 806 – 09.2004 – GB J1.13


Notes

J1.14 Ares 806 – 09.2004 – GB


J2 – PNEUMATIC BRAKING

Ares 806 – 09.2004 – GB


Notes

J2.2 Ares 806 – 09.2004 – GB


How it works

Measurement and checking points


To check the pneumatic braking circuit pressures,
proceed as follows:
– Unscrew the coupling head concerned.
– Insert a "T" fitting with the dimensions shown opposite
between the coupling head and supply line.
– Mount pressure gauge n° 60 05 705 076, compatible 16 x 150 16 x 150
with the pneumatic circuits, on the fitting.
Then check the pressures given in the different phases of
operation on pages J2.5, J2.7 and J2.9.
JIC 9/16

Parts list (following figures)


1 Compressor.
2 Air suction. 4428

3 Pressure regulator.
4 Tank 20 l.
5 Manual bleed valve.
6 Pressure indicator.
7 Solenoid valve (controlled by the stop switches).
FUNCTION: For better reactivity from the system.
8 Principal control valve.
9 Trailer control valve.
10 Black coupling head.
11 Yellow coupling head.
12 Red coupling head.
13 Handbrake [valve (8) control].
14 Brake master cylinder [valve (8) control].
15 Brake fluid reserve.
16 Bleed valve on trailer brake valve control.
17 Towards hydraulic braking valve control
(according to equipment).

Circuit under pressure.


Control circuit.
Circuit without pressure.

Ares 806 – 09.2004 – GB J2.3


How it works

With the engine running, and trailer connected, no action of brakes


Schematic diagram

16
6

15

14
5
3 4
2

9
17
5

8
3
4

13

11

10
2

12

373msm01

J2.4 Ares 806 – 09.2004 – GB


How it works

Pneumatic circuit

3
1
4
7
3

2
2
1

9
8 bar

13
8
5

3
4
3

21

41

42

2
1-2

14
3
1

12

11

10
1

8 bar

0 bar

5 bar

373msm02

Ares 806 – 09.2004 – GB J2.5


How it works

With the engine running and trailer connected, service brakes applied
Schematic diagram

16
6

15

14
5
3 4
2

9
17
5

8
3
4

13

11

10
2

12

373msm03

J2.6 Ares 806 – 09.2004 – GB


How it works

Pneumatic circuit

3
1
4
3

2
2
1

9
8 bar

13
8
5

3
4
3

21

1-2

41

42

2
14
3
1

12

11

10
1

8 bar

8 bar

0 bar

373msm04

Ares 806 – 09.2004 – GB J2.7


How it works

With the engine running and trailer connected, hand brake applied
Schematic diagram

16
6

15

14
5
3 4
2

9
17
5

8
3
4

13

11

10
2

12

373msm05

J2.8 Ares 806 – 09.2004 – GB


How it works

Pneumatic circuit

3
1
4
7
3

2
2
1

9
8 bar

13
8
5

3
4
3

21

41

42

2
1-2

14
3
1

12

11

10
1

8 bar

8 bar

0 bar

373msm06

Ares 806 – 09.2004 – GB J2.9


Main components

Pneumatic circuit layout on GTA 1040

3
4
8

10
11
12

10
11 9
12 7

14
1
2

8
3
4

373hsm00

J2.10 Ares 806 – 09.2004 – GB


Main components

Pneumatic circuit layout on GTA 3130

2
14
7

3
9

4
8
10

11

12

373msm01

Ares 806 – 09.2004 – GB J2.11


Main components

Compressor
1
Parts list
1 Air intake.
2 Discharge.
3 Tightening torque 20 daN.m.

2
Pressure regulator
Parts list
4 Supply coming from the compressor.
5 Output towards tank.
6 Pneumatic inflation socket.
7 Discharge circuit.

3
Tank
373msm07

Parts list
8 Bleed valve.
9 Towards pressure indicator.
10 Towards solenoid valve.
11 Supply coming from the pressure regulator.

4 5

373msm08

10
11

8
373msm09

J2.12 Ares 806 – 09.2004 – GB


Main components

Trailer control valve


Parts list
12 Power supply .
14
13 Towards coupling head (black).
14 Air escape.
15 Brake controls.

Solenoid valve
When it is turned on it enables pressure to be kept on standby at
the principal checking valve output. 13
Parts list
16 Supply coming from the tank. 12 15
17 Principal checking valve supply.
18 Electricity supply coming from the stop swtch.

373msm10

18

16

17

373msm11

Ares 806 – 09.2004 – GB J2.13


Main components

Principal control valve


Parts list 24
19 Supply coming from the tank. 20 21 22
20 Towards coupling head (red).
21 Supply coming from the solenoid valve.
22 Brake control circuit.
23 Towards coupling head (yellow).
24 Rod connected to the hand brake.
25 Bleed screw.
19
On refitting, position the rod (24) over the nearest
hole (26) to the centre line.

Bleeding the hydraulic and pneumatic 25

trailer braking system


23
– The principal checking valve control has a bleed 373msm12
screw (25).
– To bleed the braking system, refer to chapter C2.
N.B.: After the bleeding operation, check the braking 23
is effective by connecting the pressure gauges to the
trailer air outlets and check the pressures, (cf.
"Measurement and checking points").

19

24 20 21 22

373msm13

26

24

373msm15

J2.14 Ares 806 – 09.2004 – GB


TOOLS

Lift, front power take-off and pneumatic braking tools

Ares 806 – 09.2004 – GB


Lift, front power take-off and pneumatic braking tools

60 05 705 076

Pressure gauge

J2.16 Ares 806 – 09.2004 – GB


A0 – INJECTION SHEET CHECKING
PROCEDURE

A1 – INJECTION FEED

A2 – ENGINE TIER II

Chapter A

Ares 806 60 05 030 493 – 09.2004 publication


CONTENTS

A0 – INJECTION SHEET CHECKING PROCEDURE

CHECKING PROCEDURE
CHECKING PROCEDURE..............................................................................................................................................A0.2

MEASUREMENT SHEET
MEASUREMENT SHEET................................................................................................................................................A0.7

PRESSURE CONNECTION (APPENDIX)


100 L/MIN LS CIRCUIT ...................................................................................................................................................A0.8
110 L/MIN LS CIRCUIT ...................................................................................................................................................A0.9

A1 – INJECTION FEED

IDENTIFICATION
INJECTION PUMPS IDENTIFICATION ..........................................................................................................................A1.2

TIGHTENING TORQUES
TIGHTENING TORQUES................................................................................................................................................A1.3

OPERATING PRINCIPLES
PRE-FILTER....................................................................................................................................................................A1.5
FUEL FILTER ..................................................................................................................................................................A1.6
INJECTION PUMP ..........................................................................................................................................................A1.7
INJECTORS ....................................................................................................................................................................A1.9
SITUATION OF THE DIFFERENT SENSORS..............................................................................................................A1.10

CHECKS/ADJUSTMENTS
ACCELERATOR CONTROL ADJUSTMENT ................................................................................................................A1.12
ADJUSTING THE ENGINE INJECTOR ........................................................................................................................A1.13
SUPPLY PRESSURE CHECK ......................................................................................................................................A1.14

Ares 806 – 09.2004 – GB


REMOVAL/REFITTING
FUEL FILTER REPLACEMENT ....................................................................................................................................A1.15
INJECTION SYSTEM BLEEDING.................................................................................................................................A1.15
INJECTION PUMP REMOVAL......................................................................................................................................A1.16

DIAGNOSTICS
SHEET N° 1 "ENGINE START-UP DEFECT" ...............................................................................................................A1.20
SHEET N° 2 "IRREGULAR ENGINE OPERATION" .....................................................................................................A1.21
SHEET N° 3 "GREY OR BLACK SMOKE EMISSION" .................................................................................................A1.22
SHEET N° 4 "WHITE SMOKE EMISSION" ...................................................................................................................A1.23
SHEET N° 5 "CHECK THE FUEL FEED CIRCUIT" ......................................................................................................A1.24

A2 – ENGINE TIER II

GENERAL SPECIFICATIONS
IDENTIFICATION OF THE ENGINES.............................................................................................................................A2.2
ENGINES 6 CYLINDERS ................................................................................................................................................A2.3

DIMENSIONAL SPECIFICATIONS
CYLINDER HEAD AND VALVES ....................................................................................................................................A2.4
CYLINDER BLOCK .........................................................................................................................................................A2.7
LINERS AND PISTONS ..................................................................................................................................................A2.8
CONNECTING RODS .....................................................................................................................................................A2.9
CRANKSHAFT, BEARINGS AND FLYWHEEL.............................................................................................................A2.10
CAMSHAFT ...................................................................................................................................................................A2.11
DISTRIBUTION .............................................................................................................................................................A2.12
LUBRICATION...............................................................................................................................................................A2.13
COOLING ......................................................................................................................................................................A2.14
TURBOCHARGER ........................................................................................................................................................A2.15

TIGHTENING TORQUES
FRONT CHASSIS / ENGINE LINK................................................................................................................................A2.16
ENGINE/TRANSMISSION LINK....................................................................................................................................A2.16
CRANKSHAFT WITH STRAIGHT FRONT END ...........................................................................................................A2.19
CRANKSHAFT WITH TAPERING FRONT END...........................................................................................................A2.19

CHECKS/ADJUSTMENTS
CHECKING COMPRESSION........................................................................................................................................A2.20
CHECK OF ENGINE OIL PRESSURE..........................................................................................................................A2.20
CHECK OF VALVE LIFT (ENGINE COLD) ...................................................................................................................A2.21
VALVE CLEARANCE (ENGINE COLD) ........................................................................................................................A2.21

Ares 806 – 09.2004 – GB


VALVE ADJUSTMENT SEQUENCE.............................................................................................................................A2.22
CHECKING THE TURBOCHARGER PRESSURE .......................................................................................................A2.22
CHECK OF THE BELT AND THE TENSIONER SPRING ............................................................................................A2.23
PROCEDURE FOR CHECKING THE VISCOUS FAN COUPLING..............................................................................A2.24

REMOVAL/REFITTING
PRELIMINARY OPERATIONS......................................................................................................................................A2.25
SEPARATE ENGINE/FRONT AXLE .............................................................................................................................A2.26
SEPARATE ENGINE/GEARBOX ..................................................................................................................................A2.28
ENGINE INSTALLATION SPECIFICATIONS ...............................................................................................................A2.30
CYLINDER HEAD..........................................................................................................................................................A2.31
CAMSHAFT ...................................................................................................................................................................A2.35
CYLINDER BLOCK .......................................................................................................................................................A2.36
LINERS..........................................................................................................................................................................A2.37
PISTONS AND CONNECTING RODS..........................................................................................................................A2.40
CRANKSHAFT, BEARINGS, AND FLYWHEEL............................................................................................................A2.47
CHANGING THE FRONT BEARING SEAL ..................................................................................................................A2.53
CAMSHAFT, BALANCER SHAFTS AND DISTRIBUTOR ............................................................................................A2.55
LUBRICATION...............................................................................................................................................................A2.62
COOLING ......................................................................................................................................................................A2.68
TURBOCHARGER ........................................................................................................................................................A2.74

DIAGNOSTIC SHEETS
"EXCESSIVE OIL CONSUMPTION" SHEET ................................................................................................................A2.75
INSPECTION PROCEDURE OF THE CYLINDER HEAD GASKET.............................................................................A2.76
"ENGINE OIL PRESSURE TOO HIGH" SHEET ...........................................................................................................A2.77
CHECKING PROCEDURE OF THE HIGH OIL PRESSURE IN THE CRANKCASE ....................................................A2.78
"ENGINE OIL PRESSURE TOO LOW" SHEET ............................................................................................................A2.79
"COOLANT TEMPERATURE TOO HIGH" SHEET .......................................................................................................A2.80
"COOLANT TEMPERATURE TOO LOW" SHEET........................................................................................................A2.81
FAILURE SEARCHING PROCEDURE OF CYLINDER HEAD SEAL...........................................................................A2.82

TOOLS
ENGINE TOOLS............................................................................................................................................................A2.86

Ares 806 – 09.2004 – GB


Notes

Ares 806 – 09.2004 – GB


t

B1 – GBA 10 GEARBOX

B2 – GTA 1040 AND GPA 30 LOW-


PRESSURE HYDRAULIC CIRCUIT

B3 – GBA 31 GEARBOX
(FULL POWERSHIFT)

B4 – GBA 31 LOW-PRESSURE
HYDRAULIC CIRCUIT
(FULL POWERSHIFT)

Chapter B

Ares 806 60 05 030 493 – 09.2004 publication


CONTENTS

B1 – GBA 10 GEARBOX

GENERAL SPECIFICATIONS
MEANING OF TRANSMISSION SYSTEM DESIGNATIONS..........................................................................................B1.2
INTRODUCTION TO THE GBA 10 .................................................................................................................................B1.3
TRANSMISSION KINEMATICS ......................................................................................................................................B1.4
GTA 1041 OVERDRIVE ..................................................................................................................................................B1.5
GTA 1042 AND 42+ OVERDRIVE...................................................................................................................................B1.6
GTA 1044 OVERDRIVE ..................................................................................................................................................B1.7
GTA 1044 NON-OVERDRIVE .........................................................................................................................................B1.8
GBA 10 REMOVAL/REFITTING PROCEDURE..............................................................................................................B1.9

TIGHTENING TORQUE
ENGINE/GEARBOX COUPLING ..................................................................................................................................B1.11
GEARBOX/REAR AXLE COUPLING ............................................................................................................................B1.12

MAIN ADJUSTMENTS
MAIN ADJUSTMENTS ..................................................................................................................................................B1.14

REVERSHIFT
CLUTCH FUNCTION.....................................................................................................................................................B1.15
SHUTTLE REVERSER OPERATION ...........................................................................................................................B1.16

FRONT CLUTCH
EXPLODED VIEW .........................................................................................................................................................B1.17
REMOVAL/REFITTING (STAGE 1 PAGE B1.9) ...........................................................................................................B1.18
REMOVAL .....................................................................................................................................................................B1.20
REFITTING....................................................................................................................................................................B1.21
ADJUSTMENT...............................................................................................................................................................B1.22
PREPARING FOR ADJUSTMENT................................................................................................................................B1.22

REAR CLUTCH
EXPLODED VIEW .........................................................................................................................................................B1.23
REMOVAL/REFITTING (STAGE 2 PAGE B1.9) ...........................................................................................................B1.24
REMOVAL .....................................................................................................................................................................B1.26
REFITTING THE EPICYCLIC GEAR SET ....................................................................................................................B1.27
REFITTING THE ASSEMBLY .......................................................................................................................................B1.28

Ares 806 – 09.2004 – GB


QUADRISHIFT UNIT
GENERAL......................................................................................................................................................................B1.29
OPERATING DIAGRAM................................................................................................................................................B1.29
EXPLODED VIEW .........................................................................................................................................................B1.32
REMOVAL/REFITTING (STAGE 3 PAGE B1.9) ...........................................................................................................B1.34
REMOVING THE FRONT BRAKE AND CLUTCH ........................................................................................................B1.34
REMOVING THE PLANET CARRIER ASSEMBLY ......................................................................................................B1.36
ASSEMBLING THE PLANET CARRIERS.....................................................................................................................B1.37
REMOVING THE REAR BRAKE AND CLUTCH...........................................................................................................B1.38
REMOVING THE SECONDARY SHAFT ......................................................................................................................B1.38
REFITTING AND ADJUSTING THE SECONDARY SHAFT .........................................................................................B1.39
REFITTING THE REAR BRAKE AND CLUTCH ...........................................................................................................B1.40
REFITTING THE FRONT BRAKE AND CLUTCH.........................................................................................................B1.41
ADJUSTING THE PLANET CARRIER ..........................................................................................................................B1.43
REFITTING THE QUADRISHIFT UNIT.........................................................................................................................B1.45

GEARSHIFT COVER
GENERAL......................................................................................................................................................................B1.46
REMOVING/REFITTING THE COVER .........................................................................................................................B1.47
REPLACING THE RANGE PISTON SEALS .................................................................................................................B1.48
REMOVING AND REFITTING THE GEAR SELECTOR...............................................................................................B1.48
ADJUSTING THE FIELD/ROAD RANGE......................................................................................................................B1.49

GUIDE RODS
GENERAL......................................................................................................................................................................B1.50
EXPLODED VIEW .........................................................................................................................................................B1.50
REMOVING THE GUIDE RODS ...................................................................................................................................B1.51
REFITTING THE GUIDE RODS....................................................................................................................................B1.52
ADJUSTING THE FORKS.............................................................................................................................................B1.53

OUTPUT SHAFT
GENERAL......................................................................................................................................................................B1.54
EXPLODED VIEW .........................................................................................................................................................B1.55
REMOVING THE SHAFT (STAGE 4 PAGE B1.10) ......................................................................................................B1.56
REFITTING THE SHAFT...............................................................................................................................................B1.57
ADJUSTING THE SHAFT .............................................................................................................................................B1.58

INPUT SHAFT
GENERAL......................................................................................................................................................................B1.59
EXPLODED VIEW .........................................................................................................................................................B1.60
REMOVING THE SHAFT (STAGE 5 PAGE B1.10) ......................................................................................................B1.62

Ares 806 – 09.2004 – GB


REMOVING THE SHAFT ..............................................................................................................................................B1.63
REFITTING THE SHAFT...............................................................................................................................................B1.63
ADJUSTING THE SHAFT .............................................................................................................................................B1.64

COUNTERSHAFT
GENERAL......................................................................................................................................................................B1.65
EXPLODED VIEW (STAGE 6 PAGE B1.10) .................................................................................................................B1.65
REMOVING THE SHAFT ..............................................................................................................................................B1.66
ADJUSTING THE SHAFT .............................................................................................................................................B1.67
REFITTING THE SHAFT...............................................................................................................................................B1.67
ADJUSTING THE BEARINGS.......................................................................................................................................B1.68

CRAWLER SPEEDS
GENERAL......................................................................................................................................................................B1.69
EXPLODED VIEW .........................................................................................................................................................B1.70
REMOVING/REFITTING THE HOUSING .....................................................................................................................B1.72
REMOVING, ADJUSTING AND REFITTING THE CONTROL SYSTEM......................................................................B1.73
SETTING THE CONTROLS ..........................................................................................................................................B1.74

B2 – GTA 1040 AND GPA 30 LOW-PRESSURE HYDRAULIC CIRCUIT

LS 100 L/MIN LOW-PRESSURE CIRCUIT ON GTA 1040


CIRCUIT LAYOUT ON BEAM .........................................................................................................................................B2.2
HYDRAULIC SYSTEM ....................................................................................................................................................B2.3
GEARBOX AND REAR AXLE LUBRICATION ................................................................................................................B2.5
AXLE TUBE LUBRICATION............................................................................................................................................B2.6

LS 110 L/MIN LOW-PRESSURE CIRCUIT ON GTA 1040


CIRCUIT LAYOUT ON BEAM .........................................................................................................................................B2.7
HYDRAULIC SYSTEM ....................................................................................................................................................B2.8
GEARBOX AND REAR AXLE LUBRICATION ..............................................................................................................B2.10
AXLE TUBE LUBRICATION..........................................................................................................................................B2.11

LS 110 L/MIN LOW-PRESSURE CIRCUIT ON GPA 30


CIRCUIT LAYOUT ON BEAM .......................................................................................................................................B2.12
HYDRAULIC SYSTEM ..................................................................................................................................................B2.13
REAR AXLE LUBRICATION .........................................................................................................................................B2.15
AXLE TUBE LUBRICATION..........................................................................................................................................B2.16

Ares 806 – 09.2004 – GB


LOW-PRESSURE HYDRAULIC COMPONENTS
LS 100 L/MIN DISTRIBUTION VALVE..........................................................................................................................B2.17
LS 110 L/MIN DISTRIBUTION VALVE..........................................................................................................................B2.18
REVERSHIFT AND QUADRISHIFT CONTROL ...........................................................................................................B2.19
INDEPENDENT LUBRICATION ON GBA 10................................................................................................................B2.23

SOLENOID VALVE MEASUREMENT AND CHECKING POINTS


ELECTRICAL TESTS ON THE SOLENOIDS ...............................................................................................................B2.25

GBA 10 DISTRIBUTION UNIT MEASUREMENT AND CHECKING POINTS


DISTRIBUTION UNIT SUPPLY PRESSURE CHECK ..................................................................................................B2.27
REVERSHIFT SUPPLY PRESSURE CHECK ..............................................................................................................B2.27
QUADRISHIFT SUPPLY PRESSURE CHECK.............................................................................................................B2.28

"HYDRAULIC INSPECTION RESULTS" SHEET


"HYDRAULIC INSPECTION RESULTS" SHEET ..........................................................................................................B2.29

GBA 10 LUBRICATION MEASUREMENT AND CHECKING POINTS


INDEPENDENT LUBRICATION CHECK ......................................................................................................................B2.30

"HYDRAULIC INSPECTION RESULTS" SHEET


"HYDRAULIC INSPECTION RESULTS" SHEET ..........................................................................................................B2.31

LS 110 L/MIN MEASUREMENT AND CHECKING POINTS


LUBRICATION PRESSURE CHECK ............................................................................................................................B2.32
GBA 10 LUBRICATION PRESSURE CHECK...............................................................................................................B2.32
CHECKING THE CONTROL PRESSURE ....................................................................................................................B2.33
LUBRICATING OIL FLOW RATE THROUGH THE COOLER AT 60°C........................................................................B2.33

"HYDRAULIC INSPECTION RESULTS" SHEET


"HYDRAULIC INSPECTION RESULTS" SHEET ..........................................................................................................B2.34

LS 100 L/MIN MEASUREMENT AND CHECKING POINTS


CHECKING THE FLOW COMING FROM THE STEERING BOX.................................................................................B2.35
CHECKING THE CONTROL PRESSURE ....................................................................................................................B2.35
COOLER INLET PRESSURE CHECK ..........................................................................................................................B2.36
LUBRICATION PRESSURE CHECK ............................................................................................................................B2.36

Ares 806 – 09.2004 – GB


"HYDRAULIC INSPECTION RESULTS" SHEET
"HYDRAULIC INSPECTION RESULTS" SHEET ..........................................................................................................B2.37

B3 – GBA 31 FULL POWERSHIFT GEARBOX

GENERAL
CHARACTERISTICS.......................................................................................................................................................B3.2
DESCRIPTION OF THE TRANSMISSION SYSTEM......................................................................................................B3.3
GEARBOX ARRANGEMENT DIAGRAM ........................................................................................................................B3.4
OPERATION AND POWER TRANSMISSION ................................................................................................................B3.8

REPAIR
REPLACING THE INPUT SHAFT SEAL .......................................................................................................................B3.13
REMOVING THE GEARBOX COMPLETELY ...............................................................................................................B3.13
TIGHTENING TORQUES..............................................................................................................................................B3.14

B4 – FULL POWERSHIFT LOW PRESSURE HYDRAULIC CIRCUIT

GENERAL
OPERATION....................................................................................................................................................................B4.2
CHARACTERISTICS.......................................................................................................................................................B4.2

DESCRIPTION
TRANSMISSION HYDRAULIC CIRCUIT ........................................................................................................................B4.3
TRANSMISSION CIRCUIT LAYOUT ..............................................................................................................................B4.4
OIL FILTER......................................................................................................................................................................B4.6
THERMOSTATIC VALVE................................................................................................................................................B4.6

REPAIR
PUMP ("GEROTOR" TYPE)............................................................................................................................................B4.8
PRESSURE CONTROL VALVE....................................................................................................................................B4.10
PROPORTIONAL SOLENOID VALVE ..........................................................................................................................B4.10
DISCHARGE VALVE.....................................................................................................................................................B4.11

Ares 806 – 09.2004 – GB


MEASUREMENT AND CHECKING POINTS
CHECKING THE CONTROL PRESSURE ....................................................................................................................B4.12
LUBRICATION PRESSURE CHECK ............................................................................................................................B4.13
CHECKING THE CLUTCH FEED PRESSURES ..........................................................................................................B4.14
ELECTRICAL CHECK ON THE SOLENOIDS ..............................................................................................................B4.15

"INSPECTION RESULTS" SHEET


"INSPECTION RESULTS" SHEET................................................................................................................................B4.16

TOOLS
LOW-PRESSURE HYDRAULICS AND GEARBOX TOOLS.........................................................................................B4.17

Ares 806 – 09.2004 – GB


C1 – GPA 40 REAR AXLE
C2 – GPA 30 REAR AXLE
C3 – FOOT BRAKE
C4 – AUTOMATIC BRAKE, PARK
LOCK AND HANDBRAKE

Chapter C

Ares 806 60 05 030 493 – 09.2004 publication


CONTENTS

C1 – GPA 40 REAR AXLE

TIGHTENING TORQUES AND MAIN ADJUSTMENTS


GEARBOX/REAR AXLE COUPLING ............................................................................................................................. C1.3
REAR AXLE/PTO HOUSING COUPLING...................................................................................................................... C1.4
GENERAL CROSS-SECTION........................................................................................................................................ C1.5
5" DIFFERENTIAL .......................................................................................................................................................... C1.6
ND AXLE TUBES ........................................................................................................................................................... C1.6
HD AND HD+ AXLE TUBES........................................................................................................................................... C1.6
HDE AXLE TUBES ......................................................................................................................................................... C1.6

GPA 40 DRIVE PINION


GENERAL....................................................................................................................................................................... C1.7
REMOVAL/REFITTING .................................................................................................................................................. C1.8
SETTING AND ADJUSTING THE PROTRUSION DISTANCE OF THE DRIVE PINION ............................................ C1.11

5" DIFFERENTIAL
GENERAL..................................................................................................................................................................... C1.14
REMOVING/REFITTING THE BEARINGS .................................................................................................................. C1.16
REMOVING/REFITTING THE DIFFERENTIAL CASE................................................................................................. C1.18
REMOVING/REFITTING THE DIFFERENTIAL LOCK................................................................................................. C1.20
REMOVING/REFITTING THE PLANET GEARS, SUN GEARS AND RING GEAR .................................................... C1.21
ADJUSTING THE BACKLASH ..................................................................................................................................... C1.22
SHIMMING THE DIFFERENTIAL CASE ROLLER BEARINGS................................................................................... C1.23

ND AXLE TUBES
GENERAL..................................................................................................................................................................... C1.26
REMOVAL .................................................................................................................................................................... C1.28
REFITTING................................................................................................................................................................... C1.29
REMOVING THE PLANET CARRIER.......................................................................................................................... C1.31
REFITTING THE PLANET CARRIER .......................................................................................................................... C1.31
REMOVING THE ROLLER BEARINGS AND SEALS.................................................................................................. C1.32
REFITTING THE ROLLER BEARINGS AND SEALS .................................................................................................. C1.32
SHIMMING THE WHEEL SHAFT BEARINGS ............................................................................................................. C1.33
REPLACING THE WHEEL STUD ................................................................................................................................ C1.33

HD AND HD+ AXLE TUBES


GENERAL..................................................................................................................................................................... C1.34
REMOVAL .................................................................................................................................................................... C1.36

Ares 806 – 09.2004 – GB


REFITTING................................................................................................................................................................... C1.37
REMOVING THE PLANET CARRIER.......................................................................................................................... C1.39
REFITTING THE PLANET CARRIER .......................................................................................................................... C1.39
REMOVING THE ROLLER BEARINGS AND SEALS.................................................................................................. C1.40
REFITTING THE ROLLER BEARINGS AND SEALS .................................................................................................. C1.40
SHIMMING THE WHEEL SHAFT BEARINGS ............................................................................................................. C1.41
REPLACING THE WHEEL STUD ................................................................................................................................ C1.41

HDE AXLE TUBES


GENERAL..................................................................................................................................................................... C1.42
REMOVAL .................................................................................................................................................................... C1.44
REFITTING................................................................................................................................................................... C1.45
REMOVING THE PLANET CARRIER.......................................................................................................................... C1.47
REFITTING THE PLANET CARRIER .......................................................................................................................... C1.47
REMOVING THE ROLLER BEARINGS AND SEALS.................................................................................................. C1.48
REFITTING THE ROLLER BEARINGS AND SEALS .................................................................................................. C1.48
SHIMMING THE WHEEL SHAFT BEARINGS ............................................................................................................. C1.49
REPLACING THE WHEEL STUD ................................................................................................................................ C1.49

GPA 40 POWER TAKE-OFF CLUTCH


GENERAL..................................................................................................................................................................... C1.50
REMOVAL/REFITTING ................................................................................................................................................ C1.52
REMOVING THE CLUTCH .......................................................................................................................................... C1.53
REFITTING THE CLUTCH ........................................................................................................................................... C1.54

GPA 40 POWER TAKE-OFF UPPER SHAFT


GENERAL..................................................................................................................................................................... C1.55
PREVENTION SYSTEM............................................................................................................................................... C1.58
REMOVAL/REFITTING ................................................................................................................................................ C1.59
REMOVAL/REFITTING ................................................................................................................................................ C1.59
ADJUSTMENT.............................................................................................................................................................. C1.62
ADJUSTING THE CONTROLS .................................................................................................................................... C1.62

GPA 40 POWER TAKE-OFF LOWER SHAFT


GENERAL..................................................................................................................................................................... C1.64
POWER TAKE-OFF BRAKE ........................................................................................................................................ C1.66
REMOVING/REFITTING THE LOWER SHAFT ........................................................................................................... C1.66
ADJUSTMENT.............................................................................................................................................................. C1.68

PROPORTIONAL POWER TAKE-OFF


GENERAL..................................................................................................................................................................... C1.70
REMOVING/REFITTING THE SELECTION SYSTEM................................................................................................. C1.72

Ares 806 – 09.2004 – GB


REMOVING/REFITTING THE GEARS ........................................................................................................................ C1.73
ADJUSTING THE BEARINGS...................................................................................................................................... C1.74

C2 – GPA 30 REAR AXLE

TIGHTENING TORQUES AND MAIN ADJUSTMENTS


GEARBOX/INTERMEDIATE HOUSING COUPLING..................................................................................................... C2.2
INTERMEDIATE HOUSING/REAR AXLE COUPLING .................................................................................................. C2.3
REAR AXLE/PTO HOUSING COUPLING...................................................................................................................... C2.4
GENERAL CROSS-SECTION........................................................................................................................................ C2.5
5" DIFFERENTIAL .......................................................................................................................................................... C2.6
HD+ AXLE TUBES ......................................................................................................................................................... C2.6
HDE AXLE TUBES ......................................................................................................................................................... C2.6

GPA 30 DRIVE PINION


GENERAL....................................................................................................................................................................... C2.7
REMOVAL/REFITTING .................................................................................................................................................. C2.8
DRIVE PINION PROTRUSION DISTANCE AND SHIMMING ..................................................................................... C2.11

5" DIFFERENTIAL
GENERAL..................................................................................................................................................................... C2.16
REMOVING/REFITTING THE BEARINGS .................................................................................................................. C2.18
REMOVING/REFITTING THE DIFFERENTIAL CASE................................................................................................. C2.20
REMOVING/REFITTING THE DIFFERENTIAL LOCK................................................................................................. C2.22
REMOVING/REFITTING THE PLANET GEARS, SUN GEARS AND RING GEAR .................................................... C2.23
ADJUSTING THE BACKLASH ..................................................................................................................................... C2.24
SHIMMING THE DIFFERENTIAL CASE ROLLER BEARINGS................................................................................... C2.25

GPA 30 POWER TAKE-OFF CLUTCH


GENERAL..................................................................................................................................................................... C2.28
REMOVAL/REFITTING ................................................................................................................................................ C2.30
REMOVING THE CLUTCH .......................................................................................................................................... C2.32
REFITTING THE CLUTCH ........................................................................................................................................... C2.33

GPA 30 POWER TAKE-OFF UPPER SHAFT


REMOVAL/REFITTING ................................................................................................................................................ C2.34
ADJUSTMENT.............................................................................................................................................................. C2.35

GPA 30 POWER TAKE-OFF LOWER SHAFT


GENERAL..................................................................................................................................................................... C2.36
REMOVAL .................................................................................................................................................................... C2.38

Ares 806 – 09.2004 – GB


REFITTING................................................................................................................................................................... C2.39
ADJUSTING THE BEARINGS...................................................................................................................................... C2.41

GPA 30 CRAWLER GEARS


GENERAL..................................................................................................................................................................... C2.42
REMOVING/REFITTING THE HOUSING .................................................................................................................... C2.44
REMOVING, ADJUSTING AND REFITTING THE CONTROL SYSTEM..................................................................... C2.45
SETTING THE CONTROLS ......................................................................................................................................... C2.46

C3 – SERVICE BRAKES

TECHNICAL SPECIFICATIONS
FOOT BRAKE................................................................................................................................................................. C3.2

BRAKE PISTONS AND SEALS


DRAINING THE SERVICE BRAKE CIRCUIT ................................................................................................................ C3.3
GENERAL....................................................................................................................................................................... C3.4
REMOVAL ...................................................................................................................................................................... C3.4
REFITTING..................................................................................................................................................................... C3.5
SEALING TEST .............................................................................................................................................................. C3.6

BOOSTERS AND MASTER CYLINDERS


DESCRIPTION OF THE MASTER CYLINDERS/BOOSTERS ...................................................................................... C3.7

REPLACING THE MASTER CYLINDERS


ADJUSTING THE BRAKE PEDALS............................................................................................................................... C3.8

BLEEDING THE BRAKE CIRCUIT


BLEEDING THE CIRCUIT MANUALLY ......................................................................................................................... C3.9
CLOSED-CENTRE HYDRAULIC CIRCUIT ON GTA 3130 (LS 110 L/MIN) ................................................................ C3.10
CLOSED-CENTRE HYDRAULIC CIRCUIT ON GTA 1040 (LS 110 L/MIN) ................................................................ C3.11
CLOSED-CENTRE HYDRAULIC CIRCUIT ON GTA 1040 (LS 100 L/MIN) ................................................................ C3.12
BLEEDING THE BRAKE CIRCUIT WITH A PRESSURISING DEVICE ...................................................................... C3.13
CHECKING THE EFFECTIVENESS OF THE 110 L/MIN AND 100 L/MIN CIRCUIT AIR BLEED (BOSCH VALVE) .. C3.15
CHECKING THE SNR VALVE (100 L/MIN CIRCUIT).................................................................................................. C3.15

Ares 806 – 09.2004 – GB


C4 – AUTOMATIC BRAKE, PARK LOCK AND HANDBRAKE

AUTOMATIC BRAKE
OPERATING PRINCIPLES ............................................................................................................................................ C4.2
EXPLODED VIEW OF CONTROL UNIT ........................................................................................................................ C4.4
EXPLODED VIEW OF BRAKE MECHANISM................................................................................................................ C4.5
REMOVING/REFITTING THE AUTOMATIC BRAKE ASSEMBLY ................................................................................ C4.6
REMOVING/REFITTING THE UNIT............................................................................................................................... C4.7
REMOVING/REFITTING THE PARKING BRAKE.......................................................................................................... C4.9
BASIC PARKING BRAKE ADJUSTMENT ................................................................................................................... C4.11
ADJUSTING THE PARKING BRAKE CONTROL ........................................................................................................ C4.12

PARK LOCK
GENERAL..................................................................................................................................................................... C4.14
REMARK ...................................................................................................................................................................... C4.14
OVERALL VIEW ........................................................................................................................................................... C4.15
SCHEMATIC DIAGRAM .............................................................................................................................................. C4.16
OPERATION................................................................................................................................................................. C4.18
REMOVING/REFITTING THE SAFETY SWITCH........................................................................................................ C4.20
SAFETY SWITCH ADJUSTMENT ............................................................................................................................... C4.21
"INSPECTION RESULTS" SHEET............................................................................................................................... C4.22

HANDBRAKE
GENERAL..................................................................................................................................................................... C4.24
OPERATION................................................................................................................................................................. C4.24
EXPLODED VIEW ........................................................................................................................................................ C4.25
REMOVING AND REFITTING THE HANDBRAKE CASING ....................................................................................... C4.26
ADJUSTING THE HANDBRAKE CONTROL ............................................................................................................... C4.27
DIAGNOSING BRAKE DISC WEAR ............................................................................................................................ C4.27
REMARK ...................................................................................................................................................................... C4.28

TOOLS
GPA 40 REAR AXLE – GPA 30 REAR AXLE – SERVICE BRAKES – AUTOMATIC BRAKE – PARK LOCK –
HANDBRAKE .............................................................................................................................................................. C4.29

Ares 806 – 09.2004 – GB


D1 – FRONT AXLE
20.29
20.29-3
20.43
20.43-2

D2 – PROACTIV FRONT AXLE


20.43 SI
20.43 SI-2
20.43 SI-3

D3 – GPA 30 AND GPA 40 4-


WHEEL DRIVE POWER TAKE-OFF
HOUSING

Chapter D

Ares 806 60 05 030 493 – 09.2004 publication


CONTENTS

D1 – FRONT AXLE

DESCRIPTION
GENERAL CHARACTERISTICS - RIGID AXLE ............................................................................................................ D1.2
DRIVE CHAIN................................................................................................................................................................. D1.4

REMOVAL/REFITTING
TIGHTENING TORQUES AND SEALANTS .................................................................................................................. D1.5
ADJUSTING THE WHEEL ALIGNMENT ....................................................................................................................... D1.7

DISASSEMBLY PRIOR TO FRONT AXLE OPERATIONS


PRELIMINARY OPERATIONS....................................................................................................................................... D1.8

REMOVAL/REFITTING
STEERING CYLINDER .................................................................................................................................................. D1.9
REMOVING THE REDUCTION GEAR AND WHEEL HUB ......................................................................................... D1.10
REFITTING THE REDUCTION GEAR AND WHEEL HUB .......................................................................................... D1.11
REMOVING THE WHEEL PIVOT ................................................................................................................................ D1.13
REFITTING THE WHEEL PIVOT ................................................................................................................................. D1.15
REFITTING THE ANGLE SENSOR ............................................................................................................................. D1.17
REMOVING THE BEVEL GEAR AND DIFFERENTIAL ............................................................................................... D1.18
DISASSEMBLING THE DIFFERENTIAL...................................................................................................................... D1.20
ADJUSTING THE PINION PROTRUSION DISTANCE................................................................................................ D1.20
SETTING THE BEVEL PINION PRELOAD.................................................................................................................. D1.21
ADJUSTING THE MESHING BACKLASH ................................................................................................................... D1.22
PRELOADING THE DIFFERENTIAL BEARING BLOCKS........................................................................................... D1.22
CHECKING THE SETTINGS........................................................................................................................................ D1.23
FINAL REASSEMBLY .................................................................................................................................................. D1.23

HYDRAULIC MEASUREMENT AND CHECKING POINTS


CHECKING THE DIFFERENTIAL LOCK CIRCUIT PRESSURE................................................................................. D1.24

"HYDRAULIC INSPECTION RESULTS" SHEET


CHECKING THE DIFFERENTIAL LOCK CIRCUIT PRESSURE................................................................................. D1.25

Ares 806 – 09.2004 – GB


D2 – PROACTIV FRONT AXLE

DESCRIPTION
GENERAL CHARACTERISTICS - RIGID AXLE ............................................................................................................ D2.2
CHARACTERISTICS...................................................................................................................................................... D2.4

REMOVAL/REFITTING
TIGHTENING TORQUES AND SEALANTS .................................................................................................................. D2.5
ADJUSTING THE WHEEL ALIGNMENT ....................................................................................................................... D2.7

DISASSEMBLY PRIOR TO FRONT AXLE OPERATIONS


PRELIMINARY OPERATIONS....................................................................................................................................... D2.8

REMOVAL/REFITTING
STEERING CYLINDER .................................................................................................................................................. D2.9
EPICYCLIC REDUCTION GEAR AND WHEEL HUB .................................................................................................. D2.10
REMOVING THE EPICYCLIC REDUCTION GEAR .................................................................................................... D2.11
REMOVING THE WHEEL HUB.................................................................................................................................... D2.11
WHEEL PIVOT AND UPPER ARM .............................................................................................................................. D2.12
REMOVING THE ANGLE SENSOR............................................................................................................................. D2.13
REMOVING THE WHEEL PIVOTS .............................................................................................................................. D2.13
REMOVING THE UPPER ARM.................................................................................................................................... D2.17
SUSPENSION CYLINDER AND LOWER ARM ........................................................................................................... D2.18
REMOVING THE TORSION BAR ................................................................................................................................ D2.19
REMOVING THE LOWER ARM................................................................................................................................... D2.20
REFITTING THE LOWER ARM ................................................................................................................................... D2.20
REFITTING THE TORSION BAR................................................................................................................................. D2.23
REFITTING THE UPPER ARM .................................................................................................................................... D2.24
UNIVERSAL SHAFTS .................................................................................................................................................. D2.24
REFITTING THE WHEEL PIVOTS............................................................................................................................... D2.28
REFITTING THE WHEEL HUB .................................................................................................................................... D2.29
REFITTING THE EPICYCLIC REDUCTION GEAR ..................................................................................................... D2.29
REFITTING THE SUSPENSION POSITION SENSOR................................................................................................ D2.30
SETTING THE SUSPENSION SENSORS................................................................................................................... D2.31
LOCALLY MADE TEST HARNESS.............................................................................................................................. D2.32
CALIBRATING THE SUSPENSION ............................................................................................................................. D2.33
REFITTING THE ANGLE SENSOR ............................................................................................................................. D2.34
FINAL STEPS............................................................................................................................................................... D2.34
BEVEL GEAR AND DIFFERENTIAL............................................................................................................................ D2.35
SECTIONAL VIEW ....................................................................................................................................................... D2.36
EXPLODED VIEW ........................................................................................................................................................ D2.37
DISASSEMBLING THE DIFFERENTIAL...................................................................................................................... D2.38

Ares 806 – 09.2004 – GB


ADJUSTING THE PINION PROTRUSION DISTANCE................................................................................................ D2.38
SETTING THE BEVEL PINION PRELOAD.................................................................................................................. D2.39
ADJUSTING THE MESHING BACKLASH ................................................................................................................... D2.40
CHECKING THE SETTINGS........................................................................................................................................ D2.41
FINAL REASSEMBLY .................................................................................................................................................. D2.41
SUSPENSION CONTROL UNIT .................................................................................................................................. D2.42

HYDRAULIC MEASUREMENT AND CHECKING POINTS


SUSPENSION CYLINDER PRESSURE CHECK......................................................................................................... D2.48
CHECKING THE DIFFERENTIAL LOCK CIRCUIT PRESSURE................................................................................. D2.49

HYDRAULIC MEASUREMENT AND CHECKING POINTS


SUSPENSION CYLINDER PRESSURE CHECK......................................................................................................... D2.50
DIFFERENTIAL LOCKING CIRCUIT PRESSURE CHECK ...................................................................................................... D2.50

ELECTRIC CHECKS
CONTROL SWITCHES ................................................................................................................................................ D2.51
SUSPENSION CONTROL SOLENOIDS...................................................................................................................... D2.52

BREAKDOWN DIAGNOSIS
VALUES TO BE CHECKED ......................................................................................................................................... D2.53
INTERPRETING ERROR CODES ............................................................................................................................... D2.54

Ares 806 – 09.2004 – GB


D3 – GPA 30 AND GPA 40 4-WHEEL DRIVE POWER TAKE-OFF HOUSING

DESCRIPTION
GENERAL....................................................................................................................................................................... D3.2
CROSS-SECTIONAL VIEW OF THE 4-WHEEL DRIVE HOUSING (GPA 30 AXLE) .................................................... D3.3
CROSS-SECTIONAL VIEW OF THE 4-WHEEL DRIVE HOUSING (GPA 30 AXLE) .................................................... D3.4
EXPLODED VIEW OF THE 4-WHEEL DRIVE HOUSING (GPA 30 AXLE)................................................................... D3.5
CROSS-SECTIONAL VIEW OF THE 4-WHEEL DRIVE HOUSING (GPA 40 AXLE) .................................................... D3.6
CROSS-SECTIONAL VIEW OF THE 4-WHEEL DRIVE HOUSING (GPA 40 AXLE) .................................................... D3.7
EXPLODED VIEW OF THE 4-WHEEL DRIVE HOUSING (GPA 40 AXLE)................................................................... D3.8

REMOVING/REFITTING THE HOUSING


REMOVAL OF CLUTCH................................................................................................................................................. D3.9
REMOVING THE CLUTCH ............................................................................................................................................ D3.9
REFITTING THE CLUTCH ........................................................................................................................................... D3.10
FITTING SHIMS TO THE CLUTCH "J1" ...................................................................................................................... D3.10
FITTING SHIMS TO THE SHAFT "J2" ......................................................................................................................... D3.11
REFITTING THE SHAFT.............................................................................................................................................. D3.12

SOLENOID VALVE MEASUREMENT AND CHECKING POINTS


ON/OFF SOLENOID VALVE ........................................................................................................................................ D3.13

HYDRAULIC MEASUREMENT AND CHECKING POINT


CHECKING THE FRONT AXLE ENGAGEMENT PRESSURE.................................................................................... D3.14

"HYDRAULIC INSPECTION RESULTS" SHEET


CHECKING THE FRONT AXLE ENGAGEMENT PRESSURE.................................................................................... D3.15

TOOLS
FRONT AXLE – 4 WD POWER TAKE-OFF HOUSING ............................................................................................... D3.17

Ares 806 – 09.2004 – GB


E1 – CLOSED CENTRE HYDRAULICS
(110 L/MIN)

E2 – CLOSED CENTRE HYDRAULICS


(100 L/MIN)

Chapter E

Ares 806 60 05 030 493 – 09.2004 publication


CONTENTS

E1 – CLOSED CENTRE HYDRAULICS (110 L/MIN)

DESCRIPTION
CHARACTERISTICS.......................................................................................................................................................E1.2
HYDRAULIC CIRCUIT DIAGRAM - QUADRISHIFT TRANSMISSION...........................................................................E1.5
COMPONENT LAYOUT - QUADRISHIFT TRANSMISSION ..........................................................................................E1.6
HYDRAULIC CIRCUIT DIAGRAM - FULL POWERSHIFT TRANSMISSION .................................................................E1.7
COMPONENT LAYOUT - FULL POWERSHIFT TRANSMISSION.................................................................................E1.8
SECTIONAL VIEW OF GPA 40 REAR AXLE ...............................................................................................................E1.10
SECTIONAL VIEW OF GPA 30 REAR AXLE

REMOVING/REFITTING THE COMPONENTS


EXTERNAL VIEW OF RIGHT-HAND COVER WITHOUT BRAKE VALVE...................................................................E1.11
EXTERNAL VIEW OF RIGHT-HAND COVER WITH BRAKE VALVE ..........................................................................E1.12
INTERNAL VIEW OF RIGHT-HAND COVER ...............................................................................................................E1.13
EXPLODED VIEW OF RIGHT-HAND COVER..............................................................................................................E1.14
IDENTIFICATION OF PORTS AND LINES...................................................................................................................E1.15
SCHEMATIC DIAGRAM OF THE VARIABLE DISPLACEMENT PUMP REGULATOR ...............................................E1.16
PRIORITY UNIT (NO TRAILER BRAKE) ......................................................................................................................E1.17
PRIORITY UNITS (WITH TRAILER BRAKE) ................................................................................................................E1.18
SCHEMATIC DIAGRAM OF PRIORITY UNITS ............................................................................................................E1.19
REMOVAL OF RIGHT COVER .....................................................................................................................................E1.21
REPLACING THE RH COVER......................................................................................................................................E1.21
ADJUSTING THE SPEED SENSOR.............................................................................................................................E1.23
VARIABLE DISPLACEMENT PUMP.............................................................................................................................E1.23
EXPLODED VIEW OF THE LEFT-HAND COVER........................................................................................................E1.24
SECTIONAL VIEW OF THE LEFT-HAND COVER .......................................................................................................E1.24
SECTIONAL VIEW OF THE GPA 30 LEFT-HAND COVER .........................................................................................E1.25
SECTIONAL VIEW OF THE GPA 40 LEFT-HAND COVER .........................................................................................E1.25
REMOVAL SPECIFICATIONS ......................................................................................................................................E1.26
REFITTING SPECIFICATIONS.....................................................................................................................................E1.26
BOOSTER PUMP..........................................................................................................................................................E1.28
REPLACEMENT OF PUMP SEALS..............................................................................................................................E1.29
FITTING SPOOL VALVES ON THE GPA 40 REAR AXLE ...........................................................................................E1.30
FITTING SPOOL VALVES ON THE GPA 30 REAR AXLE ...........................................................................................E1.31
HYDRAULIC DIAGRAM OF THE LIFT SPOOL VALVE AND THE ELECTROHYDRAULIC SPOOL VALVE ..............E1.32
HYDRAULIC DIAGRAM OF THE LIFT SPOOL VALVE AND MECHANICAL SPOOL VALVE ....................................E1.33
REMOVING THE SPOOL VALVE BLOCK....................................................................................................................E1.34
REFITTING THE SPOOL VALVE UNIT ........................................................................................................................E1.35
LINKAGE SPOOL VALVE .............................................................................................................................................E1.36

Ares 806 – 09.2004 – GB


LINKAGE SPOOL VALVE (NEUTRAL POSITION).......................................................................................................E1.38
LINKAGE SPOOL VALVE (DOWN POSITION) ............................................................................................................E1.39
LINKAGE SPOOL VALVE (UP POSITION)...................................................................................................................E1.39
3-POSITION "ZF" AUXILIARY SPOOL VALVE WITH OPTIONAL "KO".......................................................................E1.40
FOUR-POSITION "ZF" AUXILIARY SPOOL VALVE ....................................................................................................E1.42
4-POSITION "ZF" AUXILIARY SPOOL VALVE WITH OPTIONAL "KO".......................................................................E1.44
AUXILIARY SPOOL VALVE WITH ELECTROHYDRAULIC CONTROLS ....................................................................E1.45
CLOSING PLATE WITH SAFETY SOLENOID VALVE.................................................................................................E1.47
AUXILIARY SPOOL VALVE CONTROL ADJUSTMENTS............................................................................................E1.48
LINKAGE RAMS............................................................................................................................................................E1.50
STEERING UNIT OSPQ 100/160 LS (110 L/MIN CIRCUIT).........................................................................................E1.52
EXPLODED VIEW OF STEERING UNIT OSPQ 100/160 LS (110 L/MIN CIRCUIT)....................................................E1.53
HYDRAULIC DIAGRAM OF STEERING UNIT OSPQ 100/160 LS (110 L/MIN CIRCUIT) ...........................................E1.54
STEERING UNIT OSPC 135 ON (100 L/MIN CIRCUIT)...............................................................................................E1.56
EXPLODED VIEW OF STEERING UNIT OSPC 135 ON (100 L/MIN CIRCUIT) ..........................................................E1.57
HYDRAULIC DIAGRAM OF STEERING UNIT OSPC 135 ON (100 L/MIN CIRCUIT) .................................................E1.58
ACCESS TO STEERING UNIT .....................................................................................................................................E1.59
SPECIFIC POINTS RELATING TO REMOVAL/REFITTING ........................................................................................E1.60

HYDRAULIC MEASUREMENT AND CHECKING POINTS


VARIABLE DISPLACEMENT PUMP BOOST PRESSURE CHECK.............................................................................E1.62
STANDBY PRESSURE AND "XLS" PRESSURE CHECK............................................................................................E1.62
MAXIMUM PRESSURE AND FLOW RATE CHECK ON THE AUXILIARY SPOOL VALVES......................................E1.63
FLOW REGULATOR CHECK ON THE AUXILIARY SPOOL VALVES.........................................................................E1.64
TRIGGER PRESSURE CHECK ON THE (KO) SPOOL VALVE...................................................................................E1.64
MAXIMUM REAR LIFT PRESSURE CHECK................................................................................................................E1.65
BRAKING VALVE CHECK ............................................................................................................................................E1.65

"HYDRAULIC INSPECTION RESULTS" SHEET


VARIABLE DISPLACEMENT PUMP BOOST PRESSURE CHECK.............................................................................E1.66
STANDBY PRESSURE AND "XLS" PRESSURE CHECK............................................................................................E1.66
MAXIMUM PRESSURE AND FLOW RATE CHECK ON THE AUXILIARY SPOOL VALVES......................................E1.67
FLOW REGULATOR CHECK ON THE AUXILIARY SPOOL VALVES.........................................................................E1.67
TRIGGER PRESSURE CHECK ON (KO) SPOOL VALVES.........................................................................................E1.68
MAXIMUM REAR LIFT PRESSURE CHECK................................................................................................................E1.68

Ares 806 – 09.2004 – GB


HYDRAULIC MEASUREMENT AND CHECKING POINTS
STEERING PRESSURE CHECK ..................................................................................................................................E1.69
MAXIMUM STEERING CYLINDER PRESSURE CHECK ............................................................................................E1.70
SHOCKPROOF VALVE OPENING PRESSURE CHECK.............................................................................................E1.71

"HYDRAULIC INSPECTION RESULTS" SHEET


STEERING PRESSURE CHECK ..................................................................................................................................E1.72
MAXIMUM STEERING CYLINDER PRESSURE CHECK ............................................................................................E1.72
SHOCKPROOF VALVE OPENING PRESSURE CHECK.............................................................................................E1.72

E2 – CLOSED CENTRE HYDRAULICS (100 L/MIN)

DESCRIPTION
CHARACTERISTICS.......................................................................................................................................................E2.2
GENERAL HYDRAULIC CIRCUIT DIAGRAM OF 100 L "LOAD SENSING" CLOSED-CENTRE CIRCUIT...................E2.5
HYDRAULIC CIRCUIT DIAGRAM - QUADRISHIFT TRANSMISSION...........................................................................E2.6
EXTERIOR VIEW OF THE RIGHT-HAND COVER.........................................................................................................E2.8
INTERIOR AND EXTERIOR VIEW OF THE RIGHT-HAND COVER..............................................................................E2.9
DESCRIPTION OF THE CIRCUIT SELECTOR (LOAD SENSING SIGNAL) ...............................................................E2.10

REMOVING/REFITTING THE COMPONENTS


BRAKE VALVE ..............................................................................................................................................................E2.11
SECTIONAL VIEW OF THE BRAKING VALVE (BOSCH) ............................................................................................E2.12
EXPLODED VIEW OF BRAKING VALVE (BOSCH) .....................................................................................................E2.13
SECTIONAL VIEW OF THE BRAKING VALVE (SNR) .................................................................................................E2.14
EXPLODED VIEW OF BRAKING VALVE (SNR) ..........................................................................................................E2.15
GEOGRAPHICAL LOCATION OF THE HYDRAULIC COMPONENTS ON THE PRIORITY UNIT ..............................E2.16
PRESSURE LIMITER DBV1 (210 BAR)........................................................................................................................E2.17
REMOVAL OF RIGHT COVER .....................................................................................................................................E2.18
REMOVAL/REFITTING THE MAIN PUMP....................................................................................................................E2.18
REPLACING THE RH COVER......................................................................................................................................E2.19
OVERALL VIEW OF THE LEFT-HAND COVER...........................................................................................................E2.20
REMOVING THE LEFT-HAND COVER ........................................................................................................................E2.21
REFITTING THE LEFT-HAND COVER.........................................................................................................................E2.21
REMOVAL/REFITTING THE STEERING PUMP ..........................................................................................................E2.21

Ares 806 – 09.2004 – GB


HYDRAULIC MEASUREMENT AND CHECKING POINTS
CHECKING THE STANDBY PRESSURE OF THE 14 CM³ PUMP ..............................................................................E2.23
PRESSURE CHECK FOR A FLOW RATE OF LESS THAN 40-L/MIN AND A FLOW RATE OF 60 L/MIN .................E2.25
TEST AT 20 L/MIN ........................................................................................................................................................E2.26
TEST AT 20 L/MIN ........................................................................................................................................................E2.26
MINIMUM/MAXIMUM FLOW RATE CHECK ON THE AUXILIARY SPOOL VALVES..................................................E2.27
BRAKING VALVE CHECK ............................................................................................................................................E2.27

"HYDRAULIC INSPECTION RESULTS" SHEET


MINIMUM/MAXIMUM FLOW RATE CHECK ON THE AUXILIARY SPOOL VALVES..................................................E2.28
CHECKING THE STANDBY PRESSURE OF THE 14 CM³ PUMP ..............................................................................E2.28
CHECK THE PRESSURE FOR A REQUIRED FLOW LESS THAN 40 L/MIN AND A FLOW OF 60 L/MIN ................E2.28

HYDRAULIC MEASUREMENT AND CHECKING POINTS


CHECKING THE STEERING PUMP.............................................................................................................................E2.29
MAXIMUM STEERING CYLINDER PRESSURE CHECK ............................................................................................E2.30
SHOCKPROOF VALVE OPENING PRESSURE CHECK.............................................................................................E2.32

"HYDRAULIC INSPECTION RESULTS" SHEET


CHECKING THE STEERING PUMP.............................................................................................................................E2.33
MAXIMUM STEERING CYLINDER PRESSURE CHECK ............................................................................................E2.33
SHOCKPROOF VALVE OPENING PRESSURE CHECK.............................................................................................E2.33

TOOLS
HYDRAULIC CIRCUIT TOOLING .................................................................................................................................E2.36

Ares 806 – 09.2004 – GB


ELECTRICITY

Chapter F

ARES 09.2004 publication


Ares 806 – 09.2004 – GB
Ares 806 – 09.2004 – GB
GENERAL CONTENTS

CHAPTER F

ELECTRICITY.........................................................................................................F

Ares 806 – 09.2004 – GB


Ares 806 – 09.2004 – GB
GENERAL CONTENTS Aid to using the MR - Electricity Chapter
Search from the schematic diagram by function
Facing the schematic diagrams are some connectors that provide additional help in understanding the diagram.
ITEM LIST.........................................................................................................................................................................................F1.2 Search from a wire number
WIRING AND GENERAL LISTS.......................................................................................................................................................F1.3 Example: 948.
SCHEMATIC DIAGRAMS ACCORDING TO FUNCTIONS .............................................................................................................F1.5 Refer to the plate "Wiring and general list", find in the figures in brackets : the example corresponds to the harness 9a:
CONNECTOR AND HARNESS TRACKING ....................................................................................................................................F2.1 Once the connector is identified, go to the chapter "Harness path and connectors" for the identification of the wire.
With this designation, refer to the corresponding function diagram or use the name of the connector.

TOOLS Search from a connector identified by the wiring path


With the designation of the wire, refer to the corresponding function diagram or use the name of the connector.
ELECTRICITY TOOLS ...................................................................................................................................................................F2.87 IMPORTANT: Some diagrams by function represent the versions with a maximum of options. The wire markers may be
different from one option to another or from one variant to another. Refer to the chapter "Harness path and connectors" for
the exact validity of the wire markers according to options.
Following the evolution of the engine in relation to depollution standards, you will find below the different representations of connectors
grids.

Abbreviations:
+AVC = Constant source
+APC = Ignition source
Ar (Rr) = rear
Av (Frt) = Front
Cde = Controls
D (RH) = Right(-hand)
Deh = Electrohydraulic spool valve
Ev = Solenoid valve
Ext = Outer/outside/exterior
G (LH) = Left(-hand)
Hdc = Top of cab
Int = Inner/inside/interior
Odb = Onboard computer
Pot = Potentiometer
Tdb = Instrument panel/dashboard
Temp = Temperature
Reh = Electrohydraulic lift

Ares 806 – 09.2004 – GB


Notes Notes

Ares 806 – 09.2004 – GB


G1 – INSTRUMENT PANEL
G2 – TCE 15/25 AND TCE 15 T
ELECTRONIC LIFT
G3 – TRANSMISSION/AXLE
CONTROL
G4 – ENGINE MANAGEMENT
G5 – INFOTRAC AND ISO SOCKET
G6 – ELECTROPILOT
G7 – WIN MÉTADIAG©

Chapter G

Ares 806 60 05 030 493 – 09.2004 publication


CONTENTS

G1 – INSTRUMENT PANEL

OPERATING PRINCIPLES
DESCRIPTION OF PANEL ............................................................................................................................................ G1.2
ALLOCATION OF LIGHT BULBS TO INDICATOR LIGHTS.......................................................................................... G1.3

CHARACTERISTICS
INDICATOR OPERATION.............................................................................................................................................. G1.4
WARNING LIGHTS (RED) ............................................................................................................................................. G1.9
SECONDARY WARNING LIGHTS (ORANGE)............................................................................................................ G1.10
OTHER INDICATOR LIGHTS ...................................................................................................................................... G1.10
INPUT/OUTPUT BY FUNCTION (REV COUNTER, VARIOUS SPEEDS AND HOUR COUNTER)............................ G1.11
INPUT/OUTPUT BY FUNCTION (GAUGE AND TEMPERATURE)............................................................................. G1.12
INPUTS/OUTPUTS RELATING TO RED LIGHTS....................................................................................................... G1.13
INPUTS/OUTPUTS RELATING TO OTHER LIGHTS.................................................................................................. G1.14
CONNECTION AND FUNCTIONS OF THE WIRES OF THE SINGLE CONNECTOR "JX1"...................................... G1.15
CONNECTION AND FUNCTIONS OF THE WIRES OF THE DOUBLE CONNECTOR "JX2" .................................... G1.16
TRANSMISSION OIL PRESSURE SENSOR (17 BAR)............................................................................................... G1.18
BLOCKAGE INDICATOR ............................................................................................................................................. G1.18
ENGINE OIL PRESSURE SENSOR ............................................................................................................................ G1.18
TRANSMISSION OIL TEMPERATURE SENSOR ....................................................................................................... G1.18
SPEED SENSORS ....................................................................................................................................................... G1.19

REMOVAL/REFITTING
CONNECTORS "JX1" AND "JX2" ................................................................................................................................ G1.20

CALIBRATION
CALIBRATION OVER 100 METRES............................................................................................................................ G1.21
OTHER OPERATIONS................................................................................................................................................. G1.22

G2 – TCE 15/25 AND TCE 15 T ELECTRONIC LIFT

DESCRIPTION
TCE 15/TCE 25 .............................................................................................................................................................. G2.2
ACCESS TO THE INSTALLED SOFTWARE VERSION (TCE 15 OR TCE 25) ............................................................ G2.3

Ares 806 – 09.2004 – GB


LIFT OPERATING CONDITIONS................................................................................................................................... G2.3
ERROR CODES ............................................................................................................................................................. G2.3
TCE 15T ......................................................................................................................................................................... G2.4
LIFT OPERATING CONDITIONS................................................................................................................................... G2.5
ERROR CODES ............................................................................................................................................................. G2.5

CHECKS AND ADJUSTMENTS


CONNECTIONS TO TCE 15/TCE 25 UNITS ................................................................................................................. G2.6
CONNECTIONS TO TCE 15T UNIT .............................................................................................................................. G2.7
POSITION SENSOR ON GPA 30 AXLE ........................................................................................................................ G2.9
POSITION SENSOR ON GPA 40 AXLE ...................................................................................................................... G2.10
DRAFT SENSOR ON GPA 30 AND GPA 40 AXLES................................................................................................... G2.12
THEORETICAL FORWARD SPEED SENSOR ON GPA 30 AND GPA 40 AXLES..................................................... G2.14
RADAR (TCE 25 ONLY)............................................................................................................................................... G2.15
LIFT SPOOL VALVE SOLENOID VALVES.................................................................................................................. G2.15

G3 – TRANSMISSION/AXLE CONTROL

DRIVETRONIC III
LOCATION OF THE LS 100 L/MIN COMPONENTS AND SENSORS .......................................................................... G3.3
LOCATION OF THE LS 110 L/MIN COMPONENTS AND SENSORS .......................................................................... G3.4
TOC, BOC SWITCHES AND ANGLE DETECTOR........................................................................................................ G3.5
DRIVETRONIC ELECTRONIC UNIT ............................................................................................................................. G3.5
SHUTTLE REVERSER LEVER CHARACTERISTICS (ILLUSTRATED IN NEUTRAL)................................................. G3.6
RANGE AND DECLUTCHING CONTROL..................................................................................................................... G3.6
CLUTCH PEDAL SWITCHES ........................................................................................................................................ G3.7
QUADRISHIFT II (244) AND QUADRACTIV (245) CONTROL SWITCHES.................................................................. G3.8
SOLENOID VALVE......................................................................................................................................................... G3.9
CONTROL PRESSURE SWITCH ................................................................................................................................ G3.11
LUBRICATION/BOOST PRESSURE SWITCH, 3 BAR................................................................................................ G3.11
BLOCKAGE INDICATOR ............................................................................................................................................. G3.11
SPEED SENSORS ...................................................................................................................................................... G3.12
TEMPERATURE SENSOR .......................................................................................................................................... G3.12
ADJUSTMENT OF TOC, BOC AND ANGLE DETECTOR SWITCHES....................................................................... G3.13
STATIC CALIBRATION OF CLUTCHES...................................................................................................................... G3.14
ADJUSTING THE CALIBRATION PROCEDURES...................................................................................................... G3.16
INPUTS/OUTPUTS BY FUNCTIONS AND AUTOMATIC SYSTEMS.......................................................................... G3.17
STEERING ANGLE CALIBRATION ............................................................................................................................. G3.20
GENERAL SCHEMATIC DIAGRAM............................................................................................................................. G3.30

Ares 806 – 09.2004 – GB


DRIVETRONIC V
INPUTS/OUTPUTS AND AUTOMATIC SYSTEMS ..................................................................................................... G3.33
SWITCH AND SOLENOID VALVE CHECK ................................................................................................................. G3.36
ERROR CODES ........................................................................................................................................................... G3.36

FULL POWERSHIFT
LOCATION OF COMPONENTS AND SENSORS ....................................................................................................... G3.37
LAYOUT ON THE REAR AXLE.................................................................................................................................... G3.40
FEATURES/SETTINGS................................................................................................................................................ G3.41
CLUTCH PEDAL SWITCHES ...................................................................................................................................... G3.42
SCHEMATIC DIAGRAM OF TC/RCC .......................................................................................................................... G3.48

G4 – ENGINE MANAGEMENT

DE 10 PUMP
LOCATION OF COMPONENTS AND SENSORS ......................................................................................................... G4.2
CHARACTERISTICS OF THE COMPONENTS............................................................................................................. G4.4
ADJUSTING THE ACCELERATOR DETECTOR ........................................................................................................ G4.12
DIAGNOSTIC HARNESS ............................................................................................................................................. G4.12

VP 44 PUMP
LOCATION OF COMPONENTS AND SENSORS ....................................................................................................... G4.14
CHARACTERISTICS OF THE COMPONENTS........................................................................................................... G4.15
SCHEMATIC DIAGRAM .............................................................................................................................................. G4.21
ADJUSTING THE ACCELERATOR DETECTOR ........................................................................................................ G4.25
DIAGNOSTIC HARNESS ............................................................................................................................................. G4.26

G5 – INFOTRAC AND ISO SOCKET

DESCRIPTION
FUNCTIONS OF THE ON-BOARD COMPUTER........................................................................................................... G5.2
OPERATING PRINCIPLES ............................................................................................................................................ G5.2
USE ................................................................................................................................................................................ G5.4

REMOVAL/REFITTING AND ELECTRICAL CHECKS


REMOVING THE UNIT AND CHANGING THE BULBS................................................................................................. G5.8
ISO SOCKET.................................................................................................................................................................. G5.7

Ares 806 – 09.2004 – GB


ISO UNIT ........................................................................................................................................................................ G5.7
EXTERNAL TEMPERATURE PROBE ........................................................................................................................... G5.7
SCHEMATIC DIAGRAM ................................................................................................................................................ G5.9
FUNCTIONS OF CONNECTOR WIRES...................................................................................................................... G5.10
ELECTRICAL CHECK ON THE ISO SOCKET ............................................................................................................ G5.11
OUTSIDE AIR TEMPERATURE SENSOR .................................................................................................................. G5.12
FORWARD SPEED CALIBRATION ............................................................................................................................. G5.13
MAINTENANCE FUNCTION ........................................................................................................................................ G5.13

G6 – ELECTROPILOT

DESCRIPTION
CONTROLS.................................................................................................................................................................... G6.2
JOYSTICK CONNECTIONS........................................................................................................................................... G6.3
DC POWER SWITCH CONNECTIONS ......................................................................................................................... G6.3
CONNECTIONS ON MODULE ...................................................................................................................................... G6.4
ELECTROHYDRAULIC SPOOL VALVE ("DEH") .......................................................................................................... G6.5

REMOVAL/REFITTING
ELECTROHYDRAULIC SPOOL VALVE ("DEH") .......................................................................................................... G6.6
CONTROL HANDLE....................................................................................................................................................... G6.6

MEASUREMENT AND CHECKING POINTS


CHECKING THE SAFETY SOLENOID VALVE ............................................................................................................. G6.7
CHECKING THE CONTROL PRESSURES................................................................................................................... G6.8

"INSPECTION RESULTS" SHEET


CHECKING THE SAFETY SOLENOID VALVE ............................................................................................................. G6.9
CHECKING THE CONTROL PRESSURE ..................................................................................................................... G6.9

TOOLS
INSTRUMENT PANEL – ELECTRONIC LIFT (AND RADAR) – TRANSMISSION/AXLE CONTROL – ENGINE
MANAGEMENT – INFOTRAC AND ISO SOCKET – ELECTROPILOT....................................................................... G6.11

Ares 806 – 09.2004 – GB


H1
CAB LIFT

H2
HEATING/AIR CONDITIONING

H3
BONDING THE WINDOWS

Chapter H

Ares 806 60 05 030 493 – 09.2004 publication


CONTENTS

H1 – CAB LIFT

DESCRIPTION
IDENTIFICATION ........................................................................................................................................................... H1.2
RIGHT SIDE (LOCATION OF OPERATIONS)............................................................................................................... H1.3
LEFT SIDE (LOCATION OF OPERATIONS) ................................................................................................................. H1.4

FULL CAB REMOVAL


SAFETY MEASURE ....................................................................................................................................................... H1.5
SLING SPECIFICATIONS .............................................................................................................................................. H1.5

REMOVAL/REFITTING
OPERATIONS 1 TO 4 .................................................................................................................................................... H1.6
PREPARING THE LIFTING BAR ................................................................................................................................... H1.6
INSTALLING THE LIFTING BAR ................................................................................................................................... H1.7
TAKING THE WEIGHT OF THE CAB ............................................................................................................................ H1.7
OPERATIONS 5 TO 6 .................................................................................................................................................... H1.7
OPERATIONS 7 TO 9 .................................................................................................................................................... H1.8
OPERATIONS 10 TO 12 ................................................................................................................................................ H1.9
OPERATIONS 13 TO 14 .............................................................................................................................................. H1.10
OPERATIONS 15 TO 18 .............................................................................................................................................. H1.11
OPERATION N° 19....................................................................................................................................................... H1.12
OPERATION N° 20....................................................................................................................................................... H1.13
OPERATION N° 21....................................................................................................................................................... H1.14

REFITTING THE CAB


SPECIAL POINTS ........................................................................................................................................................ H1.15
TIGHTENING TORQUES............................................................................................................................................. H1.15
ADJUSTMENTS ........................................................................................................................................................... H1.16

REMOVING/REFITTING THE ROOF


FULL REMOVAL WITH THE AIR CONDITIONING FANS........................................................................................... H1.17
REFITTING................................................................................................................................................................... H1.17

Ares 806 – 09.2004 – GB


H2 – HEATING/AIR CONDITIONING

DESCRIPTION
CHARACTERISTICS...................................................................................................................................................... H2.2
DIAGRAM OF OPERATING PRINCIPLE....................................................................................................................... H2.4
CONTROL PANEL ......................................................................................................................................................... H2.5

REMOVAL/REFITTING
ENGINE LAYOUT........................................................................................................................................................... H2.6
CAB LAYOUT ................................................................................................................................................................. H2.8
HEATING RADIATOR UNIT AND FANS...................................................................................................................... H2.12
HEATING RADIATOR .................................................................................................................................................. H2.13

TROUBLESHOOTING GUIDE
DIAGNOSTICS ............................................................................................................................................................. H2.17

H3 – BONDING THE WINDOWS

REMOVAL/REFITTING
WARNING! ..................................................................................................................................................................... H3.2
LIST OF EQUIPMENT TO USE – SPECIAL INSTRUCTIONS ...................................................................................... H3.3
REMOVAL ...................................................................................................................................................................... H3.4
PREPARING THE WINDSCREEN BEFORE APPLYING PRIMER ............................................................................... H3.5
APPLYING PRIMER....................................................................................................................................................... H3.6
PREPARING THE TWO-PACK SEALANT..................................................................................................................... H3.7
REPLACING THE PLOUGHING WINDOW ................................................................................................................... H3.9

TOOLS
CAB LIFT – HEATING/AIR CONDITIONING – BONDING THE WINDOWS ............................................................... H3.11

Ares 806 – 09.2004 – GB

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