PDF Workshop Manual Deutz-Fahr Agrotron 106 110 115 120 135 150 165 MK3 - 4 MB
This complete workshop manual covers the Deutz-Fahr Agrotron MK3 series, including models 106 through 165.
It contains in-depth service and repair procedures for the engine, transmission, hydraulics, and electrical systems.
This is the definitive guide for professional technicians, providing the detailed information needed for complex diagnostics and major overhauls.
Keep your Agrotron tractor running like new with this essential resource.
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--- Page 1 ---
SAME DEUTZ-FAHR DEUTSCHLAND GmbH
WORKSHOP MANUAL
AGROTRON 106 MK3
AGROTRON 110 MK3
AGROTRON 115 MK3
AGROTRON 120 MK3
AGROTRON 135 MK3
AGROTRON 150 MK3
AGROTRON 165 MK3
--- Page 3 ---
LIFTING INSTRUCTIONS
LIFTING INSTRUCTIONS
Components weighing over 25 kg or of significant size must be supported and removed using suitable lifting equip-
ment with wire rope or polyester slings.
In the paragraphs regarding removal and refitting operations, the weight of the component or assembly to be lifted is
indicated with the symbol
WIRE ROPES - SLINGS
β’ Use wire ropes or polyester slings of suitable capacity for the parts to be lifted, referring to the following tables:
WIRE ROPES POLYESTER SLINGS
(standard twisted Β«SΒ» or Β«ZΒ» type) (eye-and-eye - simple loop)
Capacity (kg) Capacity (kg)
Γ rope Width
mm 60Β° 90Β° (mm) 60Β° 90Β°
8 650 620 500 25 500 400 860 700
10 1000 1740 1420 50 1000 800 1730 1410
12 1450 2500 2050 62 1250 1000 2160 1760
14 2000 3460 2820 75 1400 1120 2420 1980
16 2600 4500 3670 100 2000 1600 3460 2820
18 3300 5710 4660 150 2500 2000 4330 3530
NOTE. Lifting capacities are calculated with a safety coefficient.
β’ The lifting hook should be attached to the central part of the rope or sling; if the hook is attached near the ends of the
rope/sling, this could cause the load to slip during lifting.
β’ Never lift a heavy load using a single rope; always use two or more symmetrically arranged ropes.
Suspension of a load from a single rope could cause the load to start rotating and consequently cause the rope
strands to untwist or the load to slip; this could lead to serious injury.
β’ Never lift a heavy load when the two branches of the ropes form a wide angle.
The permitted load (kg) decreases in inverse proportion to the angle of suspension; the table below indicates how the
permitted load varies according to the angle of suspension for two Γ 10 mm ropes each with a load capacity of 1000 kg.
2000
1900
1700
2000
Load capacity: kg
1400
1000
1000
500
30Β° 60Β° 90Β° 120Β° 150Β°
Angle of suspension: β£
00-9
--- Page 4 ---
TRANSMISSION MAIN COMPONENTS (Power Shift version)
18
19
23
22 21 20
18. Left brake cylinder
19. 30 km/h speed limiting pin
20. Mechanical gearbox shift lever
21. Right brake cylinder
D0004380 22. Differential lock control valve
23. Differential lock control solenoid valve
10-3
--- Page 5 ---
GEARBOX CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC (Power Shift version)
1.1.6 CLUTCH ENGAGEMENT AND SOLENOID VALVE OPERATION SCHEMATIC
Forward
C A C A C A C A
Input
shaft D B D B D B D B
C A
Output
shaft GF GF GF GF
L gear M gear H gear S gear
D B
Reverse
GF
C A C A C A C A
Neutral
D B D B D B D B
GF GF GF GF
L gear M gear H gear S gear
D0004501
Solenoid valve operation when shifting from L to S gear (LβMβHβS)
Forward Reverse
Solenoid valve
L M H S L M H S
Y6 β β β β
Y7 β β β β β = Solenoid valve energised
Y1 β β β β β = Solenoid valve briefly
Y2 β β β β energised
Y3 β β β β β β during gear change
Y4 β β
Solenoid valve operation when shifting from S to L gear (SβHβMβL)
Forward Reverse
Solenoid valve
S H M L S H M L
Y6 β β β β
Y7 β β β β β = Solenoid valve energised
Y1 β β β β β = Solenoid valve briefly
Y2 β β β energised
Y3 β β β β β β during gear change
Y4 β β
10-13
--- Page 6 ---
GEARBOX GEARBOX CONTROL VALVE (Power Shuttle version)
A. GEARBOX CONTROL VALVE
PRESSURE TEST POINTS
a b c d e f
g
h
l
p
n m D0004440
Pos. Function Thread size
a. A or F clutch pressure M10x1
b. B or G clutch pressure M10x1
c. Y3 or Y4 solenoid valve pressure M10x1
d. Pressure Pg to relief valve M10x1
e. Pressure Pr from relief valve (18 bar) M10x1
f. Engagement pressure of clutch C or D M10x1
g. General pressure (18 bar) M10x1
h. Engagement pressure of clutch A/B or F/G M10x1
l. Pilot pressure (10 bar) M10x1
m. D clutch pressure M10x1
n. C clutch pressure M10x1
p. Modulated pressure M10x1
10-23
--- Page 7 ---
BRAKING SYSTEM DESCRIPTION
2. BRAKING SYSTEM
DESCRIPTION
The braking system is comprised of 2 braking devices (one for each rear wheel) operated by two hydraulic pumps by way
of mechanical controls.
Each pump supplies fluid to the brake on one side (left or right) thereby allowing the operator to brake on one side only and
thus reduce the steering radius.
1
3
2
5
4
6
8
7
D0004510
1. Brake fluid reservoir 5. Rear axle
2. Right master cylinder 6 Right brake
3. Brake microswitches (nΒ° 2) 7. Left brake
4. Brake pedal 8 Left master cylinder
10-33
--- Page 8 ---
BRAKING SYSTEM COMPRESSOR
COMPRESSOR
1
2
3
4
a
b
c
D0004620
a. Port 0.1 - Compressor lubrication TECHNICAL DATA
b. Port 0 Bore: 90 mm (3.546 in.)
c. Port 2 - Compressed air delivery Stroke: 36 mm (1.418 in.)
Displacement: 229 cmΒ³
1. Cylinder head
2. Cylinder Max. pressure.: 10 bar (145 psi)
3. Flange Crankshaft end float: 0.08β0.38 mm (0.003 β 0.015 in.)
4. Crankshaft
10-43
--- Page 9 ---
FRONT AXLE
4. FRONT AXLE
B B
1710
=
A A
=
52ΒΊ β0 2
1710
D0004780
10-53
--- Page 10 ---
HYDRAULIC SYSTEM VARIABLE DISPLACEMENT PUMP
5.1 VARIABLE DISPLACEMENT PUMP
B
L1 A
M1
L
G
M2
C C
B A
X
HYDRAULIC DIAGRAM
2 3
S
X
FO
M1
B
235 bar L
L1
G 1
S
5 bar
FI
FO FI M2 4
D0004900
FUNCTION COMPONENTS
Port L: drain 1. Antishock valve
Port X: LS signal 2. Load Sensing valve
Port S: suction 3. Pressure cut-off valve
Port B: delivery 4. By-pass valve
Port G: transmission lubrication
Port FI: filter inlet
Port FO: filter outlet
10-63
--- Page 11 ---
HYDRAULIC SYSTEM LOAD SENSING VALVE, PRESSURE CUT-OFF VALVE
b. When a control lever is operated
b 1 d e a 2
c
PP T PLS
7 8
PEN
PP Min Max
f
X
M 5 6
D0004860
β’ When a control lever is moved from the NEUTRAL position, this generates an LS signal corresponding to the load
delivery pressure PLS.
β’ The LS signal pressure in chamber a causes the spool to shift to the left, thereby connecting the passages d and e.
The chamber X is depressurised and the spring (5) causes the swash plate to move to the maximum displacement
angle.
β’ System balance is restored when the pressure βPR exerts on the spool (1) a force equal to the difference in force due
to the spring (2) thus restoring the connection between the passages c and d.
10-73
--- Page 12 ---
HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE (Version with variable displacement pump)
VERSION WITH VARIABLE DISPLACEMENT PUMP
FUNCTION
The function of the auxiliary services control valve is to control the flow of pressurised oil to the auxiliary services and the
rear lift.
This control valve is of the parallel circuit Load Sensing type.
1 2 3 5 3 6 3 5
Y
R
X
Y
P
X
S
1 1
0 0
2 2
H
F F
A B R1 A A B
REAR GEARBOX 4
D0005000
DESCRIPTION
β’ The pressurised oil from the pump (1) enters the inlet section (2); from here it is distributed to the spool sections
through internal passages.
β’ All the spools, when operated, generate a pressure signal (Load Sensing signal) that is equal to the pressure demand
from each load.
The highest of these pressure signals, selected by the bistable valves (3), is sent to the variable displacement pump
through port Y of the control valve.
β’ On the lift spool section (6) there is an antishock valve (4) (on the UP control side) that serves to prevent excessive
pressure caused by jolting of the implement.
10-83
--- Page 13 ---
HYDRAULIC SYSTEM AUXILIARY SERVICES CONTROL VALVE
2. When an actuator is operated
b
CONTROL VALVE
a
1
P
y
4
R
5
c 2
D0005090
β’ When an actuator is operated, the pressure required for its operation is also directed to the channel y (Load Sensing
signal channel) and then sent to chamber c of the manifold.
β’ This causes the spool (1) to shift upwards and the oil required to operate the load is sent to the control valve.
β’ When the load pressure balances the force of the spring (4), poppet (5) is shifted to the left, allowing limitation of the
operating pressure.
10-93
--- Page 14 ---
SERDIA ENTRY AND COMUNICATION
1.1.2 HARDWARE AND SOFTWARE
You should have the following minimum system configuration in order to work with SERDIA:
Hardware:
β’ Notebook o PC (IBM-AT compatible):.... with 1 serial interface RS 232 (There should be no mouse connected) and par-
allel printer interface
β’ Grafiphs carde:....................................... VGA/SVGA
β’ Processor: .............................................. 80486 (or later)
β’ Frequenz:................................................ 100 MHz
β’ RAM:....................................................... 8 MB RAM (or later)
β’ Hard disk (free memory capacity): ......... 15 MB (or later)
β’ Diskdrive:................................................ 3,5β (1,44 MB)
ECUs (engine):
β’ EMR (Elektronischer Motor-Regler)........ Electronic engine governor,
ECU TN 0211 1910 e 0211 2017
Software Version NΒ° 12.1.08 and lower
β’ Diagnostics interface.............................. Serial in ace. with ISO 9141
Interface, connector piece between ECU (engine) and PC:
β’ Level adaptator for ISO 9141, SAE J1708 e RS 485
β’ Safety switch with dongle function, copy protection
β’ Power supply range 12-24 V
β’ Power supply side: Engine
β’ Protective switch against incorrect polarity and surge voltage
β’ Decoupling
Software:
β’ Operating system ................................... DOS versione 5.0 or later
β’ User surface ........................................... MS-Windowsο 3.11 or Windows 95
Installation is also possible under Windows 3.1; however, this creates a specific Windows problem: Conflicts may occur
when accessing serial interface COM1 (see Chapter 8, What should you do if...?). Further information is also given in the
Readme file supplied with SERDIA).
For proper display of the contents of the SERDIA windows under Windows 3.11, you should install the standard screen
driver (VGA).
1.2 ORDERING
SERDIA can be ordered, like the DEUTZ special tools, through:
SAME-DEUTZ-FAHR GROUP S.p.A.
Viale F. CASSANI, 15
24047 TREVIGLIO (BG) - ITALIA
1.2.1 FIRST-TIME USERS
For first-time users, we recommend the SERDIA package Re-order No. 5.9030.740.4/10.
Scope of supply:
β’ SERDIA software (1 x 3.5' installation diskette)
β’ Diagnostics interface with implemented user level
β’ Brief instructions on installation
β’ A list of tools and modifications usefui when troubleshooting, is included
β’ Carrying case
20-3
--- Page 15 ---
SERDIA ECU SELECTION
2. ECU SELECTION
2.1 GENERAL
DEUTZ engines may be equipped with one or several ECUs (e.g. the combination MVS with EMS). SERDIA, however, can
only communicate with one ECU. Exception: the error list can also be read from the MVS ECU via EMS.
It is therefore necessary to first select the desired ECU from the menu poin "ECU selection".
Recognition of the different ECUs is managed by SERDIA for the user.
Possible ECUs:
EMR (Electronic Engine Governor)
MVS (Magnetic Valve System)
EMS (Engine-Monitoring System)
2.2 RECOGNITION OF ECUS
SERDIA automatically assists recognition of the connected ECUs upon program start. Identification may take up to 60 sec-
onds as the possible interfaces and ECUs have to be polled one after the other.
Following successful recognition the ECU selection screen is automatically overlayed. Only the recognized ECUs are of-
fered for selection. The ECUS which are not selectable are marked by a grey font.
2.3 IDENTIFICATION DATA
2.3.1 EMR IDENTIFICATION
β’ Meaning of data displayed: DEUTZ part number.
β’ Product number: Type of selected ECU: 1 = EMR - 2 = MVS - 3 = EMS
β’ Hardware version number: This number indicates the development status of the ECU.
β’ Software version number: Number of the EEPROM contained in the ECU. If the digit left from the decimal changes
(e.g. from 2.1 to 3,1), the data set does no longer suit the ECU. In this case it is necessary to consult the headquarters.
β’ Day, month, year: Date of the latest parameterization on the ECU.
β’ Service ID: Serial number of the interface used for the previous access. The leading digit indicates the access level.
β’ Interface serial number: Serial number of the currently used interface.
20-13
--- Page 16 ---
SERDIA PARAMETERS
typ
MK 3 TTG Parameter Unit Min. Max. Description
Wert
Page 5: Position governor
Only change the following 10 parameters in consultation with the head office
Posgvnr: P part % 0 100 10 Gain factor P part
Posgvnr: 1 part % 0 100 5 Gain factor I part
Posgvnr: D part % 0 100 5 Gain factor D part
Posgvnr: DT2 part % 0 100 10 Gain factor DT2 part
Posgvnr: Gain % 100 200 180,1 Gain factor with minor speed fluctuation
Posgvnr: gain range mm 0 1 0,25 Gain fluctuation range for gain factor
QuickCurrentDecSteepness 1/min 0 65535 40000
QuickCurrentDecTime ms 0 65535 50
Page 6: Functions
Torque curve variants (2 variantsβ½),
Perm, values:
Assign config. top curve 0 2 0
0 = torque curve 1
1 = Switching betw. torque curves 1+2
Setpoint eng. speed values (6 variants β½)
Perm, values:
0 = Only variable speed governing
1 = Switching betw. eng. speeds 1 and 2
Ass spec. eng. speed config 0 6 0
2 = Switching betw. fixed / variable speed
3, 4 = Switching betw.speed variable / save:
(3 = w. setp.speed, 4 = w. actual speed)
5 = two setpoint transmitters
Speed droop selection (4 variantsβ½)
Perm, values:
0 = constant speed droop
Ass droop config 0 3 0
1 = variable speed droop
2 = switching between speed droop 1 and 2
3 = switching betw.const. / variable speed droop
Type of governing (4 variantsβ½)
Perm, values:
0 = Variable-speed governing
Ass governor config 0 6 0
1 = Min-max-speed governing
2 = Switching betw.var./min.-max.
speed governingx
For the following 14 functions: On = 1, Off = 0
BoostPressSim (on/off) 0 1 0 Boost pressure simulation
BoostPressMeas (on/off) 0 1 1 Boost pressure measurement
EngSpeed sensor2 (on/off) 0 1 0 Redundant eng. speed sensing
VehSpeedLimit (on/off) 0 1 1 Veh. speed limit
CylinderShutoff (on/off) 0 1 1 Overrun cond. with overspeed
LimpHomeOper 0 1 0 Limp-home upon control rod travel sensor failure
Torque computation (off: referred to torque curve,
Torque Indicator(on/off) 0 1 1
on: torque curve point)
SAME Output (on/off) 0 1 0 Customer-specific output function
QuickCurrentDec (on/off) 0 1 0
BOSCH EDC inline p. (on/off) 0 1 0
TempMonitoring (on/off) 0 1 0 Temperature monitoring
OilPressMon(on/off) 0 1 0 Oil pressure monitoring
20-23
--- Page 17 ---
SERDIA PARAMETERS
TERMINOLOGY EXPLANATIONS:
Acceler(SWG1): Accelerator pedal sensor (setpoint generator 1), Input 24 FS
Hand throttle(SWG2): Hand throttle potentiometer (setpoint generator 2), Input 20 FS
GENERAL PROCEDURE DURING CALIBRATION PROCESS:
β’ Select calibration size in upper window.
β’ Move accelerator pedal/hand throttle potentiometer to desired position.
β’ "Get value" switch activated: Actuate switch, the calibration value assigned to the position is shown in the editing field.
β’ "Get value" switch not activated: Enter calibration value in editing field.
β’ Upload calibration value with "PC->ECU" to ECU.
β’ Save calibration value with "Save in ECU" in ECU.
β’ Switch ignition on/off.
EXPLANATION OF FUNCTION SWITCH:
Get value: If the "Get value" switch has been set to activated, you can fetch the calibration value belonging to a pedal po-
sition using this switch.
PC->ECU: The calibration value displayed is uploaded to the ECU.
Save in ECU (only applies for EMR): The calibration data are permanently saved in the ECU.
20-33
--- Page 18 ---
SERDIA WHAT SHOULD YOU DO IF...?
8.1.2 INTERFACE CONFIGURATION WITH ISETUP
On PCs the COM1 interface may be occupied by the mouse. In this case, you should connect the interface to the second
serial interface (COM2). You can then configure this port using SETUP in order to communicate with the interface.
PROCEED AS FOLLOWS:
β’ Call program SETUP.EXE.
β’ Select the other COM port and confirm with OK..
β’ Initialization file ISODRV.INI is updated automatically.
β’ Re-start Windows.
ATTENTION!
β’ On many PCs the second serial interface is 25 pole. If this is the case, you should use a hardware adapter (con-
version from 25 to 9 poles) when connecting the 9 pole diagnostics interface.
Figure: Help file screen from SETUP.EXE
8.1.3 ACCESS CONFLICTS UNDER WINDOWS 3.1
The interface driver ISODRV.386 can only be loaded statically. You enter the driver ISODRV.386 in Windows file SYS-
TEM.INI under section [386Enh] (at the same time specifying your current directory). This can result in problems with other
application programs occurring that also access the serial interface.
REMEDY:
β’ Call program ISETUP.EXE.