T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS NOTE: Engine repair information is not contained within this tractor Repair Manual. For engine repair, refer to publication number 87515682 for the 8.3 & 9.0L 6 Cylinder, 24 Valve CNH Engine with High Pressure Common Rail Fuel System. STANDARD TORQUE SPECIFICATIONS ......................................................................SECTION 00, CHAPTER 1 TORQUE SPECIFICATIONS - METRIC HARDWARE .................................................................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS SPEED TO RANGE TRANSMISSION SPLIT ..................................................................SECTION 21, CHAPTER 3 SPECIAL TOOLS ........................................................................................................................................ 21-3-3 SPECIAL TORQUES ..................................................................................................................................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS REAR FRAME ..................................................................................................................SECTION 21, CHAPTER 8 SPECIFICATIONS ...................................................................................................................................... 21-8-3 SPECIAL TORQUES ..................................................................................................................................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS SUSPENSION FWD AXLE SYSTEM - HOW IT WORKS AND TROUBLESHOOTING ..SECTION 25, CHAPTER 5 SUSPENDED FWD AXLE OPERATION ................................................................................................... 25-5-3 SUSPENDED MFD AXLE- CALIBRATION MODE .................................................................................... 25-5-9 ERROR TABLE ....................................................................................................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS FWD PLANETARY HUB, STEERING KNUCKLE AND AXLE DRIVE SHAFT ..............SECTION 25, CHAPTER 10 SPECIFICATIONS .................................................................................................................................... 25-10-3 SPECIAL TORQUES ................................................................................................................................ 25-10-3 SPECIAL TOOLS ..............................................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS PTO CLUTCH ASSEMBLY - SINGLE, REVERSIBLE AND DUAL SPEED.....................SECTION 31, CHAPTER 2 SPECIAL TOOLS ........................................................................................................................................ 31-2-3 SPECIAL TORQUES .................................................................................................................................. 31-2-3 PTO CLUTCH ASSEMBLY .................................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS HYDRAULIC SYSTEM - HOW IT WORKS WITH TROUBLESHOOTING .......................SECTION 35, CHAPTER 2 GENERAL INTRODUCTION ...................................................................................................................... 35-2-3 REAR CHARGE/LUBE PUMP PRESSURE TEST ................................................................................... 35-2-19 REGULATED SYSTEM PRESSURE TEST AND ADJUSTMENT PROCEDURE ..................................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS PFC PISTON PUMP AND HYDRAULIC FILTER.............................................................SECTION 35, CHAPTER 8 SPECIAL TORQUES .................................................................................................................................. 35-8-3 PFC PISTON PUMP ................................................................................................................................... 35-8-3 Removal ...........................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS A/C TROUBLESHOOTING ..............................................................................................SECTION 50, CHAPTER 1 SAFETY PROCEDURES ............................................................................................................................ 50-1-5 SPECIAL TOOLS ........................................................................................................................................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS BLOWER AND BLOWER SPEED DRIVER ............................................................................................. Background ............................................................................................................................................. Power, Signal and Ground Circuit ........................................................................................................... Possible Failure Modes .....................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS Evaporator Temperature Sensor .............................................................................................................. Background ............................................................................................................................................. Electrical Test – Sensor .......................................................................................................................... Power Circuit .......
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS AIR CONDITIONER SYSTEM SERVICE.........................................................................SECTION 50, CHAPTER 2 SPECIFICATIONS ...................................................................................................................................... 50-2-4 SPECIAL TORQUES .................................................................................................................................. 50-2-4 SPECIAL TOOLS .............
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS CAB RECIRCULATION AIR FILTER SERVICE ..................................................................................... CAB PRESSURIZATION TEST .............................................................................................................. CAB PRESSURIZER MOTOR REPLACEMENT .................................................................................... VISCOUS FAN DRIVE ....................................................................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS POWER SEAT SYSTEM ........................................................................................................................ Power Seat System Circuit Operation ................................................................................................... Power Seat System Circuit Troubleshooting ......................................................................................... Power Seat System Symptom Chart ........................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS AUX/HITCH/PTO FAULT CODES TRACTOR MULTI-FUNCTION (TMF) CONTROLLER ....................................................SECTION 55, CHAPTER 3 AUX/HITCH/PTO FAULT CODE 2 ............................................................................................................. 55-3-7 AUX/HITCH/PTO FAULT CODE 4 ............................................................................................................. 55-3-8 AUX/HITCH/PTO FAULT CODE 5 ........
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS AUX/HITCH/PTO FAULT CODE 87 ......................................................................................................... AUX/HITCH/PTO FAULT CODE 88 ......................................................................................................... AUX/HITCH/PTO FAULT CODE 89 ......................................................................................................... AUX/HITCH/PTO FAULT CODE 90 .................................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS AUX/HITCH/PTO FAULT CODE 163 ....................................................................................................... 55-3-93 AUX/HITCH/PTO FAULT CODE 164 ....................................................................................................... 55-3-94 AUX/HITCH/PTO FAULT CODE 165 ....................................................................................................... 55-3-95 AUX/HITCH/PTO FAULT CODE 166 ...........
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS TRANSMISSION CONTROLLER FAULT CODES ..........................................................SECTION 55, CHAPTER 4 FAULT CODE TRANS 11 ........................................................................................................................... 55-4-5 FAULT CODE TRANS 12 ........................................................................................................................... 55-4-6 FAULT CODE TRANS 24 .........................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS FAULT CODE TRANS 129 FAULT CODE TRANS 130 FAULT CODE TRANS 131 FAULT CODE TRANS 132 FAULT CODE TRANS 133 FAULT CODE TRANS 134 FAULT CODE TRANS 135 FAULT CODE TRANS 136 FAULT CODE TRANS 137 FAULT CODE TRANS 138 FAULT CODE TRANS 139 FAULT CODE TRANS 140 FAULT CODE TRANS 141 FAULT CODE TRANS 142 FAULT CODE TRANS 143 FAULT CODE TRANS 144 FAULT CODE TRANS 145 FAULT CODE TRANS 147 FAULT CODE TRANS 148 ...............................................................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS ARMREST CONTROLLER FAULT CODES ....................................................................SECTION 55, CHAPTER 5 FAULT CODE ARM 19 ............................................................................................................................... 55-5-4 FAULT CODE ARM 29 ............................................................................................................................... 55-5-5 FAULT CODE ARM 39 ..................
T8010/T8020/T8030/T8040 MASTER TABLE OF CONTENTS CONTROLLER CONFIGURATION AND CALIBRATION ................................................SECTION 55, CHAPTER 6 FAULT CODE RETRIEVAL ........................................................................................................................ 55-6-3 INSTRUMENTATION PROGRAMMING .................................................................................................... 55-6-5 Radar Calibration .................................................
Section 00 Chapter 1 STANDARD TORQUE SPECIFICATION January, 2006
Section 00 - General Information - Chapter 1 TABLE OF CONTENTS TORQUE SPECIFICATIONS - METRIC HARDWARE .................................................................................. 00-1-4 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ................................................................... 00-1-5 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ...................................................................
Section 00 - General Information - Chapter 1 TORQUE SPECIFICATIONS - DECIMAL HARDWARE Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphites, Molydisulfide greases, or other extreme pressure lubricants are used.
Section 00 - General Information - Chapter 1 TORQUE SPECIFICATIONS - METRIC HARDWARE Use the following torques when specifications are not given. These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used. Grade 10.9 Bolts, Nuts, and Studs Grade 8.8 Bolts, Nuts, and Studs 10.9 8.
Section 00 - General Information - Chapter 1 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS Tube OD Hose ID Thread Size PoundInches Newton metres Tube OD Hose ID 37 Degree Flare Fitting Thread Size PoundInches Newton metres Straight Threads with O-ring 1/4 inch 6.4 mm 7/16-20 72 to 144 8 to 16 1/4 inch 6.4 mm 7/16-20 144 to 228 16 to 26 5/16 inch 7.9 mm 1/2-20 96 to 192 11 to 22 5/16 inch 7.9 mm 1/2-20 192 to 300 22 to 34 3/8 inch 9.
Section 00 - General Information - Chapter 1 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS Nom. SAE Dash Size Tube OD Thread Size PoundInches Newton metres Thread Size PoundInches Newton metres O-ring Boss End Fitting or Lock Nut O-ring Face Seal End -4 1/4 inch 6.4 mm 9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27 -6 3/8 inch 9.5 mm 11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41 -8 1/2 inch 12.
Section 00 Chapter 2 SAFETY, GENERAL INFORMATION, MAINTENANCE SCHEDULE January, 2006
Section 00 - General Information - Chapter 2 TABLE OF CONTENTS SAFETY .......................................................................................................................................................... 00-2-3 GENERAL INFORMATION ............................................................................................................................ 00-2-5 LUBRICATION/MAINTENANCE CHART .................................................................................................
Template Name: OML_2_col Template Date: 2001_03_06 Rac 0-00000 Section 00 - General Information - Chapter 2 SAFETY ! THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. M171B To prevent injur y al way s follow the War ning, Caution and Danger notes in this section and throughout the manual.
Section 00 - General Information - Chapter 2 ! WARNING: Always wear heat protective gloves to prevent burning your hands when handling heated parts. SM121A ! WARNING: Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service. M496 ! ! ! WARNING: Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury.
Template Name: OML_2_col Template Date: 2001_03_06 Rac 0-00000 Section 00 - General Information - Chapter 2 GENERAL INFORMATION Cleaning Gears Clean all metal parts except bearings, in mineral spirits or by steam cleaning. Do not use caustic soda for steam cleaning. After cleaning, dry and put o il o n all p ar ts. Cle an oi l pas s age s wi th compressed air. Check all gears for excessive wear or damage. Replace gears as necessary.
Template Name: OML_2_col Template Date: 2001_03_06 Rac 0-00000 Section 00 - General Information - Chapter 2 LUBRICATION/MAINTENANCE CHART Service Interval When Warning Message Displays Every 10 Hours Or Daily Every 50 Hours Every 100 Hours Every 300 Hours Every 600 Hours Every 1200 Hours Or Annually Every 1500 Hours Every 2100 Hours Every 3000 Hours As Required Maintenance Requirement Check Grease Change Air Cleaner Element Clean Drain X Engine Oil Level Transmission Oil Level Coolant Reserv
Section 00 - General Information - Chapter 2 SYSTEM CAPACITIES SYSTEM Engine Oil No Filter Change With Filter Change Cooling System All Trans / Hydraulic System Front Wheel Drive 10 Bolt Axle Differential – Standard and Suspended FWD Differential – SuperSteer FWD Planetary - Each A12 Bolt Axle Differential – Standard and Suspended FWD Differential – SuperSteer FWD Planetary - Each U.S. MEASURE METRIC MEASURE IMPERIAL MEASURE 5 Gal 5-1/2 Gal 19 L 21L 4.2 Gal 4.5 Gal 7 Gal 26.5 L 5.
Section 00 - General Information - Chapter 2 This Page Left Blank.
Section 10 Chapter 1 ENGINE REMOVAL AND INSTALLATION January, 2006
Section 10 - Engine - Chapter 1 TABLE OF CONTENTS ENGINE REMOVAL ....................................................................................................................................... 10-1-3 ENGINE INSTALLATION .............................................................................................................................
Template Name: OML_2_col Template Date: 2001_03_06 Rac 0-00000 Section 10 - Engine - Chapter 1 ENGINE REMOVAL STEP 5 NOTE: Make note of where any wire harness and hose tie straps are removed during disassembly so they can be properly installed during assembly. Remove the cooling module. See Cooling Module Section in this Repair Manual. STEP 1 STEP 6 2 1 RD05N100 RD02C070 Remove the exhaust shield mounting hardware (1) and remove the shield (2). Park the tractor on a hard, level surface.
Section 10 - Engine - Chapter 1 STEP 8 STEP 11 1 2 RD05N102 RD05N105 Properly support the muffler. Remove the mounting hardware and remove the muffler / exhaust elbow assembly. Tag and remove the heater supply hose (1) and return hose (2). STEP 12 STEP 9 2 2 1 1 RD05N106 Disconnect the A/C high pressure switch (1). Disconnect the A/C compressor clutch harness (2). RD05N103 Disconnect the turbo to charge-air cooler pipe (1) at the turbo (2) and remove.
Section 10 - Engine - Chapter 1 STEP 14 STEP 17 2 2 1 3 1 3 RD05N108 Remove the har nes s cla mp ( 1) . Remove th e compressor clutch harness (2) from the clamp. Reinstall the mounting bolt. Remove the ground wire (3) and reinstall the mounting bolt. RD05N136 Disconnect the coolant fill tube (1) at the deaeration tank hose (2) and the engine block (3). Remove the tube. STEP 15 STEP 18 2 1 RD05N109 RD05N111 Remove the high (1) and low (2) pressure A/C line. Discard the O-rings.
Section 10 - Engine - Chapter 1 STEP 20 STEP 22 1 2 1 RD05N112 RD05N114 Remove the four air cleaner housing mounting nuts (1). Remove the air cleaner assembly. Remove the alternator wire harness (2) with the air cleaner assembly. STEP 21 2 2 RD05N115 Remove the charge-air cooler to intake manifold tube bushing bolt (1). Remove the charge-air cooler to intake manifold pipe clamp (2). Remove the pipe. Discard the O-ring located at the intake manifold.
Section 10 - Engine - Chapter 1 STEP 24 STEP 27 RD05N118 RD05N121 Remove the engine heater grid power cable. Pr oper l y supp or t the hood / de aeration tank mounting assembly. STEP 25 STEP 28 2 1 RD05N119 Remove the washer bottle from its mounting bracket. Tag and remove the front washer hose and electrical connector (1). Repeat for the rear (2) if required. RD05N122 Remove right rear support bracket bolt.
Section 10 - Engine - Chapter 1 STEP 30 STEP 33 1 2 RD05N124 RD05N127 Remove the fuel supply hose. Disconnect the high (1) and low (2) pressure A/C lines. STEP 31 STEP 34 RD05N125 Remove the two support mounting bolts. RD05N128 Remove the hydraulic oil cooling lines. STEP 32 STEP 35 RD05N126 Raise the assembly slightly to gain access to the main engine connector (1) and disconnect. Continue to raise and remove from the engine.
Section 10 - Engine - Chapter 1 STEP 36 STEP 39 RD05N130 RD05N133 Remove the A / C tube exhaust shield. Properly support the hose / tube / air cleaner support bracket assembly and remove from the engine. STEP 37 STEP 40 RD05N131 Remove the right front mounting bolts. RD05N135 STEP 38 1 2 RD05N132 Remove the left front mounting bolts (1) and spacer (2). RI02C011 Properly support the engine. Place a small amount of tension on the hoist. Remove the six engine m ou n t i ng b o l ts.
Section 10 - Engine - Chapter 1 ENGINE INSTALLATION STEP 41 STEP 42 RD05N135 RD05N133 Set the hose / tube / air cleaner support bracket assembly in place on top of the engine. 2 STEP 43 2 2 1 1 2 1 2 RI02C011 RD05N132 Set the spacer (1) into place and install the mounting bolts (2). Apply a thin coat of anti seize lubricant to the transmission input shaft splines. Properly support the engine and lift into place.
Section 10 - Engine - Chapter 1 STEP 44 STEP 47 RD05N131 RD05N128 Install the right front mounting bolts. Install new O-rings on the fittings and tighten the hydraulic cooling lines. STEP 45 STEP 48 RD05N129 Install the right rear mounting bolts. Tighten ALL bracket mounting bolts at this time. Rd05N127 Install new O-rings on the fittings and tighten the A / C lines. STEP 46 STEP 49 2 1 RD05N130 Install the heat shield (1). Install and tighten mounting bolts (2).
Section 10 - Engine - Chapter 1 STEP 50 STEP 53 1 2 RD05N126 RD05N123 Connect the engine wire harness connector. If removed, install the windshield step (1) and tighten the bolts (2). STEP 51 STEP 54 RD05N125 Install the support mounting bolts and tighten to a torque of 310 to 380 Nm (230 to 280 lb. ft.). Install and tighten the right rear support bolt. STEP 52 STEP 55 RD05N122 1 2 RD05N124 RD05N120 Install the fuel supply hose.
Section 10 - Engine - Chapter 1 STEP 56 3 STEP 59 1 2 RD05N119 RD05N134 Install the front washer hose and electrical connector (1) and rear (2) if equipped. Install the bottle onto the bracket (3). Install a new O-ring on the charge-air cooler to intake manifold tube assembly. Install the tube. STEP 60 STEP 57 2 RD05N114 RD05N118 Install the engine grid heater power cable. STEP 58 1 2 1 RD05N115 3 Install the bushing bolt (1). Install the clamp (2). Tighten all hardware.
Section 10 - Engine - Chapter 1 STEP 61 STEP 64 2 1 RD05N113 RD05N110 Install the deaeration tank to coolant recovery bottle hose (1) and engine air bleed line (2). Install the air cleaner restriction switch connector. STEP 65 STEP 62 1 2 RD05N117 Connect the alternator harness. RD05N112 Install the air cleaner assembly onto the bracket and tighten the mounting nuts. Make sure the alternator wire harness is installed between the air cleaner and mounting brackets.
Section 10 - Engine - Chapter 1 STEP 67 STEP 70 2 1 2 1 RD05N108 RD05N105 Install the ground wire (1) and the clamp (2). Install the heater out (1) and in (2) hoses. STEP 68 STEP 71 RD05N107 RD05N104 Install the three alternator wires. Install the starter cables. STEP 69 STEP 72 1 1 2 2 RD05N106 RD05N103 Connect the A / C compressor clutch (1) and the high pressure switch (2) connectors. Install the turbo to charge-air cooler pipe assembly (1). Install the clamp (2).
Section 10 - Engine - Chapter 1 STEP 73 STEP 77 Recharge the A/C system. See A/C Service Section in this Repair Manual. STEP 78 Install the hood. See Hood Removal Section in this Repair Manual. STEP 79 RD05N102 Properly suppor t the muffler, lift into place and tighten the mounting bolts to a torque of 200 to 245 Nm (149 to 179 lb.ft.). STEP 74 RD02E069 Install the positive cable (+). Install the negative cable (-). Install the battery cover.
Section 10 Chapter 2 FUEL TANK / FUEL SENDER REMOVAL AND INSTALLATION January 2006
Section 10 - Engine - Chapter 2 TABLE OF CONTENTS SPECIAL TORQUES ...................................................................................................................................... 10-2-3 FUEL TANK .................................................................................................................................................... General ........................................................................................................................................
Section 10 - Engine - Chapter 2 SPECIAL TORQUES Bolts on cab steps .......................................................................................................... 37 to 67 Nm (27 to 49 lb. ft.) FUEL TANK General Removal STEP 1 STEP 2 1 1 96R-28A 95-12 Before removing the fuel tank, do the following: Remove the six step mounting bolts (1). Move the steps away from the tractor. 1. Park the tractor on a hard, level surface. 2. Place the transmission control lever in PARK. STEP 3 3.
Section 10 - Engine - Chapter 2 STEP 4 STEP 7 1 2 50-23F RD05K005 Move the left rear wheel out on the axle as far as possible to provide clearance when removing the left tank. The wheel can also be removed. Loosen hose clamp (1) on fuel tank balance hose located under the transmission speed housing. Remove the fuel injection system supply hose (2). STEP 5 STEP 8 RD05J085 95-24- Disconnect the fuel level sending unit wire harness.
Section 10 - Engine - Chapter 2 STEP 10 STEP 13 3 2 4 1 101R-19A RD05K007 Remove the fuel supply fitting (1), the fuel return fitting (2), vent fitting (3) and fuel sending unit cover (4). With prybars, lift up on the main tank and move it out a few inches. Insert a plug into the crossover hose as it comes off of the right tank. IMPORTANT: Be prepared to collect some fuel when the tank is removed. Fuel may spill onto the support bracket.
Section 10 - Engine - Chapter 2 STEP 16 STEP 19 RD02B106 101R-23A Remove the battery cables and move to the side. Remove the batteries. Lift the right tank free of the support bracket and remove the tank. STEP 17 IMPORTANT: Be prepared to collect some fuel when the tank is removed. STEP 20 1 1 RD05K005 If not already removed, loosen the clamp (1) on the fuel balance hose located under the transmission speed housing. Slip the hose off the neck leading into tank.
Section 10 - Engine - Chapter 2 Installation STEP 24 STEP 21 1 101R-19A 1 Install the fuel tank onto the support brackets with enough room to attach fittings. RD02B107 If the fuel tank suppor t bracket was removed, properly support the bracket and lift into position. Install and tighten all the retaining bolts (1). STEP 25 STEP 22 RD05K008 Install the fuel return line. Push the fuel tank into position. RD05K004 Lubricate the inside diameter of the seal with soap and install.
Section 10 - Engine - Chapter 2 STEP 27 STEP 30 95-15R 101R-23A Install and tighten two bolts through each of the two lockdown plates. Move the right tank into position. Connect the balance hose at the bottom of the tank (not shown) and tighten the clamp. Connect the loose end of the pressure equalization hose (not shown) to the top left tank. STEP 28 STEP 31 95-24 Install the pressure equalization hose on the top front of the left tank. Tighten clamp.
Section 10 - Engine - Chapter 2 STEP 33 STEP 36 RD05K002 5-23 Install battery cover and toolbox. Position the wheels to the desired position on the rear axle. STEP 34 95-12 Move steps into position. Install six bolts and tighten to a torque of 37 to 67 Nm (27 to 49 lb. ft.). STEP 35 Install fuel and check for leaks.
Section 10 - Engine - Chapter 2 FUEL LEVEL SENDER Removal STEP 40 STEP 37 RD05K003 Remove the sender. RD05J085 Disconnect the fuel sender wire harness. STEP 41 STEP 38 RD05K004 Remove the sender seal, inspect for damage and replace if necessary. RD05J087 Remove the fuel sender cover bolts. STEP 39 RD05J088 Pry the sender free of the fuel tank.
Section 10 - Engine - Chapter 2 Installation STEP 45 STEP 42 RD05J085 Connect the fuel sender wire harness. RD05K004 STEP 46 Lubricate the outside diameter of the seal with soap and install. Install fuel and check sender for proper operation. STEP 43 1 2 RD05K003 Lubricate the inside diameter of the seal (1) with soap and install the fuel sender (2). STEP 44 RD05J087 Install the fuel sender cover.
Section 10 - Engine - Chapter 2 10-2-12
Section 10 Chapter 3 HOOD REMOVAL / INSTALLATION January, 2006
Section 10 - Engine - Chapter 3 TABLE OF CONTENTS HOOD REMOVAL .......................................................................................................................................... 10-3-3 HOOD INSTALLATION ..................................................................................................................................
Template Name: OML_2_col Template Date: 2001_03_06 Rac 0-00000 Section 10 - Engine - Chapter 3 HOOD REMOVAL STEP 1 STEP 4 RD02C070 RD05N003 Park the tractor on a hard, level surface. Put the transmission shift lever in PARK. Place blocks in front of and behind the rear wheels. Remove the windshield washer nozzle hose. STEP 5 STEP 2 RD05J075 Remove the hood lanyard and fully raise the hood. RD05N001 Disconnect the hood light wire harness. STEP 6 STEP 3 RD05N004 Properly support the hood.
Section 10 - Engine - Chapter 3 STEP 7 STEP 10 1 2 RD05N006 RD05N009 Remove the safety clip from each hood strut. Lower the hood and push rearward until the hood bracket (1) is free of the hood support rod (2). While balancing the hood, raise as necessary and remove from the chassis. STEP 8 RD05N007 Remove the hood struts. STEP 9 RD05N008 Remove the locking bracket.
Section 10 - Engine - Chapter 3 HOOD INSTALLATION STEP 11 STEP 14 RD05N005 RD05N008 Properly support the hood. While balancing the hood, raise and set into place. Install the locking bracket. STEP 15 STEP 12 1 2 RD05N007 Install the hood support struts. RD05N009 Align the hood bracket (1) with the hood support rod (2) and slide forward into place. STEP 16 STEP 13 RD05N006 Install the safety pin in each strut and lock in place. Rd05N004 Raise the hood.
Section 10 - Engine - Chapter 3 STEP 17 STEP 20 RD05N004 RD05N002 Remove the support from the hood. Connect the horn wire harness. STEP 18 STEP 21 RD05J074 RD05N001 Clip the hood lanyard to the support bracket. \Connect the hood lights wire harness. STEP 19 STEP 22 RD05N003 RD02C070 Install the windshield washer nozzle supply hose. Remove all wheel blocks.
Section 10 Chapter 4 COOLING SYSTEM MODULE REMOVAL AND INSTALLATION January, 2006
Section 10 - Engine - Chapter 4 TABLE OF CONTENTS COOLING MODULE REMOVAL .................................................................................................................... 10-4-3 COOLING MODULE INSTALLATION ............................................................................................................
Template Name: OML_2_col Template Date: 2001_03_06 Rac 0-00000 Section 10 - Engine - Chapter 4 COOLING MODULE REMOVAL STEP 1 NOTE: If A/C condenser DOES NOT have to be removed, DO NOT evacuate the system. STEP 4 RD02C070 Park the tractor on a hard, level surface. Put the transmission shift lever in PARK. Turn off the engine and remove the key. Place blocks in front of and behind the rear wheels. RD05N013 Drain the engine coolant into a suitable clean container.
Section 10 - Engine - Chapter 4 STEP 5 Do the following steps if the A/C condenser does not have to be removed. STEP 6 1 RD05N015 Remove the air scoop upper (shown) (1) and lower plastic fasteners. Remove the air scoop. RD05N016 Remove the upper hydraulic cooling hose. Discard the O-ring. Have a container ready to catch any hydraulic oil that may be in the hose. STEP 7 2 1 RD05N017 Remove the swing latch locking pin (1). Remove the mounting lock nuts (2).
Section 10 - Engine - Chapter 4 Cooling Module Removal with A / C Condenser STEP 12 STEP 9 2 3 RD05N022 Remove the radiator outlet (lower) pipe at the engine. Discard the gasket. 1 RD05N019 STEP 13 Remove the fuel cooler inlet (1) and return (2) hoses. Remove the condenser outlet hose (3). Discard the O-ring. STEP 10 RD05N023 Remove the lower charge-air cooler hose. STEP 14 RD05N020 Remove the A/C dryer inlet hose. Discard the O-ring.
Section 10 - Engine - Chapter 4 STEP 15 STEP 18 1 2 2 1 RD05N025 RD05N028 Remove the lower hydraulic oil cooler tube clamp (1) and tube (2). Discard the O-ring. Have a container ready to catch any hydraulic oil that may be in the tube and cooler. Slowly raise the cooling assembly and pull the lower portion away from the cooling fan (1) to clear the fan shroud (2). NOTE: Fan blades (1) may have to be moved slightly so that they clear the fan shroud.
Section 10 - Engine - Chapter 4 COOLING MODULE INSTALLATION STEP 20 STEP 23 1 1 RD05N026 RD05N027 Properly support the cooling assembly and move into position on the front frame. Install the module mounting bolts (1) and tighten to a torque of 90 to 107 Nm (66 to 79 lb. ft.) STEP 21 STEP 24 RD05N029 RD05N023 Install the radiator drain hose. Install the lower charge-air cooler hose and tighten the clamp.
Section 10 - Engine - Chapter 4 STEP 26 Do the following step if the A/C condenser was not removed. STEP 28 RD05N022 Install a new gasket and bolt the radiator outlet / engine inlet pipe to the engine coolant inlet port. RD05N018 STEP 27 2 1 2 2 1 3 1 RD05N021 RD05N017 Install the upper radiator hose (1) and tighten the clamp. Install the air bleed hose and clamp (2). Lift the condenser from the padding and place on the mounting studs (1). Install the locking nuts (2).
Section 10 - Engine - Chapter 4 STEP 30 STEP 33 1 1 2 3 RD05N019 RD05N015 Install a new O-ring on the condenser outlet hose and tighten the fitting (1). Install the fuel cooler outlet hose (2) and inlet hose (3). Install the air cleaner scoop and install new plastic fasteners (1). Lower fastener not shown. STEP 34 STEP 31 1 3 1 1 3 2 RD05N014 Install hose clamps (1), bracket (2) and mounting hardware (3).
Section 10 - Engine - Chapter 4 STEP 36 STEP 38 RD05N013 RD02C070 Close the radiator drain. Refill the cooling system with the proper mix of ethylene glycol. See Operator Manual for coolant capacity. Install the pressure cap on the deaeration tank, start the engine and check for any leaks. Turn off key to shut engine off. Repair as necessary. Remove wheel blocks. STEP 37 2 1 RD05N011 Install the left (1) and right side panels. If necessary, top off coolant in the recovery bottle (2).
Section 10 Chapter 5 VISCOUS FAN DRIVE TEST January, 2006
Section 10 - Engine - Chapter 5 TABLE OF CONTENTS REQUIRED TOOLS ....................................................................................................................................... 10-5-3 DIAGNOSTIC PROCEDURE ......................................................................................................................... 10-5-4 FAN SPEED TEST .........................................................................................................................................
Section 10 - Engine - Chapter 5 REQUIRED TOOLS Digital Photo Tachometer OEM1057A or Equivalent OEM1057A Digital Thermometer with Probe (380001301) OR Digital Multimeter with Air Probe Equivalent 380001301 10-5-3
Section 10 - Engine - Chapter 5 DIAGNOSTIC PROCEDURE Physical Check STEP 1 Check the torque of the fan blade mounting bolts. 1. 690 Drive (40KPH Transmission): 10.3 - 14.8 lb. ft. (14 - 70 Nm). 2. 810 Drive (50 KPH Transmission): 12.1 - 14.8 lb. ft. (30 - 70 Nm). NOTE: 810 Fan Drive is installed on all models with 50 KPH transmission. 610 Fan Drive is installed on all other models. RD03C013 STEP 2 Check the torque of the fan driven pulley bolts – 20-22 lb. ft. (27-30 Nm).
Section 10 - Engine - Chapter 5 STEP 4 Check the torque on the drive shaft hub – 66.7 - 82.6 lb. ft. (90 - 112 Nm). RD03C014 STEP 5 Check the fan drive, blade assembly, shroud and radiator for signs of interference with rotating parts. If damage is present, locate and repair the problem, replacing defective parts as needed. STEP 6 Rotate the fan by hand one complete turn (360°). The fan should turn smoothly with some uniform internal resistance.
Section 10 - Engine - Chapter 5 STEP 8 Check for plugging in the fuel cooler, condenser, air cooler, oil cooler and radiator. Remove crop dust, dirt and debris in the air path to the engine. If necessary, use low pressure power wash or compressed air to clean. IMPORTANT: Do NOT steam clean or use high pressure jets to clean the fan drive. The high forces used may cause foreign material to be forced past external seals, contaminating the grease or silicone seal.
Section 10 - Engine - Chapter 5 FAN SPEED TEST STEP 10 IMPORTANT: This test is most effective at an ambient air temperature of 80° F (26.7° C) or higher. NOTE: Reading RPM with the tachometer in bright sunlight may be difficult; if possible, move the tractor to more suitable lighting conditions. Warm a cold engine to shorten the run time during this procedure: A. Turn the air conditioning system OFF. B. Close the heater supply valve on the left hand side of the engine. C.
Section 10 - Engine - Chapter 5 STEP 13 Loosen the shroud mounting screws on the left hand side of the fan, and route the temperature probe between the front of the viscous drive and the radiator. RD03C017 STEP 14 Secure the temperature probe to the rear of the radiator with wire ties so the sensing probe measures air temperature within 1 inch (25.4 mm) of the center of the fan drive. Route the electrical lead to the probe so temperature readings can be taken with the hood closed.
Section 10 - Engine - Chapter 5 STEP 17 As the engine warms up, A. The fan RPM should stabilize between 8001000 RPM. B. When engine coolant reaches 200-220° F (93.3-104.4° C), fan speed should increase to 1870 RPM on all models with 40 KPH transmission or 2125 on all models with 50 KPH transmission. C. Air temperature at the fan drive should be 165195° F (73.9-90.6° C) when the fan engages. RH03C032 With the fan engaged, record fan RPM, coolant temperature and air temperature at the drive.
Section 10 - Engine - Chapter 5 STEP 19 Remove the cover from the front of the radiator. Remove the air temperature probe and photo tachometer. Move the throttle to the low idle position and allow the engine to cool for two minutes before shutting down.
Section 21 Chapter 1 POWERSHIFT TRANSMISSION SYSTEM How It Works and Troubleshooting January, 2006
Section 21 - Transmission, Drivelines - Chapter 1 TABLE OF CONTENTS TRANSMISSION SYSTEM INTRODUCTION ................................................................................................ 21-1-3 TRANSMISSION SYSTEM CONTROLS ....................................................................................................... 21-1-5 TRANSMISSION SYSTEM COMPONENTS ..................................................................................................
Section 21 - Transmission, Drivelines - Chapter 1 TRANSMISSION SYSTEM INTRODUCTION INSTRUMENTATION CLUSTER PROGRAMMABLE DISPLAY AND CONTROLLER SEAT SWITCH TRANSMISSION SPEED SENSOR R.H.
Section 21 - Transmission, Drivelines - Chapter 1 All transmissions are full powershift transmission and controlled by the transmission controller. The standard transmission has 18 forward speeds and 4 reverse speeds. There is an optional transmission with 19 forward speeds and 4 reverse speeds. This transmission has 50Km/h roading capability. The optional creeper transmission has 23 forward speeds and 6 reverse speeds.
Section 21 - Transmission, Drivelines - Chapter 1 TRANSMISSION SYSTEM CONTROLS 2 1 4 5 3 RH05J060 6 7 9 8 RD05J155 1. 2. 3. 4. 5. THROTTLE HAND LEVER TRANSMISSION CONTROL LEVER CREEPER CONTROL SWITCH (IF EQUIPPED) FWD CONTROL SWITCH DIFF LOCK SWITCH 21-1-5 6. 7. 8. 9.
Template Name: SM_1_col Template Date: 2001_03_06 Alt= to hide template information Alt+ to display template information TRANSMISSION SYSTEM COMPONENTS 8 6 14 7 1 14 2 3 4 5 28 9 15 27 9 16 6 25 19 17 18 26 20 RI02E087 and 088
Section 21 - Transmission, Drivelines - Chapter 1 12 13 11 10 21 22 18 23 15 24 20 RI02E086 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. POWERSHIFT VALVE ODD/EVEN EVEN CLUTCH SOLENOID ODD CLUTCH SOLENOID CREEP CLUTCH SOLENOID PARK BRAKE SOLENOID PTO/DIFF LOCK VALVE PRIORITY REGULATOR VALVE REGULATED PRESSURE TO POWERSHIFT VALVES POWERSHIFT VALVE RANGE FWD SOLENOID LOW CLUTCH SOLENOID MID CLUTCH SOLENOID HIGH CLUTCH SOLENOID PTO SOLENOID MASTER CLUTCH SOLENOID 21-1-7 16. 17. 18. 19. 20. 21.
Section 21 - Transmission, Drivelines - Chapter 1 TRANSMISSION LUBE AND DISTRIBUTION TUBES 7 10 9 12 11 13 14 15 16 8 17 6 12 2 18 3 4 5 1 7 RH98C089 Rear View 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Section 21 - Transmission, Drivelines - Chapter 1 2 3 4 1 20 5 16 15 14 19 18 8 10 21 11 9 13 22 RH98C089 Top Rear View 21-1-9
Section 21 - Transmission, Drivelines - Chapter 1 POWERSHIFT TRANSMISSION CLUTCH LAYOUT Neutral DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 3/4 5/6 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW FINAL DRIVE PINION RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN HYDRAULIC PUMP DRIVE GEAR CREEPER FWD CLUTCH (SPRING ENGAGED) KEY RT98A016 Inactive Clutches Pressurized Clutches Non-Torque Transmitting Parts Torque Transmitting Parts RT98A064 NEUTRAL - In Neutral
Section 21 - Transmission, Drivelines - Chapter 1 POWERSHIFT VALVE CLUTCH ENGAGEMENTS CLUTCHES GEAR MASTER ODD EVEN 1-2 NEUTRAL PARK 1 X 2 X 3 X 4 X 5 X 6 X 7 X 8 X 9 X 10 X 11 X 12 X 13 X 14 X 15 X 16 X 17 X 18 X 19 X REV-1 X REV-2 X REV-3 X REV-4 X CR1 X CR2 X CR3 X CR4 X CR5 X CR6 X RCR-1 X RCR-2 X X X 3-4 5-6 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X MID X X X LOW X X X X HIGH X
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) FIRST GEAR - As the operator selects first speed, he simultaneously engages the odd speed clutch pack, the first speed clutch pack, and the low range clutch pack through the transmission controller. The power then flows from the drop box, through the input shaft, through the engaged odd-speed clutch pack gear, to the countershaft gear.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 1 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 3/4 5/6 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A017 Gear No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) THIRD GEAR - As the operator selects third speed, the even-speed clutch is disengaged, and the odd-speed clutch is engaged. At the same time, the first-speed clutch is disengaged, and the third-speed clutch is engaged. Power then flows from the speed transmission input shaft through the odd speed clutch, the countershaft, the third speed clutch, across the output shaft, to the master clutch.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 3 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 3/4 REV 5/6 SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A026 Gear No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) FIFTH GEAR - As the operator selects fifth speed, the even-speed clutch is disengaged, and the odd-speed clutch is engaged. At the same time, the third-speed clutch is disengaged, and the fifth-speed clutch is engaged. Power then flows from the speed transmission input shaft through the odd-speed clutch, the countershaft, the fifth speed clutch, and across the output shaft to the master clutch.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 5 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 5/6 3/4 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A028 Gear No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) SEVENTH GEAR - As the operator selects seventh speed, the even-speed clutch is disengaged, and the oddspeed clutch is engaged. At the same time, the fifth-speed clutch and the low-range clutch are disengaged, the first speed clutch and medium range clutch are engaged.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 7 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 5/6 3/4 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A030 Gear No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) NINTH GEAR - As the operator selects ninth speed, the even-speed clutch is disengaged, and the odd-speed clutch is engaged. At the same time, the first-speed clutch is disengaged, and the third-speed clutch is engaged. Power then flows from the speed transmission input shaft through the odd-speed clutch, the countershaft, the third speed clutch, and across the output shaft to the master clutch.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 9 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 5/6 3/4 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A032 Gear No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) ELEVENTH GEAR - As the operator selects eleventh speed, the even-speed clutch is disengaged, and the oddspeed clutch is engaged. At the same time, the third-speed clutch is disengaged, the fifth-speed clutch is engaged. Power then flows from the speed transmission input shaft through the odd-speed clutch, the countershaft, the fifth speed clutch, and across the output shaft to the master clutch.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 11 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 5/6 3/4 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A034 Gear No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) THIRTEENTH GEAR - As the operator selects thirteenth speed, the even-speed clutch is disengaged, and the odd-speed clutch is engaged. At the same time, the fifth-speed clutch and the medium-range clutch are disengaged, the first-speed clutch and the high-range clutch are engaged.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 13 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 5/6 3/4 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A043 Gear No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) FIFTEENTH GEAR - As the operator selects fifteenth speed, the even-speed clutch is disengaged, and the oddspeed clutch is engaged. At the same time, the first-speed clutch is disengaged, and the third-speed clutch is engaged. Power then flows from the speed transmission input shaft through the odd-speed clutch, the countershaft, the third speed clutch, and across the output shaft to the master clutch.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 15 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 5/6 3/4 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A045 Gear No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD SPEEDS) SEVENTEENTH GEAR - As the operator selects seventeenth speed, the even-speed clutch is disengaged, and the odd-speed clutch is engaged. At the same time, the third-speed clutch is disengaged, the fifth-speed clutch is engaged. Power then flows from the speed transmission input shaft through the odd-speed clutch, the countershaft, the third speed clutch, and across the output shaft to the master clutch.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Gear No. 17 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 5/6 3/4 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A047 Gear No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (REVERSE SPEEDS) FIRST REVERSE GEAR - As the operator selects first reverse speed, he simultaneously engages the odd-speed clutch pack, the reverse-speed clutch pack and the low-range clutch pack through the transmission controller. The power then flows from the drop box, through the input shaft, the engaged odd-speed clutch pack gear, to the countershaft gear.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Reverse No. 1 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 5/6 3/4 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A049 Reverse No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (REVERSE SPEEDS) THIRD REVERSE GEAR - As the operator selects third reverse speed, he simultaneously engages the odd-speed clutch, reverse-speed clutch pack and the medium-range clutch pack through the transmission controller. The power then flows from the drop box, through the input shaft, the engaged odd-speed clutch pack, to the countershaft gear.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Reverse No. 3 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 5/6 3/4 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A051 Reverse No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD CREEPER DRIVE SPEEDS) FIRST CREEP GEAR - As the operator selects first creep speed, he simultaneously disengages and locks out the odd-speed clutch pack and the even-speed clutch pack. He also engages the creep speed clutch pack, the first speed clutch pack and the low range clutch pack. This is accomplished through the transmission controller.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Creeper Gear No. 1 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 5/6 3/4 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A053 Creeper Gear No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD CREEPER DRIVE SPEEDS) THIRD CREEP GEAR - As the operator selects third-creep speed, he simultaneously disengages the third-speed clutch and engages the fifth-speed clutch. Power then flows from the speed transmission input shaft through the creep-speed clutch on the countershaft, to the fifth-speed clutch, across the output shaft to the master clutch.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Creeper Gear No. 3 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 5/6 3/4 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A055 Creeper Gear No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (FORWARD CREEPER DRIVE SPEEDS) FIFTH CREEP GEAR - As the operator selects fifth creep speed, he simultaneously disengages the first-speed clutch and engages the third-speed clutch. Power then flows from the speed transmission input shaft, through the creep-speed clutch on the countershaft, to the third-speed clutch on the output shaft, across to the master clutch.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Creeper Gear No. 5 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 5/6 3/4 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A057 Creeper Gear No.
Section 21 - Transmission, Drivelines - Chapter 1 POWER FLOW (REVERSE CREEPER DRIVE SPEEDS) CREEPER REVERSE FIRST GEAR (CR1) - As the operator selects creeper first-reverse speed, he simultaneously disengages and locks out the odd-speed clutch pack and the even-speed clutch pack. He also engages the creep-speed clutch pack, the reverse-speed clutch pack, and the low-range clutch pack. This is accomplished through the transmission controller.
Section 21 - Transmission, Drivelines - Chapter 1 Powershift Transmission Clutch Layout with Pump Drive, PTO, FWD, and Creeper Drive Creeper Reverse Gear No. 1 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1/2 3/4 5/6 REV SPEED OUTPUT SHAFT SPEED INPUT SHAFT POWER TAKE OFF SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN PUMP DRIVE GEAR FINAL DRIVE PINION CREEPER FWD CLUTCH (SPRING ENGAGED) RT98A059 Creeper Reverse Gear No.
Section 21 - Transmission, Drivelines - Chapter 1 INCHING VALVE OPERATION 4 3 5 2 6 10 7 8 9 1 RH02F070 1. 2. 3. 4. 5. PORTING TO MASTER CLUTCH INCHING VALVE BODY MODULATOR SPOOL REGULATED PRESSURE SUPPLY PROPORTIONAL CURRENT CONTROL SOLENOID 6. 7. 8. 9. 10.
Section 21 - Transmission, Drivelines - Chapter 1 4 3 5 2 10 6 7 8 9 1 RH02F071 REGULATED PRESSURE INTERMEDIATE PRESSURE TANK/SUMP PRESSURE RT98F015 1. 2. 3. 4. 5. PORTING TO MASTER CLUTCH INCHING VALVE BODY MODULATOR SPOOL REGULATED PRESSURE SUPPLY PROPORTIONAL CURRENT CONTROL SOLENOID 6. 7. 8. 9. 10. PRELOAD SPRING INNER MODULATOR SPRING PISTON CENTER PIN MODULATOR PISTON ASSEMBLY CHECK VALVE The inching valve is shown with the engine running and the inching pedal fully depressed.
Section 21 - Transmission, Drivelines - Chapter 1 4 5 3 2 6 10 7 8 9 1 RH02F072 REGULATED PRESSURE INTERMEDIATE PRESSURE TANK/SUMP PRESSURE RT98F015 1. 2. 3. 4. 5. PORTING TO MASTER CLUTCH INCHING VALVE BODY MODULATOR SPOOL REGULATED PRESSURE SUPPLY PROPORTIONAL CURRENT CONTROL SOLENOID 6. 7. 8. 9. 10.
Section 21 - Transmission, Drivelines - Chapter 1 4 3 5 2 10 6 7 8 9 1 RH02F073 REGULATED PRESSURE INTERMEDIATE PRESSURE TANK/SUMP PRESSURE RT98F015 1. 2. 3. 4. 5. PORTING TO MASTER CLUTCH INCHING VALVE BODY MODULATOR SPOOL REGULATED PRESSURE SUPPLY PROPORTIONAL CURRENT CONTROL SOLENOID 6. 7. 8. 9. 10.
Section 21 - Transmission, Drivelines - Chapter 1 INSTRUMENTATION CLUSTER - TRANSMISSION LEAKAGE CHECK The regulated circuit pump is the front section of the tandem gear pump. The pump draws oil from the system reservoir through a 100 mesh suction screen. The pump flow passes through the regulated circuit filter housing and into the priority regulator valve. The priority regulator valve maintains the regulated pressure circuit at 22.4 to 24.5 bar (325 to 355 PSI).
Section 21 - Transmission, Drivelines - Chapter 1 STEP 1 - Record Clutch Pressures in each Gear with Tractor Instrumentation NOTE: Clutch pack leaks can be identified through the tractor instrumentation pressure readings. IMPORTANT: The tractor must be driven to perform this test. Perform this test in an open outdoor location free of obstacles and people. -- Start and run the engine with the transmission control lever in the PARK position.
Section 21 - Transmission, Drivelines - Chapter 1 Low pressure for Speeds 1, 2, 7, 8, 13 and 14 ---------------------- Indicates 1st Speed Clutch Leakage. Low pressure for Speeds 3, 4, 9, 10, 15 and 16-----------------Indicates 3rd Speed Clutch Leakage. Low pressure for Speeds 5, 6,11,12, 17 and 18 -------------------Indicates 5th Speed Clutch Leakage. Low pressure for Speeds 1, 3, 5, 7, 9, 11, 13, 15, 17, R1 and R3 ---------------- Indicates Odd Clutch Leakage.
Section 21 - Transmission, Drivelines - Chapter 1 MASTER CLUTCH PRESSURE CHECK 2 1 RH98F161 1. DIAGNOSTIC TEST PORT 2. PUMP DRIVE GEAR HOUSING The master clutch pressure diagnostic test port is located on the right hand side of the transmission below the pump drive gear housing. - Place the transmission control lever in forward. - As the inching pedal is slowly let up the gauge reading should gradually increase.
Section 21 - Transmission, Drivelines - Chapter 1 • • Inspect the inching valve modulator spool and modulator piston. Both must move freely within the valve bore. See Inching Valve Operation in this section and the Transmission Control Valves and Inching Valve section of this manual for disassembly. Master clutch is leaking - see Range Transmission including FWD Clutch/ Park Brake section of this manual.
Section 21 Chapter 2 FRONT FRAME TO SPEED TRANSMISSION SPLIT January, 2006
Section 21 - Transmission, Drivelines - Chapter 2 TABLE OF CONTENTS SPECIAL TOOLS ........................................................................................................................................... 21-2-3 SPECIAL TORQUES ...................................................................................................................................... 21-2-3 FRONT FRAME TO SPEED TRANSMISSION SPLIT ...................................................................................
Section 21 - Transmission, Drivelines - Chapter 2 SPECIAL TOOLS 2 5 4 3 6 1 0507TLSR 1. SPLITTING STAND 17-526A 2. ADAPTER PLATES CAS-2604 3. SUPPORT BRACE 17-526-14 4. SUPPORT ASSEMBLY 17-526-4A 5. REAR HOUSING HANDLER 17-527 6. ADAPTER BRIGE 17-526-7 SPECIAL TORQUES Front Frame To Speed Transmission Front End Housing M16 Bolts................................................................................................................ 251 to 280 Nm (185 to 205 lb. ft.) M20 Bolts................
Section 21 - Transmission, Drivelines - Chapter 2 FRONT FRAME TO SPEED TRANSMISSION SPLIT Disassembly STEP 2 STEP 1 2 1 RD02E069 Disconnect the negative (1) and positive (2) battery cables. 96RS28A Prepare for disassembly as follows: STEP 3 1. Park the tractor on a hard level surface. 2. Put the transmission control lever in PARK. 3. Fully lower the three point hitch. 4. Stop the engine and remove the key. 5. Put blocks behind and in front of the rear wheels. 6.
Section 21 - Transmission, Drivelines - Chapter 2 STEP 5 STEP 8 RD05N119 RD05N128 If equipped, remove the rear windshield washer hose. Disconnect the hydraulic cooling lines at the fittings located at the rear of the engine. STEP 6 STEP 9 1 2 RD05N126 RD06A166 Disconnect the main electrical connector. Tag and remove the steering return hoses (1) and brake switch connectors (2). STEP 7 STEP 10 1 2 RD05N128 RD06A167 Disconnect the A/C lines at the firewall and cap the fittings.
Section 21 - Transmission, Drivelines - Chapter 2 STEP 11 STEP 13 1 2 1 1 1 1 RD06A168 RD05N124 Remove the fuel supply (1) and return (2) hoses. Remove the return hose at the fuel cooler. STEP 14 2 2 1 RD06A169 If equipped, tag and disconnect the four suspended front axle solenoid connectors (1) and remove the suspended axle valve hydraulic hoses (2). 1 RD02C175 Position the front splitting stand 17 - 526A (1) as shown. Properly support the transmission speed housing with jack (2).
Section 21 - Transmission, Drivelines - Chapter 2 STEP 15 STEP 17 1 RD02C173 RD02C177 Remove bolt (1) on the left and right hand sides. Install an alignment dowel on each side. Remove the remaining five bolts on each side. Push on the front wheels to move the front frame forward a few inches. Check to be sure there are no lines connected across the split. Continue to separate the tractor. STEP 16 RD02C174 Remove the two top inside bolts.
Section 21 - Transmission, Drivelines - Chapter 2 Assembly STEP 18 STEP 19 1 3 RD02C RD02C175 Install a bolt on both sides. Evenly tighten the bolts until the adapter plate and front frame flanges contact. Install and tighten all the side bolts except those blocked by the frame brackets. Remove the alignment dowels. 2 STEP 20 RD02C179 With alignment dowels installed on both sides of the transmission, move the front frame (1) rearward until the input shaft (2) engages the flywheel (3).
Section 21 - Transmission, Drivelines - Chapter 2 STEP 23 1 2 2 2 2 1 2 2 2 2 RD06A169 RI02D004 1............................. 251 to 280 Nm (185 to 205 lb. ft.) 2............................. 430 to 485 Nm (315 to 355 lb. ft.) 2 Remove the frame suppor t brackets to make clearance for a torque wrench. Tighten all the bolts to the values shown. STEP 21 2 2 2 RD06A168 If equipped, install the suspended front axle hydraulic fittings (1) and electrical connectors (2).
Section 21 - Transmission, Drivelines - Chapter 2 STEP 25 STEP 28 2 1 RD06A166 RD05N126 Install the steering hoses (1) and brake switch connectors (2). Connect the main electrical connector. STEP 29 STEP 26 RD05N119 If equipped, install the rear windshield washer hose. RD05N128 Install new O-ring and install the hydraulic cooling hoses. STEP 30 STEP 27 1 2 RD05N105 Install the heater supply (1) and return (2) hoses. RD05N127 Install new O-ring and install the A/C lines.
Section 21 - Transmission, Drivelines - Chapter 2 STEP 31 STEP 33 2 RD05N104 1 RD02E069 Connect the battery cables at the starter. Connect the positive (1) negative (2) and battery cables. STEP 32 STEP 34 When tractor assembly is complete, run the tractor and check for hydraulic leaks. Check the fluid level in the transmission and add as required. 96R28A Complete installation as follows: 1. Remove the jack stands, jack and front splitting stand. 2. Install the FWD drives shaft.
Section 21 - Transmission, Drivelines - Chapter 2 This Page Left Blank.
Section 21 Chapter 3 SPEED TO RANGE TRANSMISSION SPLIT January, 2006
Section 21 - Transmission, Drivelines - Chapter 3 TABLE OF CONTENTS SPECIAL TOOLS ........................................................................................................................................... 21-3-3 SPECIAL TORQUES ...................................................................................................................................... 21-3-3 SPEED TO RANGE TRANSMISSION SPLIT ..........................................................................................
Section 21 - Transmission, Drivelines - Chapter 3 SPECIAL TOOLS 4 2 5 3 7 6 1 0507TLSR 1. SPLITTING STAND 17-526A 5. REAR HOUSING HANDLER 17-527 2. ADAPTER PLATES CAS-2604 6. ADAPTER BRIDGE 17-526-7 3. SUPPORT BRACE 17-526-14 7. SUPPORT ASSEMBLY 17-526-5 4. SUPPORT ASSEMBLY 17-526-4A SPECIAL TORQUES Speed to Range Transmission Bolts 20 mm ............................................................................................................ 232 to 262 Nm (171 to 193 lb. ft.
Section 21 - Transmission, Drivelines - Chapter 3 SPEED TO RANGE TRANSMISSION SPLIT Removal STEP 1 STEP 2 96RS28A 91S17 Prepare for removal as follows: Drain the transmission fluids from the range, speed, and rear frame. Drain fluid into clean drain pans. 1. Park the tractor on a hard, level surface. 2. Put the shift control lever in PARK. NOTE: The transmission capacity is approximately 172 liters (45 gallons). 3. Fully lower the rear three-point hitch. 4. Stop the engine and remove the key. 5.
Section 21 - Transmission, Drivelines - Chapter 3 STEP 3 STEP 4 2 1 RD02C163 RD02C165 Disconnec t the wir e har nes s fr om the speed powershift valve solenoids. STEP 5 3 1 RD02C164 Position the front splitting stand 17-526A (1) and attach the adapter plates (2) on both sides. Position the rear housing handler 17-527 (3) and adjust it to suppor t the rear frame and range transmission without lifting up on them.
Section 21 - Transmission, Drivelines - Chapter 3 STEP 7 STEP 9 6 5 4 1 2 3 RD02C167 1. STEERING SENSING AND SUPPLY LINES 2. REGULATED SUPPLY JUMPER TUBE 3. MFD/DIFF LOCK SUPPLY LINE RD02C170 4. REGULATED PRESSURE SUPPLY LINE 5. OIL COOLER RETURN LINE 6. PARK LOCK RELEASE SUPPLY LINE Remove the 10 bolts attaching the speed transmission to the range transmission and install a guide stud on each side.
Section 21 - Transmission, Drivelines - Chapter 3 Installation STEP 11 STEP 12 1 2 RD02C171 Rd02C170 Install and partially tighten the 10 bolts. STEP 13 3 3 1 2 2 2 RD02C172 With the range transmission supported by the rear housing handler 17-527 and speed transmission supported by the splitting stand 17-526A, install guide studs 2 2 (1). Install a new gasket onto the range housing. Push on the front wheels to move the transmissions together. The three shaft splines must align and engage.
Section 21 - Transmission, Drivelines - Chapter 3 STEP 14 STEP 16 4 3 2 1 1. ODD EVEN VALVE RETURN LINE 2. FILTER TEMP SENDING WIRE RD02C169 RD02C168 3. OIL COOLER SUPPLY LINE 4. STEERING RETURN LINE If equipped, install the true ground speed radar on to the transmission housing and connect to the wire harness. Move the transmission wire harness into position over the speed transmission housing. STEP 17 Connect filter temperature sender wire to the hydraulic filter head.
Section 21 - Transmission, Drivelines - Chapter 3 STEP 19 STEP 21 RD02C164 96R28A Complete installation as follows: 1. Install the MFD driveshaft. See MFD Driveshaft information. 2. Install the fuel tanks. See Fuel Tank Removal and Installation information. 3. Install the cab. See Cab Raise/Removal and Installation information. 4. Install the hood. See Hood Removal information. 5. Install transmission fluid. 6. Install transmission fluid. RD02C163 7. Remove the blocks from the wheels.
Section 21 - Transmission, Drivelines - Chapter 3 This Page Left Blank.
Section 21 Chapter 4 SPEED TRANSMISSION January, 2006
Section 21 - Transmission, Drivelines - Chapter 4 TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................... 21-4-4 SPECIAL TORQUES ...................................................................................................................................... 21-4-4 TROUBLESHOOTING AFTER SPEED TRANSMISSION REPAIR ...............................................................
Section 21 - Transmission, Drivelines - Chapter 4 PICTORIAL INDEX - SPEED TRANSMISSION 2 1 3 4 5 10 9 8 6 7 85L94A 1. 1ST SPEED CLUTCH 2. 5TH SPEED CLUTCH 3. REVERSE SPEED CLUTCH 4. OUTPUT SHAFT 5. INPUT SHAFT 6. COUNTERSHAFT 7. CREEPER SPEED CLUTCH 8. EVEN SPEED CLUTCH 21-4-3 9. ODD SPEED CLUTCH 10.
Section 21 - Transmission, Drivelines - Chapter 4 SPECIFICATIONS End Play for Installed Speed Transmission Countershaft, Input Shaft and Output Shaft...................................................................0.03 to 0.13 mm (0.0012 to 0.0051 inch) Clutch Pack Oil Leakage .......................................................................................... 0.5 L/min (0.13 gpm) Maximum SPECIAL TORQUES Mounting Bolts for Front Bearing Support Cover on Speed Transmission Housing .................
Section 21 - Transmission, Drivelines - Chapter 4 SPECIAL TOOLS 1 2 3 T98826 T98826 Compression Sleeve with Notch CAS1903-3 (first used on Page 10). 1. Mounting Plate 17-52-14 2. Mounting Brackets 17-52-16 (set of two) 3. Engine Mounting Stand CAS10431 CAS1903-4 Centering Sleeve CAS1903-4 (first used on Page 52). CAS19031 Compression Plate with 6 Tangs and 2 Capscrews CAS1903-1 (first used on Page 12). CAS1903-5 Compression Sleeve CAS 1903-5 (first used on Page 37).
Section 21 - Transmission, Drivelines - Chapter 4 SPEED TRANSMISSION WITH CREEP OPTION STEP 1 STEP 3 1 2 3 886L0 1. INPUT SHAFT 2. OUTPUT SHAFT 3. COUNTERSHAFT 886L0 Remove any remaining seal material from the bolt hole threads. Install two bolts in the bearing support cover at the 1 and 7 o’clock position (front view shown). Tighten bolts only finger-tight. Remove the mounting bolts from the front bearing support cover.
Section 21 - Transmission, Drivelines - Chapter 4 Countershaft, Input Shaft, And Output Shaft Removal For Transmissions With Creep Option STEP 5 STEP 6 18-8 18-11 Remove housing as follows: 1. Connect a chain to the rear of the speed housing (shown with cab mounting bracket attached). 2. Use a suitable hoist to remove the housing from the engine stand. 3. Raise the housing up enough to put the support blocks in position under the bearing support cover as shown above. 4.
Section 21 - Transmission, Drivelines - Chapter 4 Countershaft, Input Shaft, and Output Shaft Removal for Transmissions without Creep STEP 8 STEP 10 25-32 25-20 Remove transmission housing cover as follows: Remove output shaft. 1. With the transmission housing on the engine stand, turn the housing so the cover is in the upright position. STEP 11 2. Remove the mounting bolts from the front bearing support. 3. Loosen and raise the transmission housing cover using prybars under the two lift areas.
Section 21 - Transmission, Drivelines - Chapter 4 Disassembling the Countershaft with Creeper Speed Clutch STEP 12 STEP 14 T95237 T95239 Remove the two seal rings from the shaft. Remove the caged needle bearing. STEP 13 STEP 15 T95238 A11511 Remove the rear needle thrust bearing and the two bearing thrust washers. Use a hydraulic press to remove the front bearing cone and the creeper driven gear.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 16 STEP 18 A11501 RD05M014 Remove snap ring as follows: Remove the lube management ring. 1. Install the compression sleeve CAS1903-3 with the notch over the piston retur n Belleville washers (see the Special Tools page in this section). STEP 19 2. The opening in the special tool must be over the ends of the snap ring. 3. Compress the Belleville washers with a hydraulic press and remove the snap ring.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 21 STEP 24 A11515 T95251 Use a hydraulic press to move the shaft through the clutch plate carrier, spacer and the (2nd-4th-6th) speed driven gear. Remove the spacer. STEP 25 STEP 22 T95252 Remove the (2nd-4th-6th) speed driven gear and steel ball. A10871 Remove the snap ring from inside the clutch plate carrier.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 27 STEP 28 PRESS 1 2 3 T95267 4 Remove the snap ring. DBR01 1. COUNTERSHAFT 2. 3RD-4TH DRIVER GEAR 3. 1ST-3RD-5TH DRIVEN GEAR 4. SUPPORT Turn the shaft over and use a hydraulic press to remove the (3rd-4th) speed driver gear and the (1st3rd-5th) speed driven gear. Remove the two steel balls.
Section 21 - Transmission, Drivelines - Chapter 4 Alternative Method for Snap Ring Removal STEP 31 NOTE: This method can be used on any clutch carrier. The large snap ring, backing plate, friction plates, separator plates and reaction plate must be removed first. STEP 29 T95547 Compress the Belleville washers by tightening the cap screws in the tool. STEP 32 T95545 Install the compression plate (CAS 1903-2) over the piston return Belleville washers.
Section 21 - Transmission, Drivelines - Chapter 4 ASSEMBLING THE COUNTERSHAFT WITH CREEPER SPEED CLUTCH 38 35 33 37 36 34 31 27 25 32 28 30 26 28 29 24 27 22 20 23 18 16 13 21 19 3 17 14 2 15 1 5 4 8 6 7 10 9 12 11 RI05M091M 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. SHAFT PLUG STEEL BALL PINION GEAR DRIVEN 39T PINION GEAR DRIVE 34TP SNAP RING PINION GEAR DRIVE 29T SHIM BEARING BEARING CONE 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 33 STEP 34 2 1 1 3 2 A22751R 7 4 5 6 DIMENSION 66L94 A 1. 2. 3. 4. 1ST-2ND DRIVERGEAR REAR BEARING CONE 3RD STEEL BALL 2ND STEEL BALL 5. 3RD-4TH DRIVER GEAR 6. 1ST STEEL BALL 7. 1ST-3RD-5TH DRIVEN GEAR Install steel balls as follows: 3 1. Apply petroleum jelly to the first steel ball (6) and install ball into hole in shaft for (1st-3rd-5th) driven gear (7). 2 389L7 Install countershaft components as follows: 2.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 36 5. Heat the (3rd-4th) speed drive gear (5) in a bearing oven for 3 to 4 hours at a temperature of 350 to 370° F (177-187° C). NOTE: Do not heat the gear beyond a temperature of 375 ° F (190° C). 6. Install the gear (5) over the shaft, engaging the ball and seat against the (1st-3rd-5th) speed driven gear. 7. Install the snap ring. The flat side of the snap ring must face away from the gear. 8.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 38 STEP 40 T95276A Install the spacer. T95278 STEP 39 40-35 T95277 Remove and replace teflon ring and O-ring as follows: Hit the clutch plate carrier against a wood block to remove the clutch piston. 1. Replace the teflon ring and the O-ring on the carrier and piston. 2. Install the O-ring in the groove. Install the teflon ring over the O-ring as shown below. 1 2 3 detail_b 1. PISTON 2. TEFLON RING 3.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 41 STEP 43 T95280 A10875 Install the reaction plate (thicker than separator plate). NOTE: The reaction plate is similar to a separator plate except that it is thicker. STEP 44 41-3 Apply petroleum jelly to the teflon rings. STEP 42 A10876 Install a new friction plate. NOTE: Dip all friction plates in clean transmission fluid. A10873 Install the clutch piston into the carrier with the flat side of the piston facing down.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 45 STEP 48 A10877 AA11505 Install a separator plate. Install the remaining seven new fr ic tion pl ates and six se parator pla te s, alternating the plates. Put the carrier assembly in a press. Align the oil hole in the carrier with the oil gallery hole in the shaft. Press the shaft into the carrier until fully seated. STEP 46 NOTE: Be sure the oil holes in the shaft and carrier are aligned before proceeding.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 50 STEP 53 RD05M013 A11501 1. Install the snap ring on the shaft. Install the first piston-return Belleville washer. The concave side of the washer must be facing down. 2. Install the compression sleeve CAS1903-3 with the notch over the shaft. STEP 51 3. Use a hydraulic press to compress the Belleville washers. 4. Install the snap ring in the groove. STEP 54 RD05M014 Install the lube management ring.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 56 STEP 59 T95296 A11514 Align the friction plate teeth. Install the creeper driven gea r in to the c lu tch c ar r ie r as s embly. S l igh t oscillation of the gear will help with the installation. The splined hub of the gear must engage all the friction plates. Install the bearing cone with the larger OD bearing end facing down. Press the bearing on the inner race to properly seat the bearing on the shaft.
Section 21 - Transmission, Drivelines - Chapter 4 Countershaft with Creep 2 1 3 4 5 10 9 8 6 7 85L94A 1. 1ST SPEED CLUTCH 2. 5TH SPEED CLUTCH 3. REVERSE SPEED CLUTCH 4. OUTPUT SHAFT 5. INPUT SHAFT 6. COUNTERSHAFT 7. CREEPER SPEED CLUTCH 8. EVEN SPEED CLUTCH 21-4-22 9. ODD SPEED CLUTCH 10.
Section 21 - Transmission, Drivelines - Chapter 4 Disassembly and Assembly of Countershaft without Creep 7 2 6 5 8 5 4 3 1 2 10 9 11 14 12 13 RD05N030M 1. 2. 3. 4. SHAFT SNAP RING PINION DRIVE GEAR 34T PINION DRIVEN GR 37T 5. 6. 7. 8. STEEL BALL PINION DRIVEN GR. 37T BEARING BEARING CONE 1 9. 10. 11. 12. PINION DRIVE GEAR 29T SHIM BEARING BEARING CONE 13. CAGE 14. BOLT M10 X 25 3 2 6 4 5 87L94 1. 1ST-2ND SPEED DRIVER GEAR 2. 3RD-4TH SPEED DRIVER GEAR 3.
Section 21 - Transmission, Drivelines - Chapter 4 Disassembling the Speed Input Shaft STEP 62 STEP 65 T95300a T95305a Remove the five seal rings from the speed input shaft. Remove the two snap rings. STEP 66 STEP 63 T95306a Remove the spacer. T95301a Use a bearing puller to remove the rear bearing cone. STEP 67 STEP 64 T95307a Remove the two bearing thrust washers and the needle thrust bearing. T95303a Remove the spacer.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 68 STEP 71 T95308a T95311a Remove the (1st-3rd-5th) speed drive gear. Remove the snap ring. STEP 69 STEP 72 T95309a T95312a Remove the caged needle bearing. Remove the backing plate. STEP 70 STEP 73 T95310a T95313a Remove the two bearing thrust washers and the needle thrust bearing. Remove the friction plates, separator plates and the reaction plate (thicker than separator plate).
Section 21 - Transmission, Drivelines - Chapter 4 STEP 74 STEP 77 T95315a T95317 Use a bearing puller to remove the front bearing cone. Remove the snap ring. STEP 78 STEP 75 A11538 Remove the two bearing thrust washers and the needle thrust bearing. 890L0 Non Creep Transmission Use a bearing puller to remove the gear and front bearing cone. STEP 79 STEP 76 T95319 Remove the (2nd-4th-6th) speed drive gear. T95316 Use a bearing puller to remove the creeper gear, if equipped.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 80 STEP 83 T95320 A11532 Remove the caged needle bearing. Remove the snap ring. STEP 81 STEP 84 T95321 A11531 Remove the spacer. Remove the backing plate. STEP 82 STEP 85 T95322 T95325 Remove the second caged needle bearing. Remove the friction plates, separator plates and the reaction plate (thicker than separator plate).
Section 21 - Transmission, Drivelines - Chapter 4 STEP 86 STEP 88 T95327 T95331 Remove the two bearing thrust washers and the needle thrust bearing. Remove the piston return Belleville washers and lube management ring from each side of the clutch plate carrier. STEP 87 IMPORTANT: Note orientation of Belleville washers and lube management ring for later installation. STEP 89 A11518 Install the compression sleeve CAS1903-3 with the notch over the piston return Belleville washer.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 90 STEP 91 1 T95333 Press the splined front end of the shaft so that the shaft moves through the clutch plate carrier. 2 468L72 1. MARK ON FACE OF CARRIER 2. MARK ON FRONT END OF SHAFT Make an appropriate mark with scratch awl, prick punch, etc., on the front end of the carrier. Make a similar mark on the same end of the shaft. Make sure that these marks are aligned.
Section 21 - Transmission, Drivelines - Chapter 4 Speed Input Shaft Assembly With Creep Speed Or 50 KPH Transmission 4 5 6 1 2 3 7 10 9 8 13 11 12 15 14 16 18 23 9 17 18 19 20 24 22 26 21 28 25 30 32 30 33 9 28 29 9 32 27 31 18 31 18 29 19 26 9 27 15 25 34 36 23 16 15 24 35 9 16 42 41 39 37 38 43 44 41 RI05M069M 21-4-30
Section 21 - Transmission, Drivelines - Chapter 4 1. 2. 3. 4. 5. 6. 7. 8. 9. COIL PIN SHAFT BOLT M10 X 10 BOLT M12 X 40 CARRIER BEARING CUP BEARING GEAR,CREEP/ GEAR DRVN 50KPH CIRCLIP 10. 11. 12. 13. 14. 15. 16. 17. 18. THRUST WASHER THRUST BEARING PINION GEAR 37T NEEDLE BEARING SPACER THRUST WASHER THRUST BEARING SEAL RING BELLEVILLE WSH 19. 20. 21. 22. 23. 24. 25. 26. 27. LUBE RING SHAFT PLUG SEAL SNAP RING CLUTCH DISC SEPARATOR DISC FRICTION DESC DISC 28. 29. 30. 31. 32. 33. 34. 35. 36.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 94 STEP 96 1 T95280 2 468L72 1. MARK ON FACE OF CARRIER 2. MARK ON FRONT END OF SHAFT Before pressing the shaft through the clutch plate carrier, find the mark on the end of the shaft (2) and on the face of the carrier (1). NOTE: If a new part replaces an old part, make a mark on the new part that is in the same position as the mark for the old part.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 97 STEP 99 T95340a A11519 Install the shaft on the carrier as follows: Install a clutch piston into each side of the carrier. The flat side of the piston must be down. Push the piston into the carrier by hand. 1. Align the mark on the front end of the shaft with the mark on the face of the clutch plate carrier before pressing the shaft through the carrier. Aligning the marks will align the oil holes in the shaft with the oil holes in the carrier.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 102 STEP 104 RD05M003 A11525 Install the remaining Belleville washers as follows: Install the snap ring as follows: 1. Install the second Belleville washer. The concave side of the washer must be facing up. 1. Install the snap ring over the centering sleeve. 2. Install the Belleville washer compression sleeve over the shaft and centering sleeve CAS 1903-5 and on top of the snap ring. 2.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 106 STEP 109 A11528 A11531 Install the reaction plate (thicker separator plate). Install the backing plate. The flat side of the plate must face down. STEP 107 STEP 110 A11529 Install a new friction plate. A11532 Install the snap ring. NOTE: Dip all friction plates in clean transmission fluid. STEP 111 STEP 108 A11537 Install the two bearing thrust washers and the needle thrust bearing.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 112 STEP 114 1 A11533 A11535 Install a caged needle bearing into the gear hub. 1. SEAL Install a new seal ring on the (2nd-4th-6th) speed drive gear at location shown by arrow. Align the friction plate teeth. Install the gear into the clutch pack. The splined hub of the gear must be facing down. STEP 115 STEP 113 A11536 Install a spacer into the gear hub. STEP 116 A11534 Slight oscillation of the gear will help with the installation.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 117 STEP 120 1 A11538 T95363 Install the two bearing thrust washers and the needle thrust bearing. The needle thrust bearing must be between the two bearing thrust washers. Press the creeper speed gear into position. STEP 118 STEP 121 1. LONGER HUB T95361 A11516 If the transmission has the creep option, install the snap ring against the bearing thrust washer. Install the bearing cone on the shaft.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 123 STEP 126 RD05M005 A11541a Install the lube management ring. Install the Belleville washer compression sleeve CAS1903-5 over the shaft and on top of the snap ring. The smaller OD side of the sleeve must be facing up. STEP 124 STEP 127 RD05M006 Install the remaining Belleville washers as follows: 1. Install the second Belleville washer. The concave side of the washer must be facing up.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 128 STEP 131 T95313a A11544 Install the reaction plate, fr iction plates, and separator plates as follows: Install the two bearing thrust washers and the needle thrust bearing. The needle thrust bearing must be between the two thrust washers. 1. Install the reaction plate (thicker separator plate). STEP 132 2. Install the seven new friction plates and six separator plates, alternating the plates. STEP 129 A11545 1.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 133 STEP 135 T95379 A11547a Slight oscillation of the gear will help with the installation. The splined hub of the gear must engage all the friction plates. Install the two bearing thrust washers and the needle thrust bearing. NOTE: The needle thrust bearing must be between the two bearing thrust washers. STEP 134 STEP 136 A11546 Install a caged needle bearing into the gear hub.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 138 STEP 140 A11551 T95300a Install the second spacer. Install five new seal rings on the end of the input shaft. STEP 139 A11517 Install the bearing cone on the shaft. The larger OD end of the bearing must be facing down. Press the bearing on the inner race to properly seat the bearing on the shaft.
Section 21 - Transmission, Drivelines - Chapter 4 Speed Input Shaft 2 1 3 4 6 5 9 8 7 385L7 1. (1st-3rd-5th) SPEED DRIVE GEAR 4. CREEPER SPEED GEAR (IF EQUIPPED) 7. EVEN SPEED CLUTCH PACK 2. CLUTCH PLATE CARRIER 5. FRONT BEARING CONE 8. ODD SPEED CLUTCH PACK 3. (2ND-4TH-6TH) SPEED DRIVE GEAR 6. INPUT SHAFT 9.
Section 21 - Transmission, Drivelines - Chapter 4 Disassembling the Speed Output Shaft STEP 141 STEP 144 T95386 T95391 Remove the four seal rings. Remove the reverse driven gear. STEP 142 STEP 145 T95387 A11638 Use a bearing puller to remove the front bearing cone and the reverse driven gear from the shaft. Remove the caged needle bearing and nylon spacer. STEP 146 STEP 143 A11555 Remove the two bearing thrust washers and the needle thrust bearing.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 147 STEP 150 A11556 RD05M010 Remove the snap ring from inside the clutch plate carrier. Remove one piston return Belleville washers. STEP 151 STEP 148 RD05M011 A11557 Remove the lube management ring. Remove the backing plate, friction plates, separator plates, and reaction plate (thicker separator plate). STEP 152 STEP 149 RD05M012 Remove eight Belleville washers.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 153 STEP 154 T95410 A11559 Remove the clutch plate carrier from the shaft. 1 STEP 155 A11560 Remove the snap ring from the clutch plate carrier. 2 468L72 1. MARK ON FACE OF CARRIER STEP 156 2. MARK ON FRONT END OF SHAFT Remove the snap ring. Make a mark on the carrier face that will align with the mark on the end of the shaft. These marks will be used to align the carrier on the shaft during assembly.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 157 STEP 160 A11562 RD05M012 Install the compression sleeve CAS1903-3 with the notch over the piston return Belleville washers. The opening in the sleeve must be over the ends of the snap ring. Compress the Belleville washers with a hydraulic press and remove the snap ring. Remove eight Belleville washers. STEP 161 STEP 158 T95429 Remove the snap ring. STEP 162 RD05M010 Remove one piston return Belleville washer.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 163 STEP 166 T95431 T95434 Remove the (5th-6th speed) driven gear. Remove the (3rd-4th speed) driven gear. STEP 164 STEP 167 T95432 T95435 Remove the caged needle bearing. Remove the thrust washer spacer. STEP 165 STEP 168 T95433a T95436 Remove the caged needle bearing. Remove the thrust washer.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 169 STEP 172 T95437 A11564 Remove the two bearing thrust washers and the needle thrust bearing. Remove Belleville washers as follows: 1. Install the compression sleeve with the notch CAS1903-3 over the piston return Belleville washers. The opening in the sleeve must be over the ends of the snap ring. STEP 170 2. Compress the Belleville washers with a hydraulic press and remove the snap ring. 3. Remove the Belleville management ring.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 174 STEP 177 A11566 T95469 Remove the caged needle bearing and the two bearing thrust washers and needle thrust bearing. Install the compression sleeve CAS1903-3 with the notch over the piston return Belleville washers. The opening in the sleeve must be over the ends of the snap ring. Compress the Belleville washers with a hydraulic press and remove the snap ring.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 179 T95474 1 2 468L72 1. MARK ON CARRIER FACE 2. MARK ON SHAFT FRONT Remove snap ring. Make a mark on carrier face that will align with mark on the end of shaft. This mark will help align carrier on the shaft during assembly. NOTE: If a new part replaces an old part, make a mark on the new part that is in the same position as the mark for the old part.
Section 21 - Transmission, Drivelines - Chapter 4 Speed Output Shaft Front Clutch Assembly 29 28 30 25 26 10 27 12 9 11 13 17 15 16 19 21 14 16 22 20 22 23 17 21 17 24 19 16 23 18 20 16 15 10 13 11 7 14 9 5 8 12 3 6 4 1 2 RI05N028M NOTE: If any clutch pack is disassembled, new friction plates must be installed. 1. O-RING 9. THRUST WASHER 17. BELLEVILLE SPRING 25. PINION 39T 2. SHAFT 10. THRUST BEARING 18. LUBE RING 26. NEEDLE BEARING 3. PLUG 11. RING 19.
Section 21 - Transmission, Drivelines - Chapter 4 Speed Output Shaft Rear Clutch Assembly 4 2 6 1 3 8 5 7 13 9 12 13 10 17 15 14 12 19 16 11 19 18 17 13 13 12 20 15 14 18 16 12 6 11 9 7 22 5 24 10 21 25 8 23 26 27 29 28 RI05N028M NOTE: If any clutch pack is disassembled, new friction plates must be installed. 1. O-RING 9. CLUTCH DISC 17. SEAL RING 25. BEARING CONE 2. SHAFT 10. FRICTION DISC 18. SEAL RING 26. BEARING CUP 3. NEEDLE BEARING 11. SEPARATOR DISC 19.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 181 STEP 183 1 1 T95337 DBR02 Replace the teflon ring and O-ring on the piston and carrier as follows: 1. PLUG 1. Install the plug (2) flush to the surface, as shown. 2. Make sure that all the oil passages in the shaft are clean and open. STEP 182 40-35 1. Install the O-ring in the groove. 2. Install the teflon ring over the O-ring. STEP 184 T95479 Hit the clutch carrier against a wood block to remove the clutch pistons.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 185 STEP 186 1 T95498 Assemble the clutch plate carrier as follows: 3 1. Install the front end of the rear clutch plate carrier over the rear end of the shaft. 2 2. Align the mark on the rear end of the shaft with the mark on the front face of the rear clutch plate carrier before pressing the carrier over the shaft, aligning the marks will align the oil holes in the shaft with the oil holes in the carrier. 3.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 188 STEP 190 T95280 Rd05M007 Install the first piston return Belleville washer. The concave side of the washer must be facing down. STEP 191 41-3 Apply petroleum jelly to the teflon rings. STEP 189 Rd05M008 Install the lube management ring. STEP 192 A11568 Install a piston in each side of the clutch carrier with the flat side toward the inside. RD05M009 Install the second Belleville washer. The concave side of the washer must be facing up.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 193 STEP 195 A11571 A11574 Install the centering sleeve CAS1903-4 over the shaft. Install the sleeves and snap ring as follows: 1. Install the compression sleeve with the notch over the shaft. STEP 194 2. Use a hydraulic press to press the sleeves down. The snap ring will be pushed into position in the groove with the pin between the snap ring ends. 3. Verify that the snap ring is properly seated in the groove.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 197 STEP 200 A11577 A11580 Install a new friction plate. Install the snap ring. NOTE: Dip all friction plates in clean transmission fluid. STEP 201 STEP 198 A11581 Install the needle thrust bearing and the two bearing thrust washers. The needle thrust bearing must be between the two bearing thrust washers. A11578 Install the remaining 10 separator plates and 10 friction plates, alternating the plates.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 202 STEP 204 1 A11582 A11584 1. SEAL Install the two bearing thrust washers and the needle thrust bearing. The needle thrust bearing must be between the two bearing thrust washers. Install 1st-2nd speed driven gear as follows: 1. Install a new seal ring on the (1st-2nd speed) driven gear. STEP 205 2. Align the friction plate teeth. Install the gear into the clutch pack. The splined hub of the gear must be facing down. 3.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 206 STEP 208 A11592 A11593 Turn the shaft over and install the first piston return Belleville washer. Install the second Belleville washer. NOTE: The concave side of the washer must be facing up. NOTE: The concave side of the washer must be facing down. Install the remaining seven Belleville washers, alternating the position of the washers until the last washer has the concave side facing down.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 210 STEP 212 A11596 A11599 1. Install the compression sleeve CAS1903-3 with the notch over the shaft. Install a new friction plate. NOTE: Dip all friction plates in clean transmission fluid. 2. Use a hydraulic press to press the sleeves down. The snap ring will be pushed into position in the groove. STEP 213 3. Verify that the snap ring is seated properly in the groove.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 215 STEP 217 1 A11591 A11602 Install the snap ring. 1. SEAL Install the 3rd-4th speed driven gear as follows: STEP 216 1. Install a new seal ring on the (3rd - 4th speed) driven gear. 2. Align the friction plate teeth. Install the gear into the clutch pack. The splined hub of the gear must be facing down. 3. Slight oscillation of the gear will help with the installation. 4. The splined hub of the gear must engage all the friction plates.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 219 STEP 222 1 A11607 A11604 Install the spacer. Install a new seal ring on the (5th-6th speed) gear. Install the gear on the shaft. STEP 220 NOTE: The splined hub of the gear must be facing up. STEP 223 A11605 Install the fiber thrust washer on the spacer ring. STEP 221 T95430 Install the two bearing thrust washers and the needle thrust bearing. NOTE: The needle thrust bearing must be between the two bearing thrust washers.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 224 STEP 227 T95429 RD05M010 Install the retaining ring for the piston return Belleville washers on the shaft. Install final washer with concave facing upward. STEP 225 STEP 228 RD05M012 T95424 1. Install the first washer with the concave side facing up. Install the snap ring on the shaft and let the snap ring lie on top of the last piston return Belleville washer that was installed. 2.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 230 STEP 232 A11608 T95416 Install the snap ring as follows: Install the backing plate over the gear. 1. Install the compression sleeve CAS1903-3 with the notch over the shaft. NOTE: The flat side of the place must be facing up. STEP 233 2. Use a hydraulic press to press the sleeves down. The snap ring will be pushed into position in the groove. 3. Verify that the snap ring is seated properly in the groove.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 235 STEP 237 T95419 T95337 Install the remaining six new friction plates and five separator plates, alternating the plates. STEP 236 40-35 Install the teflon and O-rings as follows: 1. Hit the clutch carrier against a wood block to remove the clutch pistons. T95420 Install the reaction plate (thicker separator plate) over the gear. 2. Replace the teflon ring and O-ring on the carrier and piston. 3. Install the O-ring in the groove. 4.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 239 STEP 240 1 T95413 2 3 Install carrier as follows: 1. Install the rear face of the carrier over the front end of the shaft. 2. Align the marks on the carrier and the shaft before pushing the carrier down on the shaft. 2 NOTE: Aligning the marks will align the oil holes in the shaft with the oil holes in the carrier. 434L7 1. FRONT FACE OF CARRIER 2. MARK 3. FRONT FACE OF SHAFT 3. Align the separator plate tabs with the slots in the carrier.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 242 STEP 244 A11610 T95411 Install the compression sleeve CAS1903-5 over the shaft. NOTE: The large OD end of the sleeve must be up. Use a screwdriver to install the snap ring that was installed on top of the gear (Step 219), into the inside groove in the carrier. Air check the clutch using the procedure in Step 252.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 246 STEP 249 RD05M012 A11614 1. Install the first washer with the concave side facing up. Install snap ring and Belleville washer compression sleeve as follows: 2. Install the second washer with the concave side facing down. 1. Install a centering sleeve CAS1903-4 over the shaft. 3. Install the next six washers, alternating the position of the washers until the last washer concave side is facing up. 2.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 251 STEP 254 T95398 T95395 Install the reaction plate (thicker separator plate). Install the backing plate. The flat side must be facing down. STEP 252 STEP 255 T95399 Install a new friction plate. T95393 Install the snap ring. NOTE: Dip all friction plates in clean transmission fluid. STEP 256 STEP 253 T95394 T95400 Install the needle thrust bearing and the two bearing thrust washers. Install a separator plate.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 257 STEP 259 1 A11616 T95389 Install the needle thrust bearing and the two bearing thrust washers. 1. SEAL Install the reverse speed driven gear as follows: 1. Install a new seal ring on the reverse speed driven gear. NOTE: The needle thrust bearing must be between the two bearing thrust washers. 2. Align the friction plate teeth. STEP 260 3. Install the reverse speed driven gear into the clutch pack.
Section 21 - Transmission, Drivelines - Chapter 4 Cross-Section View of Output Shaft 1 3 2 4 5 6 13 11 12 10 9 8 7 73I94 1. 1ST SPEED CLUTCH PACK 8. FRONT CLUTCH PLATE CARRIER 2. 3RD SPEED CLUTCH PACK 9. (5TH-6TH) SPEED DRIVEN GEAR 3. 5TH SPEED CLUTCH PACK 10. (3RD-4TH) SPEED DRIVEN GEAR 4. REVERSE SPEED CLUTCH PACK 11. REAR CLUTCH PLATE CARRIER 5. OUTPUT SHAFT 12. (1ST-2ND) SPEED DRIVEN GEAR 6. FRONT BEARING CONE 13. REAR BEARING CONE 7.
Section 21 - Transmission, Drivelines - Chapter 4 Air Check for Speed Transmission Clutch Piston Operation STEP 262 STEP 264 1 1 T95508 T95510A 1. CREEPER CLUTCH PLATES 1. EVEN CLUTCH PLATES Use an air gun to check the movement of the creeper clutch piston, if equipped, as follows: Check the even gear clutch piston operation as follows: 1. Install the tip of the air gun into the oil hole at the rear end of the countershaft. The air pressure will move the clutch plates on the creeper clutch. 1.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 266 STEP 268 1 1 T95512 T95514 1. 5TH CLUTCH PLATES 1. 3RD CLUTCH PLATES Check 5th gear clutch piston operation as follows: Check 3rd gear clutch piston operation as follows: 1. Install the tip of the air gun into the oil hole in the first groove from the rear of the output shaft. The air pressure will move the clutch plates in the 5th gear clutch. 1.
Section 21 - Transmission, Drivelines - Chapter 4 Countershaft, Input Shaft, and Output Shaft Installation - Exploded View 7 6 5 4 3 1 2 9 14 8 13 11 15 12 10 73L94AR 1. OUTPUT SHAFT REAR BEARING CAGE 9. SHIM 2. SHIM 10. COUNTERSHAFT REAR BEARING CAGE 3. BEARING CUP 11. SHIM 4. OUTPUT SHAFT ASSEMBLY 12. BEARING CUP 5. INPUT SHAFT ASSEMBLY 13. MFD NEEDLE BEARING 6. BEARING CUPS 14. COUNTERSHAFT ASSEMBLY 7. FRONT BEARING CAGE (WITH CREEP SPEED) 15.
Section 21 - Transmission, Drivelines - Chapter 4 Bearing Removal and Replacement STEP 269 STEP 271 A11623 A11621 If the MFD shaft bearing must be replaced, press the old bearing out of the housing. Press a new bearing assembly into the housing until the bearing is flush with the rear housing surface. Press a new bearing cup into the cage until the cup is fully seated.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 274 STEP 276 1 41-13 CVR901 Use a bearing puller to remove the bearing cup from the rear input shaft cage if the bearing cone on the input shaft has been replaced. 1. BEARING CUP Remove all foreign material from the rear surface of the front bearing support cover. Use a puller to remove any bearing cup from the support cover (input shaft bearing cup shown) if the bearing cone of that set was replaced.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 278 STEP 279 23-13 T95515 Install the rear bear ing shim packs that were removed during disassembly, and the rear bearing cages. Do not fully tighten the bolts. Re m ove al l fo r ei g n m a te r i al f r o m th e s p e e d transmission housing front flange.
Section 21 - Transmission, Drivelines - Chapter 4 TRANSMISSION ASSEMBLY WITH CREEP OPTION STEP 280 STEP 282 A11624 886L0 Put the bearing support cover on support blocks as shown in Step 4 in this section. Apply petroleum jelly to the seal rings. Install the three shaft assemblies in the cover. Install and tighten a bolt in the bearing support cover at the 1 and 7 o’clock position. Install bearing support cover as follows: 1. Mount the speed housing to the engine stand. STEP 281 2.
Section 21 - Transmission, Drivelines - Chapter 4 Shafts in Speed Transmission 1 2 3 85L94 1. OUTPUT SHAFT ASSEMBLY 2. INPUT SHAFT ASSEMBLY 3.
Section 21 - Transmission, Drivelines - Chapter 4 TRANSMISSION ASSEMBLY WITHOUT CREEP OPTION STEP 283 STEP 285 25-14 25-26 Install input shaft as follows: Install the countershaft as follows: 1. Mount the transmission housing in the engine stand. 1. Raise the input shaft approximately 44 mm (1-3/ 4 inches.) 2. Apply petroleum jelly to the seal rings on the shafts. 2. Install the countershaft until the gears of the countershaft are in mesh with the gears of the input shaft. 3.
Section 21 - Transmission, Drivelines - Chapter 4 Setting the End Play of the Speed Transmission Countershaft, Input Shaft, and Output Shaft STEP 287 4. Tighten two opposite bolts, alternately, in three increments until the bolts are tightened to a torque of 5.6 Nm (50 lb in). 5. To get a correct end play, rotate the shaft until the bolts torques do not change.
Section 21 - Transmission, Drivelines - Chapter 4 STEP 290 STEP 292 SCH309 SCH311 Remove the rear bearing cage. Take the average measurement from Step 275. To this average measurement, add the following amount of shims thickness: Do the following: 1. Rotate the shaft a minimum of 12 revolutions. 2. Use a dial indicator to measure the end play. 3. Use a pry bar inside the speed transmission housing to lift a gear on the shaft. Input Shaft without Creep Drive 0.009 in. (0.
Section 21 Chapter 5 RANGE TRANSMISSION TO REAR FRAME SPLIT January, 2006
Section 21 - Transmission, Drivelines - Chapter 5 TABLE OF CONTENTS SPECIAL TOOLS ........................................................................................................................................... 21-5-3 SPECIAL TORQUES ...................................................................................................................................... 21-5-3 RANGE TRANSMISSION TO REAR FRAME SPLIT .....................................................................................
Section 21 - Transmission, Drivelines - Chapter 5 SPECIAL TOOLS 2 5 4 3 6 1 0507TLSR 1. SPLITTING STAND 17-526A 4. SUPPORT ASSEMBLY 17-526-4A 2. ADAPTER PLATES CAS-2604 5. REAR HOUSING HANDLER 17-527 3. SUPPORT BRACE 17-526-14 6. ADAPTER BRIGE 17-526-7 SPECIAL TORQUES Range Transmission to Rear Frame Bolts M16 x 60 mm.......................................................................................................... 232 to 262 Nm (171 to 193 lb. ft.) M16 x 80 mm............................
Section 21 - Transmission, Drivelines - Chapter 5 RANGE TRANSMISSION TO REAR FRAME SPLIT Disassembly STEP 2 2 NOTE: Clean the entire transmission housing before beginning this procedure. STEP 1 1 3 RD02C181 96R-28A Before starting the procedure, do the following: 4 1. Park the tractor on a hard, level surface. 2. Put the gear shift control lever in PARK. 3. Fully lower the rear three-point hitch. 4. Turn the engine off and remove the key. RD02C180 5.
Section 21 - Transmission, Drivelines - Chapter 5 STEP 3 STEP 6 RD02C182 RD02C185 Remove the hitch position sensor cover. Disconnect the wire harness from the PTO (1) and MFD (2) solenoids. STEP 4 STEP 7 1 2 1 RD02C183 Disconnect the hitch position sensor connector. RD02C186 Remove the two lines (1) from the trailer brake valve (if equipped). Remove the two lines (2) from the steering priority valve.
Section 21 - Transmission, Drivelines - Chapter 5 STEP 8 STEP 11 1 2 RD02C197 RD02C193 Disconnect the remote auxiliary controller (1) from the wire harness. Move the remaining controllers and wire harness (2) forward until the harness is on the front side of the rear housing/range housing seam. Remove the top bolts. STEP 12 STEP 9 RD02C194 Remove the five bolts on each side of the housing. Install alignment dowels on each side. NOTE: Two bolts on the bottom are removed from the rear.
Section 21 - Transmission, Drivelines - Chapter 5 Assembly STEP 16 STEP 14 1 2 RD02C194 Using a bolt on both sides, draw the rear frame and range transmission together evenly. Remove guide studs when two bolts are drawn tight and replace with the bolts.Check to be sure the snap ring is fully seated in the shaft groove. RD02C196 Clean off all old gasket material in the flange area. Install alignment dowels and a new gasket.
Section 21 - Transmission, Drivelines - Chapter 5 STEP 18 STEP 20 1 3 1 1 1 RD02C188 Install tube removed from the remote valve. 2 STEP 21 2 BOLTSEQ5 Tighten the bolts to the following torques: M16 x 60mm.......... 232 to 262 Nm (171 to 193 lb. ft.) M16 x 80mm.......... 220 to 250 Nm (162 to 184 lb. ft.) M16 x 110mm........ 220 to 250 Nm (162 to 184 lb. ft.) 1 2 IMPORTANT: Failure to correctly tighten bolts could lead to failure of the bolts and housing.
Section 21 - Transmission, Drivelines - Chapter 5 STEP 23 STEP 26 RD02C185 RD02C182 Install the hitch position sensor cover and tighten the bolts. Connect the wire harness to the MFD and PTO solenoids. STEP 27 STEP 24 1 2 91S17 RD02C184 If not already done, install all removed drain plugs in the transmission. Connect the draft pin connector (1 - LH and RH side) and the transmission sump temperature sender connector (2) to the wire harness.
Section 21 - Transmission, Drivelines - Chapter 5 STEP 29 STEP 30 When tractor assembly is complete, run the tractor and check for hydraulic leaks. Check the fluid level in the transmission and add as required. 96R28A Complete the installation as follows: 1. Install the fuel tanks. See Fuel Tank Removal and Installation information. 2. Install the cab. See Cab Raise/Removal and Installation information. 3. Fill the transmission with fluid. 4. Remove the blocks from the wheels.
Section 21 Chapter 6 RANGE TRANSMISSION January, 2006
Section 21 - Transmission, Drivelines - Chapter 6 TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................... 21-6-3 TROUBLESHOOTING AFTER RANGE TRANSMISSION REPAIR .............................................................. 21-6-3 SPECIAL TORQUES ......................................................................................................................................
Section 21 - Transmission, Drivelines - Chapter 6 SPECIFICATIONS Range Input Shaft Master Clutch Spring: Free Length ........................................................................................................................... 35.82 mm (1.41 inches) Compress to 30.99 mm (1.220 inches) ............................................................................................. 42.26 N (9.5 lb.) FWD Clutch Pack Oil Leakage .......................................................................
Section 21 - Transmission, Drivelines - Chapter 6 SPECIAL TOOLS 1 2 3 T95952 1. 17-52-14 MOUNTING PLATE 2. 17-52-16 MOUNTING BRACKETS (SET OF 2) C1903H5 Compression Sleeve without notch CAS1903-5 3.
Section 21 - Transmission, Drivelines - Chapter 6 RANGE TRANSMISSION Removing the Shaft Master Clutch STEP 1 STEP 4 15S1R 12S9CUR4 After completing the procedures outlined in the Speed to Range Transmission Split Section and the Range Transmission to Differential Split Section of this Service Manual, the range transmission is ready for service. Mount the transmission on an engine stand CAS10431. Remove valve body plate. STEP 5 STEP 2 12S15 Remove feeder tubes.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 7 STEP 10 1 15S21 A22306 Remove the clutch backing plates. Enlarged View: STEP 8 1 A22306CU 1. ALIGNMENT MARK 15S24 Mark the master clutch for reassembly. Remove the snap ring that fastens the master clutch to the range input shaft. Remove the clutch hub. STEP 9 IMPORTANT: The master clutch must be aligned properly with the input shaft. STEP 11 15S27 Remove 9 friction plates and 9 separator plates.
Section 21 - Transmission, Drivelines - Chapter 6 Removing the Input Shaft, Countershaft and Mechanical Front Drive (FWD) / Park Brake Assembly STEP 12 STEP 14 15S33 16S4 Remove the lubrication tube from the input shaft bearing cage. Remove the mounting bolts from the input shaft bearing cage. STEP 13 STEP 15 16S1 16S9 Remove the master clutch carrier rear retaining ring from the input shaft. Remove the input shaft bearing cage.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 16 STEP 19 16S12 16S21 Remove the shims for the input shaft bearing cage. Keep the shims together with the bearing cage. The shims will be used again during assembly. Remove the shims for the countershaft bearing cage. Keep the shims together with the bearing cage. STEP 20 STEP 17 16S24 Remove the mounting bolts from the front bearing support cover. 16S15 Remove the mounting bolts from the countershaft bearing cage.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 22 STEP 23 A22319 A22321 Remove the input shaft. NOTE: If only the FWD/Emergency Brake Assembly needs to be removed, the range input and counter shafts DO NOT have to be removed. Remove the countershaft as follows: 1. Move the input shaft over to the side for clearance. 2. A threaded rod with a washer slightly larger than the countershaft diameter may be used to lift the shaft assembly. 3. Use a hoist to remove the countershaft.
Section 21 - Transmission, Drivelines - Chapter 6 FWD/Emergency Brake Removal STEP 24 STEP 27 RD05K011 A22326 Remove the FWD lube supply tube from the rear of the FWD / emergency brake input shaft. Remove the emergency brake supply fitting. STEP 25 STEP 28 2 1 RD05K012 Remove the supply tube (1) and fitting (2) for the FWD clutch pack. A22328 Remove the six FWD / emergency brake rear flange mounting bolts. STEP 26 RD05K014 Remove the jumper tube for the emergency brake. Repeat for the FWD.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 29 STEP 30 RD05K017 RD05K018 Properly suppor t the FWD / emergency brake assembly. Carefully lift the assembly from the range housing.
Section 21 - Transmission, Drivelines - Chapter 6 Disassembly of the Master Clutch STEP 31 STEP 33 A22350 A22347 Use a bridge and hydraulic press to compress the spring retainer plate. Remove the snap ring from the clutch carrier. Remove the 16 springs from the clutch piston. STEP 34 STEP 32 A22346 Remove the piston from the clutch carrier. A22348 Release the press and remove the spring retainer plate.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 35 STEP 36 A22343 248L7 Check seals and replace if necessary as follows: Check the clutch springs with a spring compression tester. 1. Inspect the seals (see arrows) on the master clutch carrier. The springs must have the following specifications: 2. If necessary, remove both the seals and the O-rings beneath them. Free Length ........................ 35.82 mm (1.410 inches) Compressed to 23.12 mm (0.910 inch) .................................
Section 21 - Transmission, Drivelines - Chapter 6 Exploded View of the Master Clutch 5 4 3 2 1 8 10 12 7 6 9 11 15 13 14 15 14 31L94R 1. 2. 3. 4. 5. 6. 7. 8. SEAL HUB SEAL BACKING PLATE SNAP RING SNAP RING FRICTION PLATE SEPARATOR PLATE 9. 10. 11. 12. 13. 14. 15.
Section 21 - Transmission, Drivelines - Chapter 6 Assembly of the Master Clutch STEP 37 STEP 39 A22345 A22348 Install the clutch piston into the clutch carrier. Carefully push the clutch piston down over the lubricated seals. Install the spring retainer plate. Be sure the spring locators in the plate engage each spring. STEP 40 STEP 38 A22350 Use a bridge and hydraulic press to compress the springs. Install the snap ring in the groove in the clutch carrier. A22347 Install the 16 springs.
Section 21 - Transmission, Drivelines - Chapter 6 Disassembly of the Range Transmission Input Shaft STEP 41 STEP 43 1 A22361 T95702 Put the input shaft on a clean work bench. Remove the four seal rings on the front of the shaft (1). Use a puller to remove the medium range clutch pack assembly. STEP 42 STEP 44 T95697 A10871 Use a puller to remove the low range drive gear and front bearing cone. Remove the snap ring from the clutch pack assembly.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 46 STEP 49 A10882 RD05K110 Install the compression sleeve with the notch CAS1903-3 to remove the retaining ring for the piston return Belleville springs. Remove one piston return Belleville spring. STEP 50 STEP 47 RD05K109 Remove the lube management ring. A10881 Use a press to compress the Belleville springs. Move the snap ring out of the groove in the shaft. STEP 51 STEP 48 RD05K108 Remove eight piston return Belleville springs.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 52 STEP 55 A10909 T95719 Remove the snap ring for the Belleville springs. Remove the medium range drive gear. STEP 53 STEP 56 A10910 T95720 Remove the snap ring for the bearing thrust washers and needle thrust bearing. Remove the caged needle bearing. STEP 57 STEP 54 T95721R Remove the thrust washer. T95718 Remove the two bearing thrust washers and the needle thrust bearing.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 58 STEP 61 T85722 A10908 Remove the thrust washer spacer ring. Remove the two bearing thrust washers and the needle thrust bearing. STEP 59 STEP 62 T95723 Remove the high range drive gear. A10884 Remove the piston retur n Belleville springs as follows: STEP 60 1. Install a compression sleeve with the notch CAS1903-3 over the piston return Belleville springs for removing the snap ring. 2.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 63 STEP 66 RD05K108 A10888 Remove 8 piston return Belleville springs. Use a puller to remove the rear bearing cone. STEP 64 STEP 67 RD05K109 A10889 Remove the snap ring and remove the high range clutch pack assembly from the shaft. Remove the lube management ring. STEP 65 STEP 68 RD05K110 A10871 Remove the final Belleville spring. Remove the snap ring from the clutch pack assembly.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 69 40S33 Turn the assembly over and remove the friction and separator plates. STEP 70 A10891 Remove the snap ring.
Section 21 - Transmission, Drivelines - Chapter 6 Exploded View of the Range Transmission Input Shaft 47 45 49 44 48 40 20 35 20 39 25 19 17 32 13 21 22 19 26 31 23 24 8 33 11 2 19 9 46 18 34 10 2 1 14 10 18 12 33 14 34 32 20 23 31 19 20 26 22 24 21 17 19 13 36 25 19 37 RI05N027 Exploded View of the Range Transmission Input Shaft 1. 2. 3. 4. 5. 6. 7. 8. 9. SHAFT ASSEMBLY PLUG SEAL RING THRUST WASHER RING MEDIUM RANGE GEAR HIGH RANGE GEAR NEEDLE BEARING THRUST WASHER 10. 11.
Section 21 - Transmission, Drivelines - Chapter 6 Assembly of the Range Transmission Input Shaft STEP 71 STEP 73 T95747 T95277 Hit the high range clutch plate carrier against a wooden block to remove the clutch piston. STEP 74 1 2 27L94 1. SEALING PLUG AT END OF SHAFT 2. 3 SEALING PLUGS AT END OF SHAFT 1 T95278 Inspect the sealing plugs in the input shaft. Make sure all the oil passages in the shaft are open. See illustration above.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 75 STEP 78 T95280 A10875 Install a separator plate. STEP 79 41S3 Put petroleum jelly on the teflon rings. A10876 STEP 76 Install a new friction plate. NOTE: Dip all friction plates in clean transmission fluid. STEP 80 A10873 Install the clutch piston into the carrier. The flat side of the piston must face down. Push the piston into the carrier by hand. STEP 77 A10877 Install a separator plate.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 81 STEP 83 A10878 A10889 Install the backing plate. The flat side of the plate must be facing down. Install the high range clutch pack assembly as shown. STEP 82 NOTE: The oil gallery hole in the shaft must be aligned with the hole in the carrier. Install the carrier snap ring onto the shaft. STEP 84 A10879 Install the clutch pack snap ring into the groove in the carrier. NOTE: Do not assemble the medium range clutch pack.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 85 STEP 87 2 1 RD05K110 A10899 Install the first piston return Belleville spring. The concave side of the spring must be facing down. 1. Install a snap ring (1) over the shaft. 2. Install the Belleville spring compression sleeve CAS1903-5 (smaller OD up) over the shaft and on top of the snap ring. STEP 86 STEP 88 RD05K109 Install the lube management ring. A10900 Install the snap ring as follows: 1.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 89 STEP 92 A10903 A10904 Remove the two compression sleeves. Install a new seal ring on the hub of the high range drive gear. STEP 90 STEP 93 A10908 A10906 Install the needle thrust bearing and two bearing thrust washers. The needle bearing must be between the two bearing thrust washers. Install the high range drive gear. The teeth on the gear hub align with the fr iction plates.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 95 STEP 98 T95722 T95719 Install the thrust washer spacer ring. Install a new seal ring on the medium range drive gear. Install the gear. The hub of the gear must be facing up. STEP 96 STEP 99 T95721 Install the thrust washer. T95718 Install the two bearing thrust washers and the needle thrust bearing. The needle thrust bearing must be positioned between the two bearing thrust washers.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 101 STEP 104 A10909 RD05K110 Install the snap ring for the piston return Belleville washers. This ring goes into the second groove down on the shaft. Install the final Belleville spring concave side down. STEP 105 STEP 102 A10911 Install the retaining ring onto the shaft along with the Belleville washer compression sleeve. Use tool CAS1903-5. RD05K108 Install the eight piston return Belleville springs.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 107 STEP 110 A10913 T95707 Remove the compression sleeve. Check to make sure the snap ring is properly seated in the groove on the shaft. Install a friction plate. NOTE: Dip all friction plates in clean transmission fluid. STEP 108 STEP 111 T95710 Install the clutch plate snap ring on top of the gear. T95708 Install a separator plate. Install the remaining 10 friction plates and 10 separator plates, alternating the p l a t e s.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 112 STEP 114 A10915 T95699 Install the medium range clutch plate carrier onto the shaft, open end facing down. Align holes between shaft and carrier. Carefully press the carrier on over the friction and separator plates. Install the low range drive gear. STEP 115 NOTE: The oil gallery hole in the shaft must be aligned with the hole in the carrier.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 116 Install four new seal rings (1) on the front end of the shaft. 1 A22361 Cross-Section of Input Shaft 2 3 4 1 5 7 6 11L94R2 1. 2. 3. 4. REAR BEARING CONE HIGH RANGE DRIVE GEAR MEDIUM RANGE DRIVE GEAR LOW RANGE DRIVE GEAR 5. FRONT BEARING CONE 6. MEDIUM RANGE CLUTCH PLATE CARRIER 7.
Section 21 - Transmission, Drivelines - Chapter 6 Disassembly of the Range Transmission Countershaft STEP 117 STEP 120 T95748 T95751 Put the countershaft on a clean work bench. Remove the high range driven gear. STEP 118 STEP 121 T95749 T95752 Use a puller to remove the constant mesh gear and the rear bearing cone. Remove the medium range driven gear from the carrier. STEP 119 STEP 122 T95750 A10921 Remove the gear spacer. Remove the snap ring for the medium range driven gear.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 123 STEP 126 A10923 A10926 Turn the shaft assembly over and use a hydraulic press to push the shaft through the remaining parts. Remove the four seal rings from the hub on the gear (two rings in each of two grooves). NOTE: Be careful not to let the shaft fall through. STEP 127 STEP 124 A10928 Turn the low range driven gear and clutch plate carrier over and remove the snap ring.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 129 STEP 132 T95771 T95774 Remove the caged needle bearing. Remove the two bearing thrust washers and the needle thrust bearing. STEP 130 STEP 133 T95772 Remove the bearing spacer. A10939 Remove the snap ring as follows: 1. Install compression sleeve with the notch CAS1903-3 over the shaft and on top of the piston return Belleville washers. STEP 131 2. Position the opening in the compression sleeve over the ends of the snap ring. 3.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 134 STEP 137 T95778 RD05M018 Remove the two bearing thrust washers and the needle thrust bearing. Remove eight piston return Belleville washers. NOTE: Mark the orientation of the Belleville springs and lube management ring for proper reinstallation. STEP 135 STEP 138 RD05M016 Remove three piston return Belleville washers. T95783 Use a puller to remove the roller bearing from the rear end of the shaft.
Section 21 - Transmission, Drivelines - Chapter 6 Exploded View of the Range Transmission Countershaft 45 43 47 50 41 44 21 42 36 20 36 20 31 22 37 37 24 39 39 27 23 40 21 26 25 20 10 20 33 9 32 5 8 8 5 34 6 35 12 4 1 3 11 13 18 14 19 15 RI05M088 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. SHAFT NEEDLE BEARING SNAP RING RING PINION GEAR 39T PINION GEAR 25T SPACER PINION 23T BEARING BEARING CONE BELLEVILLE SPRING LUBE RING THRUST WASHER 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Section 21 - Transmission, Drivelines - Chapter 6 Assembly of the Range Transmission Countershaft STEP 139 STEP 140 T95782 A10937 20.64 mm (0.81 INCH) 498L7 Make sure that all the oil passages in the shaft are open. DEPTH1 Install bearing inside of shaft with the numbers on the bearing facing outward. Press to a depth of 20.64 mm (0.81 inch). STEP 141 RD05M018 Install the eight piston return Belleville washers as shown.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 142 STEP 145 RD05M017 T95777 Install the lube management ring. Install the snap ring onto the shaft. STEP 143 STEP 146 1 RD05M016 A10939 Install the final three piston return Belleville washers as shown. Install the snap ring and Belleville washers as follows: NOTE: Make sure the concave side of first washer (1) is facing downward. 1.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 147 STEP 150 SNAP07 T95750 Install the snap ring for the medium range driven gear. Install the gear spacer. STEP 151 STEP 148 1 1 A10949 Install a new seal ring (1) on the medium range driven gear. Install the gear on the shaft. Install the constant mesh gear (1). Install the bearing cone. The larger OD side of the bearing cone must be facing down. Press the bearing in place to be sure the bearing is properly seated.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 152 STEP 154 2 4 1 T95774CR 40S24 Turn shaft over. Install the needle thrust bearing and the two bearing thrust washers. The needle thrust bearing must be between the two bearing thrust washers. 3 2 STEP 153 1 40S21 Remove the teflon ring (1) and O-ring (2) from the carrier (3) and piston (4). Install the new O-ring in the groove. Install the new teflon ring over the O-ring.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 156 STEP 158 40S27 A10932 Install the clutch piston into the carrier. The flat side of the piston must be down. Push the piston into the carrier by hand. Install the reaction plate (thicker separator plate). STEP 159 STEP 157 A10933 Install a new friction plate. 40S29 1 2 NOTE: Dip all friction plates in clean transmission fluid. 1 CTRINGS 1. TEFLON RING 2.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 160 STEP 163 A10934 T95785R2 Install separator plates as follows: Install the low range driven gear and clutch pack assembly onto the shaft. The gear end of the carrier must be facing up. The teeth on the medium gear hub align with the fr iction plate teeth. Slight oscillation of the low range driven gear will help with the installation. Be sure the hub passes through all the friction plates. 1. Install a separator plate. 2.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 165 STEP 167 A10942 A10945 Install the needle thrust bearing and the two bearing thrust washers. The needle bearing must be between the two bearing thrust washers. Install the front bearing cone so that the larger OD side of the bearing cone is facing down. Press the bearing in place to be sure the bearing is properly seated. STEP 166 NOTE: Be sure the tool used to press the bearing does not contact the end of the shaft.
Section 21 - Transmission, Drivelines - Chapter 6 Front Wheel Drive (FWD) - Emergency Brake Disassembly STEP 168 STEP 171 RD05K020 RD05K040 Remove the two Allen head mounting screws. Repeat for the opposite side. C o m p r e s s t h e B e l l ev i l l e s p r i n g s u s i n g To o l 380002454 and release the retaining ring. Release the tool and remove retaining ring and locking ring. STEP 169 STEP 172 1 RD05K019 Mark the shield (1) for proper reassembly. Remove the three clips.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 174 STEP 177 RD05K053 RD05K070 Remove the piston sealing ring and discard. Remove the friction plate. Continue until all friction and separator plates are removed. STEP 175 NOTE: When replacing separator and friction plates, they have to be replaced as complete assemblies. STEP 178 RD05K054 Remove the piston seal backing O-ring and discard. STEP 176 RD05K071 Remove the backing plate and mark for proper reassembly.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 180 STEP 183 1 Rd05K034 RD05K030 Remove the hub seal backing O-ring and discard. Remove the retaining ring for the emergency brake clutch assembly. STEP 181 IMPORTANT: Mark the shaft and hub (1) for proper reassembly. STEP 184 2 1 1 RD05K072 Inspect the needle bearings (1) and composite washer (2) for wear or damage. If bearings and or washer are worn or damaged, the FWD hub will have to be replaced. Bearings and washer are NOT serviced.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 186 STEP 189 RD05K075 RD05K038 Note the orientation of the Belleville springs and remove. Remove the friction plate. Continue to remove all friction and separator plates. There is a total of six separator and six friction plates. STEP 187 NOTE: When replacing separator and friction plates, they have to be replaced as complete assemblies. STEP 190 RD05K036 Remove the piston. STEP 188 RD05K042 Remove the backing plate.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 192 STEP 195 1 RD05K054 RD05K077 Remove the seal backing O-ring and discard. Remove bearing retainer ring (1) from the shaft. STEP 193 STEP 196 RD05K051 RD05K079 Remove the seal from the emergency hub. Remove the spacer and shim pack. STEP 194 RD05K052 Remove the O-ring from the emergency hub.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 197 STEP 199 2 1 2 1 RD05K043 RD05K045 Support the gear/can weldment (1) as shown and press the FWD/park brake shaft (2) free from the weldment. Remove the bearing. Using a soft drift (1), remove the bearing cup (2). STEP 200 IMPORTANT: Make sure that the shaft dose not strike the floor once it is pressed free from the weldment, as damage to the shaft may occur. IMPORTANT: Mark the bearing for location.
Section 21 - Transmission, Drivelines - Chapter 6 Exploded View of FWD and Emergency Brake 12 13 11 10 16 12 8 15 11 6 9 7 14 10 2 7 30 29 3 28 1 5 2 7 22 4 20 25 23 21 17 27 19 19 26 32 18 24 21 22 27 18 17 20 29 31 24 23 30 28 1. 2. 3. 4. SHAFT ASSY., FWD/PARK BRAKE TUBE, JUMPER W/ O-RINGS & FITTING BOLT, HEX HD M12 X 50 MM TUBE, FWD 12. 13. 14. 15. 5. 6. 7. 8. SHIELD, UPPER HALF SHIELD LOWER HALF SCREW, SOC HD M8 X 16 MM U CLIP, FWD SHIELD 16. 17. 18. 19. 9.
Section 21 - Transmission, Drivelines - Chapter 6 Assembly of the FWD / Emergency Brake STEP 204 NOTE: Be sure parts are free of all contaminants before reassembly. STEP 202 RD05K049 Press cup into place. RD05K047 Install snap rings. IMPORTANT: DO NOT overpress cup against the snap ring. STEP 203 STEP 205 RD05K048 RD05K050 Install new bearing cup in gear/can weldment. Press the second bearing cup into the weldment. IMPORTANT: DO NOT overpress cup against the snap ring.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 206 STEP 208 1 RD05K080 RD05K082 Using an appropriate tool, press bearing onto the shaft. Set Bearing Preload As Follows: 1. Attach a spring scale to one of the holes in the gear/can weldment (1). IMPORTANT: Do not press on the bearing cage. 2. As the bearing is being pressed onto the shaft, rotate the weldment until a rolling torque of 2.1 to 3.2 Nm (18 to 28 lb. inch) is obtained.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 211 STEP 213 RD05K083 RD05K062 Support the gear (1) as shown. Backseat the bearing against the retainer ring. DO NOT over press. Install the retainer ring. IMPORTANT: Over pressing the bearing may distort the retainer ring which may cause improper shaft end play. Improper end play may cause premature bearing failure. STEP 214 1 STEP 212 RD05K064 Install a backing plate. Make sure the larger cutout (1) is facing the retainer ring.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 216 STEP 218 1 2 Rd05K059 Measure the distance between the top of the hub (1) and the top of the piston (2). Rd04K066 Install a separator plate. Continue until the six friction and six separator plates are installed. If dimension is greater than 29.0 MM, use one spring spacer. STEP 217 If dimension is greater than 30.5 MM use two spring spacers. If dimension is less than 29.0 MM, DO NOT use spring spacer.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 220 STEP 223 1 2 3 RD05K087 RD05K029 Place the 5 inch long piece of PVC pipe (1) over the shaft (2). Make sure the pipe is centered at the bottom of the gear/can weldment (3). Lubricate a new seal with petroleum jelly and install. Use care not to overstretch the seal. STEP 224 STEP 221 2 1 RD05K058 Lubr i cate a new O- r i ng (1) and seal (2) with petroleum jelly and install in the piston seal grove (3).
Section 21 - Transmission, Drivelines - Chapter 6 STEP 226 STEP 229 1 2 3 RD05K088 RD05K025 Place the FWD hub (1) over the shaft (2) and set on the PVC pipe (3). Install a separator plate. Alternate separator and friction plates until there are six separator and six friction plates for the ten-bolt FWD axle and seven separator plates and seven friction plates for the heavy-duty twelve-bolt FWD axle. NOTE: Do not install shaft seals at this time.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 231 STEP 233 2 1 1 2 RD05K060 RD05K022 Measure the distance between the top of the hub flange (1) and the top of the piston (2). Place the spring spacer(s) (if required), locking ring (1) and retaining ring (2) over the shaft. If dimension is greater than 29.7 MM, use one spring spacer. STEP 234 If dimension is greater than 31.2 MM, use two spring spacers. If dimension is less than 29.7 MM, DO NOT use spring spacer.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 235 STEP 237 1 1 2 3 RD05K093 R e m ove t h e F W D c l u t c h a s s e m bl y f r o m t h e weldment. Place the 2 inch long piece of PVC pipe (1) over the shaft (2). Make sure the pipe is centered at the bottom of the gear/can weldment (3). NOTE: A strap may be placed over the end of the shaft (1) to aid in removal.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 240 STEP 243 RD05M020 RD05K096 Install a friction plate. Hand press the piston onto the hub to “size” the seal rings. Remove the piston and set aside. STEP 244 STEP 241 RD05K097 Install a separator plate. Alternate separator and friction plates until all six separator and six friction plates are installed. RD05K094 Place the hub (upside down from normal installation) over the shaft.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 245 STEP 247 RD05K098 RD05K0101 Install the piston. Place the spacer(s) (if required) and retainer ring on top of the Belleville springs. IMPORTANT: Use care when installing the piston to prevent damage to the piston and hub seals. IMPORTANT: Belleville springs must be aligned and centered so that they do not catch on the shaft when they are compressed.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 249 STEP 251 1 1 2 RD05K103 RD05K104 Turn the weldment (1) over. Lift the weldment and remove the park brake hub assembly (2) and PVC spacer (not shown). Properly support the park brake hub assembly as shown and lower into the weldment. Take care not to damage the friction plate tabs (1). STEP 250 STEP 252 1 RD05K107 RD05K073 Continue to lower the hub until it is fully seated into the weldment.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 254 STEP 257 2 1 RD05K020 RD05K033 Lubricate with petroleum jelly and install three new shaft seals. Make sure that the jumper tube supply hole (1) is not covered by the shield. Install the allen head bolts (2). Repeat for the opposite side. STEP 255 STEP 258 RD05K021 Properly suppor t the FWD clutch assembly and carefully lower into the weldment. Take care not to damage the friction plate tabs and shaft seals.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 259 STEP 261 RD05K017 A22327 Continue to lower the assembly into the housing until it is seated in the bore. Install the FWD lube tube at the shaft end and to fitting in top of range casting. NOTE: Make sure that the alignment pin located at the end of the output shaft mounting flange is aligned with the alignment hole as shown in the following step.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 263 STEP 264 1 1 2 RD05K011 RD05K012 1. Install the emergency brake release supply fittings (1). 1. Install the FWD fitting (1). DO NOT install the FWD supply tube (2) at this time. 2. Attach a portable hydraulic hand pump to the fitting and pressurize to 350 PSI (2413 kPa). Brake should be released and pressure should hold at or near the original pressurization.
Section 21 - Transmission, Drivelines - Chapter 6 Exploded View of the Range Transmission Countershaft, Input Shaft, and FWD Input Shaft 3 2 1 4 5 6 8 9 7 10 11 12 14 13 15 17 16 29L94R 1. 2. 3. 4. 5. 6. SHIMS FRONT BEARING CUP INPUT SHAFT BEARING CAGE HYDRAULIC PUMP DRIVE GEAR ROLLER BEARING COUNTERSHAFT BEARING CAGE 7. 8. 9. 10. 11. 12. FRONT BEARING CUP SHIM FRONT BEARING SUPPORT COVER COVER RANGE TRANSMISSION HOUSING BEVEL PINION CONSTANT MESH GEAR 21-6-66 13. 14. 15. 16. 17.
Section 21 - Transmission, Drivelines - Chapter 6 Installing the Range Transmission Countershaft, Input Shaft, and FWD Input Shaft into the Range Transmission Housing STEP 265 STEP 267 T95671 T95673 Drive the bearing cage for the bevel pinion shaft out of the range transmission housing, if required. Drive a new bearing cage into the bore. The bearing cage must be centered in the bore. Drive new bearing cups into the bores until the cups are seated against the housing shoulder.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 269 STEP 271 41S19 T95883R Press a new cup into the bore of the input shaft bearing cage until the cup seats against the cage shoulder. Install a snap ring pliers through the opening in the hydraulic pump drive gear which is installed on top of the range transmission countershaft bearing cage. Move the snap ring out of the groove that is in the bearing cage. STEP 270 STEP 272 40S13 Install a new seal ring on the input shaft bearing cage.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 274 STEP 277 T95886R T95889 Press a new bearing cup into the bearing cage until the bearing seats against the cage shoulder. Install a new seal ring inside the gear. STEP 278 STEP 275 T95890 Remove the snap ring from inside the hydraulic pump drive gear. Install the gear retaining snap ring inside the gear and over the hub. The flat side of the snap ring must be facing down.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 280 STEP 282 T95883R Reach through the opening in the gear and install the snap ring into the groove in the bearing cage. T95887 Install the bearing snap ring. NOTE: Make sure that the alignment pin located at the end of the output shaft mounting flange is aligned with the alignment hole as shown in the following step. STEP 281 T95884R Install the gear on the countershaft bearing cage.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 283 STEP 286 A22319 16S21 Tilt the range input shaft over to the side and install the range transmission countershaft. Place the original shims over the end of the range transmission countershaft. STEP 284 STEP 287 16S27 16S17 Apply petroleum jelly to the seal r ings on the countershaft low range driven gear. Install the front bearing support cover. Tap the support cover down over the dowel pins in the range housing.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 289 16S9 Install the range input shaft front bearing cage. Install the mounting bolts to a torque of 54 to 61 Nm (40 to 45 lb. ft.).
Section 21 - Transmission, Drivelines - Chapter 6 SETTING THE END PLAY OF THE RANGE TRANSMISSION COUNTERSHAFT AND INPUT SHAFT STEP 290 STEP 291 The end play of each shaft must be checked if any of the following parts were replaced: shaft, front bearing cage, bearing cones and cups, or front bearing support cover. 1 16S1 Install the snap ring on the input shaft that positions the master clutch. STEP 292 T95894 2 15S33 T95893 Install the lubrication tube to the input shaft bearing cage.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 293 STEP 294 14S25 15S30 Install a new O-ring onto the transmission speed sensor and install the sensor into the top of the range housing. Apply petroleum jelly to the seal ring on the input shaft front bearing cage. Align the master clutch fill hole with the range transmission input shaft fill hole. Align the marks made before removal in Step 8. Install the master clutch on the range transmission input shaft.
Section 21 - Transmission, Drivelines - Chapter 6 Installing the Range Input Master Clutch STEP 295 STEP 297 A22306 15S24 Install the snap ring that fastens the master clutch assembly to the input shaft. Align the clutch to the input shaft according to the mark made in Step 8. Install new seal on the outside of the hub. Lubricate the seal ring with petroleum jelly. Install the hub assembly onto the master clutch carrier.
Section 21 - Transmission, Drivelines - Chapter 6 STEP 299 STEP 302 A22305CR 12S15 Install a new friction plate into the master clutch. Install the remaining eight separator plates and eight friction plates, alternating the plates. Install new O-ring on the feeder tubes and lubricate with petroleum jelly. Install the feeder tubes. STEP 303 NOTE: Dip all friction plates in clean transmission fluid before installation.
Section 21 Chapter 7 TRANSMISSION CONTROL VALVES AND INCHING VALVE January, 2006
Section 21 - Transmission, Drivelines - Chapter 7 TABLE OF CONTENTS SPECIAL TORQUES ...................................................................................................................................... 21-7-3 POWERSHIFT TRANSMISSION CONTROL VALVES .................................................................................. 21-7-3 TRANSMISSION CONTROL VALVE CONFIGURATION .............................................................................. 21-7-4 INCHING VALVE ...............
Section 21 - Transmission, Drivelines - Chapter 7 SPECIAL TORQUES Transmission Control Valves Plug, M18 ................................................................................................................... 19 to 25 Nm (14 to 18 lb. ft.) Plug, M27 ................................................................................................................... 34 to 54 Nm (25 to 40 lb. ft.) Pressure Sensor .......................................................................................
Section 21 - Transmission, Drivelines - Chapter 7 TRANSMISSION CONTROL VALVE CONFIGURATION This chart matches transmission valve configuration with tractor options controlled by those valves (Figures 1 through 6).
Section 21 - Transmission, Drivelines - Chapter 7 Figure 1 - Transmission Control Valve with Four Solenoids ● Speed control valve for all tractor configurations. This type of control valve is used with thes e transmission configurations: 8 6 1 7 2 5 3 4 RI02E100 1. VALVE BODY 5. COVER PLATE 2. PWM SOLENOID 6. PLUG 3. O-RINGS 7. MOUNTING BOLT 4. GASKET 8.
Section 21 - Transmission, Drivelines - Chapter 7 Figure 2 - Transmission Control Valve with Four Solenoids ● Range control valve with FWD. This type of control valve is us ed with thes e transmission configurations: ● Odd - Even control valve with NA park and creep. 6 1 3 7 10 9 5 3 4 2 RI02E099 1. VALVE BODY 6. PLUG 2. PWM SOLENOID 7. MOUNTING BOLT 3. O-RINGS 8. SOLENOID 4. GASKET 9. SOLENOID CARTRIDGE 5.
Section 21 - Transmission, Drivelines - Chapter 7 Figure 3 - Transmission Control Valve with Three Solenoids and Plug ● Range control valve without FWD. This type of control valve is used with thes e transmission configurations: 6 1 7 3 6 5 3 4 2 RI02E096 1. VALVE BODY 5. COVER PLATE 2. PWM SOLENOID 6. PLUG 3. O-RINGS 7. MOUNTING BOLT 4.
Section 21 - Transmission, Drivelines - Chapter 7 Figure 4 - Transmission Control Valve with Three Solenoids and Plug ● Odd-even control valve with NA park without creep. This type of control valve is us ed with thes e transmission configurations: 6 1 3 7 9 8 6 5 3 4 2 RI02E097 1. VALVE BODY 6. PLUG 2. PWM SOLENOID 7. MOUNTING BOLT 3. O-RINGS 8. SOLENOID 4. GASKET 9. SOLENOID CARTRIDG 5.
Section 21 - Transmission, Drivelines - Chapter 7 Figure 5 - Transmission Control Valve with Two Solenoids, Check Valve and Plug ● Odd-even control valve with Euro park without creep. T h i s t y p e o f c o n t r o l va l ve i s u s e d w i t h t h i s transmission configuration: 6 7 1 9 3 8 5 6 3 4 2 RI02E095 1. VALVE BODY 6. PLUG 2. PWM SOLENOID 7. MOUNTING BOLT 3. O-RINGS 8. CHECK VALVE 4. GASKET 9. BALL 5.
Section 21 - Transmission, Drivelines - Chapter 7 Figure 6 - Transmission Control Valve with Three Solenoids and Check Valve ● Odd-even control valve with Euro park with creep. T h i s t y p e o f c o n t r o l va l ve i s u s e d w i t h t h i s transmission configuration: 6 7 1 9 3 8 6 5 3 1 2 RI02E098 1. VALVE BODY 6. PLUG 2. PWM SOLENOID 7. MOUNTING BOLT 3. O-RINGS 8. CHECK VALVE 4. GASKET 9. BALL 5.
Section 21 - Transmission, Drivelines - Chapter 7 Valve Removal 3. Remove the valve retaining bolts, valve body, and gasket. Discard the gasket. NOTE: Before removing any components, thoroughly clean the valve body and the area on the transmission housing adjacent to the valve body to eliminate any contamination. STEP 3 STEP 1 3 2 2 3 1 4 1 RD02E275 Remove the odd-even transmission control valve as follows: RI02E0887 1. SPEED TRANSMISSION CONTROL VALVE 2. ODD-EVEN TRANSMISSION CONTROL VALVE 3.
Section 21 - Transmission, Drivelines - Chapter 7 Disassembly STEP 7 NOTE: Disassembly of range valve shown. Other valves are similar. NOTE: Only the speed control valve is equipped with a pressure sensor. See Figure 1 - Transmission Control Valve with Four Solenoids for pressure sensor location. STEP 5 RD02E223 Remove the solenoid cover plate. Remove the solenoid assembly and discard the O-rings. STEP 8 Repeat for the remaining solenoids. RD02E221 Place the valve on a clean surface.
Section 21 - Transmission, Drivelines - Chapter 7 Assembly STEP 10 NOTE: Disassembly of range valve shown. Other valves are similar. NOTE: Only the speed control valve is equipped with a pressure sensor. See Figure 1 - Transmission Control Valve with Four Solenoids for pressure sensor location. STEP 9 RD02E222 Install new O-rings on the car tridge. Install the cartridge into the valve body. Tighten to a torque of 19 to 25 Nm (14 to 18 lb. ft.).
Section 21 - Transmission, Drivelines - Chapter 7 Valve Installation STEP 11 1 STEP 13 2 1 2 3 RD02E274 RD02E276 Install the range transmission control valve as follows: Install the speed transmission valve as follows: 1. Install a new gasket and the valve. 1. Install a new gasket and the valve. 2. Tighten the M8 socket head mounting bolts to a torque of 27 to 32 Nm (20 to 24 lb. ft.). 2. Tighten the M8 socket head mounting bolt (3) to a torque of 27 to 32 Nm (20 to 24 lb. ft.). 3.
Section 21 - Transmission, Drivelines - Chapter 7 INCHING VALVE Removal STEP 14 STEP 15 1 2 2 1 3 RI02E086 RD02E274 The inching valve (1) is located under the range transmission valve (2). Raise or remove the cab for access to the valves See the Cab Raise/Removal and Installation section of this manual. Remove the inching valve as follows: 1. Tag and remove the regulated supply tube (1). 2. Tag and disconnect the wire harness from the range valve solenoids(2). 3.
Section 21 - Transmission, Drivelines - Chapter 7 Disassembly STEP 16 STEP 18 56-34 57-10 Place the inching valve on a clean work surface. Remove plug. Remove solenoid cartridge. NOTE: The solenoid cartridge is not designed to be disassembled. STEP 17 STEP 19 57-6 Remove nut, two O-rings and coil from the solenoid assembly. 57-13 Remove plug.
Section 21 - Transmission, Drivelines - Chapter 7 STEP 20 STEP 21 57-19 54-33 Remove the plug. Remove the plug, spring and modulator spool assembly. NOTE: Parts of the modulator spool assembly are not serviced separately.
Section 21 - Transmission, Drivelines - Chapter 7 Assembly 8 9 36 7 20 28 9 21 2 6 3 29 24 11 12 22 25 13 26 27 1 5 23 35 4 RT98C002 1. VALVE BODY 9. O-RING 24. SLEEVE 2. M18 PLUG 11. O-RING 25. BALL 3. O-RING 12. O-RING 26. SPRING 4. M27 PLUG 13. O-RING 27. SPRING 5. O-RING 20. M14 PLUG 28. M14 PLUG 6. CARTRIDGE 21. O-RING 29. O-RING 7. COIL 22. SPOOL 35. GASKET 8. NUT 23. MODULATOR PISTON 36.
Section 21 - Transmission, Drivelines - Chapter 7 STEP 22 STEP 25 54-33 57-19 Install the inching modulator spool assembly and spring. Install a new O-ring on plug. Install plug in valve body and tighten to a torque of 34 to 54 Nm (25 to 40 lb. ft.). STEP 23 STEP 26 57-25 57-16 Install a new O-ring on plug. Install plug. Tighten the plug to a torque of 34 to 54 Nm (25 to 40 lb. ft.). Install a new O-ring on plug. Install plug in valve body and tighten to a torque of 34 to 54 Nm (25 to 40 lb. ft.
Section 21 - Transmission, Drivelines - Chapter 7 Installation STEP 28 STEP 31 1 2 3 57-10 Install the solenoid cartridge and tighten to a torque to 12 to 18 Nm (9 to 13 lb. ft.). RD02E274 Install the inching valve and range transmission control valve as follows: STEP 29 1. Install a new inching valve gasket on top of the range transmission. Install the inching valve and four retaining bolts. Tighten the bolts to a torque of 50 to 60 Nm (37 to 44 lb. ft.). 2.
Section 21 - Transmission, Drivelines - Chapter 7 Inching Valve Cross Section 2 1 3 4 5 6 12 7 11 10 8 9 302171AA.WMF 1. 2. 3. 4. 5. 6. VALVE BODY PLUG SOLENOID INCHING SPOOL BALL RETAINING SLEEVE 7. 8. 9. 10. 11. 12.
Section 21 - Transmission, Drivelines - Chapter 7 This Page Left Blank.
Section 21 Chapter 8 REAR FRAME January, 2006
Section 21 - Transmission, Drivelines - Chapter 8 TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................... 21-8-3 SPECIAL TORQUES ...................................................................................................................................... 21-8-3 SPECIAL TOOLS ..............................................................................................................
Template Name: OML_2_col Template Date: 2001_03_06 Rac 0-00000 Section 21 - Transmission, Drivelines - Chapter 8 SPECIFICATIONS Differential Bearing Retainer Seal Recess ..................................................................................0.8 mm (0.031 inch) Differential Bearing Rolling Torque (New)..................................................................4.5 to 7.9 Nm (40 to 70 lb. inch) Differential Bearing Rolling Torque (Used) .....................................................
Section 21 - Transmission, Drivelines - Chapter 8 DIFFERENTIAL Removal 5. Remote valve return line. 6. Regulated supply to PTO valve. STEP 1 7. Difflock supply tube. Prepare to remove the differential as follows: STEP 6 1. Start the tractor and lower the hitch. Disconnect the hydraulic lines to the hitch lift cylinders. 2. Turn the tractor OFF and remove the key. STEP 2 Remove the cab (refer to Cab Removal in this manual).
Section 21 - Transmission, Drivelines - Chapter 8 STEP 9 STEP 11 26s27b 76-6a While supporting the vertical lifting link, drive out the hitch swivel pin with a suitable tool. Repeat Steps 9 through 11 for the other vertical lifting link. Remove the bolt and locking flag plate in the upper end of the hitch lift cylinder (both sides). STEP 12 NOTE: Be prepared for the sudden drop in the vertical lifting link as the pin is driven out. STEP 10 35-24 Secure the rockshaft assembly as follows: 1.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 13 STEP 15 36s21b 36s34b Remove the two bolts that attach the rockshaft sensor shield to the hitch support C-bracket. Remove pin and free the upper end of the hitch lift cylinder. NOTE: Be sure to remove hitch position sensor (potentiometer) prior to removing the hitch lift cylinders. If the cylinders are removed first, there may be excessive travel of the rockshaft, which would damage the sensor.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 18 STEP 21 36s4 35-21 Remove the position sensor bracket. Use a long piece of wood to reach through the rockshaft and contact the rocker pin. Tap the piece of wood to dislodge the rockshaft pin. Use care not to damage the seal or bushing. STEP 19 STEP 22 36s1 Remove the split ring washer. Remove the tie rod through the opposite end from which the washer and retainer were removed.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 23 STEP 26 35-14 T98138 When both rockshaft pins are removed, lift and set aside the rockshaft casting. Remove the differential lock supply line from the differential. NOTE: Keep bearings and seals free of foreign material. STEP 27 STEP 24 69RS13 Remove the rear frame cover and the PTO clutch assembly. (Refer to PTO Assembly, Single and Dual Speeds in this manual).
Section 21 - Transmission, Drivelines - Chapter 8 STEP 29 STEP 32 T98214A T98187 Install the differential lifting tool, CAS-1952, on the differential. Connect a hoist to the differential lifting tool and put tension on the hoist chain or strap. Remove the RH bearing retainer from the housing. STEP 33 STEP 30 T98200 Remove the right-hand bearing retainer shims from the housing and tag for location. T98194 Remove the left-hand bearing retainer from the rear frame.
Section 21 - Transmission, Drivelines - Chapter 8 Disassembly STEP 38 STEP 35 T98151 Remove the differential lock separator and friction plates from the housing. t98146 Remove and discard the 12 ring gear mounting bolts. Remove the ring gear. Remove the differential housing seal rings. STEP 39 NOTE: Attach the differential case to the cover using a nut and bolt. Carefully turn the assembly over. Remove the nut and bolt.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 41 STEP 44 RD98C189 T98160 Remove the piston from the housing. Remove each short pinion shaft from the housing. STEP 42 STEP 45 T98155 T98161 Remove the short pinion shaft retaining bolts from the housing. Remove the short spacers from the housing. STEP 46 STEP 43 T98162 Remove the shor t shaft pinion gears from the housing. Remove the thrust ring and needle bearings from both short shaft pinion gears.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 47 STEP 50 T98163 T98166 Remove the thrust washers from the housing. Remove the long pinion shaft gears from the housing. Remove the thrust ring and needle bearings from both long shaft pinion gears. STEP 48 STEP 51 T98164 Remove the long shaft from the housing. T98167 Remove the thrust washers from the housing. STEP 49 STEP 52 T98165 Remove the long spacer from the housing. T98168 Remove the bevel side gear from the housing.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 53 STEP 56 88-19A T98205 Remove the thrust washer from the housing. Remove the oil seal from each bearing retainer. STEP 54 STEP 57 RD98C192 T98183 Remove the seal ring and the bearing cone from the right hand bearing retainer. Remove the bearing cup from the housing. STEP 55 STEP 58 T98171 T98174 Remove the bearing cup from the differential cover. Remove the seal ring and the bearing cone from the left hand bearing retainer.
Section 21 - Transmission, Drivelines - Chapter 8 PINION SHAFT Removal and Disassembly STEP 62 STEP 59 If required, split the rear frame and range transmission (refer to Range Transmission to Differential Split in this manual) before servicing the pinion shaft. STEP 60 T95913 Remove the shims from the bearing cage. Use a micrometer to measure all the shims and record the shim pack size. STEP 63 T95910 Remove the pinion shaft bearing cage mounting bolts.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 65 STEP 68 T95935 T95925 Press the pinion shaft and bearings out of the bearing cage. Remove the inner snap ring from the bearing cage. STEP 69 NOTE: Make sure that the rear bearing (against the gear) will clear the press. STEP 66 T95923 Remove the rear bearing cup from the bearing cage. STEP 70 T95917 Press the bearing cone from the pinion shaft. STEP 67 T95919 Be sure the hole in the button of the pinion shaft is open.
Section 21 - Transmission, Drivelines - Chapter 8 Assembly and Installation 8 7 6 1 5 4 3 9* 10* 2 12 11* 13 14 238I7 1. 2. 3. 4. 5. 6. 7. RING GEAR PINION SHAFT CUP PLUG WITH HOLE BEARING CONE BEARING CUP SNAP RING SHIM 8. 9. 10. 11. 12. 13. 14. BEARING CAGE SNAP RING* SPACER* CONSTANT MESH GEAR* SHIM RING BEARING CONE BEARING CUP NOTE: All parts marked with * remain in the range transmission.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 71 STEP 74 t95924 88-33A Press the rear bearing cup into the bearing cage until seated. Press the bearing cone on the pinion shaft until seated against the gear. STEP 72 STEP 75 T95925 T95928 Install the rear snap ring in the bearing cage groove. Install the bearing cage over the shaft and bearing. STEP 73 STEP 76 T95922 T95929 Press the front bearing cup into the bearing cage until seated against the snap ring.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 77 STEP 79 T95923 T95935 Measure the distance from the bearing cone to the front of the snap ring groove using feeler gauges. Backseat the front bearing on the snap ring with 10,000 to 15,000 lb. of force. Check the end play again. The end play must be from 0.013 to 0.102 mm (0.0005 to 0.004 inch). If the end play is incorrect, install the correct size snap ring (larger or smaller) to obtain the correct end play.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 80 How To Determine Ram Pressure Do the following to determine what the pressure gauge must show for your ram: 1. Determine the effective area of your ram. 2. Determine the minimum and maximum pressure gauge readings desired. EXAMPLE: Find the effective area of twin rams, each ram having a piston diameter of 1.5 inch. The formula for the effective area is: Effective area = (d2 + d2) x 0.7854 d = diameter of each ram (1.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 81 STEP 82 T95912 T98212 Install the pinion shaft assembly without any shims. Install and tighten retaining bolts to a torque of 102 to 113 Nm (75 to 83 lb. ft.). Install the pinion shaft depth setting tool CAS1902-1 into the differential bearing retainer bores so the bar is centered on the pinion shaft.
Section 21 - Transmission, Drivelines - Chapter 8 Differential Assembly 1. 2. 3. 4. 7. 8. 10. SHIM HOUSING PIN RING GEAR GEAR THRUST WASHER 11. 12. 13. 14. 15. 19. 20. THRUST WASHER WASHER SHAFT SHAFT BOLT SPACER SPACER 21. 22. 23. 25. 29. 30. 31. NEEDLE BEARING RING CONE BEARING CUP BEARING COVER WASHER BOLT 21-8-21 32. 33. 34. 35. 36. 40. 41. CONE BEARING CUP BEARING RETAINER PIN SEAL RING RETAINER 43. 44. 45. 46. 50. PIN SEAL RING BOLT PISTON 55. 56. 57. 58.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 83 STEP 85 T98202 T95913 Determine dimension as follows: Select the correct shim pack, determined in Step 83, within 0.03 mm (0.001 inch). Install the shims over the alignment dowels. 1. Apply 50 to 100 lbs forward loading on the pinion shaft to remove all bearing end play. 2. Measure from the face of the pinion shaft to the face of the depth setting tool bar in millimeters. This is your measured dimension. STEP 86 3.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 87 STEP 88 T95912 T95911 Place the pinion shaft assembly on the housing. Install the pinion shaft assembly mounting bolts. Apply a torque of 101.7 to 112.5 Nm (75 to 83 lb ft) to each bolt.
Section 21 - Transmission, Drivelines - Chapter 8 DIFFERENTIAL ASSEMBLY STEP 89 STEP 91 rd98c191 T98206 Install the bearing cones on both the right-hand (RH) and left-hand (LH) bearing retainer until seated against the shoulder of the retainer. 1 STEP 90 397L7 Install the oil seals into the bearing retainers. The rubber lip faces the outside of the retainer. The seal must be recessed below the retainer face (1) 0.8 mm (0.032 inch). RR98C045 Install the seal rings on both the RH and LH retainer.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 93 STEP 96 T98209 T98168 Install a new O-ring lubricated with petroleum jelly on the differential lock supply tube. Install the standard side gear in the housing so the gear teeth face away from the thrust washer. STEP 94 STEP 97 1 1 2 2 88-22A T98167 Install the bearing cup into the housing until seated against the housing. Apply petroleum jelly to the four thrust washers.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 99 STEP 102 T98207 T98164 Install the needle bearing spacers in the gears on top of the needle bearings. Install the long pinion shaft into the housing bore without locking bolts holes and through the long spacer. STEP 100 STEP 103 T98166 Install the two pinion gears for the long shaft into the housing against the thrust washers.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 105 STEP 108 T98161 RD98C189 Install the short spacers into the housing so the smaller diameter ends face the long shaft. Install the differential lock piston in the housing. STEP 109 STEP 106 T98154 Install the six dowel pins into the housing. T98160 Install the two short pinion shafts (small end first) into the housing bores, through the short spacers and into the hole in the long spacer and long pinion shaft.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 111 STEP 114 T98151 T98172 Install one separator plate in the housing so it locks on the dowel pins. Install the bearing cup into the differential cover until seated against the cover. STEP 112 STEP 115 T98152 88-28A Install one friction plate in the housing so it will mesh with the locking side gear. Apply grease to the larger thrust washer and install the washer on the cover so the tabs enter the cover cavities.
Section 21 - Transmission, Drivelines - Chapter 8 DIFFERENTIAL INSTALLATION STEP 116 STEP 118 T98149 T98146 Place the ring gear on the differential housing. Install 12 new ring gear bolts and torque to 310 Nm (230 lb. ft.). STEP 119 T98182 Install the differential cover on the housing. T98204 STEP 117 Install the differential lifting tool onto the differential. STEP 120 T98147 Install the seal rings on the housing. Make sure the ends of the rings are locked together.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 121 STEP 123 T98192 T98193 Install two aligning dowels in each bearing retainer mounting surface of the rear frame. Install bearing retainers as follows: 1. Align the lube passage on the rear frame housing with the lube passage in the bearing retainer (shown). STEP 122 2. Install the bearing retainers on the rear frame housing. 3. Gradually and evenly torque the retainer mounting bolts to 235 to 260 Nm (173 to 192 lb. ft.).
Section 21 - Transmission, Drivelines - Chapter 8 STEP 126 STEP 128 35-18 36s1 The rockshaft pins must be clean and free of oil, grease, antiseize compound, etc. Orient pin with bearing surface outboard. Insert a rockshaft pin. Use a wooden block to tap the pin until it is seated in place. Insert the other rockshaft pin. Install the tie rod as follows: 1. Place one washer and retainer in place on the end tie rod with the nut. 2.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 130 STEP 132 36s8 36s17 Install the nut that attaches the position locator bracket to the end of the tie rod. Tighten to a torque of 490 to 555 Nm (362 to 410 lb. ft.). The nut on the opposite end of the tie rod will need to be held with a wrench to achieve torque. Install the nut for the rockshaft sensor link assembly. Torque to 18 to 23 Nm (14 to 17 lb ft). STEP 133 STEP 131 36s28b Install the hitch lift cylinder as follows: 1.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 134 STEP 136 36s34b 27s12b Insert the top cylinder pin as follows: Connect the hydraulic lines to the top and bottom of the hitch cylinder. Repeat for the other hitch lift cylinder. 1. Pin must be clean and free of oil, grease, antiseize. 2. Adjust the vertical position of the rockshaft, if necessary to align holes in cylinder rod and rockshaft. STEP 137 3. Insert the top cylinder pin through the holes (groove to inside).
Section 21 - Transmission, Drivelines - Chapter 8 STEP 138 STEP 141 26s24b 91s16 Insert the slotted end of a locking flag plate into the groove on the inside of the hitch swivel pin. Install and tighten the rear frame drain plug in the housing. STEP 139 STEP 142 Install the drawbar on the tractor and secure with the pin. Torque the pivot pin retaining bolt to 125 to 150 Nm (93 to 112 lb ft). Refer to Tractor Hitch in this manual for details. STEP 143 Install the brake cylinders onto the tractor.
Section 21 - Transmission, Drivelines - Chapter 8 ADJUSTING THE DIFFERENTIAL PRELOAD STEP 151 NOTE: When the differential bearings or housing are replaced, the bearing preload must be adjusted. STEP 149 T98143 Tighten the three retainer mounting bolts to a torque of 235 to 260 Nm (173 to 192 lb ft). t98201 STEP 152 Install the differential assembly into the rear frame without the ring gear when the pinion assembly is in place or with the ring gear when the pinion assembly is removed.
Section 21 - Transmission, Drivelines - Chapter 8 STEP 153 STEP 155 T98144 T98198 Tighten the three bearing retainer bolts while rotating the differential to seat the bearings. Torque the bolts equally and evenly in steps of 2.8 Nm (25 lb inch) steps, until 11 Nm (100 lb inch) of torque is reached on each bolt. Use a depth micrometer to measure from the RH bearing retainer face to the rear frame through the three equally spaced holes. Average the three measurements and record the dimension.
Section 21 - Transmission, Drivelines - Chapter 8 ADJUSTING THE RING AND PINION BACKLASH STEP 156 3. The rolling torque of the differential must be 4.5 to 8.0 Nm (40 to 70 lb inch) for new bearings and 2 to 4 Nm (20 to 35 lb inch) for old bearings (used for more than 200 hours). The desired settings are in the upper half of the ranges. 4. To increase the rolling torque, remove approximately 0.05 mm (0.002 inch) of shim material from the right-hand bearing retainer. 5.
Section 21 - Transmission, Drivelines - Chapter 8 BEVEL PINION AND GEAR TOOTH CONTACT CHECK STEP 161 STEP 160 Put Prussian Blue or red lead onto the convex side of the gear teeth. Turn the pinion several revolutions in the forward (clockwise) direction, while applying a braking force on the gear, to determine the contact pattern. See the contact patterns in the following illustrations. NOTE: The contact pattern of the gear teeth that are shown are approximate shapes.
Section 21 - Transmission, Drivelines - Chapter 8 247L0 Pattern B The pinion is in too far. Add approximately 0.10 mm (0.005 inch) of shim material under the pinion bearing cage. Adjust the backlash to specifications. See Step 159 before checking contact pattern again. 1 2 4 3 244L0 1. RING/BEVEL GEAR 2. BEVEL PINION IN TO CORRECT PATTERN A 3. BEVEL GEAR 4.
Section 21 - Transmission, Drivelines - Chapter 8 3 2 1 4 RH98C093 1. DIFFERENTIAL LOCK ASSEMBLY 2. RING GEAR 21-8-40 3. DRIVE PINION SHAFT 4.
Section 21 Chapter 9 HYDRAULIC PUMP DRIVE January, 2006
Section 21 - Transmission, Drivelines - Chapter 9 TABLE OF CONTENTS SPECIAL TORQUES ...................................................................................................................................... 21-9-3 SPECIFICATIONS .......................................................................................................................................... 21-9-3 PUMP DRIVE .................................................................................................................
Section 21 - Transmission, Drivelines - Chapter 9 SPECIAL TORQUES Bearing Cage Bolt .......................................................................................................... 55 to 60 Nm (41 to 44 lb. ft.) Hydraulic Drive Pump Assembly Mounting Bolts............................................................ 52 to 61 Nm (38 to 45 lb. ft.) SPECIFICATIONS Driven Gear Shaft End Play.............................................................................0.026 to 0.1 mm (0.001 to 0.
Section 21 - Transmission, Drivelines - Chapter 9 Disassembly STEP 5 STEP 8 RP98B083 RP98B049 Remove the bearing cage from the pump drive housing. Mark the gear positions and remove the drive gear assembly from the pump drive housing. STEP 6 STEP 9 RP98B053 T94753 Remove the bearing cup from the bearing cage. Remove the idler gear bolt and washer from the pump drive housing. STEP 7 STEP 10 RP98B048 Remove the shims from the pump drive housing.
Section 21 - Transmission, Drivelines - Chapter 9 STEP 11 STEP 14 T94752 T94749 Remove the idler gear shaft from the pump drive housing. Remove the spacer from the idler gear. STEP 15 STEP 12 T94748 Press the other bearing from the idler gear. Discard the bearing. T94751 Remove the idler gear assembly from the pump drive housing. STEP 16 STEP 13 T94747 Remove the two snap rings from the idler gear. T94750 Drive one of the bearings from the idler gear. Discard the bearing.
Section 21 - Transmission, Drivelines - Chapter 9 STEP 17 RP98B051 Remove the front and rear bearing cone from the driven gear shaft using a bearing puller or a press and collet.
Section 21 - Transmission, Drivelines - Chapter 9 Assembly 3 5 6 5 4 3 2 12 11 1 7 10 8 9 8 7 SCRH98A5 1. 2. 3. 4. 5. 6. PUMP DRIVE HOUSING IDLER SHAFT BEARING SPACER RETAINING RING IDLER GEAR 7. 8. 9. 10. 11. 12.
Section 21 - Transmission, Drivelines - Chapter 9 STEP 18 STEP 21 RP98B051 T94749 Press the front and rear bearing cones on the drive gear shaft until the bearing cones are flush with the shaft shoulder. Install the spacer on top of the bearing in the idler gear. Install a new spacer if damaged or worn. STEP 22 STEP 19 T94750 Press the other new bearing into the idler gear until it rests solidly against the snap ring. T94747 Install the two snap rings into the grooves of the idler gear.
Section 21 - Transmission, Drivelines - Chapter 9 STEP 24 STEP 27 T94752 RR98C026 Install the idler gear shaft through the pump drive housing and the idler gear. Install the bearing cage as follows: 1. Install the bearing cage on the pump drive housing without shims or O-rings. STEP 25 2. Install two opposite bolts, rotate the shaft, and alternately, in two increments, tighten the bearing cage bolts to a torque of 3.4 Nm (30 lb. in.). 3.
Section 21 - Transmission, Drivelines - Chapter 9 STEP 29 STEP 32 RP98B083 RP98B083 Remove the bearing cage from the pump drive housing. Install the bearing cage on the pump drive housing. STEP 33 STEP 30 RR98B005 Tighten the bearing cage bolts to a torque of 55 to 60 Nm (41 to 44 lb. ft.). RP08B052 Lubricate a new O-ring with petroleum jelly. Install the O-ring on the bearing cage.
Section 21 - Transmission, Drivelines - Chapter 9 STEP 34 RR98B004 If necessary, adjust shim pack to obtain correct end play as follows: 1. Rotate and push down the drive gear shaft. 2. Install a dial indicator on the bearing cage and indicate to the end of the drive gear shaft. 3. Set the dial face to zero. 4. Move the drive gear shaft in and out of the housing as you observe the dial indicator. End play must be 0.025 to 0.1 mm (0.001 to 0.004 inch).
Section 21 - Transmission, Drivelines - Chapter 9 Installation STEP 35 STEP 38 4 1 3 2 RD02D029 RD02D002 Apply a continuous bead of Loctite® 515 Sealant, 4.76 mm (3/16 inch) wide to the mounting surface of the pump drive housing and around the bolt holes. With the hydraulic pump drive (1) installed on the transmission, install the hydraulic PFC pump (2) and the transmission filter and base (3). Refer to the PFC Piston Pump and Hydraulic Filter section in this manual.
Section 25 Chapter 1 FRONT WHEEL DRIVE FWD CONTROL SYSTEM How It Works January, 2006
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 TABLE OF CONTENTS FRONT WHEEL DRIVE (FWD) ...................................................................................................................... 25-1-3 ELECTRONIC FRONT WHEEL DRIVE (FWD) CONTROL ........................................................................... 25-1-5 FRONT WHEEL DRIVE (FWD) CONTROL MODES .....................................................................................
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 FRONT WHEEL DRIVE (FWD) General Description The PTO controller supplies current to the FWD va l v e t o o p e r a t e t h e F W D c l u t c h b a s e d o n commands from the operator (FWD switch). Signals supplied to the controller from the brake pedal switches, true ground speed circuit, hitch position control system, and transmission speed signal circuit provide for automatic operation.
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 1 2 RI02E086 1. FWD SOLENOID 2.
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 ELECTRONIC FRONT WHEEL DRIVE (FWD) CONTROL General Description All FWD operator commands are sent to the Arm Rest Control Module (hard wired to the Arm Rest Control Module), then relayed to the PTO controller via the Data Bus. Transmission speed and true ground speed signals are sent (hard wired) to the Instrument Cluster Unit (ICU) then relayed to the PTO controller.
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 1 RH05J060 1.
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 FRONT WHEEL DRIVE (FWD) CONTROL MODES OFF – When the FWD switch is placed in the OFF position, the FWD clutch will be deactivated (coil-energized) unless both brakes are applied. The FWD clutch is applied as both brake pedals are applied to allow four wheel braking. RH05J067 Manual FWD Control (ON) – When the FWD switch is placed in the ON position the FWD will be activated (solenoid deactivated) at all times.
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 FRONT WHEEL DRIVE (FWD) FUNCTIONAL TESTS Switch Position FWD Engaged/ Disengaged FWD Operation Description OFF Disengaged Except: When both brake pedals are pressed. Engaged Operator will feel engagement as switch is cycled. Check operational indicator. Disengaged Hitch is UP with UP/DOWN switch. Position lever in down position. RD05J067 ON RD05J067 AUTO Except: Both brake pedals are pressed. Except: When slip is above 15%.
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 3 4 2 1 RI02E086 1. FWD SOLENOID 2. LOW CLUTCH SOLENOID 3. MID CLUTCH SOLENOID 4. HIGH CLUTCH SOLENOID FWD Valve The FWD valve is a closed center valve and is contained as a part of the range transmission powershift valve manifold. Oil is supplied to the FWD valve from the regulated pressure circuit. The valve is mounted on top of the range transmission. Solenoid Cartridge Valve The solenoid is controlled by an armrest mounted rocker switch.
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 TROUBLESHOOTING Problem – FWD clutch will not disengage 1. Check for PTO fault codes. (FWD fault codes are monitored by PTO controller.) A. If fault codes are found, follow procedures outlined in PTO system fault code troubleshooting in this section. 2. Place the FWD switch in the OFF position. Check the tractor monitor for the FWD icon in the instrumentation display. A.
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 TROUBLESHOOTING Problem – FWD will not engage 1. Check for PTO fault codes. (FWD fault codes are monitored by PTO controller.) A. If fault codes are found, follow procedures outlined in PTO system fault code troubleshooting in this section. 2. Place the FWD switch in the ON position. Check tractor monitor for FWD icon in the instrumentation display. A.
Section 25 - Four-Wheel Drive Front Axle - Chapter 1 WARNING These tractors are equipped with a spring-applied mechanical front wheel drive (FWD) clutch and a limited slip differential. Even with the engaging switch in the OFF position, the FWD clutch can propel both front wheels if any of the following conditions exist. 1. 2. 3. 4. 5. The engine is shut off (regulated supply pressure will drain). The engine is stopped when the rear wheels are still coasting).
Section 25 Chapter 2 DIFFERENTIAL LOCK CONTROL SYSTEM How It Works January, 2006
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 TABLE OF CONTENTS DIFFERENTIAL LOCK ................................................................................................................................... 25-2-3 ELECTRONIC DIFFERENTIAL LOCK CONTROL ........................................................................................ 25-2-5 DIFFERENTIAL LOCK CONTROL MODES ..................................................................................................
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 DIFFERENTIAL LOCK General Description – The Differential Lock consists of the differential lock piston, differential lock control valve, differential lock control switch, brake pedal switches, true ground speed circuit, hitch position circuit, transmission speed circuit, and electronic control modules (through the Data Bus). Because the differential lock is electronically controlled, automatic operation is possible.
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 1 2 RI02E086 1. PTO/DIFF LOCK VALVE 2.
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 ELECTRONIC DIFFERENTIAL LOCK CONTROL General Description – The Differential Lock consists of the differential lock clutch, differential lock control valve, differential lock control switch, brake pedal switches, true ground speed circuit, hitch position circuit, transmission speed circuit, and electronic control modules (through the Data Bus). Because the differential lock is electronically controlled, automatic operation is possible.
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 1 RD05J060 1.
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 DIFFERENTIAL LOCK CONTROL MODES ON (Differential Symbol) – When the differential lock switch is placed in the ON position the differential lock will be activated. A differential symbol will be illuminated on the tractor monitor.The differential lock will disengage when either brake pedal is pushed. NOTE: It is not possible to disengage the differential lock with the switch control. Pushing either brake pedal will deactivate the differential lock.
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 DIFFERENTIAL LOCK CONTROL TRUE GROUND SPEED SENSOR ENGINE TRANSMISSION INST. CONTROL MODULE TRANSMISSION SPEED SENSOR AUX/HITCH/PTO CONTROL MODULE (TMF) KEY SWITCH DIFF.
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 DIFFERENTIAL LOCK FUNCTIONAL TESTS IMPORTANT: Hitch position and wheel slip will influence differential lock operation when tractor is in motion. Switch Position Engaged/ Disengaged Operational Comments ON Engaged The differential Lock icon will illuminate. If o n e ( or b o th ) b ra ke pe d al s i s p us h e d t h e differential lock light will go out and the differential lock will be deactivated.
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 1 2 RI02E087 1. PTO/DIFF LOCK VALVE 2. DIFF LOCK SOLENOID Differential Lock Valve The differential lock valve is a closed center valve and is contained as a part of the PTO valve. Oil is supplied to the differential lock cartridge valve from the regulated pressure circuit. The differential lock clutch supply flow is distributed internally (no external tubing) to the clutch. The valve is mounted on the top of the rear frame transmission housing.
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 Differential Lock Clutch Disengaged When the switch is in the disengaged position (middle) and a brake pedal is pushed, the solenoid will be deenergized. Regulated pressure will be at the valve cartridge. The piston of the differential lock clutch is mechanically returned to the neutral position.
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 TROUBLESHOOTING Problem – Differential lock will not engage 1. Check for PTO System fault codes. A. If fault codes are found, follow procedures outlined in PTO system fault code troubleshooting in this section. 2. Push either brake pedal switch to deactivate the differential lock. Check the tractor monitor for the differential lock icon in the instrumentation display. A.
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 Differential Lock Engaged When the switch is in the engaged position (differential symbol) the solenoid will be activated. Oil pressure, available to the valve cartridge, will be ported (internally) to the rear frame transmission housing of the tractor. The clutch will be engaged, as the piston extends, locking the friction and separator plates together.
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 TROUBLESHOOTING Problem – Differential lock will not disengage 1. Check for PTO fault codes. A. If fault codes are found, follow procedures outlined in PTO system fault code troubleshooting in this section. 2. Place the differential lock switch in the ON position. Check the tractor monitor for the differential lock icon in the instrumentation display. A.
Section 25 - Four-Wheel Drive Front Axle - Chapter 2 PTO/DIFFERENTIAL LOCK VALVE CIRCUIT P TO C L U T C H PISTON DIFFERENTIAL LOCK PISTON P TO CLUTCH LUBE P TO SOLENOID DIFF LOCK SOLENOID R E G U L AT E D SUPPLY BEVEL PIN LUBE RH02A059 NOTE: Refer to Differential Lock electrical schematic diagram.
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Section 25 Chapter 3 FWD OUTPUT SHAFT January, 2006
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 TABLE OF CONTENTS SPECIAL TORQUES ...................................................................................................................................... 25-3-3 FWD OUTPUT SHAFT ................................................................................................................................... FWD Output Shaft Removal ............................................................................................................
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 SPECIAL TORQUES FWD Output Shaft Yoke Retaining Bolt .................................................................. 252 to 280 Nm (186 to 206 lb. ft.) FWD Output Shaft Bearing Cage Bolt .................................................................... 375 to 485 Nm (276 to 358 lb. ft.) FWD Drive Shaft Retaining Bolts ................................................................................... 58 to 64 Nm (43 to 47 lb. ft.
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 FWD OUTPUT SHAFT FWD Output Shaft Removal STEP 1 STEP 3 2 1 96RS28A RD02H172 Park the tractor on a hard, level surface. Put the transmission shift lever in PARK. Turn off the engine and remove the key. Place blocks in front of and behind the rear wheels. 3 STEP 2 RD02H173 Mark the position of the sleeve on the drive shaft protector (1). Remove the drive shaft protector pins (2). Slide the drive shaft protector toward the transmission.
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 FWD Output Shaft Disassembly STEP 4 STEP 6 11S19 Remove four bolts and four washers on the output shaft bearing cage. 108RS4 Place the FWD output shaft in a vise and remove the yoke retaining bolt. STEP 5 STEP 7 11S21 Remove FWD shaft and bearing cage from drop box. 108RS7 Remove the yoke retaining bolt washer and the shim(s). NOTE: Keep the shims with the yoke.
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 8 STEP 11 108RS10 108RS28 Remove and discard the O-ring. Remove the internal retaining ring. STEP 9 STEP 12 108RS16 108RS23 Remove the yoke from the output shaft spline. Remove the bearing spacer.
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 13 STEP 15 108RS29 Remove the shim(s). The bearing spacer is shown with two shims. 2940CUP1 Remove the rear bearing cup from the bearing cage, as shown in drawing above. NOTE: Keep the shim(s) with the bearing cage. STEP 14 STEP 16 109RS7 109RS17 Remove the bearing cage as follows: Press the front bearing cone from the output shaft. 1. Rest the bottom of the drive shaft on a wooden block. STEP 17 2. Hold the bearing cage. 3.
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 18 STEP 19 109RS28 109RS11 Press the rear bearing cone from output shaft. Remove and discard the O-ring from bearing cage.
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 FWD Output Shaft Assembly 2 14 1 13 13 12 12 3 4 5 11 10 9 6 8 7 2940FUL2 1. 2. 3. 4. 5. 6. 7. SEAL YOKE WASHER BOLT SHIMS O-RING INTERNAL RETAINING RING 8. 9. 10. 11. 12. 13. 14.
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 20 STEP 23 109RS16 109RS31 Lubricate a new O-ring with clean hydraulic oil and install into the groove on the bearing cage. Install a new front bearing cone on the output shaft. Press the front bearing cone against the external retaining ring. STEP 21 STEP 24 109RS23 Install a new rear bearing cone just below the external retaining ring groove. 2940CUP2 Press a new rear bearing cup into the bearing cage.
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 25 STEP 26 1 109RS7 Install the bearings and shims as follows: 2 1. Install the output shaft into the bearing cage. 2. Install a new front bearing cup. 3. Use a press to seat the front bearing cup into the bearing cage while rotating and moving the shaft back and forth. Install the bolt into the end of the output shaft. Measure the rolling torque of the output shaft. The reading obtained must be 1.5 to 2.2 Nm (13 to 19 lb. in). 4.
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 27 STEP 29 108RS16 Install the yoke on the output shaft spline. STEP 30 2940DIAL Use a dial indicator to measure the bearing end play while slightly moving the shaft up and down. If the end play does not fall within 0.025 to 0.150 MM. (0.001 to 0.006 inch), remove the output shaft from the bearing cage and repeat Steps 25 and 26 to obtain the proper measurement. 108RS11 Lubricate a new O-ring with hydraulic fluid and install into the yoke.
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 31 STEP 33 108RS4 Place the FWD output shaft in a vise and install the yoke retaining bolt. Apply a torque of 252 to 280 Nm (186 to 206 lb. ft.) to the bolt. NOTE: Do not install the output shaft if the FWD clutch is to be serviced. Refer to FWD Clutch Removal found in the Range Section of this Repair Manual. YOKESHIM Measure from the end of output shaft to the surface of yoke. Select a shim combination to obtain a distance of 0 to 0.1 MM.
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 35 STEP 36 1 11S19 RD02H173 Install the FWD output shaft into the needle bearing in the rear wall of the speed housing. Engage the FWD output shaft with the FWD hub spline. Install the four bolts through the output shaft bearing cage and the drop box. Tighten the four bolts to a torque of 375 to 485 Nm (276 to 358 lb. ft.). 2 RD02H172 Install the FWD drive shaft and the drive shaft protector.
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 STEP 37 STEP 38 91S17 96RS28A Replace the transmission drain plug and fill the transmission with hydraulic oil. Check for oil leaks. Make sure the transmission shift lever is in Park. Remove the blocks in front of and behind the rear wheels. Start the tractor and check the operation of the FWD suspended axle and the transmission. Check the hydraulic oil level. Turn the engine off and remove the key.
Section 25 - Four-Wheel Drive Front Axle - Chapter 3 This Page Left Blank.
Section 25 Chapter 4 FWD DRIVE SHAFT January, 2006
Section 25 - Four-Wheel Drive Front Axle - Chapter 4 TABLE OF CONTENTS SPECIAL TORQUES ...................................................................................................................................... 25-4-3 FWD DRIVE SHAFT .......................................................................................................................................
Section 25 - Four-Wheel Drive Front Axle - Chapter 4 SPECIAL TORQUES Drive Shaft Retaining Bolts............................................................................................. 58 to 64 Nm (43 to 47 lb. ft.
Section 25 - Four-Wheel Drive Front Axle - Chapter 4 FWD DRIVE SHAFT Removal STEP 3 NOTE: Tractor with suspended axle shown. All drive shafts are similar. 2 STEP 1 1 RD06A007 Remove the suspended front axle hoses (1), if equipped. Remove the steering hoses (2) (right side shown) from the drive shaft cover. 96RS28A STEP 4 Park the tractor on a hard, level surface. Put the transmission shift lever in PARK. Turn off the engine and remove the key. Place blocks in front of and behind the rear wheels.
Section 25 - Four-Wheel Drive Front Axle - Chapter 4 STEP 6 STEP 7 3 2 1 RD02H168 Mark the drive shaft to FWD output shaft yolks. Remove the four drive shaft to transmission yoke retaining bolts. Remove the drive shaft. 2 RD02H191 Place the drive shaft (1) on V blocks (2). Position a dial indicator (3) over the drive shaft. Turn the drive s h a f t o n e c o m p l e t e r evo l u t i o n t o c h e c k fo r straightness. Replace the drive shaft, if necessary.
Section 25 - Four-Wheel Drive Front Axle - Chapter 4 Installation STEP 10 STEP 8 1 2 RD02H169 Support the FWD drive shaft. Align the marks on the yokes (2). Install and tighten the four drive shaft to pinion yoke bolts (2) to a torque of 58 to 64 Nm (43 to 47 lb. ft.). RD02H168 Align the marks on the yokes. Install the four drive shaft to transmission yoke retaining bolts. Tighten the bolts to a torque of 58 to 64 Nm (43 to 47 lb. ft.).
Section 25 - Four-Wheel Drive Front Axle - Chapter 4 STEP 12 STEP 13 1 2 RD06A007 96RS28A A tt ac h th e s te er i ng ho s e s ( 1) . T i e s t ra p t h e suspended axle hoses (2), if equipped to the steering hoses. Check for oil leaks. Make sure the transmission shift lever is in PARK. Remove the blocks in front of and behind the rear wheels. Start the tractor and check the operation of the FWD suspended axle and the transmission. Check the hydraulic oil level.
Section 25 - Four-Wheel Drive Front Axle - Chapter 4 25-4-8
Section 25 Chapter 5 SUSPENDED FWD AXLE SYSTEM How It Works and Troubleshooting January, 2006
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 TABLE OF CONTENTS SUSPENDED FWD AXLE OPERATION .................................................................................................... 25-5-3 SUSPENDED MFD AXLE- CALIBRATION MODE ..................................................................................... 25-5-9 ERROR TABLE ........................................................................................................................................
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 SUSPENDED FWD AXLE OPERATION The front axle suspension system: A. allows increased operating speeds with greater tractor stability in the field and on the road. B. improves ride quality and operator comfort when working on rough terrain and for high speed shuttling. C. provides better front tire to ground contact for improved tractor control and prolonged tire life.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 19 18 10 3 1 14 15 9 4 2 17 5 8 6 13 12 16 7 11 RI03A003 1. 2. 3. 4. 5. RAISE SOLENOID LOWER SOLENOID LOCKOUT SOLENOID LOCKOUT SOLENOID UNLOAD VALVE 6. 7. 8. 9. 10. RELIEF VALVE RELIEF VALVE CHECK VALVE ORIFICE RELIEF VALVE 11. 12. 13. 14. 15. CHECK VALVE ORIFICE ORIFICE CHECK VALVE ORIFICE 16. 17. 18. 19.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 When the axle hits a medium-sized bump, oil will be forced from the piston side through the lockout valve (4) and check (11) to the rod side of the cylinder and through lock out valve (3) to orifice (9) and relief valve (10). Since orifice (9) will not handle this much flow relief valve (10) will open allowing the oil to pass to the accumulator. The accumulator absorbs the shock to the axle.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 4 1 2 5 3 6 7 10 8 9 RD03A035 FRONT SUSPENDED AXLE CONTROL VALVE 1. 2. 3. 4. 5. RAISE SOLENOID - COLOR CODE RED LOWER SOLENOID - COLOR CODE GREEN PISTON SIDE LOCKOUT SOLENOID - COLOR CODE YELLOW ROD SIDE LOCKOUT SOLENOID - COLOR CODE BLUE UNLOAD VALVE 25-5-6 6. 7. 8. 9. 10.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 12 13 TOP VIEW-REAR 10 7 8 2 5 4 1 3 9 6 11 TOP VIEW-FRONT RH03A106 AND 108 1. 2. 3. 4. 5. 6. 7. RAISE SOLENOID - COLOR CODE RED LOWER SOLENOID - COLOR CODE GREEN PISTON SIDE LOCKOUT SOLENOID - COLOR CODE YELLOW ROD SIDE LOCKOUT SOLENOID - COLOR CODE BLUE UNLOAD VALVE TO ACCUMMULATOR ACCUMMULATOR 25-5-7 8. 9. 10. 11. 12. 13. 14.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 12 13 14 SIDE VIEW-REAR 11 SIDE VIEW-FRONT RH03A107 AND 109 1. 2. 3. 4. 5. 6. 7. RAISE SOLENOID - COLOR CODE RED LOWER SOLENOID - COLOR CODE GREEN PISTON SIDE LOCKOUT SOLENOID - COLOR CODE YELLOW ROD SIDE LOCKOUT SOLENOID - COLOR CODE BLUE UNLOAD VALVE TO ACCUMMULATOR ACCUMMULATOR 25-5-8 8. 9. 10. 11. 12. 13. 14.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 SUSPENDED MFD AXLE- CALIBRATION MODE STEP 1 STEP 3 RD06A021 Push and hold the PROG key for two seconds within the first ten seconds after starting the tractor. A short beep will indicate that the program mode has been accessed and the display will read CONFIG MENU. RD06A023 The display will read TRANS VIEW. STEP 4 STEP 2 RD06A024 Push the DECR key until the display reads TRANS FSUS. RD06A022 Push the DECR key until Transmission is highlighted.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 STEP 6 STEP 8 RD06A026 RD06A028 Press the PROG key. The calibration process is now activated. The lamp will flash at 2.5 Her tz. The co ntr o ll er w il l lower and ra is e the f ro nt ax l e automatically. Axle output sensor voltage will appear on the display. Seconds later the display will read FSUS Cal Done and the lamp will stop flashing. STEP 7 STEP 9 NOTE: If the display reads Cal Failed, continue with Step 10.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 ERROR TABLE ERROR MESSAGE Pot Open Ckt ERROR DESCRIPTION AND TROUBLESHOOTING Front axle potentiometer open circuit. Automatic Calibration Procedure will not work. Check wire harness. Check position sensor signal circuit. Check continuity from connector 192 pin 3 to connector 185 pin C, next from connector 185 pin C to connector 353 pin 2. Check position sensor 12 volt power.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 Slow to max Suspension unable to reach maximum height within 20 seconds. Check the raise valve installation. Check unload solenoid “GREEN” installation. Check suspension mechanics. Check hydraulic pressure. Disconnect Implement. Slow Dn Mvmnt Suspension is stationary during lowering command in the Automatic Calibration Procedure. Check unload solenoid “GREEN” harness. Check suspension mechanics. Check hydraulic pressure. Disconnect Implement.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 SUSPENDED FWD AXLE- MANUAL OPERATION MODE (TEST MODE) STEP 2 The Manual Operation Mode is used to test the front suspension system. It permits bypass of the front suspension controller and gives the operator the ability to directly command the valves. The manual operation can be done through the front suspension manual menu on the programmable display and using the front suspended axle momentary switch on the right hand fender console.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 STEP 5 STEP 7 RD06A030 RD06A031 Push the DECR key until the display reads Fsus Manual. Press the PROG key. Next use the DECR key until the display reads Raise nnnnn mV. The nnnnn reading is the millivolt reading for the position sensor output. STEP 6 Press an hold down the front suspension momentary rocker switch to energize the front suspension raise solenoid. Release the rocker switch to turn off. Press the DECR key.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 STEP 9 STEP 11 RD06A033 RD06A030 The display will read Lock nnnnn mV. The nnnnn reading is the millivolt reading for the position sensor output. The display will read Fus Manual. Press the DECR key. STEP 12 Press and hold down the front suspension momentary rocker switch to turn off both the raise and lower lockout solenoids. This can be used to troubleshoot the raise and lower lockout circuits.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 SUSPENDED FWD AXLE - DEMONSTRATION MODE STEP 3 IMPORTANT: The Electronic Service Tool (EST) must be connected to the diagnostic port to get into the Demonstration mode. STEP 1 RD06A023 The display will read TRANS VIEW. STEP 4 RD06A021 Push and hold the PROG key for two seconds within the first ten seconds after starting the tractor. A short beep will indicate that the program mode has been accessed and the display will read CONFIG MENU.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 STEP 6 STEP 9 RD06A036 RD06A039 Press the DECR key and the display will read Fsus Demo. Press the PROG key and the display now reads Demo Working. The front suspension can now be turned ON and OFF at speeds above 12 km/h (7.5 mph) by pressing the front suspension rocker switch. STEP 7 STEP 10 RD06A037 Press the PROG key. The display will read Demo Off. STEP 8 RD06A040 Press the PROG key. Press the DECR key until the display reads Demo Off.
Section 25 - Four-Wheel Drive Front Axle - Chapter 5 STEP 11 RD06A036 Press the PROG key. The display will read Fsus Demo. STEP 12 RD06A035 Press the DECR key and select Exit Fsus. STEP 13 RD06A024 Press the PROG key and the display will read TRANS FSUS. Turn the key to the OFF position.
Section 25 Chapter 6 SUSPENDED FWD AXLE REMOVAL January, 2006
Section 25 - Four-Wheel Drive Front Axle - Chapter 6 TABLE OF CONTENTS SUSPENDED FWD AXLE .............................................................................................................................. 25-6-3 Removal ...................................................................................................................................................... 25-6-3 Installation ............................................................................................................
Section 25 - Four-Wheel Drive Front Axle - Chapter 6 SUSPENDED FWD AXLE Removal STEP 1 STEP 3 Before removing the axle, do the following: 1. Park the tractor on a hard, level surface and place the transmission in PARK. Remove the keys and block the front and rear of the rear wheels. 2. See information for FWD Drive Shaft Removal and remove the drive shaft. 3. Remove the front weights and weight frame, if equipped. 4. Raise the front of the tractor and properly support.
Section 25 - Four-Wheel Drive Front Axle - Chapter 6 STEP 5 STEP 7 3 2 1 RD02K102 RD02K101 Tag and remove the axle hydraulic supply (1) and return (2) lines. Remove the axle pivot pin retaining plate bolts and retaining plate (3). Remove the jack. Lower the axle and remove from the tractor. STEP 6 RD02K104 Properly support the axle by wrapping a chain or lifting strap around each side of the axle near the steering knuckle. Lift axle slightly to remove any tension on the pivot pin.
Section 25 - Four-Wheel Drive Front Axle - Chapter 6 Installation STEP 8 STEP 10 2 1 RD02K192 RD02K114 RD02K101 Making sure the axle pivot pin bore and thrust washers are aligned with the frame bore, install the pivot pin (1).Be sure not to damage the pivot pin bore seals (2). Install the thrust washers as shown. STEP 9 RI02K095 Properly support the axle, move under the tractor and lift into place. Once in place, install a jack under the center of the axle and level.
Section 25 - Four-Wheel Drive Front Axle - Chapter 6 STEP 12 STEP 14 2 1 1 RD02K101 RD02K103 Install the axle hydraulic supply (1) and return (2) lines. Connect the right and left steering lines (1). If equipped, connect the hydraulic differential lock supply and return lines (not shown). STEP 13 STEP 15 Install the front wheels. Install the front fenders, if equipped. Install the FWD drive shaft. Installed the front weight frame and weights, if equipped.
Section 25 Chapter 7 SUPERSTEER AXLE REMOVAL AND INSTALLATION January, 2006
Section 25 - Four-Wheel Drive Front Axle - Chapter 7 TABLE OF CONTENTS SPECIAL TORQUES ...................................................................................................................................... 25-7-3 SPECIAL TOOLS ........................................................................................................................................... 25-7-3 FRONT AXLE REMOVAL ......................................................................................................
Section 25 - Four-Wheel Drive Front Axle - Chapter 7 SPECIAL TORQUES Axle Side Plate Bolt ................................................................................................ 735 to 945 Nm (542 to 627 lb. ft.) Front Pivot Pin Bolt ................................................................................................... 111 to 198 Nm (82 to 146 lb. ft.) Tie Rod Support Plate Retaining Bolt.....................................................................
Section 25 - Four-Wheel Drive Front Axle - Chapter 7 FRONT AXLE REMOVAL STEP 1 STEP 3 Park the tractor on hard, level ground, with the wheels straight ahead. Place the transmission in park. Stop the engine and remove the key. Put blocks in front of and behind the rear wheels. STEP 2 RD02B152 1 Mark the alignment of the pinion flange and universal yoke for reassembly. Remove the four drive shaft to pinion flange bolts and remove the drive shaft at the front axle.
Section 25 - Four-Wheel Drive Front Axle - Chapter 7 STEP 5 STEP 8 RD02B155 RD02B159 Properly suppor t and remove the tractor front weights. Wedge the axle (arrows) to keep the axle from moving from side to side when lifting the axle. Properly support the front axle. Use proper lifting equipment to support the front weight bracket. Remove the four retaining bolts and the weight bracket. STEP 9 STEP 6 RD02C014 RD02B157 Properly support the front axle for removal using 17527 rear housing handler.
Section 25 - Four-Wheel Drive Front Axle - Chapter 7 STEP 11 STEP 13 RD02C017 RD02C011 Remove the three axle side plate retaining bolts from both sides of the axle. Remove the pivot pin and the front and rear pivot arm shims. STEP 12 STEP 14 RD02C015 RD02C026 Remove the front pivot pin bolt. Lower the front axle and remove from under the tractor.
Section 25 - Four-Wheel Drive Front Axle - Chapter 7 FRONT AXLE INSTALLATION STEP 15 STEP 17 RD02C026 RD02C017 Properly support the front axle and carefully move under the tractor. Raise the front axle into position. Properly support the rear pivot bushing bracket to align the holes in the side plates. Install the side plate bolts on both sides of the front axle. Tighten the bolts to a torque of 735 to 945 Nm (542 to 627 lb. ft.). STEP 16 STEP 18 RD02C011 Lubricate the pivot pin with grease.
Section 25 - Four-Wheel Drive Front Axle - Chapter 7 STEP 19 1 STEP 21 2 1 1 RD02C024 RD02B158 Install the two tie rod support plate retaining bolts (1) on both sides of the axle. Tighten the bolts to a torque of 300 to 550 Nm (225 to 405 lb. ft.). If removed, install the tire rod ends. Tighten the castle nut to a torque of 373 Nm (275 lb. ft.) then advance to the next slot in the nut. Tighten the tie rod adjusting nut to 373 to 441 Nm (275 to 325 lb. ft.).
Section 25 - Four-Wheel Drive Front Axle - Chapter 7 STEP 23 STEP 25 1 RD02B155 RD02B151 Remove the axle supports and lower the front axle. Remove the wedges (arrows). STEP 24 2 RD02B150 Install the axle shield (1). Install and tighten the two shield retaining bolts (2). Properly support and install the tractor front weights. Check the hydraulic fluid level and add if necessary. Remove rear axle wheel blocks. Start the tractor. Check for leaks.
Section 25 - Four-Wheel Drive Front Axle - Chapter 7 25-7-10
Section 25 Chapter 8 LIMITED SLIP FWD DIFFERENTIAL January, 2006
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................... 25-8-2 SPECIAL TORQUES ...................................................................................................................................... 25-8-2 SPECIAL TOOLS ...........................................................................................................
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 DIFFERENTIAL CARRIER ASSEMBLY REMOVAL STEP 1 STEP 3 Remove the front axle from the tractor. Remove the axle shafts (both sides) from the axle (refer to axle disassembly information). NOTE: Do not alter the tie rod adjustment. STEP 2 RR98K029 1 Support the differential carrier with a chain or lift strap and hoist. Carefully pry the differential carrier from the axle housing.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 DIFFERENTIAL DISASSEMBLY STEP 5 STEP 8 RR98K038 RR98K015 Mark the bearing cap and differential housing for reassembly. STEP 6 RR98K016 Remove the bearing caps and adjusting rings. STEP 9 RR98K046 Remove the bolts, washers and ring clips from the bearing caps. (13 mm socket or wrench). STEP 7 RR98K047 Lift and remove the differential assembly from the carrier. Remove the differential bearing cups from the bearing cones.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 10 STEP 12 RR98K049 RR98K228 To remove the ring gear from the differential gear housing half, place shop towels over vise jaws and secure the assembly in the vise. Do not nick or otherwise damage the ring gear teeth. Remove ring gear screws and discard them. New ring gear screws will be installed during reassembly. (13/16 inch socket). Mark the housing halves for reassembly.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 14 STEP 17 RR99K229 RR99K231 Remove the differential housing bolts. (9/16 inch socket). Remove the friction discs and the separator plates. NOTE: If reused, make sure the discs and plates are kept in the same order for reassembly. STEP 15 STEP 18 RR98K032 Install a split collet and remove the bearing cone from the differential housing half. RR99K223 Remove the dished disc. STEP 16 STEP 19 RR99K230 Remove the differential housing half.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 20 STEP 23 RR98K025 RR99K238 Remove the pinion mate cross shaft, pinion mates (pinion gears), and thrust washers. Remove the dished disc, the separator plated and friction discs. STEP 21 NOTE: If reused, make sure the discs and plates are kept in the same order for reassembly. STEP 24 RR99K236 Separate the pinion mate cross shaft, the pinion mate gears and thrust washers.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Pinion Disassembly STEP 25 STEP 27 RR98K021 RR98K012 Hold end yoke or flange with tool similar to the one shown, and remove nut and washer. Discard nut as new one must be used at reassembly. (1-5/16 inch socket). If a new yoke dust shield is required, use CAS-2596 or 3800011108 Yoke Dust Shield Installer with FNH 299077 or 380001112 Handle STEP 28 STEP 26 T98483 RR98K019 Remove end yoke.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 ! STEP 31 WARNING: Gear teeth may have sharp edges. When handling gear, use care to avoid personal injury. M687 NOTE: On the spline end of the pinion, there are bearing preload shims These shims may stick to the bearing, pinion or even fall out. The shims are to be collected and kept together since they will used later in reassembly. Do not damage the shims. If the shims are damaged, replace with new ones: shims are available in thicknesses of 0.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 33 STEP 35 T98491 RR98K036 Remove inner bearing adjustment shims. Install a split collet and press the bearing cone off of the pinion shaft. STEP 34 ! WARNING: Do not allow the shaft to fall. It can strike legs or feet and may cause serious injury. Gear teeth may have sharp edges. Use care when handling to avoid injury.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 DIFFERENTIAL ASSEMBLY 4 2 5 13 1 4 3 12 1 8 9 7 6 2 6 10 11 7 8 14 RI03B004 ✲ 1. 2. 3. 4. 5. 6. 7. BEARING CUP BEARING CONE RING GEAR BOLT HOUSING HALF DIFFERENTIAL RING GEAR DISHED DISC FRICTION DISCS 8. 9. 10. 11. 12. 13. 14.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 38 STEP 40 RR99K237 RI03B005 Apply grease to the shoulder of the side gear, then install the side gear in dished disc in the flanged housing half. Be sure the plates are arranged for installation as follows: 3 Plates (in board side) 1 Discs STEP 41 1 Plate 1 Disc 1 Plate 1 Disc 1 Plate 1 Disc 1 Plate 1 Disc RR98K025 STEP 39 Lubricate the pinion mate gear ID’s. Install the pinion mate gears and thrust washers.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 43 STEP 45 RR99K233 RI03B005 Install a dished disc. Position the disc so the convex ID touched the side gear shoulder. Be sure the plates are arranged for installation as follows: STEP 44 3 Plates (in board side) 1 Discs 1 Plate 1 Disc 1 Plate 1 Disc 1 Plate 1 Disc 1 Plate 1 Disc RR99K231 Apply friction modifier (B91246) to all the discs and plate friction surfaces.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 46 STEP 47 RR99K229 RR98K035 Install the plate/disc stack into the differential housing. The end of the stack with 3 plates goes to the in board side. Install the differential ring gear to the housing half. Install new ring gear bolts. Tighten the ring gear bolts to a torque of 163 to 190 Nm (120 to 140 lb. ft.). (Use a 13/16 inch socket). Assemble the differential case halves. Make sure the marks line up on the case halves.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 DIFFERENTIAL CARRIER ASSEMBLY 7 1 2 3 8 9 6 5 4 13 10 9 8 11 12 RH98K105 1. DIFFERENTIAL CARRIER 2. SPACER 3. PINION BEARING ADJUSTMENT SHIMS 4. INPUT YOKE 5. WASHER 6. NUT 7. PINION SHAFT 8. BEARING CONE 9. BEARING CUP 10. 11. 12. 13. PINION SHAFT POSITION SHIMS OIL BAFFLE OIL SEAL BEARING CAP Pinion Position and Assembly STEP 48 NOTE: On the pinion there is etched either a zero (0), or plus (+) or minus (-) number.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Shim Pack Thickness Chart Old Pinion Marking New Pinion Marking -4 -3 -2 -1 0 +1 +2 +3 +4 +4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 +3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 +2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 +1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Setting The Pinion Depth STEP 49 STEP 52 RR98K042 T98517 Install the outer bearing cup. Install Aligning Disc FNH 00405 or 380001136 and the Gauge Disc FNH 00403 or 380001134. STEP 50 STEP 53 RB99C113 The pinion depth setting tool, FNH 00400 or 30001109, must be assembled into the differential as shown above. Follow Steps 60 through 64 to assemble tool to differential housing.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 55 STEP 57 If the pinion shaft has a “+” marking, subtract the amount shown from the measurement taken in Step 65. The remainder is your shim pack thickness. If the pinion shaft has a “-’ marking, add the amount shown to the measurement taken in Step 65. The sum will be your shim pack thickness. NOTE: The “+” and “-” markings on the pinion shaft are given in thousandths of an inch. Shims are available in thicknesses of 0.076 mm (0.003 inch), 0.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 60 STEP 62 T98491 RR98K037 Install the proper amount of shims. Assemble inner bearing cone on pinion. Drive bearing onto pinion using suitable press. STEP 61 T98513 Install the inner bearing cup.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Adjusting Bearing Preload STEP 63 STEP 66 T98610 T98531 Install the pinion into the carrier. Install a shim pack of 0.070 inch on the pinion shaft. Using an inch pound torque wrench, measure the rolling torque needed to turn the pinion shaft. The torque must be 2.26 to 5.65 Nm (20 to 50 lb. inch). If the torque is correct continue to Step 76. If torque is not correct, do the following: STEP 64 NOTE: Typically a change of 0.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 67 STEP 69 RR98K043 T98534 Remove nut and end yoke. Apply Loctite 515 to the housing face and to the outer diameter of oil seal. Use tool CAS-2596 or 380001108 and install a new dust shield (slinger) on the input yoke. Make sure sealing surface for oil seal is in good condition. STEP 68 STEP 70 RR98K044 Us e th e P i n io n S e a l I ns t al l e r FNH 0 0 41 9 o r 380001111 to install a new pinion shaft oil seal.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 DIFFERENTIAL INSTALLATION STEP 71 STEP 73 RR98K047 RR98K015 Install ring gear and differential assembly with bearing cups into carrier housing. Be sure bearing cups are seated on bearing cones, then install differential bearing caps. Install bearing cap bolts (finger tight only) so adjusting nut can still be turned. (Do not torque cap bolts to specifications).
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Checking Backlash STEP 75 STEP 76 T98549 Next, tighten the adjustment ring on the tooth side (bottom side) of the ring gear in until the bearing cup is seated. T98550 Position dial indicator on lip of differential housing and indicate to side of one tooth on ring gear. Use the Side Bearing Adjusting Wrench FNH 00409 or 380001110 to tighten the right hand and left hand rings to 115 to 129 Nm (85 to 95 lb. ft.).
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 STEP 77 STEP 79 T98562 T98561 When backlash is adjusted properly, rotating torque at the pinion shaft should be 5 to 10 lb. inch higher than the torque you had when setting pinion shaft bearing preload. Tighten all of the bearing cap bolts to a torque of 240 to 270 Nm (180 to 200 lb. ft.). STEP 78 T98560 Install the adjusting ring clips, one on each adjusting ring. Tighten adjusting ring clip bolts to a torque of 27 to 40 Nm (20 to 30 lb. ft.).
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Ring Gear and Pinion Tooth Pattern Interpretation 1. Paint the ring gear teeth with a marking compound to both the forward and reverse side. When setting the pinion position, many of the service manuals required a final pinion position check by using gauges that verify the dimension from the center line to the differential carrier (center line of the ring gear) to the face of the pinion (button).
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Pattern Movements Summarized RR98K054 3. A thicker pinion position shim with the backlash constant moves the pinion closer to the ring gear. Forward Pattern moves deeper on the tooth (flank contact) and slightly toward the toe. RR98K050 EXAMPLE OF CORRECT PATTERN Reverse Pattern moves deeper on the tooth and toward the heel. RR98K056 1. Decreasing backlash moves the ring gear closer to the pinion.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 Installation of Carrier Assembly to Axle Housing STEP 80 STEP 82 Thoroughly clean the inside of the axle housing. Remove any burrs and nicks from the carrier housing and axle housing mounting surface. 1 STEP 81 RR99K241 T98567 Apply Loctite 515 Gasket Eliminator to the axle housing mounting flange and around the outside of each bolt hole. RR98K057 Install the carrier assembly into the axle housing.
Section 25 - Four-Wheel Drive Front Axle - Chapter 8 25-8-28
Section 25 Chapter 9 LOCKING FWD DIFFERENTIAL January, 2006
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................... 25-9-3 SPECIAL TORQUES ...................................................................................................................................... 25-9-3 SPECIAL TOOLS ...........................................................................................................
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 SPECIFICATIONS Pinion Shaft Rolling Torque (Preload).......................................................... 2.26 to 4.52 Nm (20 to 40 lb. Differential Assembly Rolling Torque (without input seal)............................ 2.83 to 5.65 Nm (25 to 50 lb. Differential Ring Gear Backlash 10 Stud Wheel End Axle ................................................................0.127 to 0.254 mm (0.005 to 0.010 12 Stud Wheel End Axle .........................
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 REMOVAL OF THE FRONT DIFFERENTIAL CARRIER ASSEMBLY STEP 4 NOTE: Before starting service work, park the tractor on level ground, stop the engine and remove the key. Put blocks in front and behind the rear wheels. STEP 1 Remove the left hand and right hand axle shafts. (Refer to information in the FWD Planetary Hub, Steering Knuckle and Axle Drive Shaft Section of this Service Manual.) STEP 2 Remove the front axle from the tractor.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 REMOVAL OF THE FRONT DIFFERENTIAL FROM THE CARRIER HOUSING STEP 6 STEP 9 RD06A137 RD06A140 Place the carrier housing on a clean work surface. Remove the seal retainer. STEP 10 STEP 7 RD06A141 RD06A138 Mark the bearing cap. Remove the three socket head screws from the seal retainer. (3 mm Allen wrench). STEP 11 STEP 8 RD06A142 Remove bearing cap retaining bolts and washers then remove bearing cap. (24 mm or 15/16 inch socket).
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 12 STEP 15 RD06A143 RD06A146 Remove the adjusting ring. Remove the differential from the carrier. STEP 13 STEP 16 1 2 RD06A144 RD06A147 Mark the opposite bearing cap (1). Remove the bolt and adjusting ring retaining cup (2). Remove the bearing cup. Repeat for the opposite side. STEP 14 STEP 17 RD06A145 RD06A148 Remove the bolts, washers, bear ing cap and adjusting ring. Remove the seal.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 DISASSEMBLY OF THE DIFFERENTIAL STEP 18 STEP 21 RD06A149 RD06A153 Mark the housing halves (two places) for reassembly and remove the bolts. Remove the seal rings from the shaft. STEP 22 STEP 19 1 2 RD06A154 Remove the thrust washer. RD06A151 Remove the piston (1) from the cap half of the case (2). STEP 23 STEP 20 1 2 RD06A155 Remove the separator and friction plates.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 24 STEP 27 RD06A156 RR99K236 Remove the differential gear. Separate the pinion mate cross shaft, pinion mate gears and thrust washers. STEP 25 STEP 28 RD06A157 Remove the clutch housing. RD02H199 STEP 26 1 RD02H232 Remove the bearing cone from the flange half case and cap half case if replacement is required. RD02H196 Remove the pinon mate cross shaft, pinon mates (pinon gears) and thrust washer.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 PINION DISASSEMBLY STEP 29 STEP 32 RR98K021 RR98K019 Hold end yoke or flange with tool similar to the one shown, and remove nut and washer. Discard nut as new one must be used at reassembly. (1-5/16 inch socket). Remove the pinion by tapping with a rawhide hammer. Support the pinion to prevent it from falling and being damaged. ! STEP 30 WARNING: Gear teeth may have sharp edges. When handling gear, use care to avoid personal injury.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 34 STEP 36 T98492 RR98K039 Remove the spacer (ten bolt only) from the pinion shaft as shown. Remove the inner bearing cup. NOTE: Shims are located between the bearing cup and carrier bore. If shims are bent or nicked, they should be replaced at time of assembly. Wire the stacks together and measure each. If a stack is replaced, replace with the same thickness. STEP 35 STEP 37 T98490 Remove pinion adjustment shims from the pinion shaft.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 38 STEP 39 RR98K040 RR98K036 Turn nose of carrier down. Remove outer pinion bearing cup as shown. Locate driver on back edge cup; drive cup out of carrier if necessary. Install a split collet and press the bearing cone off of the pinion shaft. NOTE: Do not damage the carrier bore. ! WARNING: Do not allow the shaft to fall. It can strike legs or feet and may cause serious injury. Gear teeth may have sharp edges.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 ASSEMBLY OF THE DIFFERENTIAL 2 27 1 6 5 4 3 7 8 14 9 15 11 10 12 26 10 13 9 8 17 25 24 23 18 22 28 17 19 16 21 20 R106A036 1. 2. 3. 4. 5. 6. 7. 8. 9. BOLT WASHER CASE, CAP HALF OUTER SEAL RING INNER SEAL RING PISTON SEAL BEARING CONE BEARING CUP 10. 11. 12. 13. 14. 15. 16. 17. 18. SEAL ADJUSTING NUT SEAL RETAINER SOCKER HEAD SCREW SEPERATOR PLATE FRICTION PLATE CLUTCH HOUSING THRUST WASHER DIFFEERENTIAL GEAR 25-9-12 19. 20. 21.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 36 STEP 39 RD02J004 Lubricate the pinion mate gear ID’s. Install the pinion mate gears, thrust washers and cross shaft into the flange half case. RD02H200 Press bearing cone on each trunnion of each differential case half (if they were removed). NOTE: Make sure the cross shaft is installed in the same order as disassembly. Refer to the alignment marks. STEP 37 STEP 40 RD06A162 Install the thrust washer into the flange half case.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 42 STEP 43 1 RD06A163 RD05A154 Install the thrust washer. 2 STEP 44 3 RD06A164 Starting with a separator plate (1), alternate with a friction plate (2) until all plates are installed. There are ten separator plates and nine friction plates. Install new seal rings. Apply friction modifier (B91246) to all the disc and plate friction surfaces.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 46 STEP 48 2 1 1 RD06A151 RD06H149 Install the piston (1) into the cap half of the case (2). Align the assembly marks (1), place the flange half on the clutch carrier, install the mounting bolts and torque to 60 to 65 Nm (44 to 48 lb. ft.). NOTE: Use care when installing the piston to avoid damaging the seal rings. STEP 49 STEP 47 RD06A148 Install a new seal. RD06A165 Clean the mounting bolts and install Loctite® 242 to the threads.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 DIFFERENTIAL CARRIER ASSEMBLY 7 1 3 2 8 9 6 5 4 13 10 9 8 11 12 RH02J027 1. DIFFERENTIAL CARRIER 2. SPACER (10 BOLT ONLY) 3. PINION BEARING ADJUSTMENT SHIMS 4. INPUT YOKE 5. WASHER 6. NUT 7. PINION SHAFT 8. BEARING CONE 9. BEARING CUP 10. 11. 12. 13. PINION SHAFT POSITION SHIMS OIL BAFFLE OIL SEAL BEARING CAP Pinion Position and Assembly STEP 47 NOTE: On the pinion there is etched either a zero (0), or plus (+) or minus (-) number.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 Shim Pack Thickness Chart New Pinion Marking Old Pinion Marking -4 -3 -2 -1 0 +1 +2 +3 +4 +4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 +3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 +2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 +1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 SETTING THE PINION DEPTH STEP 48 STEP 51 RR98K042 T98517 Install the outer bearing cup. Install Aligning Disc CAS-1898-5 and the Gauge Disc CAS-1898-3. STEP 49 STEP 52 RB99C113 The pinion depth setting tool, CAS-1898, must be assembled into the differential as shown above. Follow Steps 50 through 54 to assemble tool to differential housing.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 54 STEP 57 Remove the depth setting tool CAS-1898 from the carrier housing. STEP 58 T98522 Install the bearing caps and cap bolts. Tighten the bolts to a torque of 244 to 271 Nm (180 to 200 lb. ft.) (Use a 24 mm socket). STEP 55 T98489 If necessary to adjust pinion position, remove the inner bearing cup. STEP 59 T98523 Position Gauge Block CAS-1898-4 under Tube CAS1898-6.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 60 STEP 61 T98513 RR98K037 Install the inner bearing cup. Assemble inner bearing cone on pinion. Drive bearing onto pinion using suitable press.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 ADJUSTING BEARING PRELOAD STEP 62 STEP 64 T98610 T98530 Install the pinion into the carrier. Install a shim pack of 0.070 inch on the pinion shaft. Torque the pinion nut to 326 to 406 Nm (240 to 300 lb. ft.) (1-5/16 inch socket). STEP 63 T98528 Use the Companion Flange Installer CAS-1898-8 to push the yoke onto the shaft.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 65 STEP 67 T98531 RR98K044 Using an inch pound torque wrench, measure the rolling torque needed to turn the pinion shaft. The torque must be 2.26 to 4.5 Nm (20 to 40 lb, inch). If the torque is correct continue to Step 66. If torque is not correct, do the following: Use the Pinion Seal Installer CAS-1899 to install a new pinion shaft oil seal. Install the seal with the lip towards the pinion shaft. NOTE: Typically a change of 0.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 DIFFERENTIAL INSTALLATION STEP 68 STEP 70 RD06A146 RD02J019 Install ring gear and differential assembly with bearing cups into carrier housing. Be sure bearing cups are seated on bearing cones, then install differential bearing caps. Install bearing cap bolts (finger tight only) so adjusting nut can still be turned. (Do not torque cap bolts to specifications).
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 72 1 A RD02J023 RD02J024 RD02J028 Position dial indicator (1) on lip of differential housing and indicate to side of one tooth on ring gear. B RD02J116 Loosen adjusting nut (B) until backlash is approximately 0.127 mm (0.005 inch). Continue loosening adjusting nut (B) until adjusting ring cap bolt, washer and clip can be installed. Torque bolt to 27 to 40 Nm (20 to 30 lb. ft.).
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 STEP 73 Install the seal retainer and retain with the three socket head screws. Torque the screws to 4.0 to 4.5 Nm (36 to 4 0 lb. inch). RD02H185 Checking Backlash STEP 74 STEP 75 T98562 RD02J023 When backlash is adjusted properly, rotating torque at the pinion shaft should be 2.5 to 5 lb. inch higher than the torque you had when setting pinion shaft bearing preload.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 Ring Gear and Pinion Tooth Pattern Interpretation 1. Paint the ring gear teeth with a marking compound to both the forward and reverse side. When setting the pinion position, many of the service manuals required a final pinion position check by using gauges that verify the dimension from the center line to the differential carrier (center line of the ring gear) to the face of the pinion (button).
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 Pattern Movements Summarized RR98K050 EXAMPLE OF CORRECT PATTERN RR98K054 3. A thicker pinion position shim with the backlash constant moves the pinion closer to the ring gear. Forward Pattern moves deeper on the tooth (flank contact) and slightly toward the toe. Reverse Pattern moves deeper on the tooth and toward the heel. RR98K056 1. Decreasing backlash moves the ring gear closer to the pinion.
Section 25 - Four-Wheel Drive Front Axle - Chapter 9 Installation of Carrier Assembly to Axle Housing STEP 76 STEP 78 Thoroughly clean the inside of the axle housing. Remove any burrs and nicks from the carrier housing and axle housing mounting surface. STEP 77 RD02K001 RD02J029 Apply Loctite 515 Gasket Eliminator to the axle housing mounting flange and around the outside of each bolt hole. RD02K002 Install new O-rings as required and install the differential lock supply and return fittings.
Section 25 Chapter 10 FWD PLANETARY HUB, STEERING KNUCKLE AND AXLE DRIVE SHAFT January, 2006
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 TABLE OF CONTENTS SPECIFICATIONS ........................................................................................................................................ 25-10-3 SPECIAL TORQUES .................................................................................................................................... 25-10-3 SPECIAL TOOLS ............................................................................................................
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 SPECIFICATIONS FWD Differential Oil Capacity (10 Bolt) ...........................................................................12.3 Liters (13 U.S. Quarts) FWD Differential Oil Capacity (12 Bolt) ........................................................................ 11.6 Liters (12.3 U.S. Quarts) Differential Oil Type........................
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 PLANETARY HUB DISASSEMBLY STEP 1 STEP 3 1 96RS34A RR98K131 Park the tractor on a hard, level surface. Put the transmission shift lever in PARK. Turn the engine off and remove the key. Place blocks in front of and behind the rear wheels. Remove the front fenders from the front axle, if equipped. Allow the axle to cool before servicing. Slowly open the axle fill plug to release any internal axle pressure. Remove the axle drain plug (1).
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 5 STEP 8 RR98K089 RR98K084 Remove the thrust washers from the top of the planetary gear. Properly support the planetary hub cover. Remove the three (3) Allen head bolts. Separate and remove the hub cover from the planetary hub. STEP 9 STEP 6 RR98K088 Remove the planetar y gear through the center opening of the gear plate. Remove the upper level of needle bearings in the planetary gear.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 11 STEP 13 RD02J001 RR98K093 Remove the eight retaining plate bolts. Discard the bolts. 2 1 NOTE: NEW BOLTS need to be installed during reassembly. STEP 14 RD02J002 Swivel the steering knuckle to gain access to the planetary input sun gear shaft. Use 380000805 Retaining Ring Offset Pliers to remove the snap ring (1). Remove the washer (2) from the planetary input sun gear shaft. NOTE: Axle purpose.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 15 STEP 18 RR98K095 RD05J177 Remove the planetary hub. Ten bolt. Remove the bearing. NOTE: The hub seal may separate into two pieces during removal. STEP 19 STEP 16 RD05J1172 Ten bolt hub. Remove the oil seal. RR098K097 NOTE: Seal may separate when hub is removed. Twelve bolt hub. Remove the oil seal and the inner planetary hub bearing cone from the planetary hub. STEP 20 STEP 17 RR98K082 Remove damaged wheel studs as needed.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 21 STEP 23 1 RR98K098 RR98K101 Use a driver to remove the inner planetary hub bearing cup. Remove the wire retaining ring (3) and remove the gear hub. STEP 22 STEP 24 RR98K100 RR98K103 Use a driver to remove the outer planetary hub bearing cup. Place the planetary gear hub in a press. Use the proper step plate adapter to remove the outer planetary hub bearing from the planetary gear hub.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEERING KNUCKLE AND KINGPIN DISASSEMBLY STEP 25 STEP 28 2 1 3 RR98K105 RR98K108 Place an identifying mark on the wheel stop before removing the clevis locking pin. Remove the clevis retaining pin (1), the clevis locking pin (2), and the wheel stop (3). Remove the cotter pin from the lower end of the steering cylinder clevis pin at the axle housing. Remove the clevis pin. Remove and discard the clevis pin bushing O-rings.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 30 STEP 33 1 2 RR98K110 Remove the cotter pin from the tie rod socket end slotted nut. Loosen the slotted nut. Unseat the tie rod socket end from the steering knuckle, using a soft metal hammer. Remove the slotted nut and the tie rod end. Remove the opposite tie rod end using the same procedure, if necessary. RR98K112 Remove the upper king pin bearing cap (1) and the shims (2).
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 36 STEP 39 1 2 RD02J013 RR99K247 Remove the axle drive shaft. STEP 37 3 RR99K249 RR99K245 Use a suitable puller (1), or a blind hole puller, to remove the upper king pin bearing outer ring (2) from the axle housing. Remove the upper axle kingpin seal. If the outer ring cannot be removed with the blind hole puller, pierce the grease retainer and drive the outer ring out with a punch (3).
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 40 STEP 41 RR98K061 RR98K062 Remove the outer and the inner axle shaft seals with a slide hammer and a suitable puller. Inspect the axle shaft bushing in the differential housing. Use a suitable puller to remove the bushing, if necessary. STEP 42 Repeat the removal procedure for the steering knuckle and kingpins on the opposite side of the FWD axle, if necessary.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 AXLE DRIVE SHAFT DISASSEMBLY STEP 43 STEP 46 RD02J015 RD02J030 Remove the universal joint retaining rings from the centering yoke on front axle drive shaft. Place the axle shaft in a press. Press the other universal cap from the yoke and remove the outer axle drive shaft yoke from the centering yoke. Repeat the preceding procedure to remove the remaining universal joint and the inner drive shaft yoke, from the centering yoke.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 AXLE SHAFT ASSEMBLY 1 2 5 3 4 7 2 3 8 6 RI02H044 1. 2. 3. 4. AXLE SHAFT UNIVERSAL JOINT RETAINING RING YOKE 5. 6. 7. 8.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 48 STEP 50 RR98K078 Install a new retaining ring into the drive shaft yoke. RD02J014 In s ta ll new u n ive r s al jo i nt s by r ever s i ng th e disassembly procedure. Use a press to seat the universal bearing caps into the axle shaft yokes and the centering yoke. STEP 49 STEP 51 RR98K080 Use a press and seal installers to install a new inner and outer yoke seal. Install the yoke seals with the lip of the seal facing away from the yoke.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 KINGPIN ASSEMBLY 1 2 3 4 5 6 7 4 3 8 2 RI99M007 1. 2. 3. 4. UPPER KINGPIN GREASE SEAL KINGPIN BEARING INNER RING KINGPIN BEARING OUTER RING GREASE RETAINING PLATE 5. 6. 7. 8. STEP 53 AXLE SHAFT BUSHING AXLE SHAFT INNER OIL SEAL AXLE SHAFT OUTER OIL SEAL LOWER KING PIN GREASE SEAL STEP 54 RR98K062 RR98K063 Use a suitable installer to install a new axle shaft bushing, if necessary. The bushing counterbore faces outward.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 55 STEP 56 5 1 3 2 4 RR98K118 1 4 RI06A23 NOTE: Lubricate the inner diameter of the seals with SAE 85W-140 gear lubricant. Install the axle shaft seals (1)(2) with the lips facing toward the differential. The inner seal (1) should be pressed flush with the bushing (4). The outer seal (2) should be pressed flush with the casting surface (5). 3 STEP 57 2 RI06A022 1. AXLE SHAFT 2. BUSHING 3. INNER OIL SEAL 4.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 58 STEP 61 RR99K254 RR99K253 Place the kingpin bearing cap in a press and install a new inner ring. Use a flat plate to evenly start the inner ring on the kingpin bearing cap. Make sure the outer ring is fully seated in the housing. Apply a layer of grease to the bearing surface. STEP 59 STEP 62 RR99K255 RR99K256 Complete the seating of the inner ring on the king pin bearing cap by using the outer ring as the installer.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 64 RD02J013 Install the FWD axle drive shaft into the axle housing. Make sure the axle shaft splines engage the differential side gears. Use care so as not to damage the axle shaft seals. Repeat the kingpin assembly procedure on the opposite side of the MFD axle, if necessary.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEERING KNUCKLE ASSEMBLY 3 4 9 15 11 10 12 13 1 2 6 7 12 4 14 5 8 RI99M006 1. 2. 3. 4. 5. PLANETARY GEAR SHAFT SEAL PLANETARY GEAR SHAFT BUSHING NUT COTTER PIN STEERING CYLINDER 6. 7. 8. 9. 10. WHEEL STOP CLEVIS PIN STEERING CYLINDER SOCKET END TIE ROD SOCKET END WASHER STEP 65 11. 12. 13. 14. 15.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 67 STEP 69 RR98K114 RR99K244 Install lifting eyes and properly support the steering knuckle. Guide the axle shaft outer yoke into the steering knuckle. Remove the king pin bearing caps after verifying that the bearings are fully seated and install the king pin shims. STEP 68 NOTE: The same thickness king pin shims can be used on top and bottom to serve as a starting point to determine the new shim packs required.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 71 STEP 72 RR99K247 RR98K130 Place a inclinometer on the top machined surface of the knuckle and level the assembly to within ± 2 degrees of zero. Clean the tie rod end stud and the tapered bore in the steering knuckle. Install the tie rod seal and washer. Install the tie rod and tighten the slotted nut to a torque of 372 Nm (275 lb. ft.). If necessary, advance the slotted nut until the cotter pin can be installed.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 74 STEP 75 2 3 1 RR98K071 Lubricate the two steering cylinder clevis pin bushing O-rings with grease. Make sure an O-ring is installed on each side of the steering cylinder at the clevis pin bushings. Make sure the flat on the head of the clevis pin is turned toward the axle housing. Install the clevis pin. Insert a cotter pin through the clevis pin. Install the steering cylinder on the opposite side of the FWD axle, if removed.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 PLANETARY HUB ASSEMBLY 4 5 1 6 2 8 3 5 7 4 9 13 10 14 15 13 16 11 17 18 12 1 19 20 21 22 23 24 23 25 20 26 RI05M071 1. 2. 3. 4. 5. 6. 7. 8. 9. RETAINING RING WASHER PLANETARY HUB SEAL BEARING CONE BEARING CUP DUST SEAL (TWELVE BOLT ONLY) STUD PLANETARY HUB NUT 10. 11. 12. 13. 14. 15. 16. 17. 18.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 76 STEP 78 RR98K104 RD02J038 Lubricate the inner diameter of the outer planetary hub bearing cone with Case 135 H EP SAE 85W-140 Gear Lubricant. Place the planetary gear hub in a press. Use the proper step plate adapter to install the bearing cone on the gear hub. Clean and inspect the planetary hub. Lubricate the outer bearing cup with Case 135 H EP SAE 85W-140 Gear Lubricant. Place the hub in a press.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 80 STEP 83 1 RR98K081 Install new wheel studs, if necessary. RD05J176 Place a shop towel in the center of the steering knuckle (1) and clean the bolt holes with compressed air. Remove the towel. STEP 81 STEP 84 RD05J173 TWELVE BOLT AXLE ONLY. Thoroughly clean the dust seal seating area. RD05J174 Thoroughly clean the steering knuckle.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 86 STEP 88 RD05J178 LIGHTLY coat the outer hub bearing with a light multipurpose oil. RD05J180 Install the planetary gear hub. NOTE: If any of the hub components have been replaced (other than the hub oil seal), the procedure for shimming the planetary hub and adjusting the rolling torque must be followed. Reuse some of the removed shims, if possible.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 90 STEP 93 RD05J182 RD05J184 Install the retaining plate with four bolts. Torque bolts to 110 to 125 Nm (82 to 92 lb. ft.) The rolling torque reading should be 11.4 to 16 Nm (100 to 140 lb. in.). If required, add shims to decrease the torque value, or subtract shims to increase the torque value. STEP 91 STEP 94 1 1 RD05J183 Install the spacers (1). RD05J185 Once the rolling torque has be established, remove the spanner plate.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 Ten Bolt Axle Only STEP 96 STEP 98 RD05M041 Remove the planetary gear hub. RD04D227 STEP 97 RD04D228 RR98K095 Remove the planetary hub. Clean the spindle in the area of seal and bearing mounting so they are free of oil, grease and dirt. Apply Loctite® 680 to the seal ID and to the spindle OD where the seal is to be mounted. Spread the Loctite® evenly around the entire spindle and seal. STEP 99 RD04D229 Install the pilot tool onto the spindle.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 100 STEP 102 RD04D230 RD04D233 Install the seal driver tool over the pilot tool so that it is resting on the seal. STEP 103 RD04D231 With the rubber facing away from the spindle, install the seal over the pilot tool. 3 1 2 STEP 101 RD04D234 Install the thrust bearing (1), flat washer (2) and nut (2) onto the threaded rod. STEP 104 RD04D232 Install the flanged tool with threaded rod onto the spindle end face.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 105 STEP 107 1 1 RD04D236 While tightening the nut, make sure the seal is squarely aligned on the spindle. Continue advancing the nut until a noticeable increase in torque is noted. There may be a very small gap (1) (0.025 to 0.50 MM.) between the seal and the spindle shoulder. This is a normal condition. RD04D238 Remove all the installation tools except the for the flanged tool (1). Install the bearing cone onto the spindle.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 110 STEP 113 RD05D241 Place the large aluminum pilot tool onto the bearing cup with the small pilot diameter facing up. RD04D245 Push the hub (by hand) onto the spindle until contact with the seal is made. The threaded rod should be exposed. STEP 111 STEP 114 1 RD05D242 Align the flat bar with the small pilot diameter (1) and fasten to the adapters using the bolts provided.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 Twelve Bolt Axle Only STEP 116 STEP 117 RD04D248 There should be a small gap (approximately 1 MM.) between the spindle and the hub. Make sure that the hub can be rotated by hand. RD05J177 Remove the inner bearing. STEP 118 RD05J186 Thoroughly clean and dry the dust seal seating area. STEP 119 RD05J187 Apply a thin bead of Loctite® 680 to the dust seal seating area.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 120 STEP 122 1 RD05J191 When installing the dust seal make sure the larger lip (1) is facing outboard. RD05J195 Place the hub in a suitable vise. STEP 123 RD05J188 RD05J194 Hand press the dust seal into place. Thoroughly clean and dry the seal counterbore. STEP 121 STEP 124 1 2 RD05J190 Place dust seal installation ring (1) against the seal (2) and LIGHTLY tap around the ring to set the seal against the machined surface.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 125 STEP 128 2 1 RD05J192 Place the centering cup into the opposite side of the hub. RD05J198 While holding the bearing (1) set the oil seal (2) into place. STEP 129 STEP 126 RD05J199 RD05J193 Place the seal driver over the threaded rod. Install the threaded rod. STEP 130 STEP 127 1 2 RD05J200 RD05J197 Set the inboard bearing into the hub cone. Install a washer and nut and hand tighten.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 131 STEP 134 RD05M026 Slowly draw seal into the hub. RD05M030 Bolt the seal installation adapter over the end of the steering knuckle. STEP 132 STEP 135 RD05M027 If seal is not being drawn into the bore straight, tap on the installation tool to “square” the seal in the bore. Once seal is seated in the bore, remove the installation tools. RD05M031 Place the installation hub on the wheel hub.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 137 STEP 139 1 2 3 RD05M033 RD05M035 Apply a light coating of multipurpose grease to the dust sealing area on the wheel hub Install a wheel nut (1) on one of the hub wheel studs (2) and place a lifting device (3) on the stud. With an assistant, carefully guide the hub into place on the steering knuckle. Take care not to damage the seal or bearing.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 All Axles STEP 141 STEP 142 1 2 RD05M040 Press the seal in until the shoulder (1) of the seal installation tool is bottomed against the hub (2). Remove the seal installation tool. RD05M041 Install the planetary gear hub and bearing. STEP 143 1 2 RD05M042 Place the shim pack (1) on the retaining plate (2) and apply a bead of Loctite ® 271 to the new bolts.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 144 STEP 146 2 1 1 1 RD02J002 RD05M043 Tighten the bolts to a torque of 110 to 125 Nm (82 to 92 lb. ft.) Remove the spacers (1). NOTE: Twelve bolt planetary hub assembly shown. Install the thrust washer used on the ten bolt planetary hub assembly, before the installation of the shims. When installing the sun gear shaft (1) into the axle drive shaft yoke (2), the drive shaft will have to be lifted by hand to align the splines.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 148 STEP 151 1 2 RD05M037 RR98K076 Apply petroleum jelly to the inner diameter of the planetary gear. Install the needle bearings in one side of the gear. Install the spacer. Install the needle bearings in the other side of the gear. Place the wire retaining ring (1) over the hub (2).
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 153 STEP 156 RR98K089 Install the upper thrust washers on the planetary gear. STEP 154 RR98K084 Properly support the planetary hub cover and install on the hub. Install the three Allen head bolts. Tighten the bolts to a torque of 10 to 16 Nm (7 to 12 lb. ft.). STEP 157 RR98K131 RR98K086 Install the planetary gear pin and the retaining ring. Repeat the proceeding procedures to install the rest of the planetary gears in the planetary hub.
Section 25 - Four-Wheel Drive Front Axle - Chapter 10 STEP 159 STEP 161 RR98K083 96RS34A Move the planetary hub cover so that the fill plug is in the horizontal position. Fill the planetary hub with Case 135 H EP Gear Lubricant until the oil is level with the bottom edge of the hole. After a few minutes, recheck the oil level. Tighten the planetary fill plug to a torque of 38 to 41 Nm (28 to 30 lb. ft.). Install the front fenders, if equipped.
Section 25 Chapter 11 SUSPENSION FWD AXLE January, 2006
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 TABLE OF CONTENTS SPECIAL TORQUES .................................................................................................................................... 25-11-2 SUSPENSION FWD AXLE ........................................................................................................................... 25-11-3 Disassembly ......................................................................................................................
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 SUSPENSION FWD AXLE Disassembly STEP 3 ATTENTION: Take time to familiarize yourself with potential pinch and crush points on this axle before service work is started. IMPORTANT: Before beginning disassembly, the axle housing must be secured to prevent rollover and falls that could cause damage or injury.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 6 STEP 9 O RD02M007 RD02M104 Remove the two sensor mounting screws and remove the sensor from the bracket. Disassembly of the following parts is from location “O”. STEP 7 STEP 10 1 RD02M009 RD02M013 Loosen the set screw (1) and remove the sensor shaft. Install a slide hammer into the swing arm cradle pin. STEP 11 STEP 8 RD02M016 Move the pin out a small amount and remove the dowel pin.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 12 STEP 14 D D E RD02M015 E RD02M105 Remove the swing arm cradle pin. The following parts are removed from locations “D” and “E”. STEP 13 STEP 15 C C RD02M105 RD02M018 Remove the snap ring from the cylinder pins. STEP 16 RD02M017 Remove the two shoulder bolts from location “C”. RD02M019 Install a slide hammer into the cylinder pin.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 17 STEP 19 G RD02M020 RD02M104 Slide the pin partially out. Do not let the spacer fall out. STEP 18 H RD02M105 The following parts are removed from location “G” and “H”. STEP 20 RD02M021 Remove the pin and spacer. RD02M022 Remove the five bolts from each retaining plate.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 21 STEP 24 RD02M023 RD02M027 Remove both retaining plates. Install a slide hammer into the upper swing arm pin. STEP 22 STEP 25 RD02M024 RD02M028 Remove and discard the O-rings. Remove the pin. STEP 23 RD02M025 Loosen and remove the shoulder bolt.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 26 STEP 28 A K J RD02M104 RD02M030 Remove the snap ring from the lower suspension swing arm. A STEP 29 K J RD02M105 The following parts are removed from locations “A”, “K”, and “J”. STEP 27 RD02M031 Use a magnet and remove the lower swing arm thrust washer. Note that there is a dowel pin in the shaft. STEP 30 RD02M029 Install a sling and carefully lift the cradle off the axle assembly.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 31 STEP 34 RD02M033 RD02M036 Remove the snap ring from the upper suspension swing arm. Remove the upper pin. STEP 35 STEP 32 RD02M037 Remove the snap ring from the suspension cradle. RD02M034 Use a magnet and remove the upper swing arm thrust washer. Note that there is a dowel pin in the shaft. STEP 36 STEP 33 RD02M038 Remove and discard the seals from both sides. NOTE: Seals are different sizes.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 37 STEP 40 E L RD02M039 RD02M104 Inspect the bushing for wear or damage. Remove and replace if necessary. The following parts are removed from locations “E” and “L”. STEP 38 STEP 41 RD02M040 RD02 M042 Connect a strap to the lower swing arm. Carefully remove the swing arm from the axle assembly. Remove the snap rings from the cylinder mounting pins.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 43 STEP 46 RD02M044 RD02M047 Remove the snap rings that retain the spherical bearings and remove the bearings. Inspect the bearings for wear or damage. The cylinder must be replaced if either is present. Remove the seals from the housing. Inspect the bores for damage. STEP 47 STEP 44 RD02M048 Remove the thrust washers. RD02M045 Remove the shoulder bolts from the cylinder mounting pins.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 49 STEP 50 RD02M050 Remove the seals from the upper swing arm. RD02M051 Use a driver to remove the bushings from the swing arm bores.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 Assembly NOTE: For ease of assembly, it is recommended that the axle be assembled with the housing upside down. 20 21 18 3 19 8 16 1 11 9 8 5 10 6 6 3 3 3 16 1 2 5 17 12 6 13 16 9 9 16 3 5 4 14 5 13 10 17 3 7 15 16 6 RI02M063 1. CRADLE 2. BEARING 8. AXLE PIN 15. PLATE 9. SHOULDER BOLT 16. THRUST WASHER 3. SNAP RING 10. SPACER 17. DOWEL 4. UPPER SWING ARM 11. LH CYLINDER 18. BRACKET 5. BUSHING 12.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 51 STEP 54 E L RD02M104 RD02M055 The following parts are assembled in location “L” and “E”. Apply grease to the counter bore. Install the thrust washer. STEP 52 STEP 55 RD02M052 Apply Loctite 609 to the new bushing. RD02M056 Apply Loctite 609 to the new seal case. Install an appropriate driver. STEP 53 STEP 56 RD02M053 Use an appropriate driver and install the bushing until it is flush with the bore.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 57 STEP 60 A O RD02M058 Apply grease to the housing bore. RD02M104 The following parts are assembled in locations “A” and “O”. STEP 58 STEP 61 RD02M059 Install the cylinder mounting pin into the bore. RD02M062 Apply Loctite 609 to the OD of the new bushing. STEP 59 STEP 62 RD02M060 Install the shoulder bolt. Tighten to a torque of 27 to 30 Nm (20 to 22 lb. ft.). RD02M063 Place the cradle on a press.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 63 STEP 66 RD02M064 RD02M068 Install the snap ring. Apply grease to the pin. STEP 64 STEP 67 RD02M065 Apply Loctite 609 to a new seal case. RD02M069 Install the pin into the housing. Align the bolt hole in the pin with the shoulder bolt bore in the housing. NOTE: The cradle uses 2 seals which are different sizes. STEP 68 STEP 65 RD02M070 Install the shoulder bolt into the pin. RD02M067 Ins tal l the seal squarely in the bore.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 69 STEP 72 RD02M071 Tighten the shoulder bolt to a torque of 27 to 30 Nm (20 to 22 lb. ft.). RD02M074 Install the snap rings. STEP 73 STEP 70 A K I RD02M105 Install the cylinder spacer on to the pin. The following parts are assembled at locations “A” “I” and “K”. STEP 71 STEP 74 RD02M072 RD02M073 Install the lift cylinders. RD02M075 Install the grease fitting into the cradle.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 75 STEP 78 RD02M076 Apply grease to the cylinder pins. Use a suitable lifting device and position the cradle so that the cylinders can be installed onto the pins. RD02M078 Install the bushing into the bore. STEP 79 STEP 76 RD02M079 Apply Loctite to a new seal case. RD02M042 Install the snap ring onto the cylinder pins. STEP 80 STEP 77 RD02M080 RD02M077 Use an appropriate driver and install the new seal into the bore.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 81 STEP 84 RD02M081 RD02M084 Apply grease to the swing arm pins. Install the dowel pin. STEP 82 STEP 85 RD02M082 Align the cradle and upper swing arm and install the pin. RD02M085 Continue to drive the pin until seated. STEP 86 STEP 83 RD02M086 RD02M083 Install the thrust washer. Align the dowel pin slot.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 87 STEP 90 RD02M087 Install the snap ring. RD02M025 Tighten the shoulder bolt to a torque of 41 to 45 Nm (30 to 33 lb. ft.). STEP 88 STEP 91 RD02M088 Install the upper cradle swing arm pin. Align the bolt hole in the pin with the shoulder bolt bore in the housing. RD02M024 Install a new O-ring in the receiver groove. STEP 92 STEP 89 RD02M023 RD02M026 Install the shoulder bolt into the pin. Apply Anti-Seize to the end of the pin.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 93 STEP 96 RD02M089 Tighten the plate bolts to a torque of 58 to 64 Nm (43 to 47 lb. ft.). RD02M091 Install the lower swing arm pins. STEP 97 STEP 94 O J N RD02M093 RD02M104 The following parts are assembled at locations “J”, “N” and “O”. Install the dowel pin. Drive the pion in until seated. STEP 98 STEP 95 RD02M949 Install the thrust washer. RD02M090 Move the lower swing arm assembly into position.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 99 STEP 102 RD02M0495 RD02M098 Install the snap ring. Install the pin. STEP 100 STEP 103 RD02M096 RD02M099 Apply grease to the ID of the bearing. Align the dowel pin slot. STEP 101 STEP 104 RD02M097 Apply grease to the lower swing arm/cradle pin. RD02M014 Install the dowel pin. Drive the pin in until seated.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 105 STEP 108 RD02M012 RD02M009 Install the thrust washer. Install the sensor shaft. STEP 106 STEP 109 RD02M100 Install the snap ring. RD02M008 Align the set screw with the flat on the shaft. Tighten the screw. STEP 107 STEP 110 RD02M010 Install the bushing into the sensor housing. RD02M007 Install the sensor onto the mounting bracket.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 STEP 111 STEP 114 RD02M006 RD02M002 Tighten the mounting screws to a torque of 4 to 4.5 Nm (36 to 40 lb. in.). Apply Loctite 243 to the male threads of the ball joint. Install the ball joint onto the axle and tighten to a torque of 19 to 20 Nm (165 to 180 lb. in.). STEP 112 STEP 115 RD02M004 Install the short link with the cutout facing up towards the bracket. Tighten the nut to a torque of 20 to 22.5 Nm (180 to 200 lb. in.).
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 Position Sensor Adjustment STEP 116 RD02M101 The angle position sensor must be checked at the fully collapsed and fully extended positions. Adjust the sensor as follows: 1. Apply 10 to 30 volts DC to pin 2. 2. Measure the signal current at pin 3. (4 to 20 mA) 3. Adjust the sensor slots to achieve 4 to 6 mA when axle is compressed and 18 to 20 mA when the axle is extended.
Section 25 - Four-Wheel Drive Front Axle - Chapter 11 25-11-26
Section 25 Chapter 12 SUPERSTEER AXLE VERTICAL CONTROL LINKAGE January, 2006
Section 25 - Four-Wheel Drive Front Axle - Chapter 12 TABLE OF CONTENTS SPECIAL TORQUES .................................................................................................................................... 25-12-3 VERTICAL LINK DISASSEMBLY AND REPAIR .......................................................................................... Vertical Link Removal ...............................................................................................................................
Section 25 - Four-Wheel Drive Front Axle - Chapter 12 SPECIAL TORQUES M20 x 70 mm Socket Head Screws........................................................................ 295 to 530 Nm (215 to 315 lb. ft.) Special Hex Head Bolts .......................................................................................... 220 to 280 Nm (160 to 205 lb. ft.) M24 x 355 mm Mounting Bolts ............................................................................... 710 to 915 Nm (525 to 675 lb. ft.
Section 25 - Four-Wheel Drive Front Axle - Chapter 12 Roller Replacement STEP 5 STEP 7 RD02K007 If the bushings need replaced in the axle links and the vertical link, remove the bushing seals. RD02K009 STEP 6 RD02K008 Use a press to remove the bushings from the axle links and vertical link if required. RH02K003 If the rollers need replaced, remove the two M20 x 70 mm socket head screws and remove the roller pin, washers and roller.
Section 25 - Four-Wheel Drive Front Axle - Chapter 12 Articulation Bearing Removal and Installation STEP 8 STEP 10 2 3 5 4 6 1 RD02K011 RH02K005 Remove the safety guard to gain access for removal of the air to air aftercooler pipe. STEP 9 1 RD02K010 Support the bottom of the front axle rear support (1) to keep it from falling when the retaining ring (4) is removed. RD05N023 1. Remove the dust cap retainer ring (2).
Section 25 - Four-Wheel Drive Front Axle - Chapter 12 Vertical Link Assembly STEP 11 STEP 13 6 6 1 2 RD02K008 RD02K003 Press the bushings into the axle links and vertical link (if required). Install the bushing seals into the vertical link and axle links. 2 STEP 12 2 3 3 3 4 4 5 1 RH02K002 1 RH02K002 2 Support the vertical link assembly (1) with a lift stra[p and hoist. Install a 55.5 x 88 x 3 mm washer (4) on the linkage pins (3) in the axle.
Section 27 Chapter 1 REAR AXLE AND PLANETARIES January, 2006
Section 27 - Rear Axle - Chapter 1 TABLE OF CONTENTS SPECIAL TOOLS ........................................................................................................................................... 27-1-3 SPECIAL TORQUES ...................................................................................................................................... 27-1-5 SPECIFICATIONS ............................................................................................................................
Section 27 - Rear Axle - Chapter 1 SPECIAL TOOLS RH02D122 RH02D124 Rear Housing Handler 17-527 Brake Disc Alignment Tool 89-581-5 RH02D123 CAS2601 Pushing Bridge 89-525-18 Alignment Guide Pins (studs) CAS2601 RD02E109 Cab Raising Bracket Kit CAS2577 27-1-3
Section 27 - Rear Axle - Chapter 1 400I7 Puller Set with 30-Ton Ram CAS10030 T82109 T82107 Bushing Bearing And Seal Driver Set CAS 10387 Universal Driver Set (3-1/16 Inch To 4-1/2 Inch Diameter) CAS10389 Tool Organizer Board CAS10390 T82108 Universal Driver Set (1/2 Inch To 4-1/2 Inch Diameter) CAS10388 27-1-4
Section 27 - Rear Axle - Chapter 1 SPECIAL TORQUES Axle Mounting Bolts................................................................................................ 220 to 250 Nm (171 to 193 lb. ft.) SPECIFICATIONS Axle Rolling Torque Without Outer Seal Set Torque 4 inch Axle ......................................................................... 250 to 300 lb. in. (28.0 to 34.0 4.5 inch Axle ............................................................................ 290 to 420 lb. in. (28.0 34.
Section 27 - Rear Axle - Chapter 1 REAR AXLE REMOVAL STEP 1 STEP 2 91S16 13S23 Move the rear housing handler CAS17-527 into position under the tractor. STEP 3 91S10 Drain the rear axle as follows: 1. Put a container under the transmission housing. 2. Remove the drain plug and drain the fluid from the transmission housing. 13S29 Raise the front lift of the rear housing handler. Turn the rear threaded rods until the rear frame is supported. 3.
Section 27 - Rear Axle - Chapter 1 STEP 4 STEP 7 1 2 86S1 RD02F104 Remove the wheel and tire assemblies from both axles. Remove the cab mounting bolt (1) from the cab mount. Lifting bracket (2) can be left in place. STEP 5 STEP 8 Raise the rear of the cab. See Cab Raise Procedure in this Service Manual. 2 STEP 6 1 1 RD06A002 Remove the axle bolts that retain the draft pin wiring tub bracket (1) and the hitch cylinder hose bracket (2). Move the brackets out of the way.
Section 27 - Rear Axle - Chapter 1 STEP 10 STEP 12 1 RD06A004 T97974 Install a lifting strap at the axle balance point. Install a bolt (1) on each side of the axle, this will prevent the lifting strap from possibly sliding off. Put tension on the lift strap. Remove the remaining bolts and remove the axle. Remove the retaining ring from the axle shaft. STEP 13 NOTE: It will be necessary to break loose the axle flange sealant by hitting the axle end with a soft faced mallet.
Section 27 - Rear Axle - Chapter 1 AXLE HOUSING DISASSEMBLY STEP 15 STEP 17 512L0 T97981 Remove the nylon wear insert from the axle shaft end. Remove the retaining ring from the axle shaft. Press on the thrust ring to relieve pressure on the retaining ring before removing retaining ring from shaft. Remove the shims from the axle shaft. STEP 18 STEP 16 T97984 Install a pulling bridge and a 30-ton ram on the axle housing. Press the axle assembly out of the axle housing.
Section 27 - Rear Axle - Chapter 1 STEP 20 STEP 23 T97986 T97994 Use a puller to remove the bearing from the axle shaft. Use a puller to remove the inner bearing cup from the axle housing. STEP 21 STEP 24 T97988 T97997 Remove and discard the O-ring used on 4-in. axles from the axle bushing. Use a puller to remove the outer bearing cup from the axle housing. STEP 22 T97991 Use a puller to remove the bushing from the axle shaft.
Section 27 - Rear Axle - Chapter 1 PLANETARY DISASSEMBLY STEP 25 STEP 27 T98000 T98002 If the planetary gears are to be used again, make marks so that the gears are assembled in their original location in the gear carrier. Remove the planet gear shaft from the planetary gear carrier. STEP 28 STEP 26 T98003 Remove the planetary gear and bearing assembly from the gear carrier. T97999 Drive the roll pin into the planet gear shaft.
Section 27 - Rear Axle - Chapter 1 STEP 29 STEP 30 RD98C193 RD98C194 Remove the thrust washer and needle bearings from one side of the planet gear. Remove the thrust ring. Turn the planet gear over and remove the other thrust washer and needle bearings. STEP 31 Repeat Steps 22 through 27 for the other planet gear assemblies.
Section 27 - Rear Axle - Chapter 1 DIFFERENTIAL CARRIER SEAL REPLACEMENT STEP 32 STEP 33 T98027 T98028 Remove the seal from the differential carrier. Use a driver to install a new seal until the seal is flush with the surface of the differential carrier.
Section 27 - Rear Axle - Chapter 1 PLANETARY ASSEMBLY - THREE PIN 2 5 7 1 9 3 4 6 8 107l94A 1. THRUST WASHER 2. NEEDLE BEARING 3. PLANET GEAR 4. THRUST RING 5. NEEDLE BEARING 6. THRUST WASHER 27-1-14 7. ROLL PIN 8. PLANET GEAR CARRIER 9.
Section 27 - Rear Axle - Chapter 1 PLANETARY ASSEMBLY - FOUR PIN 10 13 12 11 4 10 9 8 7 3 14 6 5 1 2 RI06A014 1. 2. 3. 4. 5. RING GEAR GEARS CARRIER SHAFT PIN RETAINER RING 6. 7. 8. 9. 10. GEAR SHAFT HUB WASHER RETAINER RING WASHER 27-1-15 11. 12. 13. 14.
Section 27 - Rear Axle - Chapter 1 STEP 34 STEP 36 RD98C0194 T98003 Lubricate the needle bearings with petroleum jelly to keep them in place and install the bearings on one side. Turn the planet gear around and install the thrust ring. Install the remaining needle bearings lubricated with petroleum jelly. Put the planet gear assembly into position in the gear carrier. Make sure that the assemblies are installed in their original locations. NOTE: Three-gear planetary shown.
Section 27 - Rear Axle - Chapter 1 STEP 38 STEP 39 T98001 T97999 Slide the bearing shaft through the planet gear bearings until the roll pin hole can be seen in the planet gear carrier. Install the roll pin in the bearing shaft until the end of the pin is flush with planet gear carrier housing. STEP 40 Repeat the procedure for the other planet gears in the remaining planetary assembly.
Section 27 - Rear Axle - Chapter 1 AXLE HOUSING ASSEMBLY 8 9 1 2 3 4 5 10 11 6 7 15 12 13 14 16 17 18 RI06A013 1. 2. 3. 4. 5. 6. RETAINING RING THRUST RING SHIMS BEARING CONE BEARING CUP DOLL PIN 7. 8. 9. 10. 11. 12. AXLE HOUSING WASHER BOLT BEARING CONE BEARING CUP O-RING 27-1-18 13. 14. 15. 16. 17. 18.
Section 27 - Rear Axle - Chapter 1 STEP 41 STEP 43 T97967 T97988 Install the retaining ring in the groove of the sun gear shaft. 1 4-Inch Axle 2 STEP 42 115RING Lubricate a new O-ring (1) with transmission fluid or petroleum jelly and install in the groove of the axle bushing (2). 4-Inch Heavy Duty Axle 1 STEP 44 399L7 Press the bushing (1) onto the axle shaft with 89 000 N (20 000 lb.) force so that it is seated tightly on the shoulder.
Section 27 - Rear Axle - Chapter 1 4.5-Inch Axle STEP 48 STEP 45 1 2 T97995 Put antiseize compound on the OD of the inner bearing cup. Use a driver to install the bearing cup into the axle housing until the cup is seated. 115BSHG Lubricate a new O-ring (1) with transmission fluid or petroleum jelly and install into the groove in the axle bushing (2). Press the axle bushing with O-ring installed on the axle shaft with 89000 N (20 000 lb.) force so that it is seated tightly on the shoulder.
Section 27 - Rear Axle - Chapter 1 4-Inch Standard Axle 4-Inch Heavy Duty Axle STEP 50 STEP 51 T98042 T98042 Press the inner bearing onto the axle shaft with about 93 450 N (21 000 lb.) force while oscillating and rotating the axle until a rolling torque of 28 to 34 Nm (250 to 300 lb. in.) is obtained. The torque may be checked with a torque wrench on the nut installed on the threaded rod. Press the inner bearing onto the axle shaft with about 93 450 N (21 000 lb.
Section 27 - Rear Axle - Chapter 1 For All Axles STEP 54 3 STEP 53 4 2 1 375L0 T97976 Determine shim pack requirements as follows: 1. Remove threaded rod, ram, and spacer. 2. Do not rotate the axle. 3. Measure the distance from the bearing to the far side of the bearing snap ring groove. 4. Select a shim pack whose total height when combined with the thrust ring and retaining ring is equal to the distance obtained in step 3. 5. Install the shim pack, thrust ring, and retaining ring on the axle.
Section 27 - Rear Axle - Chapter 1 HOW TO DETERMINE RAM PRESSURE STEP 55 STEP 56 Do the following to determine what the pressure gauge must show for your ram: 1. Determine the effective area of your ram. 2. Determine the minimum and maximum pressure gauge readings desired. Example: Find the effective area of twin rams, each ram having a piston diameter of 1.5 inch. The formula for the effective area is: Effective Area = (2d + 2d) x 0.7854 T97977 d = diameter of each ram (1.
Section 27 - Rear Axle - Chapter 1 STEP 57 STEP 60 T97975 T98015 Put the planetary in place on the inner axle shaft (three planetary gears shown). 1 STEP 58 280L7 4 Inch Axle T97974 Install the planetary assembly retaining ring in the groove on the axle shaft. 1 STEP 59 2 115SEAL 4-1/2 Inch Axle Fill the inner two grooves of the axle seal approximately half full with 251H EP Lithium grease (1). 1 512L0 1. NYLON WEAR INSERT 1. AXLE END Install a new nylon wear insert in the axle.
Section 27 - Rear Axle - Chapter 1 STEP 61 STEP 63 95S3 T97973 Apply Loctite 515 gasket eliminator on the OD of the seal. Install the seal over the axle shaft and into the axle housing. The edge of the seal must be flush with the axle housing. Install the ring gear on the axle housing assembly. STEP 64 Repeat Steps 50 through 71 for the remaining axle if being serviced. IMPORTANT: Use flat bar (not shown) between driver and seal to install seal flush with housing.
Section 27 - Rear Axle - Chapter 1 AXLE INSTALLATION STEP 65 STEP 67 87S13 87S19 Use a brake aligning tool to align the teeth of the brake discs. Remove the brake aligning tool from the brake discs. STEP 68 STEP 66 92S5 Install the sun gear shaft through the brake discs and into the rear frame. If removed, install the guide pins in the rear frame. Apply Loctite© 515 gasket eliminator on the mounting surface in the rear frame.
Section 27 - Rear Axle - Chapter 1 STEP 70 STEP 73 RD06A005 86S24CU Use a suitable tool and rotate the axle until the sun and planet gears engage. Tighten the axle housing mounting bolts to a torque of 232 to 262 Nm (171 to 193 lb. ft.). STEP 71 STEP 74 1 2 RD06A003 RD02F104 Install a few axle housing mounting bolts and tighten until the axle housing contacts the rear housing flange. Remove the aligning dowels. Install the cab mount bolt (1).
Section 27 - Rear Axle - Chapter 1 STEP 78 STEP 76 Remove the rear housing handler from the tractor. STEP 79 Fill the transmission with fluid. See the Operator’s Manual for the correct fluid type. Run the tractor and check the fluid level. Add as necessary. RD02F026 Install the washer and nut. Torque cab mounting nut to 190 to 244 Nm (140 to 180 lb. ft.) STEP 77 86S1 Install the wheel and tire assemblies on the rear axles.
Section 27 - Rear Axle - Chapter 1 1 2 3 4 7 6 5 21 18 6 20 7 19 22 8 17 9 15 12 10 16 15 11 14 13 RH98C007 1. 2. 3. 4. 5. 6. AXLE SHAFT BUSHING SEAL RING AXLE HOUSING BEARING CUP 7. 8. 9. 10. 11. 12. BEARING CONE PLANET GEAR CARRIER RING GEAR WEAR INSERT SUN GEAR SHAFT NEEDLE BEARINGS 13. 14. 15. 16. 17. 18. LOCATOR BUTTON (RIGHT HAND ONLY) SEAL THRUST WASHER THRUST RING ROLL PIN PLANET GEAR SHAFT 27-1-29 19. 20. 21. 22.
Section 27 - Rear Axle - Chapter 1 AXLE SEAL WEAR SLEEVE INSTALLATION (4-Inch Axle Only) STEP 80 STEP 82 93S28 94S6 Remove the old seal from the axle housing. Clean the axle bushing of any foreign material and remove any scratches. Make sure that the axle bearing is not contaminated. STEP 81 STEP 83 93S32 Remove the old wear sleeve, if equipped. Check wear sleeve dimensions. If a thick sleeve was installed, a puller may be required to remove the sleeve.
Section 27 - Rear Axle - Chapter 1 STEP 84 STEP 86 94S10 94S26 Apply Loctite 290 to seal the area between the axle bushing and axle. Install the wear sleeve as follows: 1. Heat the new wear sleeve in a bearing oven to 191° to 204°C (375° to 400°F). STEP 85 ! WARNING: Always wear heat protective gloves to prevent burning your hands when handling heated parts. SM121A 2. Install the sleeve onto the axle bushing with the OD chamfer to the outside. The wear sleeve must just touch or be no more than 0.
Section 27 - Rear Axle - Chapter 1 STEP 87 STEP 88 T98015 94S34 Apply Loctite 515 gasket eliminator to the OD of the axle shaft. 1 STEP 89 280L7 Fill the inner two grooves of the axle seal approximately half full with 251H EP Lithium grease (1). 95S3 Start the axle seal over the axle and into the axle housing. The edge of the seal must be flush with the axle housing. IMPORTANT: Place a flat bar (not shown) between the drive and seal to install the seal flush with the axle housing.
Section 31 Chapter 1 POWER TAKE OFF CONTROL SYSTEM How it Works January, 2006
Section 31 - PTO - Chapter 1 TABLE OF CONTENTS POWER TAKE OFF ....................................................................................................................................... 31-1-3 ELECTRONIC PTO CONTROL ..................................................................................................................... 31-1-4 PTO SYSTEM CONTROL ..............................................................................................................................
Section 31 - PTO - Chapter 1 POWER TAKE OFF General Description - The PTO system consists of the of the PTO control switch, engine RPM speed circuit, PTO shaft speed circuit, dual speed sensor, PTO control valve, PTO clutch, PTO control module, arm rest control module, and Instrument cluster unit, (through the Data Bus). The PTO valve is mounted externally on top of the rear frame transmission housing. The control valve is supplied with regulated circuit pressure from the priority regulator valve.
Section 31 - PTO - Chapter 1 ELECTRONIC PTO CONTROL General Description - The PTO system consists of the PTO control switch, engine RPM speed circuit, PTO shaft speed circuit, dual speed sensor, PTO control valve, PTO clutch, PTO control module, arm rest control module, and instrument control unit, (through the Data Bus). PTO Control Switch - This switch provides the operator interface with the PTO system. The PTO switch has a yellow cover for easy identification.
Section 31 - PTO - Chapter 1 1 RD05J060 1.
Section 31 - PTO - Chapter 1 PTO Control Module - The PTO control module is located under the SMV cover at the back of the cab. The PTO control module provides the electrical current to apply the PTO clutch when instructed by the operator. All PTO operator commands are sent to the Arm Rest Control Module (PTO switch is hard wired to the Arm Rest Control Module), then relayed to the PTO controller via the Data Bus.
Section 31 - PTO - Chapter 1 PTO SYSTEM CONTROL ENGINE SPEED KEY SWITCH ENGINE AUX/PTO/HITCH CONTROL MODULE (TMF) ALTERNATOR ENGINE SPEED W DIFF. L SWITCH MFD SWITCH PTO SWITCH OFF/ON OFF/ OFF ON ON PTO CONTROL TRANSMISSION ARMREST CONTROL MODULE PTO CLUTCH VALVE PTO CLUTCH PTO SHAFT SPEED SENSOR INST.
Section 31 - PTO - Chapter 1 PTO CONTROL MODES OFF - When the PTO switch is placed in the OFF position, the PTO clutch will be deactivated. The PTO switch OFF signal is directed to the armrest controller and communicated to the PTO control module through the Data Bus. NOTE: PTO switch ON signal is directed to the PTO control module directly (hard wired to PTO controller). Fill Mode - The PTO switch ON signal is hard wired to the PTO controller.
Section 31 - PTO - Chapter 1 Excessive PTO Slip Detection - Excessive slip is defined as one of the following: 1. Slip is greater than 15% for 100 milliseconds continuously. 2. Slip of 3-15% for a period of 2 seconds continuously. 3. Slip is greater than 3% for 100 milliseconds continuously and then increases to more than 15% for 10 milliseconds continuously.
Section 31 - PTO - Chapter 1 PTO VALVE OIL SUPPLY PTO Differential Lock Valve The PTO differential lock valve is a closed center valve supplying regulated circuit pressure to the PTO and differential lock control circuits. Regulated circuit oil is supplied to the PTO valve through the priority/regulator valve. Pressure is regulated to approximately 2240 to 2450 kPa (325 to 355 PSI) and can be adjusted if required.
Section 31 - PTO - Chapter 1 PTO DIFFERENTIAL LOCK VALVE 7 12 12 6 5 2 8 1 2 9 4 2 11 3 10 13 13 RT98A023 RI02B035 AND B036 PORT IDENTIFICATION 1. 2. 3. 4. 5. VALVE INLET PORT PLUGGED PORT LUBE INLET PORT PTO LUBE TANK 6. PTO CLUTCH SUPPLY 7. BLOCKED PASSAGE 8. 9. 10. 11. 12. REMOTE VALVE PILOT SUPPLY DIF LOCK SUPPLY TANK MESH LUBE PTO PROPORTIONAL CURRENT CONTROL SOLENOID 13.
Section 31 - PTO - Chapter 1 TROUBLESHOOTING Problem - PTO clutch will not disengage 1. Check for PTO fault codes. A. If fault codes are found, follow procedures outlined in PTO system fault code troubleshooting in this section. 2. Place the PTO switch in the OFF position. Check tractor monitor for PTO icon in the instrumentation display. A. If the PTO icon is not displayed, this is an indication the electrical control circuit is functioning correctly. Go to step 4. B.
Section 31 - PTO - Chapter 1 PTO Clutch Engaged When the PTO switch is actuated, the PTO controller sends a fixed current signal to the PTO solenoid. The solenoid spool shifts, metering oil to the top of the modulator piston (2). As pressure builds the piston moves down against the force of both the inner and outer modulator springs (3 and 4). As the piston moves down the center stem of the piston moves into the bore of the modulator spool (5).
Section 31 - PTO - Chapter 1 TROUBLESHOOTING Problem - PTO will not engage 1. Check for PTO fault codes. A. If fault codes are found, follow procedures outlined in PTO fault code troubleshooting in this section. 2. Place the PTO switch in the ON position. Check tractor monitor for PTO icon in the instrumentation display. A. If the PTO icon is displayed, this is an indication the electrical control circuit is functioning correctly. Go to Step 4. B.
Section 31 - PTO - Chapter 1 P TO C L U T C H PISTON DIFFERENTIAL LOCK PISTON P TO CLUTCH LUBE P TO SOLENOID DIFF LOCK SOLENOID R E G U L AT E D SUPPLY BEVEL PIN LUBE RH02A059 31-1-15
Section 31 - PTO - Chapter 1 Problem PTO engages too rapidly 1. Check for PTO fault codes. A. If fault codes are found, follow procedures outlined in PTO fault code troubleshooting in this section. B. If no fault codes are found, go to step 2. 2. PTO clutch not filling and modulating properly. A. Solenoid cartridge valve spool opening too far. 3. Replace solenoid cartridge. B. PTO spool assembly sticking, or damaged. 4. Replace PTO spool. C. PTO clutch plates damaged. 5. Repair PTO clutch. D.
Section 31 - PTO - Chapter 1 Problem PTO engages then stops 1. Check for PTO faults codes. A. If fault codes are found, follow procedures outlined in PTO fault code troubleshooting in this section. B. If no fault codes are found, go to step 3. 2. PTO clutch slipping excessively. A. Load on PTO too heavy. B. Reduce load 3. PTO clutch pressure too low. A. PTO solenoid not energizing properly. 4. Check wires 597A (LU) and 598A (BK) ground for excessive resistance. 5. Check for loose connections. 6.
Section 31 - PTO - Chapter 1 P TO C L U T C H PISTON DIFFERENTIAL LOCK PISTON P TO CLUTCH LUBE P TO SOLENOID DIFF LOCK SOLENOID R E G U L AT E D SUPPLY BEVEL PIN LUBE RH98H048 31-1-18
Section 31 Chapter 2 PTO CLUTCH ASSEMBLY Single, Reversible and Dual Speed January, 2006
Section 31 - PTO - Chapter 2 TABLE OF CONTENTS SPECIAL TOOLS ........................................................................................................................................... 31-2-3 SPECIAL TORQUES ...................................................................................................................................... 31-2-3 PTO CLUTCH ASSEMBLY ............................................................................................................................
Section 31 - PTO - Chapter 2 SPECIAL TOOLS RI05F022 CAS19956 380002454 PTO Clutch Brake Spring Compressor CAS-1995-6 Guide Pins SPECIAL TORQUES Reversible PTO Output Shaft Rolling Torque ....................................................................................... 2 to 18 in. lbs. Cover for PTO Clutch Assembly Bolts .................................................................... 490 to 550 Nm (361 to 406 lb. ft.) Output Shaft Housing Bolts ...............................................
Section 31 - PTO - Chapter 2 PTO CLUTCH ASSEMBLY General ● Thoroughly clean the top, sides and rear of the PTO components to prevent any dirt or debris from entering the final drive. ● If the PTO clutch and or brake is to be serviced, the complete PTO clutch assembly must be removed from the final drive housing.
Section 31 - PTO - Chapter 2 STEP 3 Remove the third link support/PTO clutch cover plate and gasket. Discard gasket. RD05A014 STEP 4 The PTO manifold plate (1) and speed sensor (2) are located on the rear frame cover plate between the remote valves and remote valve couplers. Disconnect the wire harness (3) from the speed sensor and remove the sensor (2). Remove the PTO manifold plate (3). 3 1 2 NOTE: Hitch rock shaft removed for photographic purposes.
Section 31 - PTO - Chapter 2 STEP 7 Install two CAS-1995-6 guide pins (1) then remove the two lower mounting bolts (2). 1 2 RD05A047 STEP 8 Remove the PTO assembly. RD05A048 Disassembly STEP 9 Place the PTO assembly in a press. Press down on the carrier just enough to free the snap ring. Remove the snap ring.
Section 31 - PTO - Chapter 2 STEP 10 1 Place a puller (1) on the clutch carrier with the jaws under the tabs of a separator plate (2). Once the carrier is free from the shaft, place on a clean work surface. NOTE: Use care, separator plate tabs may bend when removing clutch carrier. 2 RD05A020 STEP 11 Remove the snap ring. RD05A022 STEP 12 Remove the clutch backing disc. RD05A024 STEP 13 Remove the eight friction plates and eight separator plates and discard.
Section 31 - PTO - Chapter 2 STEP 14 Turn the carrier over as shown and tap the carrier on a hard surface to dislodge the piston. RD05A027 STEP 15 Remove the piston. RD05A028 STEP 16 Remove the seal ring and discard. RD05A029 STEP 17 Remove the O-ring and discard.
Section 31 - PTO - Chapter 2 STEP 18 Remove the seal and O-ring from the clutch carrier and discard. RD05A031 STEP 19 Remove the brake pusher disc. RD05N141 STEP 20 Remove the Belleville washer retaining ring. RD05N144 STEP 21 Remove the seven Belleville washers. Remove the second retaining ring. IMPORTANT: Note the position of the washers so that they are reinstalled in the same way.
Section 31 - PTO - Chapter 2 STEP 22 Once all Belleville washers are removed, remove the third retaining ring. RD05N142 1 STEP 23 3 Remove the thrust washers (1) and thrust bearing (2). 2 1 RD05N145 STEP 24 Lift the hub off the shaft, taking care not to damage the bearings. RD05B032 STEP 25 1 Place Special Tool 380002454 (1) over the hub so that the feet of the tool are sitting on the three brake adjuster pins.
Section 31 - PTO - Chapter 2 STEP 26 Remove the snap ring. RD05N146 STEP 27 1 Remove the top brake holder plate (1). Note the tabs (2) on the holder plate are facing towards the friction plate. 2 RD05N147 STEP 28 Remove the brake friction plate. RD05N148 STEP 29 Remove the three brake adjuster pins.
Section 31 - PTO - Chapter 2 STEP 30 Remove the second brake holder plate. Note the tabs (1) on the holder plate are facing towards the friction plate. 1 RD05N150 1 STEP 31 3 Remove the first brake apply disc spring. RD05N151 STEP 32 Remove the second brake apply disc spring. RD05N152 1 STEP 33 3 Remove the two needle bearings (1) and needle bearing support ring (2) from the PTO drive shaft assembly.
Section 31 - PTO - Chapter 2 STEP 34 Remove the two needle bearing thrust washers (1) and the needle bearing (2). 2 1 RD05B034 STEP 35 Place the drive shaft assembly in a press as shown and press down on the inner race of the bearing. Press only far enough to remove tension on the snap ring. RD05B036 STEP 36 Remove the snap ring. RD05B037 STEP 37 Remove bearing spacer.
Section 31 - PTO - Chapter 2 STEP 38 Remove shim pack. RD05B039 STEP 39 Place the bearing cage (1) between two support blocks (2) and press the drive shaft assembly (3) free of the bearing cage. 3 IMPORTANT: Do not allow the shaft to fall to the floor. 1 2 RD05B040 STEP 40 Remove the three seal rings and discard. RD05D001 STEP 41 Press the bearing from the shaft.
Section 31 - PTO - Chapter 2 STEP 42 Remove bearing cones from each side of the bearing cage.
Section 31 - PTO - Chapter 2 Assembly Exploded View of PTO Clutch 2 3 4 1 5 4 7 6 9 4 10 12 11 6 13 5 14 4 15 3 16 8 17 18 21 19 3 20 22 23 24 28 23 26 29 25 27 32 31 30 33 30 31 36 30 38 35 34 37 RI05D013 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. COUNTERSHAFT PTO DRIVE SHAFT RETAINING RING THRUST WASHER THRUST BEARING NEEDLE BEARING NEEDLE BRG SUPPORT RING BELLEVILLE WASHERS JUMPER TUBE O-RING RETAINING RING SPACER SHIM PACK BEARING CONE 15. 16. 17. 18. 19. 20.
Section 31 - PTO - Chapter 2 STEP 43 Press bearing cup into bearing carrier. RD05D011 STEP 44 Press second cup into bearing carrier. RD05D012 STEP 45 Press bearing onto the PTO drive shaft. Make sure the bearing is seated against the bearing spacer. NOTE: DO NOT press on the bearing cage. DO NOT overpress or deflection of the retaining ring will occur. This will affect the shimming. RD05D006 STEP 46 Apply petroleum jelly or Lubriplate® to the seal rings and install.
Section 31 - PTO - Chapter 2 STEP 47 Apply petroleum jelly or Lubriplate® to the seal ring bore and chamfer of the bearing cage. Place the bearing cage over the shaft and press the bearing until a slight drag is felt on the cage as it is turned. RD05B041 STEP 48 Install the shim pack. RD05B039 STEP 49 Install the bearing spacer. RD05B038 STEP 50 Adjust the shim pack until a slight drag is felt on the retaining ring when it is placed in the groove. REDUCE the shim pack by 0.002 inch.
Section 31 - PTO - Chapter 2 STEP 51 Install the retaining ring. RD05B037 STEP 52 Back press the bearing cone against the shims, s p a c e r a n d r e t a i n i n g r i n g . B a ck p r e s s i n g i s accomplished by supporting the bearing cage (1) on the rear flange face (2) and pressing down against the front of the shaft (3) where the internal spline is. 3 NOTE: DO NOT overpress or deflection of the spacer and retaining ring will occur. This will affect the shimming.
Section 31 - PTO - Chapter 2 STEP 55 Install the second brake apply disc spring. Make sure spring fingers (1) are pointed away from the hub gear (2). 1 2 RD05N151 1 STEP 56 3 Discs should be installed as shown. RD05N158 STEP 57 Install the first brake holder plate. Make sure the tabs (1) are pointed away from the disc spring (2). 2 1 RD05N150 STEP 58 Set the retainer ring (1) on the brake adjuster pin (2) so that it is approximately 1/2 inch from the end of the pin. Repeat with the other pins.
Section 31 - PTO - Chapter 2 STEP 59 Install the three adjusting pins. RD05N149 STEP 60 Install the brake friction plate. RD05N148 1 STEP 61 Install the second brake holder plate with the tabs (1) facing down. Align the holes in the plate with the brake adjuster pins. Make sure the tabs on the second plate are NOT aligned with the tabs of the first plate.
Section 31 - PTO - Chapter 2 STEP 62 2 Place the retaining ring (1) over the clutch pack hub. Using Special Tool 380002454, compress the brake holder plates until the retaining ring is fully seated into the groove. 1 NOTE: Make sure the cutouts (2) of the tool are NOT over the brake adjuster pins (3). Tool has to push the brake adjuster pins flush with the holder plate (4) to allow the retaining ring to seat into the groove.
Section 31 - PTO - Chapter 2 STEP 65 Install thrust washer (1), bearing (2) and thrust washer (1). 2 1 RD05B034 STEP 66 Install needle bearing (1), bearing spacer (2) and needle bearing (3). 1 2 3 RD05B033 1 STEP 67 3 Place the gear /hub assembly over the shaft. RD05B032 STEP 68 Install a thrust washer (1), bearing (2) and thrust washer (1).
Section 31 - PTO - Chapter 2 STEP 69 Install the first retaining ring. NOTE: There should be three retaining ring grooves left after installing this retaining ring. RD05N142 STEP 70 Install the second retaining ring. Install the seven Belleville washers. NOTE: When installing the Belleville washers, make sure they are orientated as shown below. RD05N143 RD05N157 STEP 71 Install the Belleville washer retaining ring.
Section 31 - PTO - Chapter 2 STEP 72 Install the brake pusher plate. RD05N141 STEP 73 Apply petroleum jelly to the carrier seal groove. Apply petroleum jelly to a new O-ring and install. NOTE: Make sure the O-ring is not twisted when installed. RD05B028 STEP 74 Apply petroleum jelly and install a new seal and install the seal ring. IMPORTANT: DO NOT stretch new seal any more than required. RD05B029 STEP 75 Apply petroleum jelly to a new O-ring and install on the piston.
Section 31 - PTO - Chapter 2 STEP 76 Apply petroleum jelly to a new seal and install. IMPORTANT: DO NOT stretch new seal any more than required. RD05A033 STEP 77 Making sure all sealing surfaces are well-lubed, install the piston into the clutch carrier. RD05A028 STEP 78 Install the first separator plate. RD05A026 STEP 79 Alternate the friction plates and separator plates as shown. Starting with a friction plate, install the eight friction plates and seven separator plates.
Section 31 - PTO - Chapter 2 STEP 80 Install the clutch backing disc. RD05A024 STEP 81 Install the snap ring. RD05A023 STEP 82 1 3 With a depth micrometer, measure the distance from the top of the hub (1) to the top of the pusher plate (2) at each pin (3). Average the three measurements. Record this measurements to obtain “A”. 1 2 3 RD05N153 With a depth micrometer, measure the distance from the backing plate (4) to the top of the hub (5) at three locations. Average these measurments.
Section 31 - PTO - Chapter 2 STEP 83 Align the teeth of the friction plates as shown. RD05B027 STEP 84 Place the clutch pack assembly over the hub, making sure all friction plate teeth are engaged in the splines. NOTE: It may be necessary to rotate and LIGHTLY tap the end of the clutch carrier to align the friction brake teeth with the splines. IMPORTANT: BE SURE not to break any friction brake teeth during installation. RD05D024 STEP 85 1 3 Press down on the clutch carrier and install the snap ring.
Section 31 - PTO - Chapter 2 STEP 87 Place the clutch assembly on the CAS-1995-6 guide pins (1) and slide into place. Install the two lower mounting bolts (2). 1 NOTE: Clutch assembly may have to be rotated slightly to align the splines of the clutch drive shaft with the countershaft. 2 RD05A047 STEP 88 1 3 1 3 Remove the guide pins and install the two upper mounting bolts. RD05A046 STEP 89 Install new O-rings on both ends of the jumper tubes (1) and push into place.
Section 31 - PTO - Chapter 2 STEP 91 Install the third link support/PTO clutch cover plate with a new gasket. RD05A014 STEP 92 1 3 1 3 If equipped, install the quick coupler. RD05A013 STEP 93 If equipped with a hydraulic cylinder-assisted third link, note the position of the hoses and install into the quick couplers.
Section 31 - PTO - Chapter 2 Cross Section of PTO Clutch and Output Shaft Assembly 2 1 3 24 25 21 22 24 23 27 26 20 28 4 6 19 11 12 15 5 19 7 8 6 18 9 10 16 17 14 13 11 12 RI05C001 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. SPEED SENSOR PTO MANIFOLD PLATE PTO JUMPER TUBE PTO DRIVE SHAFT ASSEMBLY PTO INTERMEDIATE DRIVE SHAFT TAPPER ROLLER BEARING / CONE COUNTERSHAFT RETAINER RING SHIM PACK PTO DRIVE GEAR BEARING CAGE MFD CLUTCH BEARING SPACER 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Section 31 - PTO - Chapter 2 SINGLE SPEED REVERSIBLE SHAFT PTO Disassembly STEP 94 Remove cotter pin and washer (1). Remove pivot rod, washers and spring (2). Remove the PTO top shield (3). 1 3 2 RD05A014 STEP 95 Push quick disconnect coupler (1) to expose the locking ring (2) and remove the ring. 1 NOTE: Hitch components and draw bar rear support are removed for photographic purposes. 2 RD05B016 STEP 96 Remove the coupler.
Section 31 - PTO - Chapter 2 STEP 97 Remove the four coupler retaining balls. RD05B014 STEP 98 Remove the shaft seal and discard. RD05B018 STEP 99 Remove the eight mounting bolts. RD05B011 STEP 100 Remove the housing cover. Clean both mounting surfaces.
Section 31 - PTO - Chapter 2 STEP 101 1 Remove the output sleeve shaft. NOTE: If bearing and cup on the PTO driven gear (1) needs service, see Single Speed Reversible Shaft Driven Gear Section. RD05A059 STEP 102 Remove the bearing cone from the housing. 83LS9 STEP 103 Press the bearing from the output sleeve shaft.
Section 31 - PTO - Chapter 2 Assembly Exploded View of PTO Output Shaft and Driven Gear Assembly 6 5 3 4 7 8 1 9 10 11 16 12 2 17 13 14 15 18 RI05D011 1. 2. 3. 4. 5. 6. OIL SHIELD COVER RETAINING CLIP PTO DRIVEN GEAR BEARING BEARING CUP OIL SHIELD 7. 8. 9. 10. 11. 12. SHIMS BEARING CAGE BOLT, M10 X 30; 10.9 WASHER, 11 X 20 X 2MM TRANSMISSION SLEEVE BEARING 31-2-35 13. 14. 15. 16. 17. 18.
Section 31 - PTO - Chapter 2 STEP 104 Press bearing onto the output sleeve shaft. Be sure the bearing is fully seated. IMPORTANT: Do not press on the bearing cage as permanent damage to the bearing will occur. RD05B022 STEP 105 Press bearing cone into housing. Be sure cone is fully seated. IMPORTANT: Before final reassembly, the rolling torque needs to be checked. See Reversible PTO Output Shaft Bearing Adjustment Section. 83LS3 STEP 106 Apply grease to the splines and install the output shaft sleeve.
Section 31 - PTO - Chapter 2 STEP 108 Install the eight mounting bolts and torque to 95 Nm (70 lb. ft.). IMPORTANT: Before installing the seal, check the rolling torque of the output shaft. See Reversible PTO Output Shaft Bearing Adjustment Section. RD05B011 STEP 109 Apply Loctite® 721 to the O.D. of the seal and seal bore. RD05B017 STEP 110 1 Press the seal in until the face of the seal (1) is 41 MM from the outer face of the housing (2).
Section 31 - PTO - Chapter 2 STEP 112 Install a ball in each of the four holes. RD05B014 STEP 113 Slide the coupler over the shaft. RD05B015 STEP 114 Push the coupler inward to expose the ring grove and install the locking ring. RD05B016 STEP 115 Set the PTO top cover (1) in place, install the pivot rod with washers and spring (2). Install the final washer with a new cotter pin (3).
Section 31 - PTO - Chapter 2 SINGLE SPEED REVERSIBLE SHAFT PTO DRIVEN GEAR Removal Before servicing the PTO Driven Gear, the following will be necessary: ● ● ● ● ● Remove the cab (See Cab Removal Section). Remove the rockshaft (See Hitch Removal Section). Remove the final drive top cover (See Final Drive Section). Remove PTO clutch assembly (See PTO Assembly Section). Remove PTO drive assembly (See PTO Assembly Section). STEP 116 Remove the four oil shield retaining clips.
Section 31 - PTO - Chapter 2 STEP 119 Remove the front half of the oil shield. RD05A054 STEP 120 Remove bearing cage and shim pack from the housing. RD05A053 STEP 121 Remove the shim pack from the bearing cage. Measure the thickness of the shim pack and note for reinstallation. RD05A052 STEP 122 Remove the bearing cone from the bearing cage.
Section 31 - PTO - Chapter 2 STEP 123 Remove the bearing from the gear. RD05A056 Assembly NOTE: Thoroughly clean and inspect all components and replace as necessary. STEP 124 Press the bearing onto the gear, making sure it is properly seated. IMPORTANT: Do not press on the bearing cage as permanent damage to the bearing will occur. RD05A057 STEP 125 Press the bearing cone into the bearing gear cage, making sure it is properly seated.
Section 31 - PTO - Chapter 2 STEP 126 Install the original shim pack on the bearing cage. NOTE: If starting with all new parts, start with a shim pack of 0.025”. RD05A052 STEP 127 Install the bearing cage with shim pack. RD05A053 STEP 128 Install the front portion of the PTO oil shield. RD05A054 STEP 129 Install the six bearing carrier bolts and torque to 55 Nm (41 lb. ft.).
Section 31 - PTO - Chapter 2 STEP 130 Place the rear half of the PTO oil shield (1) over the gear (2) and lower them into place. 2 1 RD05A058 STEP 131 Install the four shield retaining clips. RD05B019 Reversible PTO Output Shaft Bearing Adjustment STEP 132 Install the output shaft sleeve.
Section 31 - PTO - Chapter 2 STEP 133 Install the output shaft cover. DO NOT apply Loctite® 515 at this time. RD05A060 STEP 134 Install the mounting bolts and torque to 95 Nm (70 lb. ft.). DO NOT install the seal at this time, the following rolling torque measurements are taken without the seal. RD05B011 STEP 135 ● Install the output shaft (1). ● Place a socket over the end of the output shaft 1 and rotate the shaft several revolutions in both directions to seat the bearing.
Section 31 - PTO - Chapter 2 SINGLE SPEED REVERSIBLE SHAFT PTO Cross Section of PTO Output Shaft Assembly 3 2 1 4 5 6 16 15 7 8 6 7 10 14 11 9 13 12 RI05C002 1. 2. 3. 4. 5. 6. PTO OUTPUT SHAFT, REVERSIBLE BOLT, M10 X 30 CL. 10.9 WASHER, 11 X 21 X 2.5 MM PTO DRIVEN GEAR BRG CAGE PTO DRIVEN GEAR BEARING 7. 8. 9. 10. 11. 12. BEARING CUP SHIMS PTO DRIVEN GEAR OIL SHIELD PTO OIL SHIELD COVER OIL SHIELD RETAINING CLIP APPLY LOCTITE® AS REQUIRED 31-2-45 13. 14. 15. 16. BOLT, M12 X 45 CL. 10.
Section 31 - PTO - Chapter 2 This Page Left Blank.
Section 33 Chapter 1 BRAKE VALVE January, 2006
Section 33 - Brakes - Chapter 1 TABLE OF CONTENTS SPECIAL TORQUES ...................................................................................................................................... 33-2-2 BRAKE VALVE ............................................................................................................................................... Removal ...........................................................................................................................................
Section 33 - Brakes - Chapter 1 BRAKE VALVE Removal STEP 3 NOTE: Park the tractor on a hard, level surface and place the transmission in PARK. Remove the keys and block the rear wheels. NOTE: Before removing the brake valve, remove the fixed hood. (See Hood Removal Section in this manual). STEP 1 102R-4 Remove top cover from steering column. 1 STEP 4 2 1 RD02K118 Tag and remove the four brake valve lines (1). Tag and remove the two brake switch connectors (2).
Section 33 - Brakes - Chapter 1 Disassembly STEP 6 STEP 7 RD02K119 Remove the three brake valve mounting bolts. Remove the brake valve and gasket from the firewall. RD02K106 Place the valve on a clean surface and remove the three Allen head screws. STEP 8 RD02K107 Remove the firewall brake plate. STEP 9 RD02K112 Remove and discard the brake valve gasket.
Section 33 - Brakes - Chapter 1 STEP 10 STEP 12 5 2 1 4 3 00RD02K108 RD02K110 Remove the poppet (1) and outer feathering spring (2) from the sleeve (3). Remove the sleeve from the body. Remove the spool (4) and return spring (5) from the spool. Inspect all par ts for damage or wear.Repeat steps for the second spool assembly. Remove both brake switches. Discard O-rings. Inspect for damage or wear. STEP 13 STEP 11 1 RD02K111 Remove and discard the two poppet sleeve seals.
Section 33 - Brakes - Chapter 1 Assembly 1 4 5 12 6 14 13 7 8 9 15 10 3 11 2 RI02K072 1. 2. 3. 4. 5. BODY SWITCH O RING SPRING RETAINING RING 6. 7. 8. 9. 10. SPOOL O-RING SEALRING SLEEVE SPRING STEP 14 11. 12. 13. 14. 15. POPPET GASKET PLATE SEAL SCREW STEP 15 1 RD02K109 RD02K110 Install a new backing O-ring, then a new seal. Install new O-rings and install the brake switches.
Section 33 - Brakes - Chapter 1 STEP 16 STEP 19 5 2 1 4 3 RD02K108 RD02K107 Install the return spring (5) into the spool (4) and install the spool into the sleeve (3). Lubricate the valve bore and sleeve seal and install the sleeve into the valve body. Install the feathering spring (2) into the poppet (1) and install the poppet into the spool. repeat for the second spool. Install the firewall brake plate onto the brake body.
Section 33 - Brakes - Chapter 1 Installation STEP 23 STEP 21 3 3 3 1 2 101RS35A Install the right side air duct. Rd02K119 STEP 24 Install a new firewall to brake valve gasket and install the brake valve, making sure that the brake link rods (1) are installed into the poppet sleeves (2). Install and tighten the three mounting bolts (3). See the Pedal and Pedal Switch Adjustment Section of this Service Manual for the brake pedal adjustment procedure.
Section 33 - Brakes - Chapter 1 STEP 26 102RS5 Install the right side cover.
Section 33 - Brakes - Chapter 1 33-1-10
Section 33 Chapter 2 BRAKE CYLINDERS January, 2006
Section 33 - Brakes - Chapter 2 TABLE OF CONTENTS SPECIAL TORQUES ...................................................................................................................................... 33-2-3 SPECIFICATIONS .......................................................................................................................................... 33-2-3 BRAKE CYLINDERS ..............................................................................................................................
Section 33 - Brakes - Chapter 2 SPECIAL TORQUES Brake Cylinder Mounting Bolts ............................................................................... 177 to 179 Nm (130 to 145 lb. ft.) SPECIFICATIONS Friction Disc Minimum Thickness ..............................................................................................3.45 mm (0.136 inch) BRAKE CYLINDERS Disassembly STEP 3 STEP 1 87-35 Lift the supply tubes out of the brake cover.
Section 33 - Brakes - Chapter 2 STEP 5 STEP 8 T97947 T97952 Remove the remaining bolts and the brake cover from the rear frame. R e m ove t h e t h r e e b r a ke a d j u s t e r s f r o m t h e differential retainer. STEP 6 STEP 9 T98031 T97953 Remove the adjuster return plate from the brake dics. Remove the five locating pins from the differential retainer. STEP 7 STEP 10 TBD T97955 Remove the friction and separator plates from the rear frame.
Section 33 - Brakes - Chapter 2 Assembly 7 12 14 13 1 11 10 3 3 2 4 4 5 9 6 8 RH98B044 1. 2. 3. 4. 5. BEARING RETAINER OIL SEAL SEPARATOR PLATE (4) FRICTION PLATE (4) BELLEVILLE WASHER 6. 7. 8. 9. 10. EXTERNAL RETAINING RING AXLE ASSEMBLY HOUSING BRAKE ADJUSTER ASSEMBLY LOCATING PIN ADJUSTER RETURN PLATE 33-2-5 11. 12. 13. 14.
Section 33 - Brakes - Chapter 2 STEP 11 STEP 13 T97970 A21050 Inspect the brake separator plates. If there is damage or heavy wear, replace the plates. Use compressed air to push the brake piston out of the brake cover. STEP 12 STEP 14 T97969 A21052 Inspect the brake friction plates. If there is damage or heavy wear (the grooves worn away), replace the friction plates. The minimum thickness for a friction plate is 3.45 mm (0.136 inch). Carefully remove the piston from the cover.
Section 33 - Brakes - Chapter 2 STEP 15 STEP 18 A21051 T97953 Lubricate the brake cover inner and outer piston seats with petroleum jelly. Start the piston into the cover evenly by hand. Gently tap the piston with a soft face hammer until the piston is fully seated. Be careful not to damage the bonded seals. Install the five locating pins in the differential carrier. STEP 19 1 3 STEP 16 2 RH97K064 15. DOWEL 16. RETAINING RINGS 17.
Section 33 - Brakes - Chapter 2 STEP 20 STEP 22 T97952 T98031 Install the three brake adjuster assemblies into the differential carrier. The Belleville washer ends go into the differential carrier. Install the adjuster return plate on the locating pins. The tabs on the plate must contact the adjuster dowel assemblies. STEP 21 STEP 23 T97949 T97947 Install plates as follows: Install the brake cover onto the locating dowels. 1.
Section 33 - Brakes - Chapter 2 STEP 25 STEP 27 87-35 RD02D050 Lubricate new O-rings with petroleum jelly and install the O-rings on the supply tubes. Install the tubes into the brake cover. See Rear Axle and Planetaries Section in this Service Manual for the installation of the rear axle housing. STEP 26 1 2 RD02D051 Install the brake supply tube (1) and connect the diff lock tube (2). Repeat installation procedures for the other brake cylinder.
Section 33 - Brakes - Chapter 2 33-2-10
PTO CLUTCH/BRAKE A B DIFF LOCK CLUTCH PTO CLUTCH LUBE PTO/DIFF LOCK VALVE LUBE SUPPLY MFD CLUTCH MED LOW CLUTCH CLUTCH REVERSE FIFTH THIRD CLUTCH CLUTCH CLUTCH HIGH CLUTCH CREEP EVEN ODD CLUTCH CLUTCH CLUTCH (OR 50 KPH) FIRST CLUTCH TANK SUPPLY SIGNAL RELIEF A B 14 KPa TANK 14 KPa 14 KPa BEVEL PINION LUBE SUPPLY SIGNAL RELIEF 0.75 L 10 BAR TRANSMISSION CONTROL VALVES SIGNAL SUPPLY 1.07Ø MASTER CLUTCH SERVICE BRAKE TANK INLET REGULATED INLET 23.
A B PTO CLUTCH/BRAKE DIFF LOCK CLUTCH PTO CLUTCH LUBE PTO/DIFF LOCK VALVE TANK SUPPLY MFD CLUTCH MED LOW CLUTCH CLUTCH REVERSE FIFTH THIRD CLUTCH CLUTCH CLUTCH HIGH CLUTCH CREEP EVEN ODD CLUTCH CLUTCH CLUTCH (OR 50 KPH) FIRST CLUTCH LUBE SUPPLY SIGNAL RELIEF A B 14 KPa 14 KPa 14 KPa TANK SUPPLY BEVEL PINION LUBE SIGNAL RELIEF 0.75 L 10 BAR TRANSMISSION CONTROL VALVES SIGNAL 1.
Section 35 Chapter 1 HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC January, 2006
Section 35 - Hydraulic Systems, 3PT - Chapter 1 TABLE OF CONTENTS HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC ....................................................................... 35-1-3 SIMPLE SCHEMATIC .................................................................................................................................. 35-1-13 COMMON SYMBOLS ..................................................................................................................................
Section 35 - Hydraulic Systems, 3PT - Chapter 1 HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC Introduction Using Schematic Symbols Reservoirs Accurate diagrams of hydraulic circuits are essential to the man who must repair them. The diagram shows how the components will interact. It shows the field technician how it works, what each component should be doing and where the oil should be going so that he can diagnose and repair the system.
Section 35 - Hydraulic Systems, 3PT - Chapter 1 Lines, Tubes and Hoses A hydraulic line, tube, hose or any conductor that carries the fluid between components is shown as a line. RESERVOIR WITH SUCTION LINE ATTACHED AT THE BOTTOM 7108G A hydraulic line connected to the bottom of the reservoir may be drawn from the bottom of the symbol if the bottom connection is essential to the systems operation. 710L8H A working line, such as an inlet pressure or return, is shown as a solid line.
Section 35 - Hydraulic Systems, 3PT - Chapter 1 Crossing or Joining Lines LINES THAT ARE NOT CONNECTED 711L8E 710L8L 710L8M VARIABLE DISPLACEMENT The shor test distance between two components that are connect is a straight line. There are lines that cross other lines but are not connected. There are several ways to show crossing lines.
Section 35 - Hydraulic Systems, 3PT - Chapter 1 Hydraulic Motor Symbols PORT SINGLE ACTING CYLINDER 711L8P REVERSIBLE MOTOR PORTS NONREVERSIBLE MOTOR 711L8M 711L8N Hydraulic motor symbols are circles with black triangles, but opposite a pump the triangles point inward to show the motor is a receiver of oil. One triangle is used in a nonreversible motor and two triangles are used for a reversible motor.
Section 35 - Hydraulic Systems, 3PT - Chapter 1 Pressure Control Symbols Some cylinders have cushions built into them. The cushion slows down the movement of the piston as it nears the end of its stroke. Cylinder cushions are shown as a smaller rectangle on the piston. If the cushion has an adjustable orifice, a slanted arrow is drawn at 45 degrees across the symbol.
Section 35 - Hydraulic Systems, 3PT - Chapter 1 Relief Valve Sequence Valve PRESSURE LINE SUPPLY LINE RELIEF VALVE TO PRIMARY CYLINDER PUMP SEQUENCE VALVE PUMP TO SECONDARY CYLINDER 712L8G RELIEF VALVE 712L8F A relief valve is shown as a nor mally closed symbol connected between the pressure line and the reservoir. The flow direction arrow points away from the pressure line port and toward the reservoir. This shows very graphically how a rel ief va lve op erat es.
Section 35 - Hydraulic Systems, 3PT - Chapter 1 Composite Symbols Three Position Valves One Way Valves FREE FLOW NO FLOW MENTALLY VISUALIZE A BUILD UP OF PRESSURE ON THE RIGHT SIDE OF THE VALVE OPEN CENTER THREE POSITION VALVE 713L8A ONE WAY VALVE SHOWN IN THE CLOSED POSITION 714L8A A more complex one way valve is now shown. This directional control symbol uses a multiple envelope (square) system that has a separate square for each position.
Section 35 - Hydraulic Systems, 3PT - Chapter 1 Valve spools are controlled by levers, pedals, pilot oil, electric solenoids, etc., which are called actuating controls. These actuating controls are shown by symbols placed on the ends of the envelopes. SOLENOID CONTROL WITH INTERNAL PILOT PRESSURE SPRING SPRING THREE POSITION, SPRING CENTERED 713L8C To show that a valve is spring centered, a spring symbol is placed at each end of the envelope.
Section 35 - Hydraulic Systems, 3PT - Chapter 1 Accessories An oval with details inside indicate an accumulator. The details inside will tell you what type of accumulator it is; spring loaded, gas charged, or other features. Filters, strainers and heat exchangers are represented as squares that are turned 45 degrees and have the por t connection at the corners. The divider line indicates there is a separator between the charge and the oil. A hollow triangle indicates gas.
Section 35 - Hydraulic Systems, 3PT - Chapter 1 NOTES 35-1-12
Section 35 - Hydraulic Systems, 3PT - Chapter 1 SIMPLE SCHEMATIC Now that you have completed hydraulic symbols, we have put some of the symbols together to form a simple hydraulic schematic. See if you can find your way around the schematic without reading the text for each valve. The text explains the function of each valve in the hydraulic system.
Section 35 - Hydraulic Systems, 3PT - Chapter 1 Valve A Valve C This valve is a three position valve. The spool is lever operated and spring centered. It is an open center valve. Visually place the envelopes into the center position and you will see that the valve will direct oil into one end or the other of cylinder A. When the spool in valve A is moved out of the centered position, the valves downstream will receive no oil.
Section 35 - Hydraulic Systems, 3PT - Chapter 1 Lines and Line Functions COMMON SYMBOLS Mechanical Devices SOLID LINE MAIN LINE 710L8H 730L8G MECHANICAL CONNECTIONS TWO PARALLEL LINES (SHAFTS, LEVERS, ECT) DASHED LINE PILOT LINE 711L8A VARIABLE COMPONENT (RUN ARROW THROUGH SYMBOL AT 45 DEGREES DOTTED LINE EXHAUST OR DRAIN 711L8B 730L8H ENCLOSURE OUTLINE SPRING 730L8J 729L8M Pumps and Motors 711L8E LINES CROSSING HYDRAULIC PUMP FIXED DISPLACEMENT 729L8D 710L8M HYDRAULIC PUMP VARIABLE DISPLAC
Section 35 - Hydraulic Systems, 3PT - Chapter 1 Cylinders HYDRAULIC MOTOR FIXED DISPLACEMENT SINGLE ACTING 711L8P 711L8M DOUBLE ACTING SINGLE ROD END 711L8P HYDRAULIC MOTOR VARIABLE DISPLACEMENT DOUBLE ACTING DOUBLE ROD END 730L8B 712L8A HYDRAULIC OSCILLATOR SINGLE ROD END FIXED CUSHION BOTH ENDS 730L8C 749L8EP Reservoirs SINGLE ROD END ADJUSTABLE CUSHION ROD END ONLY RESERVOIR OPEN TO ATMOSPERER 710L8B 730L8E DIFFERENTIAL CYLINDER PRESSURIZED RESERVOIR 710L8A 730L8F Valves LINE TO RESERVOI
Section 35 - Hydraulic Systems, 3PT - Chapter 1 REGULATING OR SELECTOR VALVES 749L8A 749L8F PRESSURE REDUCING VALVE 712L8H 2 POSITION - 2 WAY VALVE 731L8C NON - ADJUSTABLE RESTRICTOR 716L8H 2 POSITION - 3 WAY VALVE 731L8D ADJUSTABLE RESTRICTOR 716L8B 2 POSITION - 4 WAY VALVE 731L8E ADJUSTABLE RESTRICTOR PRESSURE COMPENSATED 3 POSITION - 4 WAY VALVE 716L8C 729L8K ADJUSTABLE RESTRICTOR (TEMPERATURE AND PRESSURE COMPENSATED) 2 POSITION - 4 WAY OPEN CENTER CROSS OVER 716L8D 729L8L VALVE CAPABLE O
Section 35 - Hydraulic Systems, 3PT - Chapter 1 Valve Actuators PRESSURE COMPENSATED SOLENOID 729L8H G731L8L PILOT PRESSURE REMOTE SUPPLY DETENT 731L8F 729L8 LIQUID SUPPLY SPRING 730L8J 731L8M Accessories MANUAL FILTER 729L8A 716L8E PUSH BUTTON COOLER 716L8F 729L8B HEATER PUSH PULL LEVER 731L8G 729L8C TEMPERATURE CONTROLLER 731L8H PEDAL 713L8F ACCUMULATOR HYDRO - PNEUMATIC 716L8G MECHANICAL 729L8G 35-1-18
Section 35 - Hydraulic Systems, 3PT - Chapter 1 PRESSURE SWITCH REVERSING MOTOR 730L8P 730L8K STATION OR TEST POINT QUICK DISCONNECTS (DISCONNECTED) 730L8L 731L8J PRESSURE INDICATOR QUICK DISCONNECTS (CONNECTED) 730L8M 731L8K TEMPERATURE INDICATOR 730L8N 35-1-19
Section 35 - Hydraulic Systems, 3PT - Chapter 1 35-1-20
Section 35 Chapter 2 HYDRAULIC SYSTEM HOW IT WORKS WITH TROUBLESHOOTING January, 2006
Section 35 - Hydraulic Systems, 3PT - Chapter 2 TABLE OF CONTENTS GENERAL INTRODUCTION .......................................................................................................................... 35-2-3 REAR CHARGE/LUBE PUMP PRESSURE TEST ...................................................................................... 35-2-19 REGULATED SYSTEM PRESSURE TEST AND ADJUSTMENT PROCEDURE ....................................... 35-2-21 FRONT/REGULATED SYSTEM PUMP FLOW TEST .....................
Section 35 - Hydraulic Systems, 3PT - Chapter 2 GENERAL INTRODUCTION The tractor uses three hydraulic pumps which are driven through a drive housing on the right side of the range transmission. The pump drive housing gears are driven by the PTO driveline and all the pumps turn at approximately 1.33 times engine speed. A PFC piston pump is attached to the front of the pump drive housing while the tandem gear pumps are attached to the rear of the pump drive housing.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Optional High Flow PFC Piston Pump An optional high flow PFC piston pump is available. The high flow rate maximum pump flow rate at rated speed 2667 RPM (2000 engine speed) is 220 L/min (58 GPM). 2 1 4 3 RI06A091 1. CHARGE/LUBRICATION PUMP OUTLET (REAR SECTION) 2. REGULATED CIRCUIT PUMP OUTLET (FRONT SECTION) 3. PFC PISTON PUMP 4.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Optional MegaFlow PFC Piston Pump The axial piston pump has a variable flow output and can operate at variable pressures.The pump matches the hydraulic power output to the actual load requirements to ensure maximum efficiency and the minimum use of fuel. The pump inlet is charged to prevent cavitation. The pump output flow is supplied directly to the remote auxiliary manifold.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Standard Flow PFC Pump Layout 1 3 6 2 4 5 RI06A090 9 8 3 7 4 2 RI06A074 1. 2. 3. 4. 5. REMOTE MANIFOLD LOAD SENSE PFC PUMP TO PRIORITY REGULATOR VALVE REMOTE MANIFOLD RETURN (HOSE) MAIN FILTER ASSEMBLY PUMP LOAD SENSE 6. 7. 8. 9.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 High Flow PFC Pump Layout 1 3 2 6 4 5 RI06A077 9 8 3 7 4 2 RI06A074 1. 2. 3. 4. 5. REMOTE MANIFOLD LOAD SENSE PFC PUMP TO PRIORITY REGULATOR VALVE REMOTE MANIFOLD RETURN (HOSE) MAIN FILTER ASSEMBLY PUMP LOAD SENSE 6. 7. 8. 9.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 MegaFlow PFC Pump Layout 3 4 6 5 1 2 2 RH02K092 1 3 4 5 2 RI06A099 1. REMOTE MANIFOLD RETURN (HOSE) 2. MAIN FILTER ASSEMBLY 3. MEGAFLOW PFC PUMP LOAD SENSE LINE 4. MEGAFLOW REMOTE MANIFOLD SUPPLY 5. MEGAFLOW PFC PISTON PUMP 6.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Charge Pump Layout 2 3 1 5 4 RI02D107 5 6 7 RI02D109 1. 2. 3. 4. DUAL GEAR PUMP ASSEMBLY PRIORITY REGULATOR VALVE REGULATOR SECTION INLET REGULATED CIRCUIT FILTER (6 MICRON) 5. LUBE RELIEF VALVE ASSEMBLY 6. PUMP INLET SCREEN 7.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Lubrication Circuit The lubrication flow is a combination of both dual gear pumps outputs. Filtered charge pump flow and filtered/ cooled excess regulated circuit flow. Inlet charge pressure and lubrication are limited to 5 bar (75 PSI) by a lube relief valve.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 7 10 RI06A081 7. RIGHT BRAKE LUBE 10. LUBE RELIEF HOSE 11 12 RI06A080 11. DROP BOX OUTPUT LUBE (WITHOUT CREEPER) 35-2-11 12.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Regulated Pressure Circuits The regulated circuit is supplied by the front dual gear pump. The pump flow passes through the regulated circuit filter housing and onto the priority regulator valve. The pressure regulator portion of the valve maintains the regulated pressure at 22.4 to 24.5 bar (325 to 355 PSI).
Section 35 - Hydraulic Systems, 3PT - Chapter 2 6 RI06A085 6. MASTER CLUTCH DIAGNOSTIC COUPLER 9 2 10 RI06A084 2. SPEED TRANSMISSION CONTROL VALVE REGULATED SUPPLY-UPPER TUBE 9. REGULATED CIRCUIT ACCUMULATOR 10.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Steering And Brake Tube Layout 3 2 1 4 5 6 RI06A083 7 8 RI06A082 1. STEERING RETURN TO FILTER 5. PARK BRAKE (LEFT HAND) 2. STEERING SENSE LINE 6. STEERING SUPPLY 3. BRAKE SUPPLY 7. PARK BRAKE (RIGHT HAND) 4. BRAKE VALVE RETURN TO SUMP 8.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Standard Brake Valve Plumbing Layout 1 7 6 5 3 4 2 RI06A087 1. BRAKE VALVE RETURN TO SUMP 5. BRAKE SUPPLY TUBE (RIGHT SIDE) 2. BRAKE HOSE (RIGHT SIDE) 6. BRAKE SUPPLY TUBE (LEFT SIDE) 3. BRAKE VALVE SUPPLY 7. BRAKE VALVE 4.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Hitch System Plumbing Layout 3 5 1 4 2 3 5 4 2 1 RI06A098 1. HITCH CYLINDER RIGHT HAND RETURN 4. HITCH CYLINDER LEFT HAND RETURN 2. HITCH CYLINDER RIGHT HAND SUPPLY 5. HITCH VALVE SECTION 3.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Power Beyond Layout 3 10 1 5 4 2 6 7 RI06A064 2 3 10 11 9 8 RI06A065 / RH02J002 1. POWER BEYOND LOAD SENSE TUBE 7. POWER BEYOND RETURN FLOW COUPLER 2. POWER BEYOND SUPPLY TUBE 8. CHECK VALVE 3. POWER BEYOND RETURN TUBE 9. INTERNAL PLUG 4. CASE DRAIN 10. EXTERNAL PLUG 5. LOAD SENSE COUPLER 11. VALVE ASSEMBLY PILOT RELIEF 6. POWER BEYOND COUPLER (SUPPLY) NOTE: Remove internal plug (9) to maintain high pressure standby condition.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Motor Return Layout 2 1 RI06A064 3 3 RI06A076 1. MOTOR CASE DRAIN COUPLER 2. MOTOR RETURN COUPLER 35-2-18 3.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 REAR CHARGE/LUBE PUMP PRESSURE TEST Perform this test when experiencing problems with all the PFC pump circuits. All remote sections and the hitch system are not operating normally. The symptoms could be low flow, aerated oil, or unusually loud pump operation possibly due to cavitation. The rear section of the tandem gear pump supplies oil to the system filter base where it combines with the remaining pump flow from the front regulated system pump.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEP 2- Charge Pressure Measurement - Place the transmission control lever in the “P” park position. - Start and run the engine at low idle. - Heat the transmission oil to a minimum of 120°F (49°C). - Place a piece of cardboard over the oil cooler to help heat the oil. - Increase the engine speed to 2000 RPM. Record the charge pressure ____________ Charge Pressure Specification: 50 PSI (3.4 bar) Minimum at 2000 RPM engine speed A.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 REGULATED SYSTEM PRESSURE TEST AND ADJUSTMENT PROCEDURE Perform this test to verify the condition of the regulated system before adjusting the regulated pressure. Low regulated pressure can cause clutches to slip, hinder remote and hitch operation and decrease brake effectiveness. Even if the regulated pressure meets the specification, there could be substantial leakage in one of the regulated circuit functions that is not in use.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEP 2- Regulated System Leakage Test A regulated system leak can be identified by a slight drop in regulated pressure at low engine RPM. As a regulated circuit is engaged and disengaged, the pressure reading on the gauge will dip slightly as each circuit is actuated. IMPORTANT: If the regulated pressure did not dip as a circuit is actuated, then that circuit is not functioning.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PTO CIRCUIT C. Turn the PTO ON and back OFF. Pressure Reading with PTO ON at 1000 RPM:____________ If the pressure dipped when the circuit was actuated, but does not return to the Regulated Circuit Baseline Reading the PTO clutch is leaking. If the pressure does not dip when the circuit is actuated check the solenoid function and electrical system connections. See PTO System Section and double check for fault codes on the PTO controller.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEP 3- Regulated Pressure Adjustment Test Fitting and Tool Requirements: • 1-1/4 Inch Crowfoot wrench and 7/16 Allen wrench. If the regulated pressure measurement recorded for Step 2 was out of specification adjust the pressure as follows: Regulated Pressure Specification: 325 to 355 PSI (22.4 to 24.5 bar) at 1500 RPM engine speed 1 RI02D107 1. REGULATED PRESSURE ADJUSTMENT SCREW - Start and run the engine at 1500 RPM.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 FRONT/REGULATED SYSTEM PUMP FLOW TEST Always perform the Regulated System Pressure Test and adjustment procedure before this test. 1 2 RI02F030 1. OUT OF FRONT PUMP SECTION TO FLOWMETER INLET 2. FROM OUTLET OF FLOWMETER TO REMOTE FLOW RETURN MANIFOLD TUBE NOTE: Right hand side view, tire removed for clear view. The front section of the tandem gear pump supplies oil flow to the priority/regulator valve.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEP 2- Flow Measurement NOTE: It is not necessary to heat the hydraulic system for this test, but the system should be near room temperature 70°F (21°C). - Place the transmission control lever into “P” park position. - Start and run the engine at 2000 RPM. - Adjust the flowmeter load setting to approximately 300 PSI (20.7 bar). - Record the flow reading: Front Regulated pump flow reading at 2000 RPM_____________ at 300 PSI (20.7 bar).
Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEERING RELIEF PRESSURE TEST AND ADJUSTMENT PROCEDURE If excessive effort is required for steering, or steering is slow or sluggish the steering relief valve may be leaking or need adjustment. Test Fitting and Tool Requirements: • • 5000 PSI (344 bar) pressure gauge Run tee fitting (ORFS) and diagnostic coupler from Test Fitting Kit 380040106. STEP 1 - Preparation −Place the transmission control lever in the “P” park position.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEP 3 - Steering Relief Pressure Adjustment Test Fitting and Tool Requirements: • • 1/4 inch Allen wrench 15/16 inch wrench The steering relief valve is located in the priority/regulator valve. The priority/regulator valve is located on the top, right hand side of the range transmission. 1 RI02D107 1. STEERING RELIEF ADJUSTMENT −Start and run the engine at 1000 RPM. Turn the steering against the stops.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 STEERING SYSTEM PROBLEMS PROBLEM: Excessive effort required for steering POSSIBLE CAUSE PROCEDURE A. Excessive load on front axle. A. Reduce load see Operator’s Manual. B. Mechanical interference in steering column. B. Inspect and correct, see Steering Column and Hand Pump Section. C. Misadjusted steering relief pressure. C. Perform Steering Pressure procedure in this section. D. Steering priority spool is stuck or spring is broken. D.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PROBLEM: Steering cylinder does not react when steered (freewheeling) POSSIBLE CAUSE PROCEDURE A. Internal steering hand pump leakage. A. Cap left and right steering cylinder supply lines and retest. If the rotation stays the same, the problem is in the steering hand pump. Repair or replace as necessary. B. Steering cylinder piston leakage. B. Repair or replace as necessary. C. Steering cylinder side loading. C. Repair or replace as necessary.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PRIORITY AND REGULATOR VALVE The Priority/Regulator Valve is located on the top right side of the range transmission. The valve consists of the following components: priority spool, regulator spool, and steering relief valve.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Steering Relief Valve The steering relief valve (9) is located in the Priority/Regulator Valve and is adjustable. The steering relief valve (9) is set to open at 2970 psi (205 bar) +/- 80 psi (5.5 bar). 4 13 1 6 2 5 9 8 7 10 RD99M135 1. PRIORITY/REGULATOR VALVE 2. SUPPLY FROM PFC PISTON PUMP 8. REGULATED PRESSURE ADJUSTMENT 9. STEERING RELIEF ADJUSTMENT 3. SUPPLY TO STEERING 10. STEERING SIGNAL TO HAND PUMP 4. REGULATED SUPPLY TO SYSTEM 11.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 11 12 6 3 7 2 13 5 1 8 10 9 RI02E009 1. PRIORITY/REGULATOR VALVE 2. SUPPLY FROM PFC PISTON PUMP 8. REGULATED PRESSURE ADJUSTMENT 9. STEERING RELIEF ADJUSTMENT 3. SUPPLY TO STEERING 10. STEERING SIGNAL TO HAND PUMP 4. REGULATED SUPPLY TO SYSTEM 11. PRIORITY SPOOL 5. EXCESS FLOW TO COOLERS 12. REGULATOR SPOOL 6. REGULATED SUPPLY TO BRAKES 13. SUPPLY TO REMOTES 7.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PFC AXIAL PISTON PUMP NOTE: The principles of operation for the optional high flow pump are the same as the standard flow pump. The artwork supporting the PFC pump operation depicts only the standard flow pump. Principal of Control All remote valves, the hitch control valve and the trailer brake option each contain a signal port. If a power beyond circuit has been installed, it also contains a signal port to the pump.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 18 5 6 20 9 8 10 11 7 12 13 RH02B011 5. CONTROL PISTON 6. CONTROL SPRING 7. DRIVE SET 8. PUMP HOUSING 9. SWASH PLATE 10. PISTON 11. PISTON BLOCK LOADING SPRING 12. PISTON BLOCK 13. BACK PLATE 35-2-35 18. COMPENSATOR ASSEMBLY 20.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 21 18 19 1 15 16 4 2 17 3 RH02B010 1. SIGNAL LINE PRESSURE 14. OUTLET PORT (NOT SHOWN) 18. FLOW COMPENSATOR SPOOL 2. PUMP CASE DRAIN 15. FLOW COMPENSATOR SPOOL 19. HIGH PRESSURE COMPENSATOR SPOOL 3. CONTROL PISTON PRESSURE 16. HIGH PRESSURE COMPENSATOR SPOOL 21. COMPENSATOR ASSEMBLY 4. PISTON PUMP OUTLET PRESSURE 17.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Engine Start Up Before the engine is started, the pump swash plate angle will be at its maximum angle. Therefore, as soon as the engine is cranked by the starter the PFC axial piston pump will produce flow and, as explained above, pressure will build in the pump delivery passage. As soon as this pressure reaches 340 to 390 psi (23.5 to 27 bar) the pump will be put into its low pressure standby mode.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 21 18 19 1 15 16 4 2 17 3 RH02B010 1. SIGNAL LINE PRESSURE 14. OUTLET PORT (NOT SHOWN) 18. FLOW COMPENSATOR SPOOL 2. PUMP CASE DRAIN 15. FLOW COMPENSATOR SPOOL 19. HIGH PRESSURE COMPENSATOR SPOOL 3. CONTROL PISTON PRESSURE 16. HIGH PRESSURE COMPENSATOR SPOOL 21. COMPENSATOR ASSEMBLY 4. PISTON PUMP OUTLET PRESSURE 17.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Increased Flow Demand When an additional control valve is operated, it will cause a slight pressure drop at the pump pressure passage. The compensator spool will move up and allow the oil behind the control piston to drain to tank. The swash plate will move and the pump flow will be increased until the extra demand for flow has been met. Pressure at the pump outlet will increase until it is 340 to 390 psi (23.5 to 27 bar) above the signal line pressure.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 18 5 6 20 9 8 10 11 7 12 13 RH02B012 5. CONTROL PISTON 6. CONTROL SPRING 7. DRIVE SET 8. PUMP HOUSING 9. SWASH PLATE 10. PISTON 11. PISTON BLOCK LOADING SPRING 12. PISTON BLOCK 13. BACK PLATE 35-2-40 18. COMPENSATOR ASSEMBLY 20.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 21 18 19 1 15 16 4 2 17 3 RH02B010 1. SIGNAL LINE PRESSURE 14. OUTLET PORT (NOT SHOWN) 18. FLOW COMPENSATOR SPOOL 2. PUMP CASE DRAIN 15. FLOW COMPENSATOR SPOOL 19. HIGH PRESSURE COMPENSATOR SPOOL 3. CONTROL PISTON PRESSURE 16. HIGH PRESSURE COMPENSATOR SPOOL 21. COMPENSATOR ASSEMBLY 4. PISTON PUMP OUTLET PRESSURE 17.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Return to Low Pressure Standby The pump will remain in the high pressure standby mode until the valve in operation is returned to neutral. When this occurs, the feed into the signal line from that valve will be cut off. The signal pressure will drop because of the drain orifice plug passage is open to the pump case drain. When there is no signal line pressure the pump immediately returns to a low pressure standby condition.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 21 18 19 1 15 16 4 2 17 3 RH02B010 1. SIGNAL LINE PRESSURE 14. OUTLET PORT (NOT SHOWN) 18. FLOW COMPENSATOR SPOOL 2. PUMP CASE DRAIN 15. FLOW COMPENSATOR SPOOL 19. HIGH PRESSURE COMPENSATOR SPOOL 3. CONTROL PISTON PRESSURE 16. HIGH PRESSURE COMPENSATOR SPOOL 21. COMPENSATOR ASSEMBLY 4. PISTON PUMP OUTLET PRESSURE 17.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PFC PUMP HIGH PRESSURE STANDBY CHECK AND ADJUSTMENT PROCEDURE Perform this test when all remote circuits and hitch system do not operate with full power. This would be noticeable when maximum power is needed such as when lifting heavy hitch loads, or maximum pressure is required by a remote circuit. Test Fitting Tool Requirements: • 17 mm wrench and 3 mm Allen wrench.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PFC PISTON PUMP FLOW TEST Perform this test when all remote circuits and the hitch system are not operating at full flow. This would be noticeable by slower operation of remote circuit systems along with a slower hitch raise time. - Set all the remote valve variable flow controls to the maximum flow position. - Set the remote valve timer control to the maximum time position. - Cover the oil coolers on to help heat the oil.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PFC PISTON PUMP FLOW COMPENSATOR SETTING Preparation Test Fitting Tool Requirements: • 17 mm wrench and 3 mm Allen wrench. • Two 5000 PSI (350 bar) gauges with hose. • CAS-10280 Flowmeter. Remove the plug from behind the high pressure compensation spool and install the diagnostic fitting from fitting kit 380040106 into the pump compensator. - Install a 5000 PSI (350 bar) pressure gauge with hose onto the diagnostic fitting at the compensator.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 Flow Compensator Setting - Increase the engine speed to 2000 RPM. - Adjust the load valve on the flowmeter to 1000 PSI (69 bar) on the remote manifold gauge. - Adjust the remote valve variable flow control until the remote flow is approximately one half the maximum flow rate: Adjust flow to approximately 18 GPM for standard flow pump. Adjust flow to approximately 26 GPM for high flow pump.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 STANDARD PUMP COMPENSATOR VALVE INSPECTION Perform this inspection only after completing the high pressure standby check and the piston pump flow test. 6 4 5 3 1 2 RH98D014 1. HIGH PRESSURE SPOOL 2. HIGH PRESSURE ADJUSTMENT SCREW 3. LOW PRESSURE ADJUSTMENT SCREW 4. LOW PRESSURE SPOOL 5. CAP 6.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 PFC PUMP OPERATIONAL PROBLEMS POOR OVERALL HYDRAULIC PERFORMANCE LOW FLOW TO HITCH AND ALL REMOTE VALVE CIRCUITS A. Low hydraulic oil level in transmission. B. Low charge/lube pressure. Perform rear charge/lube pump pressure test in this section. Complete the entire test procedure C. Perform the PFC pump high pressure standby test. D. Perform the PFC piston pump flow test. E.
Section 35 - Hydraulic Systems, 3PT - Chapter 2 This Page Left Blank.
Section 35 Chapter 3 PTO AND DIFFERENTIAL LOCK VALVE January, 2006
Section 35 - Hydraulic Systems, 3PT - Chapter 3 TABLE OF CONTENTS SPECIAL TORQUES ...................................................................................................................................... 35-3-2 SPECIFICATIONS .......................................................................................................................................... 35-3-2 PTO AND DIFFERENTIAL LOCK VALVE ..............................................................................................
Section 35 - Hydraulic Systems, 3PT - Chapter 3 PTO AND DIFFERENTIAL LOCK VALVE Troubleshooting STEP 1 STEP 2 If other regulated pressure functions such as braking or transmission control are not operating properly, Check the regulated pressure. See the Hydraulic Systems How It Works With Troubleshooting Section of this Service Manual. RH98F160 The PTO and diff lock valve can be serviced after the cab is either raised or removed.
Section 35 - Hydraulic Systems, 3PT - Chapter 3 Removal STEP 3 2 3 5 4 1 RI02D105 1. INLET 4. DIFF LOCK SOLENOID 2. LUB INLET 5. MOUNTING BOLT 3. PTO PWM SOLENOID NOTE: Clean the surface of the PTO valve and all tube connections before doing any service work. Tag tube and electrical connections. Cap or plug all open hydraulic connections. NOTE: Depending on how your tractor is equipped, it may be necessary to remove hydraulic tubes that run across the top of the valve in order to remove the valve.
Section 35 - Hydraulic Systems, 3PT - Chapter 3 Disassembly STEP 6 5 STEP 4 2 1 3 6 4 RD02E112 Remove the preload spring (1) from the spool assembly. Compress the modulation spring (2) by pushing on the retaining sleeve (3) and separate the modulator spool(4) from the modulator piston (5). Be careful not to lose the two steel balls (6) when the assembly comes apart. RD02E110 Place the PTO valve on a clean workbench. STEP 5 STEP 7 RD02E111 Remove the plug and PTO modulation spool.
Section 35 - Hydraulic Systems, 3PT - Chapter 3 Inspection STEP 9 66L7 1. Check the two PTO modulation spool springs with a compression tester. Check each spring for free length and for compressed load force per specifications in this section. 2. Inspect the valve spool and piston for heavy wear or damage. If present, the complete assembly must be replaced. 3. Replace all O-rings. 4. Clean the valve body with suitable cleaning fluid.
Section 35 - Hydraulic Systems, 3PT - Chapter 3 Assembly NOTE: Lubricate spools and cartridges with clean hydraulic fluid during assembly. 12 3 3 8 7 11 6 10 5 3 9 3 2 1 RI98G167 1. DIFF LOCK SOLENOID 5. MODULATOR SPOOL 2. CARTRIDGE 6. STEEL BALL 3. O-RING 7. MODULATOR PISTON PIN 11. MODULATION PISTON 4. PTO SOLENOID 8. RETAINER SLEEVE 12. BODY 35-3-7 9. MODULATION SPRING 10.
Section 35 - Hydraulic Systems, 3PT - Chapter 3 STEP 10 STEP 12 1 2 4 RD02E115 3 5 RI02E060 Install new O-rings on the solenoid cartridges. Install the cartridges and tighten to a torque of 12 to 18 Nm (9 to 13 lb. ft.) STEP 11 RD02E113 Assemble the modulator piston (1), modulation spring (2) and retaining sleeve (3). Apply petroleum jelly to the steel balls (4) and insert them into the bore at the end of the modulator spool (5).
Section 35 - Hydraulic Systems, 3PT - Chapter 3 Installation STEP 14 RI02E059 Apply petroleum jelly to new O-rings and install the O-rings onto the valve mounting plate. STEP 15 2 3 5 4 1 RI02D105 1. INLET 4. DIFF LOCK SOLENOID 2. LUB INLET 5. MOUNTING BOLT 3. PTO PWM SOLENOID 3. Connect and tighten the tube to the lube inlet fitting (2). 1. Position the valve onto the mounting plate. Install the mounting bolts (5) and tighten to a torque of 41 to 46 Nm (30 to 34 lb. ft.). 4.
Section 35 - Hydraulic Systems, 3PT - Chapter 3 PTO And Diff Lock Valve Cross Section 10 9 2 8 6 5 7 3 4 2 1 RT98A024 1. DIFF LOCK SOLENOID 6. MODULATOR PISTON PIN 2. CARTRIDGE 7. RETAINER SLEEVE 3. PTO SOLENOID 8. MODULATION SPRING 4. MODULATOR SPOOL 5. STEEL BALL 9. PRELOAD SPRING 10.
Section 35 Chapter 4 REMOTE VALVE AND COUPLER SERVICE January, 2006
Section 35 - Hydraulic Systems, 3PT - Chapter 4 TABLE OF CONTENTS SPECIAL TORQUES ...................................................................................................................................... 35-4-2 REMOTE VALVE AND COUPLER SERVICE ................................................................................................ 35-4-3 REMOTE VALVE REMOVAL AND SERVICE ................................................................................................
Section 35 - Hydraulic Systems, 3PT - Chapter 4 REMOTE VALVE AND COUPLER SERVICE Load Check Inspection On The Tractor STEP 3 IMPORTANT: Always fully lower and disconnect any implements from the remote hydraulic couplers before doing service work on the remote valve sections. STEP 1 See the Remote Hydraulic System How it Works and Troubleshooting Section in this Service Manual before star ting remote valve service.
Section 35 - Hydraulic Systems, 3PT - Chapter 4 STEP 5 1 STEP 7 3 5 2 RD98K201 RD98E128 Install the load check assembly and plunger into the valve section. Tighten the cap to a torque of 30 t0 41 Nm (22 to 30 lb. ft.). 4 5 RD98K202 Remove the cap (1) from the load check body (2). There will be a light load from the spring (3). Make sure the stem (4) on the main poppet (5) is in place. Inspect the poppet and poppet seat for wear or damage. STEP 6 RD98K200 Replace all backup rings and O-rings.
Section 35 - Hydraulic Systems, 3PT - Chapter 4 REMOTE VALVE REMOVAL AND SERVICE Removal STEP 10 IMPORTANT: Always fully lower and disconnect any implements from the remote hydraulic couplers before doing service work on the remote valve sections. 2 STEP 8 1 See the Remote Hydraulic System How it Works and Troubleshooting Section of this Service Manual before star ting remote valve service. Once it is determined that repair or replacement is necessary, follow the procedures in this section.
Section 35 - Hydraulic Systems, 3PT - Chapter 4 STEP 12 RI02E044 1 1 RD02D053 Remove the three mounting bolts and the 4th and 5th remote sections. NOTE: There are two signal check springs (1) on the mating side of each valve. Be sure that the springs are not lost during disassembly.
Section 35 - Hydraulic Systems, 3PT - Chapter 4 Disassembly STEP 15 NOTE: If there is heavy wear ar damage in a valve bore, the valve section must be replaced. STEP 13 RD02D056 Remove the main valve spool and washers. Note the end of the spool that is toward the load check cap end of the valve. Inspect the spool and bore for heavy wear or damage. The spool must move freely in the bore. RD02D054 Thoroughly clean the valve section and place on a clean work surface.
Section 35 - Hydraulic Systems, 3PT - Chapter 4 STEP 17 STEP 18 1 5 3 2 RD02E057 RD98K201 Remove the load check valve. Remove the plunger from the bore. Check for wear or damage. The plunger must move freely within the bore. 4 5 RD98K202 Remove the cap (1) from the load check body (2). There will be a light load from the spring (3). Make sure the stem (4) on the main poppet (5) is in place. Inspect the poppet and poppet seat for wear or damage.
Section 35 - Hydraulic Systems, 3PT - Chapter 4 Assembly STEP 21 NOTE: Always replace damaged or heavily worn parts. If the parts are not serviceable, the entire valve section must be replaced. NOTE: Always install new O-rings, backup rings and seals during assembly. STEP 19 4 3 1 2 RD02D057 Install the spring and pressure compensated flow control spool into the valve body. Install the plug and tighten to a torque of 50 to 58 Nm (37 to 43 lb. ft.).
Section 35 - Hydraulic Systems, 3PT - Chapter 4 STEP 23 STEP 25 RD02D055 RD02D054 Install new O-rings onto the solenoid bodies. Install the two springs and a solenoid block onto each side of the valve body. Be sure that the 27.16 mm (1.069 inch) inner spring is on the return side. Install new O-rings on the solenoids. Install the solenoids and tighten the mounting screws. Be sure the solenoids are positioned on the bodies as noted during disassembly.
Section 35 - Hydraulic Systems, 3PT - Chapter 4 Installation STEP 27 STEP 29 2 1 RI02E044 RI02E042 Position the valve sections on the valve stack and install the three retaining bolts. Tighten the M10 bolt to a torque of 25 to 30 Nm (18 to 22 lb. ft.). Tighten the M12 bolts to a torque of 40 to 45 Nm (30 to 33 lb. ft.). Connect the wiring harness to the solenoids (1). Install the seven pin connector mounting plate (2).
Section 35 - Hydraulic Systems, 3PT - Chapter 4 Remote Valve Cross Section 8 9 7 6 2 5 4 10 3 1 RI02B027 1. SOLENOID 6. LOAD CHECK CAP 2. SOLENOID BLOCK 7. LOAD CHECK BODY 3. PRESSURE COMPENSATING FLOW CONTROL SPOOL 8. MAIN POPPET 4. MAIN SPOOL 9. LOAD CHECK PLUNGER 5. MAIN SPOOL SPRINGS 10.
Section 35 - Hydraulic Systems, 3PT - Chapter 4 REMOTE COUPLERS 2 3 9 8 9 6 8 5 10 4 RI02E027 1. COVER AND GASKET (ON EXPLODED VIEW) 6. CARTRIDGE 2. SPRING RETAINER 7. BODY 3. COIL SPRING 8. SLIPPER SEAL 4. SNAP RING 5. SPRING 9. O-RING 10. O-RING 1. Remove the cover plate and gaskets (1). Remove the spring retainer (2) and coil spring (3). 2. Remove the snap ring (4) and spring (5). 3. Remove the coupler cartridge (6) from the coupler body (7). 4.
Section 35 - Hydraulic Systems, 3PT - Chapter 4 Exploded View 2 3 7 9 8 6 10 5 4 1 RI02E028 1. COVER AND GASKET 6. CARTRIDGE 2. SPRING RETAINER 7. BODY 3. COIL SPRING 8. SLIPPER SEAL 4. SNAP RING 9. O-RING 5. SPRING 10.
Section 35 Chapter 5 REMOTE HYDRAULIC SYSTEM How It Works and Troubleshooting January, 2006
Section 35 - Hydraulic Systems, 3PT - Chapter 5 TABLE OF CONTENTS REMOTE HYDRAULIC SYSTEM INTRODUCTION ...................................................................................... 35-5-3 REMOTE VALVE SYSTEM COMPONENTS ................................................................................................. 35-5-5 REMOTE VALVE SYSTEM CONTROLS ..................................................................................................... 35-5-10 REMOTE VALVE OPERATION ................
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE HYDRAULIC SYSTEM INTRODUCTION REMOTE CONTROLS FLOW CONTROLS ARM REST CONTROLLER STANDARD INSTRUMENTATION HYDRAULIC VALVE TIMER DATA BUS DATA BUS AUX-PTOHITCH CONTROLLER (TMF) REG SUPPLY PCS PCS PCS PCS PCS R E M O T E R E M O T E R E M O T E R E M O T E R E M O T E #1 #2 #3 #4 #5 PCS PCS PCS PCS PCS PFC TO HITCH PCS = PROPORTIONAL CURRENT SOLENOID RI99F043 35-5-3
Section 35 - Hydraulic Systems, 3PT - Chapter 5 The remote controller will repor t any problems directly to the instrument controller. The instrument controller will display any system faults or fault code information through the standard instrumentation display. All remote hydraulic controls are located in the righthand Armrest Control Console. These controls include the: Remote Hydraulic Control Levers When a fault occurs, a 3 second continuous audible alarm will sound.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE SYSTEM COMPONENTS 1 1 RD02D042 1. REMOTE COUPLERS The remote valve assembly is located at the rear of the tractor. Remove the Controller cover to access the valve assembly by removing two bolts from each side of the cover (the bolts do not go through the fender assemblies).
Section 35 - Hydraulic Systems, 3PT - Chapter 5 1 8 2 3 6 4 RI06A062 5 7 RI02J006 1. 2. 3. 4. PROPORTIONAL CURRENT CONTROL SOLENOIDS HIGH PRESSURE ACCUMULATOR MANIFOLD SUPPLY (INLET) MANIFOLD RETURN TUBE 35-5-6 5. 6. 7. 8.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 15 8 8 18 16 10 6 2 1 3 4 5 7 12 13 14 7 11 9 17 RI02J007 THRU J010 AND RH02J047 1. 2. 3. 4. 5. 6. 7. 8. 9. REMOTE SECTION NO. 1 REMOTE SECTION NO. 2 REMOTE SECTION NO. 3 REMOTE SECTION NO. 4 REMOTE SECTION NO. 5 HITCH VALVE LOAD CHECKS INLET INTERNAL CHECK VALVE 36 PSI (2.5 BAR) 10. 11. 12. 13. 14. 15. 16. 17. 18.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 3 10 5 1 4 2 12 6 7 RI02D103 2 3 12 10 11 9 8 RI02D105 AND RH02J002 1. 2. 3. 4. 5. 6. POWER BEYOND LOAD SENSE TUBE POWER BEYOND SUPPLY TUBE POWER BEYOND RETURN TUBE CASE DRAIN LOAD SENSE COUPLER POWER BEYOND COUPLER (SUPPLY) 7. 8. 9. 10. 11. 12.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 1 2 RD05M054 1. AUX - PTO - HITCH (TMF) 2.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE SYSTEM CONTROLS Remote Hydraulic Control Levers FLOAT There are three or four remote hydraulic control levers (and a switch to control a 5th remote if equipped) on the arm rest control console depending on the number of remote circuits on your tractor. The No. 1 remote hydraulic control lever will operate the lower left rear hydraulic coupler. RETRACT DETENT MOMENTARY NEUTRAL MOMENTARY Each remote coupler has an identification plate.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 Full Function Position No Float Position RH97J002 RH97J002 Remote Valve Function Control Full Function Position Remote Valve Function Control In the full function position the remote control lever will have full function including the float position. FLOAT To operate the remote hydraulics in a float condition, make sure the remote function control is in the full function position and push the remote control lever fully forward.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 Loader Position Hydraulic Motor Position FLOAT FLOAT RETRACT DETENT RETRACT DETENT MOMENTARY MOMENTARY NEUTRAL NEUTRAL DETENT LOCKED OUT EXTEND DETENT Remote Control Lever Positions - Loader Position Remote Control Lever Positions Hydraulic Motor Position When operating a front end loader the remote function control MUST be rotated to the loader position. This prevents the remote control lever from moving into the detent positions.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 Hydraulic Valve Timer Control Variable Flow Control The timer control located under the arm rest cover determines the amount of time a remote circuit has hydraulic flow after the control lever is moved to the detent position. Turning the knob clockwise increases the amount of time and turning the knob counterclockwise decreases the amount of time. The timer can be set from the minimum of 1 second up to a maximum of 30 seconds.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE OPERATION General MAIN VALVE SPOOL - The main valve spool is spring centered in neutral and is positioned by the proportional current control solenoids. The spool position determines the flow rate and the flow path of the supply flow. When lowering, oil is fed to the left hand side of the plunger. The plunger will be forced up against the load check pilot poppet to relief trapped pressure.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 Neutral A load check valve is installed into the extend port, which will prevent the settling of a load (in neutral) due to main valve spool land leakage. It also serves as a check valve to prevent a drop in a partially raised cylinder when that valve is operated. All the remote valve sections function in the same way. In neutral the position of the main valve spool is spring centered.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 4 3 5 6 1 2 7 12 11 10 9 8 RI02C044 PFC PUMP SUPPLY PRESSURE INTERMEDIATE PRESSURE WORKING PRESSURE RETURN PRESSURE RI02E014 1. 2. 3. 4. 5. 6. PROPORTIONAL SOLENOID VALVE ASSEMBLY MAIN VALVE SPOOL RETRACT PORT LOAD CHECK PLUNGER EXTEND PORT LOAD CHECK 7. 8. 9. 10. 11. 12.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 Extend The main valve spool can now direct flow from the intermediate pressure area to the work pressure area and on to the remote valve coupler. As oil flows across the main valve spool there is always a 100 PSI pressure drop. This constant pressure drop results in a constant flow across the main spool out to the remote coupler.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 4 3 5 6 1 2 7 12 11 10 9 8 RI02C046 PFC PUMP SUPPLY PRESSURE INTERMEDIATE PRESSURE WORK PRESSURE RETURN TO FILTER INLET PRESSURE RI02E014 1. 2. 3. 4. 5. 6. PROPORTIONAL SOLENOID VALVE ASSEMBLY MAIN VALVE SPOOL RETRACT PORT LOAD CHECK PLUNGER EXTEND PORT LOAD CHECK 7. 8. 9. 10. 11. 12.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 Retract poppet which allows the return oil to flow back to the inlet side of the filter base. (Differential pressure between the raise port and the spring side of the main poppet also contribute to unseating the main poppet). When the remote hydraulic control lever is moved to the retract position, the main valve spool is shifted to the right a fixed distance by the proportional solenoid pressure supply.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 4 3 5 6 1 2 7 12 10 11 9 8 RI02C048 PFC PUMP SUPPLY PRESSURE INTERMEDIATE PRESSURE WORK PRESSURE RETURN TO FILTER INLET PRESSURE RI02E014 1. 2. 3. 4. 5. 6. PROPORTIONAL SOLENOID VALVE ASSEMBLY MAIN VALVE SPOOL RETRACT PORT LOAD CHECK PLUNGER EXTEND PORT LOAD CHECK 7. 8. 9. 10. 11. 12.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 Float pressure standby pressure is direc ted to the backside of the load check plunger. The plunger moves to the right, unseating the load check main poppet. When the remote hydraulic control lever is moved to the float position, the main valve spool is moved to the far right position by the proportional solenoid pressure supply.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 4 3 5 6 1 2 7 12 10 11 9 8 RI02D003 PFC PUMP SUPPLY PRESSURE INTERMEDIATE PRESSURE WORK PRESSURE RETURN TO FILTER INLET PRESSURE RI02E014 1. 2. 3. 4. 5. 6. PROPORTIONAL SOLENOID VALVE ASSEMBLY MAIN VALVE SPOOL RETRACT PORT LOAD CHECK PLUNGER EXTEND PORT LOAD CHECK 7. 8. 9. 10. 11. 12.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE PROBLEMS AND WHERE TO LOOK 5 3 4 6 7 1 2 8 14 13 12 11 10 9 RI02B027 1. 2. 3. 4. 5. 6. 7. PROPORTIONAL SOLENOID VALVE ASSEMBLY MAIN VALVE SPOOL FLOW CONTROL SPRING RETRACT PORT LOAD CHECK PLUNGER EXTEND PORT LOAD CHECK 8. 9. 10. 11. 12. 13. 14.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 Load Check Implements leak down. See load check inspection in this section. Signal Check To Pump Compensator If a single signal check is leaking. The leaky signal check remote section will function normally. The remaining remote sections will show reduced flow. Signal Check To Pilot Relief A leaky pilot relief valve (located in remote manifold) can decrease system flow and pressure for both remote and hitch circuits.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE PROPORTIONAL CURRENT CONTROL (PCC) SOLENOID OPERATION The distance that the spool will shift is determined by the flow control setting for that remote section. Increasing the flow control setting will increase the current supply to the proportional solenoid, which in turn increases the hydraulic pressure in the spool end cavity.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE SYSTEM TESTING Each of the remote hydraulic system circuits is made up of four different systems. A problem with any one o f t h e s e s y s t e m s w i l l e f fe c t r e m o t e v a l v e performance. Talk to the owner/operator about the problem. Gather a s m u c h i n fo r m a t i o n a b o u t w h a t s h o u l d b e happening versus what is happening. Note as many symptoms as possible.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE HIGH PRESSURE TEST Test Fitting Tool Requirements: • 5000 PSI (350 bar) gauge with male remote valve coupler tip. Test Procedure: • PFC pump high pressure standby is set low. • Problem with PFC pump compensator valve. • Hitch signal line has excessive leakage. If only one remote valve section fails to engage, or build correct pressure, check the following: 1. Start and run the engine at 1500 RPM. • Female coupler problem.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 PFC PUMP HIGH PRESSURE STANDBY CHECK AND ADJUSTMENT PROCEDURE Test Procedure: Perform this test when all remote circuits and hitch system do not operate with full power. This would be noticeable when maximum power is needed such as when lifting heavy hitch loads, or maximum pressure is required by a remote circuit. - Install a 5000 PSI (350 bar) pressure gauge with hose onto the diagnostic fitting at the compensator. - Start and run the engine at 1500 RPM.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 PFC PISTON PUMP FLOW TEST - Start and run the engine at 1000 RPM. Perform this test when all remote circuits and the hitch system are not operating at full flow. This would be noticeable by slower operation of remote circuit systems along with a slower hitch raise time. NOTE: Use 3/4 inch hose with a minimum working pressure of 3000 PSI (206 bar) for this flow test. - Install the CAS-10280 Flowmeter into the No. 1 remote section.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 STANDARD PUMP COMPENSATOR VALVE INSPECTION Perform this inspection only after completing the high pressure standby check and the piston pump flow test. 6 4 5 3 1 2 RH02B010 1. HIGH PRESSURE SPOOL 2. HIGH PRESSURE ADJUSTMENT SCREW 3. LOW PRESSURE ADJUSTMENT SCREW 4. LOW PRESSURE SPOOL 5. CAP 6. LOCK NUT Test Fitting and Tool Requirements: • • • - Remove low pressure spool. Make sure it moves freely within the bore.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE SIGNAL CHECK AND HITCH SIGNAL CHECK REMOTE SIGNAL CHECK LEAKING: All remaining remote circuits and hitch are operating at reduced flow. The leaking remote section operates normally. Each remote section and the hitch circuit are equipped with a signal check. If any one signal check is leaking it will effect the performance of all the other circuits. HITCH SIGNAL CHECK LEAKING: All remotes operating at reduced flow. Hitch operates normally.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 REMOTE VALVE COUPLER TEST − Find out what type of male coupler tip is being used. Remote valve couplers seal leaks will cause the following problem. −Check the male tip and make sure it is compatible with the • tractor (the male tip must have ball on the end or it will damage the female cartridge tip). Male coupler tip spit out when remote valve lever is engaged.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 LOAD CHECK INSPECTION Remote Valve Load Check Valves The remote hydraulic valve is equipped with a single load check on all five remote sections on the “B” (extend) port. The load check is used in applications w h e r e a r e m o t e hy d r a u l i c c y l i n d e r m u s t b e hydraulically locked in position with a minimal amount of leak down. 1 RI06A064 - Lower suspended/ raised implements. - Clean the load check area.
Section 35 - Hydraulic Systems, 3PT - Chapter 5 OPERATIONAL PROBLEMS F. Bypass coupler to determine if the problem is with the remote valve/hydraulic system or coupler. Connect the flowmeter directly to the lower and raise tubes. IMPLEMENT SETTLES OR LEAKS DOWN A. Problem with implement cylinder. Raise implement and disconnect hoses to isolate cylinder. COUPLER SPITS OUT IN EXTREMELY COLD WEATHER B. Internal coupler leak. Perform remote valve coupler test. A. Turn the flow control down.
Section 35 Chapter 6 PRIORITY AND REGULATOR VALVE January, 2006
Section 35 - Hydraulic Systems, 3PT - Chapter 6 TABLE OF CONTENTS SPECIAL TORQUES ...................................................................................................................................... 35-6-3 PRIORITY VALVE AND REGULATOR .......................................................................................................... 35-6-4 Removal ........................................................................................................................................
Section 35 - Hydraulic Systems, 3PT - Chapter 6 SPECIAL TORQUES Socket Head Plug ........................................................................................................... 16 to 24 Nm (12 to 18 lb. ft.) PFC Pump Signal Orifice and Screen Plug .................................................................... 14 to 21 Nm (10 to 15 lb. ft.) Logic Check Valve Plug .................................................................................................. 16 to 19 Nm (12 to 14 lb. ft.
Section 35 - Hydraulic Systems, 3PT - Chapter 6 PRIORITY VALVE AND REGULATOR Removal STEP 1 STEP 2 2 1 3 2 4 1 RD02E055 RD02D088 Remove the steering supply line (1). Remove the brake valve supply line (2). 5 6 STEP 3 1 7 8 RD02E056 1. REMOTE HYDRAULIC MANIFOLD SUPPLY LINE 2. PTO SUPPLY LINE 3. REGULATED SUPPLY LINE 4. OIL COOLER SUPPLY LINE 5. SIGNAL LINE TO REMOTE VALVE 6. PFC COMPENSATOR SIGNAL LINE 7. STEERING SENSING LINE 8.
Section 35 - Hydraulic Systems, 3PT - Chapter 6 STEP 4 STEP 5 1 1 RD02D089 RD02D093 Remove the three priority valve mounting bolts (1). Remove the pr ior ity valve from the top of the transmission. Remove the O-ring (1) in the top of the transmission housing and discard.
Section 35 - Hydraulic Systems, 3PT - Chapter 6 Disassembly STEP 6 STEP 9 RD02D112 RD02D106 Unscrew the logic check valve plug. Remove the four plugs from the priority and regulator valve and discard the O-rings. STEP 10 STEP 7 RD02D114 RD02D108 Remove the logic check valve plug and discard the O-ring and backup ring. Inspect the spring and valve for damage or wear. Unscrew the PFC pump signal orifice and screen plug. STEP 8 RD02D110 Remove the plug. Inspect the screen and clean as needed.
Section 35 - Hydraulic Systems, 3PT - Chapter 6 STEP 11 STEP 13 1 RD02D120 RD02D117 Remove the pilot relief valve assembly. Remove the steering line orifice fitting and discard the O-ring (1). Remove the priority valve spring and spool. Inspect the spring and spool for damage or wear. STEP 14 STEP 12 2 1 RD02D124 Remove and discard the O-rings (1) and the backup ring (2) from the pilot relief valve orifice fitting.
Section 35 - Hydraulic Systems, 3PT - Chapter 6 STEP 16 STEP 18 RD02D128 NOTE: Measure the distance from the adjustment end of the regulator spool to the body of the valve before removing the lock nut. RD02D134 Remove and discard the O-ring from the adjusting plug. Remove the spring and the regulator spool. Inspect for damage or wear. Remove the lock nut from the regulator spool adjusting plug. STEP 17 RD02D130 Unscrew the regulator spool adjusting plug.
Section 35 - Hydraulic Systems, 3PT - Chapter 6 Assembly STEP 19 STEP 21 RD02D128 Install the regulator spool lock nut. Tighten the nut to a torque of 41 to 48 Nm (30 to 35 lb. ft.). RD02D134 Lubricate the adjusting plug O-ring with hydraulic fluid and install on the plug. Lubricate the regulator spool and the spring. Install the spool and spring in the priority valve. STEP 22 STEP 20 1 RD02D126 Lubricate and install a new O-ring (1) on the pilot relief valve adjuster.
Section 35 - Hydraulic Systems, 3PT - Chapter 6 STEP 23 STEP 25 2 1 RD02D124 RD02D119 Lubricate and install a new backup ring (1) and new O-rings (2) on the pilot relief valve assembly. Install the pilot relief valve lock nut. STEP 26 NOTE: Install the backup ring (1) before the O-ring, as shown. STEP 24 1 RD02D117 Lubricate the priority valve spool and the spring. Install the spool and the spr ing into the valve assembly.
Section 35 - Hydraulic Systems, 3PT - Chapter 6 STEP 27 STEP 29 2 1 RD02D114 RD02D110 Lubricate the logic check valve and the spring. Install the check valve and the spring in the priority valve. Lubricate and install a new backup ring (1) and Oring (2) on the logic check valve plug. Apply a fine strip of Loctite® 242 adhesive on the internal land of the priority valve casting. Install the PFC pump signal orifice and screen plug. STEP 30 NOTE: Install the backup ring (1) before the O-ring.
Section 35 - Hydraulic Systems, 3PT - Chapter 6 Installation STEP 32 STEP 34 1 1 RD02D093 RD02D104 Install a new O-ring (1) in the top of the transmission housing. Place the priority valve on the top of the transmission. Install the PFC pump supply hose to the priority valve (1). STEP 35 STEP 33 1 2 1 RD02D088 Install the steering supply line (1). Install the brake valve supply line (2). RD02D089 Install the three priority valve mounting bolts (1).
Section 35 - Hydraulic Systems, 3PT - Chapter 6 STEP 36 STEP 37 Lower the cab. Refer to the information in this service manual for the cab lowering procedure. Check the tra c tor hy dr au li c f lu i d leve l a nd a dd f lu i d as necessary. The steering priority valve and regulator must be adjusted after disassembly. Refer to the Hydraulic System - How It Wor ks and Troubleshooting Section of this Repair Manual for the adjustment procedure. 4 3 1 2 RD02D081 8 7 6 5 RD02D084 1.
Section 35 - Hydraulic Systems, 3PT - Chapter 6 CROSS SECTION OF PRIORITY AND REGULATOR VALVE 6 5 7 4 8 3 2 9 1 12 9 11 10 RI02E009 1. 2. 3. 4. PRIORITY AND REGULATOR VALVE LOGIC CHECK VALVE ASSEMBLY ORFICE AND SCREEN PLUG REGULATOR SPRING 5. 6. 7. 8. PRIORITY VALVE SPOOL PLUG REGULATOR SPOOL STEERING SPRING 35-6-14 9. 10. 11. 12.
Section 35 Chapter 7 CHARGE PUMP January, 2006
Section 35 - Hydraulic Systems, 3PT - Chapter 7 TABLE OF CONTENTS CHARGE PUMP ............................................................................................................................................. 35-7-3 Removal ...................................................................................................................................................... 35-7-3 Installation .........................................................................................................
Section 35 - Hydraulic Systems, 3PT - Chapter 7 CHARGE PUMP Removal STEP 3 1 STEP 1 2 2 4 3 1 4 3 RD02D009 Remove the charge pump outlet hose (1) to the filter head. Remove the outlet line to the priority valve (2). Remove the connector from the hydraulic filter pressure sender (3). Remove the two charge pump to hydraulic pump drive mounting bolts and remove the charge pump. Remove the O-ring from the suction hose flange (4).
Section 35 - Hydraulic Systems, 3PT - Chapter 7 Installation STEP 4 1 2 3 RD02D009 Install the two charge pump to hydraulic pump drive mounting bolts. Install the charge pump outlet hose (1) to the filter head. Install the outlet line to the priority valve (2). Install the connector to the hydraulic filter pressure sender (3). STEP 5 2 1 RD02D006 Install a new O-ring on the suction hose flange.
Section 35 Chapter 8 PFC PISTON PUMP January, 2006
Section 35 - Hydraulic Systems, 3PT - Chapter 8 TABLE OF CONTENTS SPECIAL TORQUES ...................................................................................................................................... 35-8-3 PFC PISTON PUMP ....................................................................................................................................... 35-8-3 Removal ........................................................................................................................
Section 35 - Hydraulic Systems, 3PT - Chapter 8 SPECIAL TORQUES Compensator Valve Orifice .......................................................................................... 1.7 to 2.3 Nm (15 to 20 lb. in.) Compensator Valve Inlet Port Plug.............................................................................. 1.7 to 2.3 Nm (15 to 20 lb. in.) Filter Head Retaining Bolts............................................................................................. 62 to 80 Nm (46 to 59 lb. ft.
Section 35 - Hydraulic Systems, 3PT - Chapter 8 Installation STEP 7 STEP 5 2 2 1 1 RD02D019 RD06A136 Install a new O-ring on the piston pump and install the two piston pump mounting bolts (1) to the hydraulic pump drive cage. Install a new O-ring on the priority valve supply tube split flange and install the four mouning bolts (2) to the piston pump. Tighten the bolts to a torque of 40 to 60 Nm (30 to 44 lb. ft.). Install new O-rings on all hydraulic lines.
Section 35 Chapter 9 HITCH SYSTEM How it Works January, 2006
Section 35 - Hydraulic Systems, 3PT - Chapter 9 TABLE OF CONTENTS THREE POINT HITCH ................................................................................................................................... 35-9-3 ELECTRONIC HITCH CONTROL .................................................................................................................. 35-9-4 ELECTRONIC HITCH CONTROL SYSTEM FEATURES ..............................................................................
Section 35 - Hydraulic Systems, 3PT - Chapter 9 THREE POINT HITCH GENERAL DESCRIPTION - The Three Point Hitch consists of the rockshaft supports, rockshaft, upper link, lift links, draft arms and the external lift cylinders. The hitch conforms to ASAE standard dimensions for a Category III/IIIN hitch. The hitch is controlled with an electronic hitch system which provides position control of soil engaging implements.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL GENERAL DESCRIPTION - The Electronic Hitch Control (EHC) system consists of the operator controls, electronic hitch controller, hitch position sensor, hitch control valve and the wiring harness. All operator commands except Remote Up/Down commands are sent to the Arm Rest Control Unit then relayed to the Hitch Controller by way of the Data Bus.
35-9-5 True Ground Speed Wheel Speed Remote Up/Down Switches Up/Down Switch Load Control Data Bus Instrumentation Cluster Controller Position Control Upper Limit Slip Value Diagnostics Travel Control Rockshaft Position Sensor Drop Rate Left Draft Sensor FWD Switch Right Draft Sensor PFC Pressure PFC Signal Arm Rest Controller Diff Lock Switch Aux/PTO/Hitch Controller (TMF) Slip Select Switch Operator Controls and Settings ELECTRONIC HITCH CONTROL RI06A039A Hitch Cylinders Hitch C
Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL POSITION CONTROL - In the Position Control Mode, the hitch position and movement is directly related to the position of the control lever. The Electronic Hitch Control (EHC) monitors the position of the hitch by signals received from a hitch position sensor on the hitch rockshaft and raises or lowers the hitch to match the signal from the hitch position control lever sensor.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL SYSTEM FEATURES HITCH POSITION CONTROL KNOB - The Position Control knob (1) is used to raise and lower implements, and select the maximum working depth of the implement. To lift an implement with the three point hitch, the Position Control Knob is rotated clockwise. To lower an implement, rotate the Knob counterclockwise.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL 1 3 2 8 4 5 7 6 RD05J154 / RD05J116 1. 2. 3. 4. HITCH POSITION CONTROL KNOB LOWER LIMIT STOP RING UP DOWN SWITCH HITCH LOAD CONTROL 5. 6. 7. 8.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL SYSTEM FEATURES UPPER LIMIT CONTROL - The Upper Limit Control (5) limits the amount of upward travel when the hitch is raised. The control knob is mounted under the armrest cover on the armrest control console and has number settings from “1” to “11”. Turning the knob counterclockwise limits the upward travel of the hitch and turning clockwise allows the hitch to raise further.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL SYSTEM FEATURES 1 3 2 8 4 5 7 6 RD05J154 / RD05J116 1. 2. 3. 4. HITCH POSITION CONTROL KNOB LOWER LIMIT STOP RING UP DOWN SWITCH HITCH LOAD CONTROL 5. 6. 7. 8.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL SYSTEM FEATURES TRAVEL CONTROL KNOB - The TRAVEL CONTROL KNOB (7) is located under the arm rest control console cover. Travel Control varies the range of hitch corrections in response to load variations when operating in the LOAD CONTROL MODE.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 ELECTRONIC HITCH CONTROL SYSTEM FEATURES 10 1 9 3 2 8 4 5 7 6 RD05J154 / MT04M013 / RD05J116 1. 2. 3. 4. 5. HITCH POSITION CONTROL KNOB LOWER LIMIT STOP RING UP DOWN SWITCH HITCH LOAD CONTROL UPPER LIMIT CONTROL 6. 7. 8. 9. 10.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 EHC SYSTEM FEATURES END OF ROW FUNCTION - The END OF ROW feature involves the Differential Lock and the Front Wheel Drive (FWD) (if equipped) and the Brake Switches. The FWD and Diff Lock control systems are equipped with an automatic function that disengages both Diff Lock and FWD when the hitch is raised for a turn around and reengages them when the hitch is lowered after the turn.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE General The hitch control valve is a closed center valve that receives oil from the PFC hydraulic system. To control the pump during hitch operations, signal pressure is sent from the valve to the PFC pump. The raise and lower functions of the valve are operated by regulated pressure received from the regulated hydraulic system.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE 9 16 18 15 8 7 17 6 10 1 3 2 4 14 12 13 5 11 13 12 14 RI02B003 1. 2. 3. 4. 5. 6. 7. 8. 9. RAISE SOLENOID LOWER SOLENOID RAISE PILOT SPOOL LOWER PILOT SPOOL RAISE SPOOL OVERLOAD RELIEF LOWER CONTROL PISTON LOWER PILOT POPPET LOWER POPPET 10. 11. 12. 13. 14. 15. 16. 17. 18.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE Neutral Function and Troubleshooting FUNCTION Hitch Control Valve in Neutral - The hitch control valve is a closed-center valve. In neutral there will be no electric current supplied to the raise or lower solenoids (1) and (2) and no oil flow through the valve. The pilot spools (3) and (4) are blocking the supply of oil from the regulated circuit.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE - NEUTRAL 9 16 18 15 8 7 17 6 10 1 3 2 4 14 12 13 5 11 13 12 14 RI02B003 1. 2. 3. 4. 5. 6. 7. 8. 9. RAISE SOLENOID LOWER SOLENOID RAISE PILOT SPOOL LOWER PILOT SPOOL RAISE SPOOL OVERLOAD RELIEF LOWER CONTROL PISTON LOWER PILOT POPPET LOWER POPPET 10. 11. 12. 13. 14. 15. 16. 17. 18.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE Raise Function and Troubleshooting FUNCTION Hitch Control Valve in Raise - To raise the hitch, the hitch raise solenoid (1) must be energized by the Electronic Hitch Controller. When the solenoid is energized, the armature in the solenoid moves toward the valve contacting a control pin (14) which moves the raise pilot spool (3) inward.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE Raise Function and Troubleshooting 9 16 18 15 8 7 17 6 10 1 3 2 4 14 12 13 5 11 13 12 14 RI02B006 1. 2. 3. 4. 5. 6. 7. 8. 9. RAISE SOLENOID LOWER SOLENOID RAISE PILOT SPOOL LOWER PILOT SPOOL RAISE SPOOL OVERLOAD RELIEF LOWER CONTROL PISTON LOWER PILOT POPPET LOWER POPPET 10. 11. 12. 13. 14. 15. 16. 17. 18.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE Lower Function and Troubleshooting FUNCTION Hitch Valve in Lower - To lower the hitch, the lower solenoid (2) must be energized by the Electronic Hitch Controller based on the commands entered by the operator. Activation of the PFC system is not required to lower the hitch. When the lower solenoid (2) is energized, the armature will move toward the valve, contacting the control pin (14), which pushes the lower pilot spool (4) inward.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 HITCH CONTROL VALVE Lower Function and Troubleshooting 9 16 18 15 8 7 17 6 10 1 3 14 2 4 12 13 5 11 13 12 14 RI02B007 1. 2. 3. 4. 5. 6. 7. 8. 9. RAISE SOLENOID LOWER SOLENOID RAISE PILOT SPOOL LOWER PILOT SPOOL RAISE SPOOL OVERLOAD RELIEF LOWER CONTROL PISTON LOWER PILOT POPPET LOWER POPPET 10. 11. 12. 13. 14. 15. 16. 17. 18.
Section 35 - Hydraulic Systems, 3PT - Chapter 9 SETUP / ADJUSTMENT SEQUENCE SET POSITION CONTROL ABOUT 1 TO 2 INCHES BELOW DESIRED DEPTH TURN LOAD CONTROL CCW TO WHERE PLOW RAISES TO DESIRED DEPTH MOVE POSITION CONTROL LEVER DEEPER THAN DESIRED DEPTH AS THE DRAFT LOAD VARIES, THE HITCH CONTROL WILL ADJUST THE DEPTH OF THE IMPLEMENT TO FINE TUNE TRAVEL, TURN THE TRAVEL CONTROL CCW TO LIMIT TRAVEL SURFACE DESIRED DEPTH SLIGHTLY BELOW OPTIMUM OPERATING DEPTH VARIANCE POTENTIAL DEPTH 35-9-22
Section 35 Chapter 10 HITCH CONTROL VALVE January, 2006
Section 35 - Hydraulic Systems, 3PT - Chapter 10 TABLE OF CONTENTS HITCH CONTROL VALVE ........................................................................................................................... 35-10-3 Removal .................................................................................................................................................... 35-10-3 Disassembly ...................................................................................................................
Section 35 - Hydraulic Systems, 3PT - Chapter 10 HITCH CONTROL VALVE Removal STEP 3 STEP 1 RD02D043 If equipped, remove the power beyond supply line to help obtain access to the hitch valve to case return line. RD02D041 The hitch control valve is located on the left hand side of the remote valve stack (viewed from rear). Gaining access to the return line fittings at the bottom o f t h e va l ve w i l l d e p e n d o n w h a t hy d r a u l i c accessories your tractor is equipped with, i.e.
Section 35 - Hydraulic Systems, 3PT - Chapter 10 STEP 6 STEP 9 RD02D045 RI02D045 Disconnect the hitch valve load sensing signal lines. Remove the three hitch valve mounting bolts and remove the hitch valve. STEP 7 RD02D046 If equipped, remove the hydraulic trailer brake line mounting clamp. STEP 8 RI02D067 Remove the case drain line.
Section 35 - Hydraulic Systems, 3PT - Chapter 10 Disassembly STEP 13 STEP 10 RD02D037 Remove the raise spool. Discard the O-ring. Inspect for heavy wear or damage. Replace the valve assembly if necessary. RD02C198 Place the hitch valve on a clean work surface. STEP 14 STEP 11 RD02D038 Remove the solenoid coils from the valve. Remove the load check spring and ball. Discard the O-ring. STEP 12 STEP 15 RD02C199 RD02C200 RD02F147 Remove the raise solenoid core, control pin and pilot spool.
Section 35 - Hydraulic Systems, 3PT - Chapter 10 STEP 16 STEP 18 RD02F148 RD02D040 Inspect the check for debris and that the check ball moves freely. Remove the poppet body, lower pilot and spring assembly and lower poppet. Discard the three O-rings and backup ring. Inspect for heavy wear or damage. Replace the valve assembly if necessary. STEP 17 RD02D039 Remove the overload relief body, spring and poppet Discard the O-rings. Inspect for heavy wear or damage.
Section 35 - Hydraulic Systems, 3PT - Chapter 10 Assembly STEP 21 STEP 19 RD02F148 Install the load sense check into the valve. RD02D040 STEP 22 Lubricate the new O-rings and backup ring with petroleum jelly. Install two new O-rings on the poppet body. Install a new backup ring and a new O-ring on the lower pilot and spring assembly. The backup ring will be on top of the O-ring. Lubricate all parts with clean hydraulic fluid.
Section 35 - Hydraulic Systems, 3PT - Chapter 10 STEP 24 STEP 26 RD02D037 RD02C199 Lubricate the new O-ring with petroleum jelly. Install the O-ring onto the plug. Lubricate the raise spool with clean hydraulic fluid and install the spool into the valve. Install and tighten the plug to a torque of 14 to 28 Nm (10 to 21 lb. ft.). Install the coils and coil nuts. Tighten the coil nuts to a torque of 2 to 4 Nm (17 to 35 lb. in.). STEP 25 RD02C200 Lubricate the new O-rings with petroleum jelly.
Section 35 - Hydraulic Systems, 3PT - Chapter 10 Installation STEP 29 STEP 27 RI02D067 Install and tighten the case drain line. RI02D046 Apply petroleum jelly to the new O-rings and install them to the back of the hitch valve. STEP 30 STEP 28 1 1 2 RD02D046 If equipped, install the hydraulic trailer brake line mounting clamp. RI02D045 STEP 31 Position the hitch valve on the remote valve stack and install the three mounting bolts.
Section 35 - Hydraulic Systems, 3PT - Chapter 10 STEP 32 STEP 35 RD02D047 Connect the valve supply line. RD02D042 If removed, install the seven pin connector mounting bracket. STEP 33 RD02D044 Connect the hitch valve solenoids to the wire harness. STEP 34 RD02D043 If equipped, connect the power beyond supply line.
Section 35 - Hydraulic Systems, 3PT - Chapter 10 HITCH CONTROL VALVE CROSS SECTION 9 16 18 15 8 7 17 6 10 1 3 2 4 14 12 13 5 11 13 12 14 RI02B003 1. 2. 3. 4. 5. 6. 7. 8. 9. RAISE SOLENOID LOWER SOLENOID RAISE PILOT SPOOL LOWER PILOT SPOOL RAISE SPOOL OVERLOAD RELIEF LOWER CONTROL PISTON LOWER PILOT POPPET LOWER POPPET 10. 11. 12. 13. 14. 15. 16. 17. 18.
Section 35 - Hydraulic Systems, 3PT - Chapter 10 35-10-12
Section 35 Chapter 11 TRACTOR HITCH January, 2006
Section 35 - Hydraulic Systems, 3PT - Chapter 11 TABLE OF CONTENTS SPECIAL TORQUES .................................................................................................................................... 35-11-3 TRACTOR HITCH ........................................................................................................................................ 35-11-3 EDC PIN ASSEMBLY ...............................................................................................................
Section 35 - Hydraulic Systems, 3PT - Chapter 11 SPECIAL TORQUES Nut for Position Locator Bracket ............................................................................. 490 to 555 Nm (362 to 410 lb. ft.) Bolts for Hitch Support C-Bracket........................................................................... 845 to 950 Nm (624 to 700 lb. ft.) Nuts for Hitch Potentiometer Bushing......................................................................... 3.5 to 6.3 Nm (2.6 to 4.6 lb. ft.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 Rear Hitch Disassembly 10 9 11 4 7 3 12 13 7 1 6 5 7 2 8 IMPORTANT: Position round area of pin toward the wire exit in cover. 1. 2. 3. 4. 5. 6. COVER EDC PIN TUBE GROMMET HEX HEAD BOLT (2) SHOULDER BOLT 7. 8. 9. 10. 11. 12. 13.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 4 STEP 6 6 5 4 3 10 1 11 9 8 2 26-35 Remove t he electronic draft control (EDC) components as follows: 7 DRAFT ARMS 1. Disconnect the EDC pin electrical connector from the top of the EDC tube (3). 2. Remove the hex head bolt (9) through the bracket at the top of the EDC tube. 14. 15. 16. 17. 18. 3. Remove the three bolts from the cover over the electronic draft control (EDC) pin and the EDC tube in the rear of the draft arm. 4.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 8 STEP 9 1 VERTICAL LIFT LINK 2 27-12 Remove the hydraulic lines to the hitch lift cylinder as follows: 3 1. Be prepared to catch hydraulic fluid as the hydraulic system is opened. 2. Remove the hydraulic line from the top of the hitch lift cylinder and then from the bottom of the hitch lift cylinder (both sides). 1. SWIVEL MUST BE POSITIONED OUTWARD. 2. FLAGS MUST FACE REARWARD ON BOTH SIDES. 3. FLAGS FOR FLAG PIN ASSY MUST FACE INWARD.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 11 STEP 13 36S21 36S15 Remove the two bolts that attach the linkage shield to the hitch support C-bracket. If necessary remove the three nuts from the bolts that attach the hitch potentiometer bushing to the sensor bracket and sensor. IMPORTANT: Be sure to remove hitch position sensor (potentiometer) prior to removing the hitch lift cylinders.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 Hitch Position Sensor A 8 2 1 6 3 A 4 A-A 9 NOTE 1: Link assembly shown in position with hitch down. NOTE 2: Items 1,2,3,4,5,7 & 8 make up the sensor subassembly. See “Potentiometer (Hitch Position Sensor)” later in this section for details. 7 5 10 11 INF6913 1. 2. 3. 4. 5. 6. BRACKET SENSOR BUSHING LINK ASSEMBLY SNAP RING NUT 7. 8. 9. 10. 11.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 Basic Hitch Assembly 11 15 16 4 2 A A 12 17 13 12 3 14 9 1 8 10 7 6 5 7 12. 13. 14. 15. 16. 17. 18. 19. 20. HITCH SUPPORT C-BRACKET ROCKSHAFT BOLT PIN RETAINER WASHER TIE ROD POSITION LOCATOR BRACKET NUT 21. 22. 23. 24. 25. 26. 27. 28.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 14 STEP 16 1 RD03F019 36-9 Support the nut that attaches the position locator bracket to the tie rod. NOTE: Right side nut (shown) should be held in place while nut on left side is removed. STEP 17 2 RD03g003 Remove the bolt, washer, spacer and nut (1). Remove pin (2) of the hitch lift cylinder (both sides). STEP 15 36-5 Remove the position sensor bracket.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 18 STEP 20 36-2 35-21 Remove the split ring washer that holds the pin-torockshaft retainer in place. Remove the tie rod through the opposite end from which the washer and retainer were removed. If tires are on tractor, the tie rod may be disassembled by sliding tie rod through c h a i n s up p o r t h o l e o n t i r e. O r i en t t i r e ( s ) a s necessary. Use a long piece of wood to reach through the rockshaft and contact the rocker pin.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 22 STEP 24 35-14 35-8 When both rockshaft pins are removed, lift and set aside the rockshaft casting. Remove the seven attaching bolts that pass through the hitch support C-brackets into the rear frame housing. NOTE: Keep bearings and seals free of foreign material. STEP 25 STEP 23 35-5 Lift off and set aside the hitch support C-bracket.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 Installation of the 3-Point Hitch STEP 27 STEP 29 35-5 All six mating surfaces of the hitch support C-bracket and rear frame must be clean and free of paint, oil, grease, anti-seize, etc. Move a hitch support Cbracket into place with a hoist and sling. These components should be replaced with new components during installation: 35-10 Remove the sling and hoist. STEP 30 1. Bushing and seals 2. M24 bolts and nuts 3.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 31 STEP 34 35-18 79S9 Pins must be clean and free of oil, grease, antiseize, compound, etc. Orient pin with bearing surface outboard. Insert a rockshaft pin. Use a wooden block to tap the pin until it is seated in place. Replace the other rocker pin. Adjust the hoist to allow the pins to slide easily. Install the tie bolt. Install the washer and M24 nut on the opposite (left hand) side.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 Bolt Tightening Sequence 2 1 Note 1: Numbers 3-9 on bolt heads denote bolt torque sequence. Note 2: Use same sequence on both sides. Note 3: Bolts tightening sequence numbers 1 and 2 are for nuts on both ends of the tie rod (not shown here) (performed in Step 38). INF4919 29. HITCH SUPPORT C-BRACKET 30.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 37 STEP 39 36-28 Attach the hitch lift cylinder as follows: 1. Pin must be clean and free of dirt, grease, oil and anti-seize compound, etc. 2. Move a hitch lift cylinder into place. Insert the holding pin through the hole in the lower end of the cylinder shaft and the shaft support. 36-18 Install the nut for the link assembly. Tighten to a torque of 18 to 23 Nm (14 to 17 lb. ft.). STEP 40 3. Install the bolt, washer and spacer.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 41 STEP 43 RD03F074 Insert a holding pin as follows: 1. Pin must be clean and free of oil, grease, antiseize. 2. Adjust the vertical position of the rockshaft, if necessary. 27-12 Attach the hydraulic line to the top of the hitch. Repeat for the other hitch lift cylinders. STEP 44 3. Move the upper end of the shaft into place so that the hole in the shaft of the hitch lift cylinder is aligned with its mating holes.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 45 STEP 46 26-21 26-33 Install the hex-head bolt, washer, spacer and nut. Tighten it to a torque of 82 to 106 Nm (60 to 78 lb. ft.). Repeat for the other vertical lifting link. Insert a hitch swivel pin through the inside hole at the bottom of the vertical lifting link. Lift up the draft arm and insert pin. Pin must be clean and free of oil, grease, anti-seize compound, etc. NOTE: Be sure the lift link is properly timed.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 48 STEP 49 27-5 Install the EDC components (refer to exploded view for Step 4) as follows: 26-16 Check hitch operation as follows: 1. Turn on the ignition key. 1. Move a lower draft arm into position for installation. If necessary, refer to the view in Step 10. 2. Operate the hitch slowly for one cycle. 2. Install the cover, EDC pin, and tube subassembly in place to secure the draft arm 3.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 EDC PIN ASSEMBLY STEP 50 26-36 Install electronic draft control (EDC) pin and pin wire tube as shown in the exploded view for Step 4. Continue installation as follows: 1. Apply RTV sealant on the inner surface of the cover, lower end of tube, and grommet. On the tube and cover, the bead of sealant should surround the entire 360 degrees of the component. On the grommet, the bead should be applied where wire exits at the top and between the grommet and tube.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 POTENTIOMETER (HITCH POSITION SENSOR) Unused hole subassembly in A 8 2 1 3 6 A 4 7 Section A-A 5 9 10 RIGHT SIDE OF VEHICLE 11 INF6913 31. 32. 33. 34. BRACKET SENSOR BUSHING LINK ASSEMBLY 35. 36. 37. 38. RING NUT BOLT NUT 39. SHIELD 40. WASHER 41.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 Disassembly Assembly NOTE: Be sure to remove the M8 nut that attaches the link to the position locator bracket located on the rockshaft. STEP 55 STEP 51 After the linkage shield for the potentiometer (hitch position sensor) is removed. The potentiometer subassembly can be removed as a unit. Lubricate the link and slide it into the bushing as far as possible. Install an E-ring on the backside of the bushing.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 CAM SWAY LIMITER Removal 1 3 1 4 2 3 4 INF5577A 42. CAM 43. PIVOT BOLT 44. CLEVIS PIN 45. LOCKING PIN STEP 59 Remove the sway limiter cam as follows: 1. Place a suitable support under the sway limiter cam to stop the cam from dropping when the bolt is removed. 2. Remove the locking pin from the clevis pin. 3. Remove the clevis pin. 4. Remove pivot bolt. 5. Remove cam.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 Installation STEP 60 27-27 Install the sway limiter cam as follows: 1. Move cam into position. 2. Install the pivot bolt. Turn the bolt until bolt head contacts the drawbar support bracket. Back out the pivot bolt by 1/8th turn. 3. Install clevis pin. 4. Install locking pin. 5. Remove support.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 CAM BUMPERS FOR DRAFT ARM 4 4 4 3 2 1 4 A 1 5 A 5 A-A 6166H2 1. DRAFT ARM (LOWER LINK) ASSEMBLY 2. SHIM 3. SPACER 4. BUMPER 5. LOCKING BOLT Removal Installation NOTE: Each cam bumper is located on a lower draft arm of the hitch. STEP 62 Install a cam bumper as follows: STEP 61 1. Place a bolt through the draft arm from the back side. Remove a draft arm cam bumper as follows: 2. Stack shims over the bolt shank on front side. 1.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 DRAWBAR, HIGH VERTICAL CAPACITY 16 17 14 13 8 10 15 4 7 19 20 5 18 21 3 22 11 6 1 12 9 9 2 RH98H044 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. HEAVY-DUTY DRAWBAR SAFETY CHAIN SUPPORT DRAWBAR STRAP SPACER HAMMERSTAP SPACER HAMMERSTRAP WASHER DRAWBAR SUPPORT M20X220 BOLT NUT M20X260 BOLT WASHER 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
Section 35 - Hydraulic Systems, 3PT - Chapter 11 STEP 66 Installation STEP 65 Install the pin retainer and washer; tighten the bolt to a torque of 134 to 151 Nm (99 to 111 lb. ft.). Install the drawbar support (assist casting) under the drawbar as shown. Tighten the three M20 x 150 bolts to a torque of 485 to 620 Nm (358 to 458 lb. ft.). Install the spacers and hammerstrap. Install the two M20 x 260 bolts and tighten to a torque of 486 to 620 Nm (358 to 458 lb. ft.).
Section 35 - Hydraulic Systems, 3PT - Chapter 11 This Page Left Blank.
Section 41 Chapter 1 STEERING COLUMN AND STEERING HAND PUMP REMOVAL AND INSTALLATION January, 2006
Section 41 - Steering - Chapter 1 TABLE OF CONTENTS SPECIAL TOOLS ........................................................................................................................................... 41-1-2 SPECIAL TORQUES ...................................................................................................................................... 41-1-3 STEERING COLUMN REMOVAL ..................................................................................................................
Section 41 - Steering - Chapter 1 SPECIAL TORQUES Bolt for Steering Hand Pump Bracket and Isolator ......................................................... 32 to 36 Nm (24 to 27 lb. ft.) Lock Nut for Steering Column Base ............................................................................... 29 to 32 Nm (22 to 24 lb. ft.) Nut for Steering Wheel ................................................................................................... 45 to 54 Nm (33 to 40 lb. ft.
Section 41 - Steering - Chapter 1 STEP 5 STEP 7 RD02C095 RD02C098 Remove the retaining screw from the steering column upper control housing. STEP 8 1 3 3 2 RD02C093 Use a Torx screwdriver to remove the upper and lower steering column covers. RD02C096 STEP 6 R e m o ve t h e t w o s t e e r i n g c o l u m n e l e c t r i c a l connectors (1). Remove the cable clip with pin (2) from the steering column tilt mechanism cable.
Section 41 - Steering - Chapter 1 STEP 10 STEP 12 1 2 RD02C109 RD02C111 Remove the boot support washer (1). Remove the steering column boot (2) along with the boot support plate and wire stiffener. Remove the four steering column lock nuts and washers at the column base. Support the steering column in the cab while an assistant removes the steering hand pump from the cab firewall. Remove the steering column.
Section 41 - Steering - Chapter 1 STEERING HAND PUMP SERVICE STEP 13 STEP 16 114S26 114S9 Mark the position of the pump bracket and isolator on the steering hand pump. Loosen the bolts and remove as a unit. Remove and replace the outer seal of the steering hand pump, if necessary. STEP 17 STEP 14 114S12 Install a new shaft noise seal. 114S15 Remove the four washers. STEP 18 STEP 15 114S15 Install the four washers. 114S12 Remove the shaft noise seal.
Section 41 - Steering - Chapter 1 STEP 19 STEP 20 114S26 114S29 Check the pump bracket to make sure it is not war ped or bent. Using the marks made during disassembly, install the pump bracket and isolator on the steering hand pump. Tighten the pump bracket bolts evenly in a crossing pattern to a torque of 32 to 36 Nm (24 to 27 lb. ft.). Lubricate the internal splines of the steering hand pump with grease. NOTE: The pump bracket must be squarely aligned with the housing of the pump.
Section 41 - Steering - Chapter 1 STEERING COLUMN ASSEMBLY 1 2 3 7 6 5 4 2 RI02G035 1. 2. 3. 4. BELLOW SET COVER SET RELEASE DEVICE SET BEARING SET 5. STEERING COLUMN 6. SEGMENT SET 7.
Section 41 - Steering - Chapter 1 STEP 21 STEP 23 2 1 3 RD02C111 RD02C109 Support the steering column in the cab while an assistant installs the steering hand pump. Install the steering column over the four studs and into the steering hand pump. Install the four washers and hand tighten the four new lock nuts at the column base. Install the steering wheel on the column just far enough to engage the steering mechanism.
Section 41 - Steering - Chapter 1 STEP 25 STEP 27 1 3 3 2 RD02C096 RD02C090 Connect the two steering column electrical connectors (1). Install the cable clip with pin (2) for the steering column tilt mechanism cable. Install the cable into the anchor bracket and tighten the lock nuts (3). Use the steering wheel position mark made during disassembly, and the steering column shaft centering mark made during assembly, install the steering wheel. Install the steering wheel retaining nut and flat washer.
Section 41 - Steering - Chapter 1 STEP 29 STEP 31 1 1 RD02C085 RD02C075 Pull up on the cab floor mat and install the left console heat duct into the cab floor duct. Install the retaining screw. Position the right console heat duct and install the retaining screw. Connect the electrical plugs to the ignition switch and the light switch. Install the two screws (1) for the lower console panel. STEP 32 STEP 30 Make sure the transmission shift lever is in PARK.
Section 41 - Steering - Chapter 1 41-1-12
Section 41 Chapter 2 WHEEL TOE IN SETTING SuperSteer FWD Axle January, 2006
Section 41 - Steering - Chapter 2 TABLE OF CONTENTS WHEEL TOE IN SETTING ............................................................................................................................. 41-2-3 WHEEL TOE IN SETTING DIAGRAM ........................................................................................................... 41-2-9 SPECIAL TOOL LAYOUT DRAWINGS .......................................................................................................
Template Name: OML_2_col Template Date: 2001_03_06 Rac 0-00000 Section 41 - Steering - Chapter 2 WHEEL TOE IN SETTING NOTE: The toe in setting must be done on a clean, level surface. NOTE: See the special tool layout drawings at the end of this section to fabricate the required spacer tubes and straightedge before starting wheel setting procedure. STEP 1 Install appropriate lift straps in the weight package (if equipped). Remove the weight package retaining bolts.
Section 41 - Steering - Chapter 2 STEP 4 Steer the axle until the string (1) hangs vertically and bisects the dowel hole (2) and threaded hole (3) in the drag link. The axle will then be “Dead Centered”. NOTE: The string must hang freely between the drag link and weight support bracket. 1 2 NOTE: If this step is not performed correctly, all other measurements and adjustments will be incorrect. 3 RD05E080 STEP 5 Remove two nuts and washers from the rim mounting bolts from the location shown.
Section 41 - Steering - Chapter 2 STEP 7 Be sure the rim surface in the nut area is free of dirt rust or debris as this will affect the accuracy of future measurements. Install and tighten the measured washers and nuts. RD05E083 STEP 8 Install the two fabricated threaded spacer tubes onto the rim bolts. Hand tighten firmly against the rim. RD05E084 STEP 9 Install the fabricated straightedge onto the two spacer tubes using two M16 bolts.
Section 41 - Steering - Chapter 2 STEP 10 Make sure that the wheel/rim is positioned so that the straightedge is parallel to the floor when mounted on the spacer tubes. RD05E086 STEP 11 Locate two points about 500 mm (20 in.) apart on the machine frame milled surface. Mark these points “A” and “B”. RD05E087 STEP 12 Measure and record the distance from the straightedge to point “A”.
Section 41 - Steering - Chapter 2 STEP 13 Measure and record the distance from the straightedge to point “B”. The difference between measurements “A” and “B” must not exceed 1mm. Measurement “A” should not be larger than measurement “B”. RD05E089 STEP 14 If adjustment is necessary, loosen the tie rod tube locking nut (1). Disconnect the steering lines from the outboard ends of both steering cylinders to avoid repositioning of the axle.
Section 41 - Steering - Chapter 2 Setting Verification Verification of the toe in setting is done by taking plumb bob measurements from the rims. Be sure the axle is still dead centered before starting the checking procedure. STEP 15 Install a magnetic base (1) for a dial indicator on the front inside of the rim. Locate the base on the rim at the center line of the axle (so that it is on the most forward part of the rim). 1 Hang a plumb bob (2) on the base.
Section 41 - Steering - Chapter 2 WHEEL TOE IN SETTING DIAGRAM Top View Of Front Axle 4 3 5 2 1 6 7 RI05E015 1. MAINE CHASSIS FRAME 5. STRAIGHTEDGE 2. AXLE 6. 500 MM (20 IN.) 3. AXLE DEAD CENTERED 7. MACHINED FRAME PADS 4.
Section 41 - Steering - Chapter 2 SPECIAL TOOL LAYOUT DRAWINGS 3 1 2 RI05F002 1. 30 TO 38 MM (1-1/4 TO 1-1/2 INCH) BARSTOCK (TUBES MUST BE WITHIN 0.05 MM) 2. 300 MM (12 INCHES) 3. M16 X 2.0 X 30 MM DEEP INTERNAL THREAD 1 3 4 2 RI05F001 1. 1.5 X 1/8 INCH X 72 INCH 2. 62 INCHES 3. 16 INCHES 41-2-10 4.
Section 50 Chapter 1 AIR CONDITIONING SYSTEM Troubleshooting and Fault Codes January, 2006
Section 50 - Climate Control - Chapter 1 TABLE OF CONTENTS SAFETY PROCEDURES ............................................................................................................................... 50-1-5 SPECIAL TOOLS ........................................................................................................................................... 50-1-6 A/C THERMAL OPERATION ....................................................................................................................
Section 50 - Climate Control - Chapter 1 Blower Speed And Temperature Control Potentiometers ......................................................................... Background ............................................................................................................................................. Possible Failure Modes - Fault Codes 120, 121 ..................................................................................... Electrical Test ............................................
Section 50 - Climate Control - Chapter 1 Blower Speed Switch And Blower Motor .................................................................................................. Background ............................................................................................................................................. Power and Ground Circuit ....................................................................................................................... Possible Failure Modes ..............
Section 50 - Climate Control - Chapter 1 SAFETY PROCEDURES ! THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. M171B ATTENTION: Only authorized technicians certified by an approved training and certification organization may service or repair motor vehicle or mobile air conditioning systems. 3. Keep refrigerant containers in correct upright position.
Section 50 - Climate Control - Chapter 1 SPECIAL TOOLS 1 RD99K079 299L7C 1. COMPRESSOR DIPSTICK Belt Tension Tool CAS10808 Compressor Tool Set, CAS10747A The compressor dipstick can be found in the Compressor Tool Set or purchased separately CAS10747-19.
Section 50 - Climate Control - Chapter 1 A/C THERMAL OPERATION The refrigerant circuit of the air conditioning system contains five major components: compressor, condenser, receiver-drier, expansion valve and evaporator. These components are connected by tubes and hoses and operate as a closed system. The air conditioner system is charged with HFC-134a refrigerant. (See diagram on next page to follow refrigerant flow.) The compressor receives the refrigerant as a low pressure gas.
Section 50 - Climate Control - Chapter 1 5 4 1 2 3 LOW PRESSURE GAS LOW PRESSURE LIQUID HIGH PRESSURE GAS HIGH PRESSURE LIQUID 209L95 1. COMPRESSOR 2. CONDENSOR 3. RECEIVER-DRIER 4. THERMAL EXPANSION VALVE 50-1-8 5.
Section 50 - Climate Control - Chapter 1 A/C SYSTEM COMPONENTS Cab HVAC Box Components - Automatic Temperature Control 1 9 7 2 3 5 6 4 RI05H007 8 RI05H008 1. BLOWER SPEED DRIVER 2. ATC CONTROLLER 3. THERMAL EXPANSION VALVE 4. HEATER CONTROL VALVE 5. BLOWER MOTOR ASSEMBLY 6. EVAPORATOR CORE 50-1-9 7. EVAPORATOR TEMPERATURE SENSOR 8. CAB TEMPERATURE SENSOR 9.
Section 50 - Climate Control - Chapter 1 Cab HVAC Box Components - Automatic Temperature Control 1 2 5 4 3 9 15 6 8 10 12 7 11 13 14 16 17 RI00A009 1. LID ASSEMBLY 2. ATC CONTROLLER 3. BLOWER SPEED DRIVER 8. A/C SUCTION LINE TUBE 15. THERMAL EXPANSION VALVE 9. A/C LIQUID LINE TUBE 16. DRAIN HOSE 10. HEATER SUPPLY HOSE 17. CHECK VALVE 4. BLOWER ASSEMBLY 11. HEATER RETURN HOSE 5. A/C LOW PRESSURE SWITCH 12. EVAPORATOR TEMPERATURE SENSOR 6. HEATER CONTROL VALVE ASSY 13. BASE WELDMENT 7.
Section 50 - Climate Control - Chapter 1 Chassis Components TOP 5 6 8 7 3 RIGHT HAND SIDE 1 3 4 2 FRONT 1. 2. 3. 4. 5. 6. 7. 8.
Section 50 - Climate Control - Chapter 1 AUTOMATIC TEMPERATURE CONTROL (ATC) OPERATION The operator selects a desired cab temperature with the temperature control. The controller uses the compressor, heater control valve and blower speed to drive to and maintain the desired setpoint. It also uses the mode door to effectively distribute the cooled or warmed air in the cab.
Section 50 - Climate Control - Chapter 1 1 A 5 M E 2 3 D B O N F C RD05J039 1. Blower Speed Control Manual selection of blower speed which overrides controller selection A. Blower OFF B. Maximum Blower Speed C. Automatic Mode 2. ATC Switch Selects operational mode D. OFF E. Manual Mode 3. Defog/Defrost Switch F.
Section 50 - Climate Control - Chapter 1 N 4 M G 4. Instrument Cluster Display Displays temperature setpoint and system status I H L RD05J048 G. Digital Temperature Display: Displays current setpoint selected by the operator for desired cab temperature. On start-up flashes “88” for short time to indicate that the controller is initializing. When system fault occurs, display toggles between temperature display and fault code number. H. Displays °F or °C for Fahrenheit or Celsius.
Section 50 - Climate Control - Chapter 1 Operation Modes Automatic Mode Maximum Heating in Automatic Mode - Maximum heating is selected by moving the Temperature Control Knob fully clockwise. In that mode, the blower fan is automatically set to full speed and the heating system delivers maximum heating capacity. Blower speed can be manually changed to a lower speed. Automatic mode is selected by placing the three position mode switch in Auto mode (down position).
Section 50 - Climate Control - Chapter 1 Automatic Operation Summary (ATC switch set to “Auto,” and “Auto” displays on the Instrument Cluster Display. No fault codes active.) Temperature Argument Blower Speed Controller needs a 2°F (1°C) difference between the setpoint and temperature sensed at cab sensor before responding - engaging the compressor or opening the heater valve. Selecting a setpoint one degree cooler or warmer than the temperature desired may increase operator comfort.
Section 50 - Climate Control - Chapter 1 Defog/Dehumidify Operation Summary (Defog/Dehumidify switch “ON”, Defog light ON. No fault codes active.) Temperature Argument Blower Speed Controller needs a 2°F (1°C) difference between the setpoint and temperature sensed at cab sensor before responding - engaging the compressor or opening the heater valve. Selecting a setpoint one degree cooler or warmer than the temperature desired may increase operator comfort.
Section 50 - Climate Control - Chapter 1 ATC Fault Codes ATC fault codes display on the Instrument Cluster display. The display toggles between the current cab temperature setpoint and the fault code. ATC fault codes are not recorded or stored. If more than one fault code is active, the codes display sequentially on the Instrument Cluster Display and alternate with the temperature setpoint. The service required icon also flashes on the Instrument Cluster Display whenever a fault code is active.
Section 50 - Climate Control - Chapter 1 ATC Fault Code 112 Cab temp sensor shorted to ground Cause: Wire harness/connector failure Temperature sensor failure ATC module failure Possible failure modes: ATC module defaults to manual mode. Solution: 1) Disconnect cab temp sensor and check its resistance. It should measure around 10K Ohms at room temperature. Replace if faulty. 2) Inspect harnesses and connectors for possible shorting between cab temp sensor wire and other wires or ground.
Section 50 - Climate Control - Chapter 1 ATC Fault Code 116 Evap temp sensor shorted to ground Cause: Wire harness/connector failure Temperature sensor failure ATC module failure Possible failure modes: Compressor clutch disabled. Solution: 1) Disconnect evap temp sensor and check its resistance. It should measure around 10K Ohms at room temperature. Replace if faulty. 2) Inspect harness and connectors for possible shorting between evap temp sensor wire and other wires or ground.
Section 50 - Climate Control - Chapter 1 ATC Fault Code 121 Temperature select pot open or shorted to power Cause: Wire harness/connector failure Temperature pot failure ATC module failure Possible failure modes: ATC module defaults to 72 oF (22 oC) setpoint. Solution: 1) Disconnect temperature pot and verify its operation. Its resistance should vary when rotated. Replace if faulty.
Section 50 - Climate Control - Chapter 1 ATC Fault Code 125 High pressure switch (+) shorted to power Cause: Wire harness/connector failure NOTE: If system is properly charged, then the high pressure switch will be closed and the short could be on either leg of the switch. ATC module failure Possible failure modes: Compressor clutch disabled. Solution: 1) Inspect harness and connectors for possible shorting between high pressure switch wires (both leads) and other wires.
Section 50 - Climate Control - Chapter 1 ATC Fault Code 127 High pressure switch (-) shorted to power Cause: Wire harness/connector failure NOTE: If system is properly charged, then the high pressure switch will be closed and the short could be on either leg of the switch. ATC module failure Possible failure modes: Compressor clutch disabled. Solution: 1) Inspect harness and connectors for possible shorting between high pressure switch wires (both leads) and other wires.
Section 50 - Climate Control - Chapter 1 ATC Fault Code 129 High pressure switch cycling error (2 times in 1 minute) Cause: Incorrect charge in system Wire harness/connector failure NOTE: If system is properly charged, then the high pressure switch will be closed and the failure could be on either leg of the switch. High pressure switch failure ATC module failure Possible failure modes: Compressor clutch locked out until unit is cycled off then back on.
Section 50 - Climate Control - Chapter 1 ATC Fault Code 131 Low pressure switch (+) shorted to ground Cause: Wire harness/connector failure NOTE: If system is properly charged, then the low pressure switch will be closed and the short could be on either leg of the switch. ATC module failure Possible failure modes: Compressor clutch disabled. Solution: 1) Inspect harness and connectors for possible shorting between low pressure switch wires (both leads) and other wires.
Section 50 - Climate Control - Chapter 1 ATC Fault Code 133 Low pressure switch (-) shorted to ground Cause: Wire harness/connector failure NOTE: If system is properly charged, then the low pressure switch will be closed and the short could be on either leg of the switch. ATC module failure Possible failure modes: Compressor clutch disabled. Solution: 1) Inspect harness and connectors for possible shorting between low pressure switch wires (both leads) and other wires.
Section 50 - Climate Control - Chapter 1 Locating System Problems Without Fault Codes Controller-Based Resistance Tests Pin ID 36-Pin Conn Description Wire/ Color 1 --> Can Low CAN LO 2 --> Can High CAN HIGH 3 --> Heat Signal Output 9C-Or 4 --> Heat Actuator Power 6D-Or 5 --> Blower Speed Output SBC-Or 6 --> Blower Actuator Power 252-Or 7 --> Mode 1 Output 102-Or 8 --> Mode 1 Act Power MD-Or 9 --> Mode 2 Output OPEN 10 --> Mode 2 Act Power OPEN 11 --> Recirc Output OPEN 12
Section 50 - Climate Control - Chapter 1 27 C/F Ground Selection 143-N 28 Blower Input 326-Or 29 Set Point Input 103-Or 30 Air Direction Input 154-Or 31 Defog Switch 32 Cab Pressure Input OPEN 33 High Pressure + Input 80-Or 34 High Pressure - Input HP-Bk 35 Low Pressure + Input LP-Or 36 Low Pressure - Input LP-N DEFSWOr To perfor m the above resistance tests at the controller, with the keyswitch OFF: 1. Disconnect the harness to the 36-pin connector at the ATC controller. 2.
Section 50 - Climate Control - Chapter 1 ATC Controller Test (Connector J8 Test Points) The following tests determine whether the ATC controller requires replacement, since it tests primary input and output circuits. Some test steps isolate system problems to specific circuits which can simplify general troubleshooting. In general, the service technician should resist the temptation to replace the controller as the solution to all A/C system problems.
Section 50 - Climate Control - Chapter 1 CONNECTOR J8 TEST POINTS Test Instructions and Actions Test ground continuity to controller: Pin 18 to HVAC ground 1 Condition(s): ATC Switch OFF Expected Result: Less than 1 ohm Action: Restore clean ground and retry the unit. Confirm switched B+ is present at controller: Pin 17 to Battery GND 2 Condition(s): Keyswitch ON Expected Result: 12V Action: Restore 12V and retry the unit. See Controller Power Supply and Ground Test in this Section.
Section 50 - Climate Control - Chapter 1 CONNECTOR J8 TEST POINTS Test Instructions and Actions Test cab temperature sensor: Pin 21 to Battery GND 10 Condition(s): Keyswitch ON and ATC Switch to “AUTO” Expected Result: 0.5V at 70°F (21°C) at the sensor. Voltage decreases as temperature increases. Actions: If no voltage, replace the controller. If voltage out of range for temperature, test sensor. See sensor test.
Section 50 - Climate Control - Chapter 1 ATC Field Reported Symptoms/Causes Symptom Hot air discharge out of vents - above 100°F (38°C) - without adjusting the temperature control with cooling request. No fault codes displayed. System fails to heat or cool correctly, but otherwise appears to function normally. No fault codes. Correction/Test Point 1. Test cab temperature and evaporator temperature sensors and circuits. See Sensors. 2. Test heater control valve for leakage. See valve “leak through”. 1.
Section 50 - Climate Control - Chapter 1 Compressor And Clutch Operational Check 1. When functioning normally, the compressor clutch is always grounded to the chassis, and switched 12V is supplied by a controller-activated relay to energize the clutch coil and engage the compressor. W i t h k e y s w i t c h O N , AT C s w i t c h t o “ A ,” temperature control on maximum cool, check that clutch is engaged and the compressor is operating. RD02H026 2. Disconnect the clutch at the harness.
Section 50 - Climate Control - Chapter 1 4. With the clutch still engaged, momentarily touch the suction and discharge hoses at the compressor for temperature difference. The suction line should be cool to cold, and the discharge line should be hot to very hot. ! 2 WARNING: This is only a momentary contact with the hose. M636 Little or no temperature difference between the hoses is another indication of compressor failure: internal leakage between discharge and suction sides. 1 RD02H031 1.
Section 50 - Climate Control - Chapter 1 6. Check for loose mounting bolts for the compressor. Tighten the bolts to the correct torque. NOTE: Loose mounting can cause a “knocking” sound at the compressor. A refrigerant overcharge also causes a knocking sound at the compressor. RD02H025 7. Clutch drive belt should be running smooth and straight. Clutch pulley and the drive pulley must be aligned within 1/16 inch (1.6 mm) of each other. Use a straight edge to check pulley ali gnment.
Section 50 - Climate Control - Chapter 1 Electrical Test See Electrical Schematic sections 60, 61, 6 at the end of this section. Background The compressor clutch is cycled On or Off by the controller based on the difference between the selected cab temperature setpoint and the temperature sensed at the cab temperature sensor. When functioning normally, the clutch is always grounded to the engine through the compressor mounting bracket.
Section 50 - Climate Control - Chapter 1 Steps and Test Point Corrective Actions YES - Go to next Step. RI01H035 NO - If open line or resistance is severely out of range, replace the clutch. 2. Measure resistance from C72-1 through clutch screw to ground screw on bracket. Is resistance between 3.6-4.2K ohms? NOTE: If clutch is shorted, also check condition of fuse 36 (5 amp). The clutch draws enough amperage to cause fuse 36 to blow. 3. Keyswitch ON and DEFOG/DEFROST switch ON.
Section 50 - Climate Control - Chapter 1 Steps and Test Point Corrective Actions 12. Check continuity from clutch relay, pin 1 to pin 2. OKAY - Go to next Step NOT OKAY - Replace the clutch relay. 13. Check continuity from clutch relay, pin 1 to ground. OKAY - Go to next Step NOT OKAY - Locate and repair the open condition between clutch relay pin 1 to ground. 14. Trouble may be intermittent. Double check all test points.
Section 50 - Climate Control - Chapter 1 High And Low Pressure Switch Clutch Latching Circuit Background High pressure switch activation is generally caused by a restriction or clog on the high pressure side of the system. However, a refrigerant or SP-20 PAG oil overcharge, the presence of refrigerants other than R134A or engine cooling problems can also cause high pressure switch activation.
Section 50 - Climate Control - Chapter 1 Possible Failure Modes - Fault Codes 129 and 134 Fault Code Description Controller has detected an open condition in high pressure switch circuit. Compressor clutch is latched OFF. 129 Smart Pressure Switch Counting Causes Code 129 is not activated until two occurrences within a 60 second interval, starting with the first occurrence. Actual interval may be as short as 10 seconds if open condition is constant.
Section 50 - Climate Control - Chapter 1 Electrical Test Refer to Schematic Sections 60 through 62 at the end of this section. Power and Ground With high pressure switch activation, 5V is present at pin 33 at controller and pin 1 at the switch. The switch is grounded to the chassis. With low pressure switch activation, 5V is present at pin 35 at the controller and pin B at the switch. The switch is grounded to 36 at the controller. With no pressure switch activation, both circuits test 0.
Section 50 - Climate Control - Chapter 1 Low Pressure Switch and Circuit Test Steps and Test Point Corrective Actions 1. Refer to A/C Troubleshooting Foldout and follow the conditions for performance testing. Install A/C high and low side pressure gauges. Low reading below 4 psi ± 2 psi (28 kPa ± 14 kPa)? Y E S - Pe r fo r m c o r r e c t i v e a c t i o n s f r o m A / C Troubleshooting Foldout. 2. Shut off the tractor. Disconnect the switch from the harness and the unit.
Section 50 - Climate Control - Chapter 1 Heater Control Valve Operational Check The controller opens or closes the heater control valve based on the operator selected input at the temperature control and the temperature sensed at the cab and evaporator sensors. 2 The heater control valve can fail mechanically in any position: open, closed or anywhere in the middle. 1 To confirm proper valve operation, observe the slot on the front of the valve.
Section 50 - Climate Control - Chapter 1 Electrical Test NOTE: See Electrical schematic sections 60 and 61. Power, Signal and Ground Circuit The controller feeds 12V to the heater valve motor from pin 4 on the control module 36-pin connector to pin 10 on the motor. The control signal (1.5 to 11.5V) is fed from the controller on pin 3 of the connector to pin 8 on the motor. The motor is grounded from pin 7 at the motor to HVAC ground. Possible Failure Modes 1. Motor failure or valve physical failure. 2.
Section 50 - Climate Control - Chapter 1 Blower Speed And Temperature Control Potentiometers Background Common Features T h e bl o w e r s p e e d a n d t e m p e r a t u r e c o n t r o l potentiometers are identical. All three have the same resistance rating: 0-10K ohms.
Section 50 - Climate Control - Chapter 1 Electrical Test NOTE: See Electrical Schematic sections 60 and 61. Power and Ground Circuit The two pots are grounded from pin C, through C139-S, to HVAC Ground. B+ read from the controller varies with the position of the pot: 0.0-3.xV. Blower Speed: B+ is fed from CJ8-28 through C139H to pin B on the potentiometer. Temperature Control: B+ is fed from CJ8-29 through C139T to Pin B on the potentiometer.
Section 50 - Climate Control - Chapter 1 BLOWER AND BLOWER SPEED DRIVER NOTE: See Electrical Schematic sections 60 and 61. Background In automatic and defog/defrost modes, blower speed is selected by the controller based on the difference between the desired setpoint and the actual cab temperature. Refer to ATC Operation in this section for further information on how blower speed is selected, overridden and exceptions.
Section 50 - Climate Control - Chapter 1 Blower Motor/Blower Driver Power, Signal and Ground Test Steps and Test Point Corrective Actions NOTE: If blower motor intermittently cycles to full speed for short periods, blower speed driver may be entering thermal protection mode. Check for an intermittent short to chassis at blower motor on wire SBC-Or or wiring short to heat sink on the blower driver. NOTE: The blower speed driver is equipped with a short crossover harness.
Section 50 - Climate Control - Chapter 1 Cab And Evapator Temperature Sensors Background The cab temperature sensor (1), located behind and under the recirculation air filter, supplies a key value to the controller for heating and cooling. Another key value is the desired setpoint. The greater the difference between the desired setpoint and the temperature sensed at the cab sensor, the greater the ATC system response.
Section 50 - Climate Control - Chapter 1 The cab temperature sensor must be installed in the recirculation air stream which enters the HVAC box at the rear. Do not install the sensor in contact with any metal surface; see illustration for view from inside the HVAC box.
Section 50 - Climate Control - Chapter 1 Electrical Test Both sensors have the same resistance vs temperature response even though they look dramatically different. Both sensors should measure 10-25K ohms at room temperature for normal operation. Both sensors are thermistors - thermal resistors. With these thermistors the colder the environment, the greater the electrical resistance; and the warmer the environment, the less electrical resistance.
Section 50 - Climate Control - Chapter 1 Possible Failure Modes - Fault Codes 111, 115 and 116 Since input from the sensors is essential for automatic control of heating and cooling functions, the controller displays fault codes on the Instrument Cluster Display when it detects a sensor failure: Fault Code Description Controller has detected an open, or shorted to power condition in the cab temperature sensor circuit.
Section 50 - Climate Control - Chapter 1 Cab Temperature Sensor and Circuit Test Steps and Test Point Corrective Actions 1. Keyswitch OFF. Disconnect the cab temperature sensor from harness. Measure the resistance across the sensor leads. Measure the ambient temperature at the sensor. Compare the readings to the Temperature versus Resistance table on page 55. Is the resistance reading within the minus or plus 2.5% range in the table? YES - Go to next Step. 2. Keyswitch ON and ATC switch to “Auto”.
Section 50 - Climate Control - Chapter 1 Evaporator Temperature Sensor and Circuit Test Steps and Test Point Corrective Actions 1. Keyswitch OFF. Disconnect the cab temperature sensor from harness. Measure the resistance across the sensor leads. Measure the ambient temperature at the sensor. Compare the readings to the Temperature versus Resistance table on page 55. Is the resistance reading within the minus or plus 2.5% range in the table? YES - Go to next Step. 2.
Section 50 - Climate Control - Chapter 1 Temperature Versus Resistance Table Ambient Temperature °F Ambient Temperature Range 0 °C -17.78 -2.5% 170.820 Kohms 175.200 +2.5% 179.580 1 2 -17.22 -16.67 165.360 160.095 169.600 164.200 3 -16.11 155.025 4 -15.56 5 6 °F °C Range -2.5% Kohms +2.5% 61 16.11 29.179 29.927 30.675 173.840 168.305 62 16.67 28.434 29.163 29.892 63 17.22 27.710 28.421 29.132 159.000 162.975 150.150 154.000 157.850 64 65 17.78 18.33 27.008 26.
Section 50 - Climate Control - Chapter 1 Controller Power, Ground, And ATC Switch NOTE: See Electrical Schematic sections 60 and 61. Background HVAC ground is a grounding bolt at the back of the HVAC box. Ground is additionally provided from the common wires through CJ6R1 on wire 309- or to ring terminal C2. Since so many controlled directed components interact, intermittent HVAC ground can make reliable troubleshooting very difficult.
Section 50 - Climate Control - Chapter 1 ATC Switch and Circuit Test Steps and Test Point Corrective Actions 1. Disconnect ATC switch from harness. ATC switch to “AUTO.” Measure resistance between pins 4 and 5 on switch? Less than 1 ohm? YES - Go to next Step. 2. Measure resistance from pin 5 at the ATC harness to terminal ground. Less than 1 ohm? YES - Go to next Step. 3. Keyswitch ON. Is 5V present between pin 4 and chassis ground at the harness connector. YES - Go to next Step. 4.
Section 50 - Climate Control - Chapter 1 Cab Pressurizer Blower Background Whenever engine rpm is greater than 500, the cab pressurizer motor should operate. The motor/blower assembly draws air from the cab cap through the left hand cab post and fresh air filter and feeds it directly to the HVAC box under the operator’s seat. The motor/blower assembly is located under the instructional seat behind a trim panel.
Section 50 - Climate Control - Chapter 1 ACCESSING THE HVAC BOX STEP 6 NOTE: The following procedure applies to both the standard control units and Automatic Temperature Control (ATC) systems. After completion of ser vice, reinstall the seat harness. Realign ATC controller mounting plate, if equipped, with mounting holes and reinstall seat mounting hardware. Reconnect right hand control harness. Ensure cab recirculation air filter is properly installed.
Section 50 - Climate Control - Chapter 1 STANDARD AIR CONDITIONING (STD) TROUBLESHOOTING Important Notes ABBREVIATIONS: Connectors and their pins or t e r m i n a l s a r e a b b r ev i a t e d t h r o u g h o u t t h e troubleshooting section. C139-T represents pin T on connector 139; C333-15 represents pin 15 on connector 333. IMPORTANT: The standard controller and many components are grounded to “HVAC ground.
Section 50 - Climate Control - Chapter 1 Standard A/C Operation The standard controller opens the heater control va l ve f r o m f u l l c l o s e d t o f u l l o p e n p o s i t i o n proportional to the temperature control potentiometer position from 12 o’clock to full clockwise. The standard A/C controller is an open loop control device. The controller provides electronic thermostat control. The compressor clutch is engaged and disengaged by the standard controller.
Section 50 - Climate Control - Chapter 1 Standard A/C Controls and Their Function 2 3 A 1 C B RH03B058 Manual selection of blower speed: Low, Medium or High or OFF. 1. Blower Speed Control With A/C switch in the OFF position and any blower speed selected, the control provides fresh air circulation for the cab with outside ambient air introduced with the cab pressurizer blower to the HVAC box. 2. A/C ON/OFF Switch Toggles cooling On or Off 3.
Section 50 - Climate Control - Chapter 1 Symptom-Based Standard A/C Troubleshooting Symptom A/C system is inoperative Possible Cause Blower speed switch defective Fuse 49 Compressor operates, but blower is inoperative. Power and ground to blower motor Blower operates, compressor is inoperative.
Section 50 - Climate Control - Chapter 1 Symptom Blower operates but not at all speeds: no low speed and/or no medium speed but high speed operates. Too little cooling, too little heating with system pressures and components normal Cab pressurization blower does not run when switched B+ is present.
Section 50 - Climate Control - Chapter 1 Standard Controller Test In general, the service technician should resist the temptation to replace the controller as the solution to all A/C system problems. Double check your test results to avoid a return service call. The absence of key control voltages or switched ground does require controller replacement. The following tests determine whether the A/C controller requires replacement, since it tests primary input and output circuits.
Section 50 - Climate Control - Chapter 1 Test Instructions and Actions Confirm power output to heater valve: Pin E (5-pin) to Battery GND 3 Condition(s): Keyswitch and A/C Switch ON Expected Result: 12V Action: If no voltage, replace the controller. Confirm control signal to heater control valve: Pin D (5-pin) to Battery GND 4 Condition(s): Keyswitch and A/C Switch ON Expected Result: 1.5 to 11.
Section 50 - Climate Control - Chapter 1 Compressor And Clutch Operational Check 1. When functioning normally, the compressor clutch is always grounded to the chassis, and switched 12V is supplied by a controller-activated relay to energize the clutch coil and engage the compressor. W i t h k e y sw i t c h O N , A / C sw i t c h t o O N temperature control on maximum cool, check that clutch is engaged and the compressor is operating. RD02H026 2. Disconnect the clutch at the harness.
Section 50 - Climate Control - Chapter 1 4. With the clutch still engaged, momentarily touch the suction and discharge hoses at the compressor for temperature difference. The suction line should be cool to cold, and the discharge line should be hot to very hot. ! 2 WARNING: This is only a momentary contact with the hose. M636 Little or no temperature difference between the hoses is another indication of compressor failure: internal leakage between discharge and suction sides. 1 RD02H031 1.
Section 50 - Climate Control - Chapter 1 6. Check for loose mounting bolts on the compressor. Tighten the bolts to the correct torque. NOTE: Loose mounting can cause a “knocking” sound at the compressor. A refrigerant overcharge also causes a knocking sound at the compressor. RD02H025 7. Clutch drive belt should be running smooth and straight. Clutch pulley and the drive pulley must be aligned within 1/16 inch (1.6 mm) of each other. Use a straight edge to check pulley ali gnment.
Section 50 - Climate Control - Chapter 1 Electrical Test – Compressor Clutch NOTE: See Electrical Schematic sections 58, 60 and 61. Background The compressor clutch is cycled On or Off by the controller based on the temperature sensed at the evaporator. (+) When functioning normally, the clutch is always grounded to the chassis through ring terminal 199F at the compressor mounting bolt. The blower speed switch must be in any position but OFF to engage the compressor.
Section 50 - Climate Control - Chapter 1 Clutch Relay Power Supply and Ground Test Steps and Test Point Corrective Actions NOTE: If both the blower motor and the compressor are not operating, check fuse 49 and the blower control circuit before testing the clutch relay. NOTE: This procedure assumes that the clutch has NOT been latched OFF by the controller due to high or low pressure switch activation and that the pressure warning lamp is not flashing on the A/C switch. YES - Go to next Step.
Section 50 - Climate Control - Chapter 1 Steps and Test Point Corrective Actions 5. Is 12V present at pin 3 of compressor clutch relay? YES - Go to next Step. 6. A properly functioning relay can be heard engaging. Toggle the A/C switch OFF and ON, and listen for a clicking sound. Is the relay functioning? YES - Relay coil functioning normally. Go to next Step. 7. Is 12V present at terminal 5 on the relay? YES - Go to next Step.
Section 50 - Climate Control - Chapter 1 High And Low Pressure Switch Clutch Latching Circuit Background High pressure switch activation is generally caused by a restriction or clog on the high pressure side of the system. However, a refrigerant or SP-20 PAG oil overcharge, the presence of refrigerants other than R134A or engine cooling problems can also cause high pressure switch activation.
Section 50 - Climate Control - Chapter 1 Possible Failure Modes - Flashing Pressure Warning Lamp Warning Lamp Description Controller has detected an open condition in high pressure switch circuit. Compressor clutch is latched OFF. Warning lamp flashes rapidly, about 13 times in a 10 second period. Pressure Switch Counting Causes Clutch latching is not activated until two occurrences within a 60 second interval, starting with the first occurrence.
Section 50 - Climate Control - Chapter 1 Electrical Test – Pressure Switches NOTE: See Electrical Schematic sections 58. 60 and 61. Power and Ground The controller feeds 5V from pin C (CCU1) to pin B on the high pressure switch. The switch is grounded to the chassis. The controller feeds 5V from pin B (CCU2) to pin B on the low pressure switch. The switch is grounded to the grounding stud in the HVAC box. High Pressure Switch and Circuit Test Steps and Test Point Corrective Actions 1.
Section 50 - Climate Control - Chapter 1 Low Pressure Switch and Circuit Test Steps and Test Point Corrective Actions 1. Refer to A/C Troubleshooting Foldout and follow the conditions for performance testing. Install A/C high and low side pressure gauges. Low reading below 4 psi ± 2 psi (28 kPa ± 14 kPa)? Y E S - Pe r fo r m c o r r e c t i v e a c t i o n s f r o m A / C Troubleshooting Foldout. 2. Shut off the tractor. Disconnect the switch from the harness and the unit.
Section 50 - Climate Control - Chapter 1 Heater Control Valve Operational Check The controller opens or closes the heater control valve based on the operator selected input at the temperature control and the temperature sensed at the evaporator sensor. 1 The heater control valve can fail mechanically in any position: open, closed or anywhere in the middle. To confirm proper valve operation, observe the slot on the front of the valve.
Section 50 - Climate Control - Chapter 1 Electrical Test NOTE: See Electrical Scheamtic section 58, 60 and 61. Power, Signal and Ground Circuit The controller feeds 12V to the heater valve motor from pin E (CCU2) to pin 10 on the motor. The control signal (1.5 to 11.5V) is fed from the controller on pin D (CCU2) to pin 8 on the motor. The motor is grounded from pin 7 at the motor to the HVAC ground stud. Possible Failure Modes 1. Motor failure or valve physical failure. 2.
Section 50 - Climate Control - Chapter 1 Temperature Control Potentiometer Background If the potentiometer fails, the controller attempts to maintain the last temperature request it received when it had input. If the heater valve was opened 40% at the last request, that is the position it maintains. An operator experiences this as cab temperature cannot be varied with the control.
Section 50 - Climate Control - Chapter 1 Blower Speed Switch And Blower Motor NOTE: See Electrical Schematic sections 58, 60 and 61. Background Various blower speeds are accomplished by passing voltage through step-down resistors for low and medium speeds. Voltage is jumpered directly to the motor for high speed. If only high speed operates, resistor failure or an open condition in the in-line connector are the likely suspects. Resistor failure requires replacement of the motor.
Section 50 - Climate Control - Chapter 1 Blower Speed Switch and Power Circuit Test Steps and Test Point Corrective Actions NOTE: If the blower motor does not run at any speed, test the switch and power circuit - fuse 49. If the blower motor does not operate on all speeds, test the control circuit for the motor. 1. Keyswitch ON. Measure voltage at blower speed switch on pin 2. Is 12V present? YES - Go to Step 3. 2. Measure voltage at fuse 49 (30 amp).
Section 50 - Climate Control - Chapter 1 Steps and Test Point Corrective Actions 7. Measure voltage at in-line C139-D. Is 12V present? YES - Repair open circuit between C139-D and in-line connector on terminal 2. NO - Go to next Step. 8. Measure voltage at blower speed switch pin 5. Is 12V present? YES - Locate and repair open circuit between switch pin 5 and C139-D. NO - Test the Switch. 9. Turn blower control to MEDIUM? Does blower motor operate at medium speed? YES - Go to Step 13.
Section 50 - Climate Control - Chapter 1 Evaporator Temperature Sensor Background The evaporator temperature sensor, sometimes called the “freeze” or ”core” sensor, is located in the evaporator/heater assembly. The sensor measures the effectiveness of system response to the current demand for heating or cooling. 1 2 “Freeze” Control The evaporator sensor also prevents the system from operating in low ambient temperatures where d a m a g e t o t h e s y s t e m m i g h t o c c u r.
Section 50 - Climate Control - Chapter 1 Power Circuit The sensor is grounded to the HVAC ground stud. Minimal voltage is fed to the sensor - about 0.5V at 70°F (21°C) - and voltage drops as the temperature increases. Current is fed to the evaporator sensor from pin B at the controller (CCU1). Service Note: Too Little Cooling/Too Much Heating without Symptoms The sensor fails in a consistent pattern: It senses a lower temperature then is actually present.
Section 50 - Climate Control - Chapter 1 Temperature Versus Resistance Table Ambient Temperature °F Ambient Temperature Range 0 °C -17.78 -2.5% 170.820 Kohms 175.200 +2.5% 179.580 1 2 -17.22 -16.67 165.360 160.095 169.600 164.200 3 -16.11 155.025 4 -15.56 5 6 °F °C Range -2.5% Kohms +2.5% 61 16.11 29.179 29.927 30.675 173.840 168.305 62 16.67 28.434 29.163 29.892 63 17.22 27.710 28.421 29.132 159.000 162.975 150.150 154.000 157.850 64 65 17.78 18.33 27.008 26.
Section 50 - Climate Control - Chapter 1 Controller Power, Ground And A/C Switch NOTE: See Schematic Sections 58, 60 and 61. Background Intermittent Ground Inter mittent HVAC groun d ca n make r eli abl e troubleshooting very difficult. The “intermittent” nature of the problem is further complicated since the fault can appear to move from component to component. Early testing for a stable and consistent ground at the ground bolt and ring terminal 172F can greatly simplify troubleshooting.
Section 50 - Climate Control - Chapter 1 A/C Switch and Circuit Test Steps and Test Point Corrective Actions 1. Disconnect A/C switch from harness. With switch ON, measure resistance across pins 5 and 6 on switch. Less than 1 ohm? YES - Go to next Step. 2. Measure resistance across pins 9 and 10 at switch. Less than 1 ohm? YES - Go to next Step. 3. Measure resistance from pin 5 at the harness connector to chassis ground. Less than 1 ohm? YES - Go to next Step. 4. Keyswitch ON.
Section 50 - Climate Control - Chapter 1 Cab Pressurizer Blower NOTE: See Electrical Schematic sections 58, 60 and 61. Background The motor is energized by a relay, activated by switched B+. Whenever switched power is present, the cab pressurizer motor should operate. The motor/blower assembly draws air from the cab cap through the left hand cab post and fresh air filter and feeds it directly to the HVAC box under the operators seat. The motor/blower assembly is located behind the fresh air filter.
Section 50 - Climate Control - Chapter 1 Cab Pressurizer Blower & Relay Power Supply and Ground Test Steps and Test Point Corrective Actions 1. Keyswitch ON. Check fuse 10 (15 amp). Is 12V present? YES - Go to next Step. NO - Replace fuse 10 and/or locate and repair open condition to the fuse. RD02E272 2. Measure the voltage on pin A at the pressurizer motor. Is 12V present? YES - Go to next Step. 3.
Section 50 - Climate Control - Chapter 1 NOTES 50-1-90
Section 50 Chapter 2 AIR CONDITIONER SYSTEM SERVICE January, 2006
Section 50 - Climate Control - Chapter 2 TABLE OF CONTENTS SPECIFICATIONS .......................................................................................................................................... 50-2-4 SPECIAL TORQUES ...................................................................................................................................... 50-2-4 SPECIAL TOOLS .......................................................................................................................
Section 50 - Climate Control - Chapter 2 CONTROLLER AND BLOWER SPEED DRIVER REPLACEMENT ......................................................... ATC Controller ........................................................................................................................................ Standard A/C Controller .......................................................................................................................... Blower Speed Driver (ATC Units Only) ..............................
Section 50 - Climate Control - Chapter 2 SPECIFICATIONS Air Conditioning System Refrigerant Capacity ...............................................................4.63 lb. (U.S.) (2.1 kg.) Clutch Front Plate Air Gap............................................................................... 0.016 to 0.031 inch (0.41 to 0.79 mm) SPECIAL TORQUES Compressor Clutch Retaining Nut ........................................................................ 15 to 20 Nm (11 to 15 lb. ft.) Oil Filler Plug ........
Section 50 - Climate Control - Chapter 2 Refrigerant Identifier OEM4450 RR99M070 Air-Powered Recovery Station with Tank OEM1691 RR00D078 Additional 50 lb.
Section 50 - Climate Control - Chapter 2 Electronic Leak Detector OEM1437 A22090 UV Leak Detection Lamp and Goggles BSL750 RR00F098 Recovery Station UV Dye Injector for R-134a Refrigerant - BSL734 RR00F101 UV Leak Detection Dye for R-134a Refrigerant B726012 RR00F102 50-2-6
Section 50 - Climate Control - Chapter 2 R134a Quick and Easy Dye Injector Tool BSL738 RD01F248 Quick and Easy R134a Charge Cans 6-Pack BSL634 RD01F249 UV Fluorescent Dye Cleaner - B795016 RR00F100 Power Flush Model 17550 BS33801 - A/C Flushing Solution, Case of Six 1-Gallon Containers RR00F093 50-2-7
Section 50 - Climate Control - Chapter 2 Flush Gun Kit Model 17585 BS33801 - A/C Flushing Solution, Case of Six 1-Gallon Containers RP00G007 Coalescing Air Filter/Dryer (1) Similar to Ingersoll-Rand Model IR5CHE or Grainger Model 4KR65 1 RI00F041 Pressure Regulator Capable of Providing 45 psi at 4.0 cfm (310 kPa at 0.
Section 50 - Climate Control - Chapter 2 SAFETY PROCEDURES ! THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. M171B ATTENTION: Only authorized technicians certified by an approved training and certification organization may service or repair motor vehicle or mobile air conditioning systems. 5.
Section 50 - Climate Control - Chapter 2 AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY IMPORTANT: There are no repair procedures for the compressor or compressor clutch. If the clutch or compressor are defective, replace them. ! WARNING: 134a is the only refrigerant approved in 134a systems. Alter native refrigerants which boast better cooling c apabilities are in most c ases highly flammable. Do not expose contaminated refrigerant to spark, flame or yourself.
Section 50 - Climate Control - Chapter 2 Overview In many c oun tr ies, r ecov er y, recycling an d reclamation have legal definitions and standard meanings in the mobile A/C industry. Recovery is transferring refrigerant in any condition from a system to a storage container without testing or purifying the refrigerant in any way. Recycling is the cleaning of refrigerant for reuse by oil-separation, non-condensable gas removal and single or multiple passes through filter/moisture absorption devices.
Section 50 - Climate Control - Chapter 2 RECOVERING PURE 134A REFRIGERANT STEP 1 Start the tractor and run the engine at 1500 RPM. If possible, operate the air conditioner for 15 minutes at maximum cooling and maximum blower speed. ATC switch set to DEFOG/DEFROST, standard A/C switch set to ON. 1 3 2 RH02J044 Standard A/C Controls 1 3 ATC A/C Controls 1. BLOWER CONTROL 2. ATC OR STANDARD A/C SWITCH 2 4 RH05J039 3. TEMPERATURE CONTROL 4.
Section 50 - Climate Control - Chapter 2 STEP 3 IMPORTANT: Use Refrigerant Identifier OEM4450 to verify refrigerant purity. If refrigerant is 98% pure HFC-134a and/or the only non-condensibles test as air and moisture, then proceed with Step 4. If not, go to Step 12. With the charging station manifold gauge valves in the closed position, connect the hoses from the test gauges to the service ports. Connect the hose from the low pressure gauge to the port on the suction hose. Turn in valve depressor.
Section 50 - Climate Control - Chapter 2 STEP 5 Open the high and low valves. A22114 STEP 6 Make cer tain the refrigerant tank gas and liquid valves are open. A22107 STEP 7 Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position and depress the RECOVER switch. The compressor will shut OFF automatically when recovery is complete. Wait for 5 minutes and observe the manifold pressure gauges for a pressure rise. If no pressure rise, recovery is complete.
Section 50 - Climate Control - Chapter 2 STEP 8 Some recovery units require a manual air purge to remove non-condensables from the recovery tank. Refer to the operators manual for your unit. Air purge is automatic on an OEM1415 when it evacuates the A/C system. A22108 STEP 9 Slowly open the oil drain valve and drain the oil into the reservoir. When the oil stops draining, close the oil drain valve completely. MK96C017 STEP 10 Record the amount of oil in the reser voir.
Section 50 - Climate Control - Chapter 2 RECOVERING CONTAMINATED REFRIGERANT WITH OEM1691 I M P O R TA N T: R e a d a l l s a fe t y w a r n i n g a n d maintenance sections of the operator’s manual before operating the station. IMPORTANT: When contaminated refrigerant is discovered with Refrigerant Identifier OEM4450, additional care is necessary to protect your safety and prevent the contamination of service equipment and your refrigerant supply.
Section 50 - Climate Control - Chapter 2 STEP 14 A 1/4 inch FFLX to 1/2 inch Acme adapter (OEM1693) should have been ordered with the unit. Connect the adapter to the red tank valve. RR00E144 STEP 15 Connect the 96 inch (2.4 m) blue hose with the R134a service coupler to the adapter. RR00E152 STEP 16 Connect the R134a service coupler to the tee fitting on top of the vac uum pump on O EM1 415 or OEM1418. Open the valve on the service coupler by turning it clockwise.
Section 50 - Climate Control - Chapter 2 STEP 17 Open the valve on the tank. RR00E155 STEP 18 Open the low side manifold on the control panel of OEM1415 or OEM1418. RR00E156 STEP 19 Press SHIFT/RESET and ENTER at the same time. P r e s s 1 . T h e va c u u m p u m p s t a r t s a n d r u n s continuously until any other key is depressed. Run the vacuum pump for a minimum of 5 minutes. Then press 1 to stop the pump.
Section 50 - Climate Control - Chapter 2 STEP 20 Press SHIFT/RESET again to return to the normal display mode. Close the valve on the tank. Close the valve on the service coupler by turning it counterclockwise and disconnect the blue hose from the vacuum pump. RR00E155 STEP 21 Set the tank on the platform at the rear of the station. Tighten the black strap securely around the tank. RR00E143 STEP 22 Disconnect the R134a hose from the adapter.
Section 50 - Climate Control - Chapter 2 Recovery Process IMPORTANT: If a recovery tank becomes full during a recovery, the float switch will automatically turn off the scavenger. See Step 35 for changing tanks in the middle of a recovery. STEP 23 ! WARNING: Do not operate the vehicle or the A/C system if the refrigerant identifier shows more than 2% hydrocarbon in the mixture. M801 Start the tractor and run the engine at 1500 RPM.
Section 50 - Climate Control - Chapter 2 STEP 26 Turn the control panel valve to START. NOTE: This will equalize pressure on both sides of the compressor for easier starting. RR00E132 STEP 27 Connect a compressed air line to the air inlet on the regulator at the rear of the station. NOTE: The air system must offer a minimum of 120 psi (827 kPa) and a maximum of 200 psi (1379 kPa) at sustained volume of 10 cfm (0.28 cmm).
Section 50 - Climate Control - Chapter 2 STEP 28 Connect the red power lead to the + (positive) post of the vehicle’s battery or to another 12V DC power supply. Connect the black ground lead to a ground source away from the battery, NOT the battery (negative) post. The compressor should start idling. NOTE: Batteries generate explosive gases during normal battery operation. Use the remote ground to reduce the risk of sparks around the contaminated system.
Section 50 - Climate Control - Chapter 2 STEP 30 When inlet pressure gauge shows a vacuum, disconnect the air line. Wait five minutes. If inlet pressure rises above 0 psi, repeat Steps 33 and 35. NOTE: Refrigerant may pool inside the system. When the station is turned off, the refrigerant will vaporize in the ambient heat causing the system pressure to rise again. Repeat the recovery process until the system remains at a vacuum for at least two minutes. 2 1 RR00E157 1. A/C SYSTEM PRESSURE GAUGE 2.
Section 50 - Climate Control - Chapter 2 STEP 33 Disconnect the black ground lead. Disconnect the red power lead from the 12V power source. RR00E134R STEP 34 After each recovery, carefully open the accumulator oil drain and drain any collected compressor oil in a proper container. NOTE: Small amounts of refrigerant may remain in the accumulator and build a slight pressure. Drain the accumulator when the inlet pressure gauge shows a vacuum.
Section 50 - Climate Control - Chapter 2 STEP 35 If a recovery tank becomes full during a recovery, the float switch will automatically turn off the station. To change a full tank in the middle of a recovery: A. Close the blue tank valve and the valve on the black hose from the station. B. Unscrew and remove the float cable from the tank. C. Disconnect the hose from the tank valve. D. Remove the tank from the station. E.
Section 50 - Climate Control - Chapter 2 AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING IMPORTANT: Replace the receiver-drier if one or more of the following conditions occurs before you remove the air and moisture from the system: A. The system has been opened for service before. B. Receiver-drier has operated two or more years. C. Disassembly of compressor shows small particles of moisture removing material (gold or brown particles). D. Large system leak (broken hose, break in line). E.
Section 50 - Climate Control - Chapter 2 STEP 39 Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position. If program and vacuum do not appear at the top of the display press the VACUUM key. Program a minimum of 45 minutes and press the ENTER key. The display will flash once indicating the programmed data has been accepted. A22113 STEP 40 Fully open the low and high pressure valves. A22114 STEP 41 Open the red (vapor) and blue (liquid) valves on the tank.
Section 50 - Climate Control - Chapter 2 STEP 42 Press the VACUUM key. Automatic will show on the display. VACUUM will appear on the display and after a slight delay, the vacuum pump will star t. The display will show the amount of time programmed and begin a countdown to zero. When the programmed time has elapsed, an automatic hold occurs. Check the low pressure gauge to see that the A/C system maintains a 28 to 29-1/2 inches of mercury (Hg).
Section 50 - Climate Control - Chapter 2 STEP 45 Program the proper refrigerant amount for your tractor and press the ENTER key: All MX/Magnum Tractor Models ....4.63 lbs (2.1 kg) T h e d i s p l ay w i l l f l a s h o n c e i n d i c a t i n g t h e programmed data has been accepted. A22113 STEP 46 P r es s t he CH AR G E key to be gi n r ef r i g era n t charging. AUTOMATIC and CHARGE will appear on the display. The display shows the programmed amount and counts down to zero as charging proceeds.
Section 50 - Climate Control - Chapter 2 STEP 48 Start the tractor and run the engine at 1500 RPM. Operate the air conditioner system at maximum cooling setting and blower speed with the door and service door open, Standard A/C switch ON or ATC switch in DEFOG/DEFROST position. 1 NOTE: The compressor does not operate if the system pressure is too low or too high because the clutch is latched off by the controller.
Section 50 - Climate Control - Chapter 2 STEP 49 Observe the pressure gauge readings to determine that the correct amount of refrigerant has entered the system. See chart on page 33 for temperature and pressure variations. Check louver temperature for proper cooling at the mid-cab vents. A22117 RD02F045 STEP 50 Close any open valves on the couplers and carefully remove the gauge hoses from the por ts on the suction and discharge lines.
Section 50 - Climate Control - Chapter 2 STEP 51 Install the caps on the service ports on the suction and discharge lines.
145 to 172 kPa (21 to 25 psig) 179 to 207 kPa (26 to 30 psig) 200 to 241 kPa (29 to 35 psig) 228 to 276 kPa (33 to 40 psig) 255 to 319 kPa (37 to 45 psig) 27°C (80°F) 32°C (90°F) 38°C (100°F) 43°C (110°F) 49°C (120°F) 283 to 345 kPa (41-50 psig) 255 to 319 kPa (37 to 45 psig) 228 to 276 kPa (33 to 40 psig) 207 to 234 kPa (30 to 34 psig) 172 to 207 kPa (25 to 30 psig) 145 to 172 kPa (21 to 25 psig) High Relative Humidity 2034 to 2482 kPa (295 to 360 psig) 1813 to 2213 kPa (263 to 321 psig)
Section 50 - Climate Control - Chapter 2 A/C SYSTEM FLUSHING PROCEDURE The receiver-drier has a fine mesh screen to capture contaminants, but the contaminants may penetrated the screen. Check the discharge port of the receiverdrier to see if contaminants have penetrated the screen. If so, individual flushing of the hose between the receiver-drier and the expansion valve and c l e a n i n g t h e t h e r m a l ex p a n s i o n v a l v e a r e appropriate.
Section 50 - Climate Control - Chapter 2 Additional system flushing is at the discretion of the service technician who can best judge how far the contamination has traveled and what components may have been damaged and require replacement. 3. Rotate the compressor clockwise to check for binding caused by the presence of particles. 4. Drain or add PAG to return the compressor to measured dipstick level. IMPORTANT: Flushing solvent CANNOT be used to remove compressor contaminants.
Section 50 - Climate Control - Chapter 2 Precautions ! WARNING: Do NOT use solvent containing alcohol, lacquer thinner, brake cleaner or other non-approved solvents. Use only New Holland approved flushing solvent. Other flushing agents or solvents may damage A/C system components. M815 New Holland A/C flushing solvent is a hazardous material. Read all warnings on the flushing solvent container prior to use and observe these safety precautions: 1. The flushing solvent is combustible.
Section 50 - Climate Control - Chapter 2 Component Flushing Procedure with Power Flush 17550 STEP 52 All refrigerant must be recovered from the system before flushing. STEP 53 The 17550 power flush unit uses shop air to atomize the flushing solvent and a pulsing action to scrub residue and contaminants out of components. Attach flushing adapters to the component to be flushed. These adapters can be shop built or a universal A/C flushing fitting set is available - Model 17582.
Section 50 - Climate Control - Chapter 2 STEP 56 Remove the flushing tank hose quick coupler from the evaporation plug. RP00G018 STEP 57 Connect the flushing tank hose quick coupler to an extension or an adapter hose. RD00H203 STEP 58 Connect CLEAN and DRY shop air supply to the quick coupler on the flushing valve.
Section 50 - Climate Control - Chapter 2 STEP 59 Connect flushing and drain hoses to flushing adapters on component being flushed so the flushing solvent moves in the opposite direction of refrigerant flow - back flushing. Reinforced clear hose is preferred to monitor the condition and removal of the used solvent. IMPORTANT: Secure the lid on the return bucket so all flush vapors pass through the bucket filter.
Section 50 - Climate Control - Chapter 2 STEP 62 Turn the flushing valve to the AIR position. Allow air to flow through the component until no noticeable mist is discharged. NOTE: Air pressure is the only means to remove the flushing solvent from the A/C system, and no solvent must remain in the system when it is evacuated and recharged. Turn the component so gravity can assist in solvent removal. RD00H207 STEP 63 Turn the flushing valve to the CLOSED position.
Section 50 - Climate Control - Chapter 2 Complete Circuit Flushing Procedure with Power Flush 17550 STEP 65 All refrigerant must be recovered from the system before flushing. STEP 66 The 17550 power flush unit uses shop air to atomize the flushing solvent and a pulsing action to scrub residue and contaminants out of components. Fill the flushing reservoir 3/4 full with approved New Holland flushing solvent. Do not overfill the reservoir or you will restrict the pulsing action of the unit.
Section 50 - Climate Control - Chapter 2 STEP 69 Disconnect the suction and discharge lines from the compressor. Attach flushing adapters to the lines. Universal A/C Flush Fittings Shown STEP 70 RH01F112 1 Close the air and the flushing valves. 2 RD00H200 1. AIR VALVE 2. FLUSH VALVE STEP 71 Remove the flushing tank hose quick coupler from the evaporation plug.
Section 50 - Climate Control - Chapter 2 STEP 72 Connect the flushing tank hose quick coupler to an extension or adapter hose. RD00H203 STEP 73 Connect CLEAN and DRY shop air supply to the quick coupler on the flushing valve. RD00H202 STEP 74 Connect flushing and drain hoses to adapters on compressor lines so flushing solvent moves in the opposite direction of refrigerant flow - back flushing.
Section 50 - Climate Control - Chapter 2 STEP 75 Open the air valve 1/2 to 3/4 turn. 1 IMPORTANT: Do not exceed this rate of air delivery. This rate delivers one gallon per minute of flush solvent which is ideal for the orifice openings in the circuit being flushed. Turn the flushing valve to the FLUSH position and flush the circuit until the solvent appears clear at the return hose to the solvent waste container. 2 RD00H205 1. AIR VALVE 2. FLUSH VALVE STEP 76 Close the flushing and air valves.
Section 50 - Climate Control - Chapter 2 STEP 78 Turn the flushing valve to the CLOSED position. Disconnect the flushing and drain hoses and adapters from the compressor lines. Install the flushing tank hose quick coupler on the evaporation plug to prevent evaporation of the solvent remaining in the tank during storage. See Post Flushing Procedures, page 48.
Section 50 - Climate Control - Chapter 2 Back Flushing the Thermal Expansion Valve or Refrigerant Line STEP 79 Flush gun 17585 can be used to back flush the thermal expansion valve or a refrigerant line. Solvent is added to the canister, and then the canister is pressurized with CLEAN and DRY shop air. Pulse the tr ig g er o n t he fl u s h g un fo r gr e a te r fl us h i n g effectiveness. RP00G007 STEP 80 To fill the canister, remove the cap assembly. Add no more than 20 oz.
Section 50 - Climate Control - Chapter 2 STEP 82 Connect the hose with flush gun to the canister. RP00G010 STEP 83 NOTE: To prevent sprayback, press the rubber nose cone on the gun into the opening on the refrigerant line or thermal expansion valve when flushing. When back flushing the thermal expansion valve, the suction and discharge por ts must be flushed in different directions. Collect used solvent in a container for proper disposal.
Section 50 - Climate Control - Chapter 2 Post Flushing Procedures STEP 85 Identify and remove the source of the contamination. STEP 86 Reconnect all fittings using new HNBR “green” HFC-134a compatible O-rings. Lubricate the O-rings with mineral oil prior to installation. RP00G006 STEP 87 Install a new receiver-drier. NOTE: The receiver-drier should be replaced just before the system is drawn to a deep vacuum to avoid saturating it with moisture.
Section 50 - Climate Control - Chapter 2 STEP 89 Install a new compressor if required. RD02H039 STEP 90 Adjust the level of SP-20 PAG oil in the system. When each component was flushed, some SP-20 PAG oil was removed from the system. Use the following guidelines when adjusting PAG oil: If the compressor is to be replaced and the entire system was flushed, the new compressor will contain all the SP-20 PAG oil needed and no fur ther adjustment is required.
Section 50 - Climate Control - Chapter 2 Final System Oil Check 3. Recover refrigerant from the system. Use the dipstick method to check the PAG oil level in the compressor. If needed, adjust the oil level. See Dipstick Method, page 80. For all Tractor Models, the oil should cover five lines on the dipstick. After the system has been drawn to a deep vacuum and recharged, 1. Operate the A/C system for 15 minutes to thoroughly circulate the PAG oil throughout the system. 2.
Section 50 - Climate Control - Chapter 2 LEAK DETECTION ! WARNING: Never leak test with an open flame or a flame-type detector. M816 ! WARNING: When refrigerant comes in contact with an open flame, it can form dangerous gas. Never br eathe these fumes. SM109A Two methods are recommended to test the A/C system for refrigerant leaks: electronic leak testing with OEM1437 and UV-florescent leak detecting.
Section 50 - Climate Control - Chapter 2 Electronic Testing with OEM1437 When performing electronic leak detection with OEM1437, follow these general guidelines: 1. There must be enough refrigerant in the system to produce normal pressures (at least 50 psi). 2. Leak test in an area free of wind and drafts. 3. Operate the tractor long enough to circulate the refrigerant and produce nor mal system pressures. 4. Shut the tractor and system off when leak testing. RD02H049 5.
Section 50 - Climate Control - Chapter 2 Fluorescent Leak Detection The dye, which dissolves into the SP-20 PAG oil in the system, is par ticularly helpful in detecting intermittent leaks that occur only when the system is running because of change of temperature, high system pressures, vibration or contact between components. Flu or e s ce nt t rac er or dye s ol uti o ns ar e now commonly used to detect refrigerant leaks.
Section 50 - Climate Control - Chapter 2 Recovery Station Dye Injector Tool with a System in a Vacuum The R134a dye injector tool is designed to be used with the OEM1415 recycling station. 2 1 1. Disconnect the low pressure hose (blue) from the 1/2 inch Acme flare fitting on the rear of the station. Connect the dye injector to the fitting. 2. Connect the low pressure hose to the dye injector.
Section 50 - Climate Control - Chapter 2 Recovery Station Dye Injector Tool with a Charged System The R134a dye injector tool is designed to be used with the OEM1415 recycling station. 2 1 1. Disconnect the low pressure hose (blue) from the 1/2 inch Acme flare fitting on the rear of the station. 2. Connect the dye injector to the fitting. 4 3. Connect the low pressure hose to the dye injector.
Section 50 - Climate Control - Chapter 2 Quick and Easy Dye Injector Tool with a Charged System The quick and easy R134a dye injector tool is designed to insert the dye in a charged system. The dye injector tool has a quick coupler, for connecting to the low pressure port of the tractor A/C system, and a valve with T-handle on the other end. 3 2 1. Examine the threaded end of the valve to see if the point of the valve stem is flush with the rubber washer.
Section 50 - Climate Control - Chapter 2 Compressor Oil Port 1. Recover the refrigerant from the A/C system. 2. Remove the oil filler plug and pour the contents o f o n e b o tt l e o f f l u o r e s c e n t d ye i n t o th e compressor. 3. Check the O-ring on the oil filler plug and replace if necessar y. Reinstall the oil plug on the compressor and torque to 11 to 18 lb ft (15 to 24 Nm). 4. Evacuate and recharge the A/C system with the proper amount of refrigerant. RD02H047 5.
Section 50 - Climate Control - Chapter 2 SP-20 PAG Oil Return Bottle NOTE: This is the least preferred method for injecting the dye since it requires very careful measurement of the PAG oil in the bottle and risks the introduction of air into the system if the dip tube in the bottle is exposed. 1. Recover the refrigerant from the A/C system. 2. Carefully measure the amount of SP-20 PAG oil in the reservoir which was separated from the refrigerant. 3.
Section 50 - Climate Control - Chapter 2 Fluorescent Leak Testing To perform UV fluorescent leak testing: 1. Operate the tractor long enough to circulate the refrigerant and produce nor mal system pressures. 2. Shut the tractor and system off when leak testing. 3. Always wear fluorescent glasses when leak testing. enhanced safety 4. Attach the lamp to a fully charged 12V battery or an alternate 12V power supply for best lamp performance. RR00F098 5.
Section 50 - Climate Control - Chapter 2 A/C SYSTEM COMPONENTS Cab HVAC Box Components - Automatic Temperature Control 1. ATC CONTROLLER 2. BLOWER MOTOR/FAN ASSEMBLY 3. HEATER CONTROL VALVE (NOT SCHOWN) 4. BLOWER SPEED DRIVER 2 1 5. COMPRESSOR CLUTCH RELAY 6. CAB TEMPERATURE SENSOR 7. EVAPORATOR TEMPERATURE SENSOR 8. THERMAL EXPANSION VALVE 9. LOW PRESSURE SWITCH 10.
Section 50 - Climate Control - Chapter 2 Cab HVAC Box Components - Automatic Temperature Control 1 9 5 4 2 15 3 6 8 10 7 11 12 14 13 16 17 RH05H006 11. 12. 13. 14. 15. 16. LID ASSEMBLY ATC CONTROLLER BLOWER SPEED DRIVER BLOWER ASSEMBLY A/C LOW PRESSURE SWITCH HEATER CONTROL VALVE ASSY 17. 18. 19. 20. 21. 22. HEATER/EVAPORATOR ASSEMBLY A/C SUCTION LINE TUBE A/C LIQUID LINE TUBE HEATER SUPPLY HOSE HEATER RETURN HOSE EVAPORATOR TEMP. SENSOR 50-2-61 23. 24. 25. 26. 27.
Section 50 - Climate Control - Chapter 2 Cab HVAC Components - Standard Systems 1. STANDARD CONTROLLER 2. COMPRESSOR CLUTCH RELAY 3. EVAPORATOR/HEATER ASSEMBLY 4. EVAPORATOR TEMPERATURE SENSOR 1 5. HVAC BOX GROUND 2 6. HEATER CONTROL VALVE 7. THERMAL EXPANSION VALVE 8. LOW PRESSURE SWITCH 9.
Section 50 - Climate Control - Chapter 2 Cab HVAC Components - Standard Systems 1 17 14 7 6 4A 9 13 10 8 4B 2 16 15 18 19 11 12 3 RI99M043 1. 2. 3. 4. LID ASSEMBLY STANDARD A/C CONTROLLER BLOWER ASSEMBLY RESISTOR ASSEMBLY A. RESISTOR B. MOUNTING BRACKET 5. WIRE HARNESS (NOT SHOWN) 6. 7. 8. 9. 10. 11. 12. LOW PRESSURE SWITCH HEATER/EVAPORATOR COIL ASSY HEATER CONTROL VALVE ASSY A/C SUCTION LINE TUBE A/C LIQUID LINE TUBE HEATER SUPPLY HOSE HEATER RETURN HOSE 50-2-63 13. 14. 15. 16. 17.
Section 50 - Climate Control - Chapter 2 Chassis Components TOP 5 8 6 7 3 RIGHT HAND SIDE 4 3 FRONT 1. 2. 3. 4. 5. 6. 7. 8.
Section 50 - Climate Control - Chapter 2 A/C COMPRESSOR CLUTCH Clutch Removal NOTE: This procedure shows a compressor with six screws holding the dust cover on the clutch. Your unit has three Torx ® screws for attaching the dust cover and only differs in this manner. STEP 91 See this section for compressor removal. Clean the external surfaces of the compressor before doing any work on the compressor. A21250 STEP 92 Remove the three Torx ® screws for the clutch dust cover.
Section 50 - Climate Control - Chapter 2 STEP 94 Remove the retaining nut for the front plate. Use the special spanner wrench from the service tool set to keep the plate and shaft from turning. A21253 STEP 95 Install the special puller from the service tool set on the clutch front plate. A21254 STEP 96 Turn the center screw to pull the clutch front plate.
Section 50 - Climate Control - Chapter 2 STEP 97 Remove the shim(s) from the shaft. A21256 STEP 98 Carefully remove the dust cover. A21257 STEP 99 Remove the key from the rotor shaft.
Section 50 - Climate Control - Chapter 2 STEP 100 Remove the external snap ring for the bearing and pulley assembly. A21260 STEP 101 Install the special puller internal collars into the groove in the pulley. Install the special tool onto the shaft. Tighten the mounting screws finger tight. A21261 STEP 102 Turn the center screw on the puller.
Section 50 - Climate Control - Chapter 2 STEP 103 Remove the pulley and bearing assembly. A21263 STEP 104 Remove the snap ring for the clutch coil assembly. A21265 STEP 105 Disconnect the clip for the lead wire.
Section 50 - Climate Control - Chapter 2 STEP 106 Remove the clutch coil assembly. A21266 STEP 107 Remove the internal snap ring and remove the bearing from the pulley.
Section 50 - Climate Control - Chapter 2 Exploded View of Clutch 8 1 2 3 6 7 4 5 1016L9 1. COIL ASSEMBLY 2. PULLEY 3. BEARING 4. BEARING DUST COVER 5. FRONT PLATE 6. SHIM(S) 7. DUST COVER 8. COMPRESSOR Compressor Clutch Replacement STEP 108 Method 1: Use a ammeter, voltmeter and a 12 volt battery to check the amperage of the clutch coil. The current draw must be 3.6 to 4.2 amperes at 12 volts. A reading of more than 4.2 amperes indicates a short within the coil.
Section 50 - Climate Control - Chapter 2 STEP 109 Install a new clutch coil assembly. Align the coil so the lead wire is next to the clip mounting hole. A21266 STEP 110 Install the clip for the coil lead wire. A21264 STEP 111 Install the snap ring for the clutch coil assembly.
Section 50 - Climate Control - Chapter 2 STEP 112 Install the bearing in the pulley and install the internal snap ring. A21267 STEP 113 Put the pulley and bearing assembly on the front housing hub. Install a driver on the pulley assembly. Make sure that the tool is on the inner race of the bearing. RR99D245 STEP 114 Support the compressor on the four mounting ears at the compressor rear. Press the pulley assembly on the front housing hub. Make sure the bearing is against the bottom of the hub.
Section 50 - Climate Control - Chapter 2 STEP 115 Install the external snap ring on the front housing hub. A21260 STEP 116 Install the key in the rotor shaft. A21259 STEP 117 Place the bearing dust cover in the bore. Place driver from special tool kit over the dust cover.
Section 50 - Climate Control - Chapter 2 STEP 118 Install the dust cover. A21270 STEP 119 Install the shim(s) on the rotor shaft. A21256 STEP 120 Install the front plate on the rotor shaft. Make sure the keyway in the plate is aligned with the key in the shaft. Install the driver over the shaft.
Section 50 - Climate Control - Chapter 2 STEP 121 Use a hammer to tap the plate onto the shaft. Make sure the plate is against the clutch shims. As the plate is tapped onto the shaft you can hear the difference in sound when the plate is fully installed. A21272 STEP 122 Install the nut on the rotor shaft. Use the spanner wrench and a torque wrench to tighten the nut to a torque of 11 to 15 lb. ft. (15 to 20 Nm).
Section 50 - Climate Control - Chapter 2 STEP 123 Two methods can be used to measure and adjust the air gap between the clutch plate and pulley: Magnetic Dial - Mount a magnetic base dial indicator on the outer face of the pulley so that there is no interference with the clutch plate. Apply battery ground to compressor body and 12V B+ to clutch wire lead.
Section 50 - Climate Control - Chapter 2 STEP 125 Install and tighten the three Torx® screws that attach the dust cover to the compressor clutch. Torque to 5 to 8 lb. ft. (7 to 11 Nm).
Section 50 - Climate Control - Chapter 2 A/C COMPRESSOR Oil Level Check or Adjustment During normal servicing - recovery, evacuation and recharge, oil is simply injected back into the system during the recharge process. Use the dipstick method to check the compressor oil level or to adjust oil level when any of the following occurred: Since the refrigerant is recovered as a gas, during a typical recovery only about 25% of the oil in the vehicle’s A/C system is recovered and separated.
Section 50 - Climate Control - Chapter 2 Dipstick Method STEP 127 When all refrigerant has been recovered, remove the oil filler plug. RD02H047 STEP 128 Use a Torx® socket to remove the three screws, and remove the dust cover from the clutch. Use a wrench to rotate the compressor shaft clockwise until the internal parts are in a position to allow dipstick insertion. ALTERNATE METHOD: Use a jumper wire to supply 12V B+ to the compressor clutch and rotate by hand.
Section 50 - Climate Control - Chapter 2 STEP 130 If the oil level is not correct, add or subtract oil to the correct level described above. Always add oil in small quantities to avoid overfilling; to subtract oil the compressor must be removed and drained. IMPORTANT: Use only SP-20 PAG oil. STEP 131 Check O-ring on the oil filler plug and replace if necessary. Install the plug and tighten to a torque of 11 to 18 lb. ft. (15 to 24 Nm).
Section 50 - Climate Control - Chapter 2 Compressor Removal STEP 132 Open the hood and remove the right hand panel for access to the fan drive belt. Recover the refrigerant. RD02H035 STEP 133 Use a 1/2 inch ratchet drive in the belt tensioner to relieve pressure on the belt and remove the belt from the compressor pulley. RD02H038 STEP 134 Disconnect the compressor clutch wire above the test ports on the suction and discharge lines.
Section 50 - Climate Control - Chapter 2 STEP 135 D i s c o n n e c t t h e h i g h p r e s s u r e sw i t c h a t t h e connector. RD02H033 STEP 136 Disconnect the high pressure line from the discharge port. Install protective caps on the open port and line. RD02H040 STEP 137 Suppor t the 90° fitting to the suction por t, and disconnect the low pressure line from the fitting. Remove the 90° fitting from the suction port. Install protective caps on the open ports and lines.
Section 50 - Climate Control - Chapter 2 STEP 138 Remove the three mounting bolts (lower front bolt not shown) and remove the compressor/clutch assembly from the tractor for service or replacement. NOTE: Note the location of the ring terminal ground on the upper front mounting bolt.
Section 50 - Climate Control - Chapter 2 Compressor Installation IMPORTANT: If a new compressor is to be installed, its oil level must be adjusted to match the removed compressor. See Oil Level Check or Adjustment, page 79. STEP 139 Install the compressor with the three bolts removed earlier. Torque to 29 ± 4 ft lb (39 ± 4 Nm). IMPORTANT: Install the ring terminal ground to the upper front bolt when installing the compressor.
Section 50 - Climate Control - Chapter 2 STEP 142 Install a new O-ring and connect the high pressure line to the discharge port on the compressor. NOTE: Lubricate the O-ring with mineral oil before installation. RD02H041 STEP 143 Reconnect the high pressure switch at the connector. RD02H033 STEP 144 Reconnect the clutch at the connector. RD02H034 STEP 145 Use a 1/2 inch ratchet drive on the belt tensioner to release tension and install the belt over the clutch pulley. Reinstall the right hand panel.
Section 50 - Climate Control - Chapter 2 CONDENSER AND RECEIVER-DRIER Condenser STEP 146 Keep the condenser (and fuel cooler) fins clean and straight to make sure that there is maximum air flow though the condenser and radiator at all times. Use c om p r e s s ed a i r o r a s of t b r u s h t o c le a n t h e condenser. Also check and clean the grille screen and radiator. Maximum air flow prevents engine overheating and offers the most efficient A/C operation.
Section 50 - Climate Control - Chapter 2 STEP 148 Remove the upper and lower bolts (1) of the condenser/fuel cooler to replace the unit. NOTE: Hydraulic cooling line (2) shown removed, dose not need to be removed for this procedure. 1 2 RD05N017 STEP 149 When installing a new condenser, also install new O-rings on the A/C lines before connecting. Lubricate the O-rings with clean mineral oil prior to installation.
Section 50 - Climate Control - Chapter 2 STEP 151 Use the two hand, two wrench method to prevent damage to the tubes and fittings when you loosen or tighten the tube connections. Always install new O-rings when the receiver-drier is connected to the system. Lubricate the O-rings with clean mineral oil prior to installation.
Section 50 - Climate Control - Chapter 2 ACCESSING THE HVAC BOX NOTE: The following procedure applies to both the standard and Automatic Temperature Controlled (ATC) systems. STEP 152 Disconnect the harness to the right hand control console. STEP 153 For tractors equipped with mechanical remote hydraulic controls, the right hand control console must be disconnected from the seat: A. Loosen the 13 mm nut at the front of the right hand side of the seat. B.
Section 50 - Climate Control - Chapter 2 STEP 157 Disconnect the seat harness. RD02F049 STEP 158 Hinge seat forward and rest on steering wheel for access to the box. NOTE: Seat may have to be braced to prevent it from falling. ATC HVAC Box Shown STEP 159 After completion of service: A. Return the seat to its operating position, and reinstall the four bolts removed earlier. B. Reinstall the seat harness and floor mat wrap. C. Reinstall right applicable). hand control console (if D.
Section 50 - Climate Control - Chapter 2 THERMAL EXPANSION VALVE TESTING IMPORTANT: The following test is performed with the thermal expansion valve mounted in the system. No repair or adjustment is recommended for the valve. STEP 160 See ACCESSING THE HVAC BOX, page 90. STEP 161 Disconnect the low pressure cutout switch. Install a jumper wire across the harness leads. STEP 162 Start the tractor and run the engine at 1500 RPM.
Section 50 - Climate Control - Chapter 2 THERMAL EXPANSION VALVE REPLACEMENT STEP 166 Recover all refrigerant from the system. Remove the ther m al ins ulatio n tape fr om the fi tti ngs an d expansion valve to replace the expansion valve. STEP 167 Using the two hand, two wrench method, disconnect the liquid and suction lines fr om the ther mal expansion valve. Discard the O-rings in the fittings.
Section 50 - Climate Control - Chapter 2 STEP 170 Lubricate new O-rings with clean mineral oil and install in the fittings on the suction and liquid lines. Connect the liquid and suction lines to the expansion valve using the two hand, two wrench method. STEP 171 Remove air and moisture from the system and charge the system. Leak test all connections with OEM1437 before reapplying any thermal insulation tape.
Section 50 - Climate Control - Chapter 2 EVAPORATOR AND CAB TEMPERATURE SENSOR LOCATION STEP 173 The evaporator temperature sensor MUST be installed 4.2 inches (107 mm) from the left hand rear side of the evaporator. The sensor must be installed below the second refrigeration tube row at a 30° downward angle. 2 1 Insert the sensor in the evaporator up to the angled section, being careful not to kink the sensor. 3 Rear View Side View RH99D218 RI00A055 1. EVAPORATOR TEMPERATURE SENSOR 2. 4.
Section 50 - Climate Control - Chapter 2 BLOWER MOTOR REPLACEMENT STEP 175 To replace the blower motor: 1. See ACCESSING THE HVAC BOX, page 90. 2. Disconnect the blower motor assembly from the harness at the connector. RD06A191 3. Remove the four screws across the top of the motor assembly and two screws (not visible on photo) at the sides, and remove the assembly. 4. Install a new motor assembly with the existing hardware and connect the motor to the harness.
Section 50 - Climate Control - Chapter 2 HEATER CONTROL VALVE REPLACEMENT STEP 176 To replace the heater control valve: 1. See ACCESSING THE HVAC BOX, page 90. 2. Move the controller mounting plate forward to gain better access to the valve. 3. Disconnect the control valve from the harness. NOTE: Be prepared to collect a small amount of coolant when the valve hoses are disconnected. RD02G116 4. Pinch the clamp (1) and disconnect the inlet hose to the core from the valve.
Section 50 - Climate Control - Chapter 2 EVAPORATOR/HEATER ASSEMBLY Evaporator/Heater Assembly Removal NOTE: The thermal expansion valve, heater valve and evaporator/heater assembly are located under the operator seat. See ACCESSING THE HVAC BOX, page 90. NOTE: Rotate the cab temperature control to the Maximum Heat position before shutting off the tractor for service. This fully opens the heater control valve and allows more coolant to drain from the evaporator/heater assembly.
Section 50 - Climate Control - Chapter 2 STEP 180 Pinch the clamp with a pliers to open it and move it to the side. Disconnect the heater return line (1) from the evaporator heater core. Loosen the clamp and disconnect the short hose (2) between the heater valve and evaporator/heater core. Be prepared to collect a small amount of coolant that will drain into the HVAC box. 1 2 RD02G124 STEP 181 Remove the two screws securing the blower speed driver and its mounting plate at the rear of the box.
Section 50 - Climate Control - Chapter 2 STEP 183 Remove the evaporator top gasket and save for reinstallation. Remove the grommet (1) and sensor harness from the evaporator by sliding it out of the slot opening. NOTE: The gasket seals the top of the evaporator and forces the air to move through the core rather than around it. Replace the gasket if it is worn or damaged. STEP 184 Slide the evaporator assembly straight up and out of its side mounting brackets.
Section 50 - Climate Control - Chapter 2 Evaporator/Heater Assembly Installation STEP 186 Lubricate new O-rings with clean mineral oil and install new O-rings on the evaporator suction and discharge lines. RD02G128 STEP 187 Install the expansion valve. Tighten the fittings to a torque of 18 to 25 lb ft (25 to 34 Nm). Use the two wrench, two hand method when installing the expansion valve to prevent damage to evaporator lines.
Section 50 - Climate Control - Chapter 2 STEP 190 Install the evaporator temperature sensor in the evaporator /heater as sembly. The evaporator temperature sensor MUST be installed 4.2 inches (107 mm) from the left hand rear side of the evaporator. The sensor must be installed below the second refrigeration tube row at a 30° downward angle. Insert the sensor in the evaporator up to the angled section, being careful not to kink the sensor.
Section 50 - Climate Control - Chapter 2 STEP 192 Connect the short hose (1) from the heater valve to the evaporator/heater core. Pinch the clamp to open it and secure the hose at the evaporator line. Connect the heater return line (2) to the evaporator heater core and secure with the clamp. 2 1 RD02G124 STEP 193 Remove the caps or plugs from the liquid and suction lines to the thermal expansion valve. Install new O-rings on the lines before reconnecting.
Section 50 - Climate Control - Chapter 2 Post Replacement Procedures STEP 195 Since the evaporator assembly has been replaced, adjust compressor oil level. Evacuate and charge the air conditioning system. Test system performance following procedures on the foldout. Leak test the valve and evaporator connections with OEM1437. RD02H029 STEP 196 The thermal expansion valve and line along with the inlet and outlet to the evaporator must be insulated for maximum evaporator performance.
Section 50 - Climate Control - Chapter 2 EVAPORATOR/HEATER ASSEMBLY SEALING AND CLEANING Sealing The top and bottom of the evaporator/heater assembly must be properly sealed to allow air movement through the assembly but not around it. 1 Check the condition of the foam seal on the top of the assembly where it seals with the HVAC box cover. Check the condition of the sealing strip at the front of the evaporator/heater bottom.
Section 50 - Climate Control - Chapter 2 BLOWER AND EVAPORATOR REFERENCE ILLUSTRATION 1 8 7 2 6 5 3 4 3 RI99D080 1. THERMAL EXPANSION VALVE 2. BLOWER MOTOR 3. BOX DRAINAGE 4. CHECK VALVE 5. CONDENSATE DRAIN TUBE 6. EVAPORATOR BOX ASSEMBLY 50-2-106 7. EVAPORATOR TEMP SENSOR 8.
Section 50 - Climate Control - Chapter 2 CONTROLLER AND BLOWER SPEED DRIVER REPLACEMENT ATC Controller STEP 198 With the ignition switch in the OFF position, to replace the ATC controller: A. See ACCESSING THE HVAC BOX, page 90. B. Disconnect the multi-pin wiring harnesses (1) connected to the ATC controller. 1 2 IMPORTANT: Do not touch exposed pins on ATC controller to avoid static electricity voltage spikes. Voltage spikes may result in equipment damage. C.
Section 50 - Climate Control - Chapter 2 Blower Speed Driver (ATC Units Only) STEP 200 To replace the blower speed driver in ATC systems, with the keyswitch in the OFF position: A. See ACCESSING THE HVAC BOX, page 90. B. Remove the two screws securing the blower speed driver assembly to the rear of the HVAC box. RD02G073 C. Disconnect the six pin connector to the blower speed driver. RD02G074 D. Remove the four screws securing the driver to the mounting plate. E.
Section 50 - Climate Control - Chapter 2 CAB AIR FILTER SERVICE NOTE: The cab intake air filter will need service at different intervals according to local operating conditions. Clean the filter as required. Replace the filter if there is damage or when the filter cannot be cleaned for efficient operation. STEP 201 The cab air filter is located under the cab entry door. The cab pressurizer blower draws outside air from the vents in the cab cap through the filter and feeds it directly to the HVAC box.
Section 50 - Climate Control - Chapter 2 STEP 204 Clean the filter element by one of two methods: A. Tap the outside of the filter. This method can be used to clean the filter when most of the dirt is dust. Tap the filter against a flat surface. Do not use force that can cause damage to the filter. B. Clean with compressed air. The compressed air method is used if most of the dirt is dust. Direct the air flow from the inside of the filter outward.
Section 50 - Climate Control - Chapter 2 CAB PRESSURIZATION TEST NOTE: Perform the cab pressurization test whenever an unusual amount of dirt accumulates in the cab or in the evaporator box or if the evaporator core is plugged. NOTE: When performing this test, the door and window must be closed and latched.
Section 50 - Climate Control - Chapter 2 STEP 209 Partially fill the looped section of tubing with water. (Food coloring may be added to the water to improve visibility.) RD99M025 STEP 210 Insert the long end of the tube through the access panel in the right hand corner of the rear cab window provided for monitor harness routing between the cab and the implement. NOTE: Do not attempt this test through the door since the metal reinforcement in the seal will pinch off the sensing tube.
Section 50 - Climate Control - Chapter 2 CAB PRESSURIZER MOTOR REPLACEMENT NOTE: The cab pressurizer motor is located under the cab entry and behind the cab air filter. To replace the motor/ blower assembly, the cab fresh air filter must be removed. STEP 213 Remove the two screws and remove the trim panel at the filter front. RD02E266 STEP 214 Open the two clamps and remove the cover for the fresh air filter. RD02E268 STEP 215 Remove the air intake line from the cab filter housing the post.
Section 50 - Climate Control - Chapter 2 STEP 216 Remove the four bolts and remove the filter housing. RD02E270 STEP 217 Disconnect the motor assembly from the harness. RD02E272 STEP 218 Remove the bolt, nut and washer and remove the assembly from the tractor.
Section 50 - Climate Control - Chapter 2 STEP 219 Remove the four screws to disconnect the motor/ blower assembly (1) from the mounting bracket (2). STEP 220 Reverse the steps to install a replacement motor/ blower assembly.
Section 50 - Climate Control - Chapter 2 VISCOUS FAN DRIVE Since the viscous fan c reates air flow at the condenser, a properly functioning fan drive is essential to proper air conditioning performance. A defective fan drive can cause engine overheating and/or high pressure switch activation. But a plugged grille, radiator, condenser and oil cooler can also cause the same. To separate a fan drive problem from other possible causes, perform the Viscous Fan Drive Test in this manual.
ELECTRICAL SCHEMATIC DIAGRAM EURO MX MAGNUM SERIES TRACTOR COLOR ABBREVIATIONS ACTUATORS ABBREVIATION---COLOR CIRCUIT DESCRIPTION SECTION CIRCUIT DESCRIPTION R--------------RED SECTION T--------------TAN W--------------WHITE AIR CONDITIONING 58-61 AUTOGUIDANCE LEVER 73-78 AUTOHITCH 25 ARMREST CONTROLLER 46-50 AUXILIARY CONTROL SYSTEM 53-54 - OPTIONAL FRONT HITCH 27 - OPTIONAL FRONT BELTLINE 28 - OPTIONAL HIGH INTENSITY LAMP 31 HAND FOOT SECTION CIRCUIT FUSE SECTION CIRCUIT
POWER DISTRIBUTION BOX ARMREST CONTROLLER SHT 2, SECTION 57 TO CONN 161F, CAV 1 5 2 4 5 2 4 5 2 RELAY SHUT & SIDE HI BEAM BEAM BEAM OFF F2 30A F3 F6 25A 25A DO NOT INSTALL F7 25A A B C D E F G H 121M C A 65M C A 64M GRAY 7M BLACK A B G D E F H C CRUISE CONTROL 57 MECHANICAL FRONT DRIVE (MFD) DIFFERENTIAL LOCK 44 POWER MIRRORS EGRESS LIGHTING 27 PTO CONTROLLER SYSTEM OPERATOR SUPPLIED POWER 102N R-3.0 TO CONN 9M, CAV 5 179BF Bk -3.0 SHT1 SECTION 35 620B R-5.
ARMREST CONTROLLER (ARU) ARMREST CONTROLLER (ARU) UNSWITCHED POWER UNSWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER SHT1 SECT 21 NONE ON (MOM) OFF OFF ON POS C ON POS A CREEPER 171D Bk -0.
UNSWITCHED POWER SWITCHED POWER SWITCHED POWER SWITCHED POWER FUSE #24 #19 10A 10A 94M FRONT WASHER PUMP 870D Or-2.0 212M M 22 870B Or-0.8 13F 13M L AUX IN 23 T T 727B K-1.0 AUX SHIELD GND 24 V V 871A R-1.0 U U AUX COM 25 R AUX IN 26 AUX ON OFF 27 N/C 28 HIGH 177R Bk -0.8 130M CDX L IN 29 BRAKE TO DIAGNOSTIC CONN 177AM Bk -1.0 R R-0.5 7 2 8 6 5 10 30 14 LG LG-0.5 14 CDX BATTERY 31 15 O Or-0.5 15 CDX R IN 32 16 W W-0.
Section 55 Chapter 1 ELECTRICAL SYSTEM How It Works And Troubleshooting January, 2006
Section 55 - Electrical System - Chapter 1 TABLE OF CONTENTS SPECIAL TOOLS ........................................................................................................................................... 55-1-4 FUSES AND RELAY IDENTIFICATION ......................................................................................................... 55-1-5 Cab Fuses/Relay Location ........................................................................................................................
Section 55 - Electrical System - Chapter 1 STARTING SYSTEM .................................................................................................................................. Starting System Circuit Operation ........................................................................................................... Starter Motor Circuit Troubleshooting ..................................................................................................... Starting System Symptom Chart ..........
Section 55 - Electrical System - Chapter 1 SPECIAL TOOLS RD05C001 RD05C002 Electr ical Connector and Ter minal Repair Kit AJI1400004. See the Parts Merchandiser Catalog for o r d e r i n g i n fo r m a t i o n a n d i d e n t i f i c a t i o n o f components. Digital Multimeter CAS-1559.
Section 55 - Electrical System - Chapter 1 FUSES AND RELAY IDENTIFICATION Cab Fuses/Relay Location Fuses and relays are located to the rear of the operator’s seat, under the floor cover mat and metal cover. RD02E266 Engine Compartment Fuse/Relay Identification (Power Distribution Box) Additional fuses and relays are located in the Power Distribution box on the left hand side of the tractor engine.
Section 55 - Electrical System - Chapter 1 Fuse Identification RI05G042 Fuse No. Circuit Fuse Amp 31 ISO 17783 10 Fuse No.
Section 55 - Electrical System - Chapter 1 Relays The 20 amp relays are located to the rear of the operator’s seat, under the floor cover mat and metal cover. Cab Relay Identification (Facing Rear Window) 4 1 10 7 16 13 22 19 5 2 11 8 17 14 23 20 6 3 12 18 15 24 21 9 26 25 RI05G040 1. 2. 3. 4. 5. 6. 7. 8. 9. BRAKE LAMPS OPEN REAR ROOF WORK LAMPS WORK LAMP INTERLOCK PARK LATCH NEUTRAL RELAY FRONT ROOF HID LAMPS BELTLINE WORK LAMPS FRONT ROOF WORK LAMPS 10. 11. 12. 13. 14. 15. 16. 17.
Section 55 - Electrical System - Chapter 1 INSTRUMENTATION AND CONTROLS RD05J040 INSTRUMENTATION CLUSTER 55-1-8
Section 55 - Electrical System - Chapter 1 1 3 2 RD05J066 INSTRUMENT PANEL CONTROLS 1. ROAD LAMPS/AMBER WARNING LAMPS SWITCH 2. KEY SWITCH 1 3. WORK LAMP SWITCH 2 RH02G113 STEERING COLUMN CONTROLS 1. DIRECTION TURN SIGNAL LEVER; HORN BUTTON; HIGH/LOW BEAM SWITCH 2.
Section 55 - Electrical System - Chapter 1 4 3 2 7 6 5 5 1 RD05J060 ARM REST CONTROLS 1. 2. 3. 4. 5. 6. 7. HAND THROTTLE LEVER TRANSMISSION CONTROL LEVER GEAR SELECT BUTTON REMOTE CONTROL LEVERS (1-4) FIFTH REMOTE CONTROL 5TH REMOTE FLOW CONTROL REMOTE FUNCTION CONTROL (1-4) 10 12 13 14 15 7 11 9 8 18 19 20 16 177 21 RD05J059 ARM REST CONTROLS 7 8. 9. 10. 11. HITCH UP /DOWN CONTROL HITCH LOAD CONTROL HITCH POSITION CONTROL HITCH LOWER LIMIT POSITION RING 12.
Section 55 - Electrical System - Chapter 1 1 1 6 1 3 5 4 1 2 RD05J092 ARM REST CONTROLS (SECONDARY PANEL) 1. 2. 3. 4. 5. 6. 1 HYDRAULIC FLOW CONTROLS HYDRAULIC VALVE TIMER CONTROL HITCH UPPER LIMIT HITCH TRAVEL CONTROL HITCH DROP SPEED /TRANSPORT LOCK CONTROL RECORD/PLAY STANDBY CONTROL (IF EQUIPPED) 2 4 3 5 6 7 13 8 14 9 10 11 12 RD05J033 RIGHT HAND FENDER CONTROLS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Section 55 - Electrical System - Chapter 1 CONNECTOR AND COMPONENT LOCATIONS 9 10 6 3 1 4 2 7 11 12 8 5 13 RD05M054 REAR OF CAB 1. 2. 3. 4. 5. 6. 7. *AUX/HITCH/PTO CONTROLLER (TMF CONTROLLER) TRANSMISSION AND FRONT AXLE CONTROLLER CONNECTOR NO. 54 CONNECTOR NO. 55 CONNECTOR NO. 56 CONNECTOR NO. 58 CONNECTOR NO. 53 8. 9. 10. 11. 12. 13. CONNECTOR NO. 57 CONNECTOR NO. 355 CONNECTOR NO. 353 CONNECTOR NO. 350 CONNECTOR NO. 351 CONNECTOR NO.
Section 55 - Electrical System - Chapter 1 3 2 1 RD06A187 REAR CAB AREA BELOW CONTROLLERS 1. CHASSIS TO CAB HARNESS CONNECTOR NO. 10 2. BUSSMAN FUSE 100 AMP (SECTION 19 OF SCHEMATIC) 3. TRACTOR ECU (ISO11783) CONNECTOR NO. 282 2 4 5 1 3 7 6 RD02E267 POWER DISTRIBUTION BOX - LEFT SIDE ENGINE COMPARTMENT 1. 2. 3. 4. 5. 6. 7. ENGINE FUSE BOX POWER DISTRIBUTION-CONNECTOR NO.7M (BLACK) ENGINE CONNECTOR NO.108 (GRAY) SWITCHED POWER CONNECTOR NO.64 (BLACK() UNSWITCHED POWER CONNECTOR NO.
Section 55 - Electrical System - Chapter 1 12 6 9 1 10 11 8 2 3 15 4 20 5 16 7 17 13 18 19 14 RI02E086A TRANSMISSION SOLENOID LOCATIONS AND CONNECTOR IDENTIFICATIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. POWERSHIFT VALVE ODD/EVEN EVEN CLUTCH SOLENOID (CONNECTOR NO. 30) ODD CLUTCH SOLENOID (CONNECTOR NO. 29) CREEP CLUTCH SOLENOID (CONNECTOR NO. 39) PARK BRAKE SOLENOID (CONNECTOR NO. 49) PTO/DIFF LOCK VALVE POWERSHIFT VALVE RANGE FWD SOLENOID (CONNECTOR NO. 160) LOW CLUTCH SOLENOID (CONNECTOR NO.
Section 55 - Electrical System - Chapter 1 2 1 3 4 5 6 7 RH02H281 REMOTE AND HITCH VALVE CONNECTOR IDENTIFICATIONS 1. 2. 3. 4. 5. 6. 7. REMOTE SECTION NO. 1, TOP CONNECTOR 140, LOWER CONNECTOR 340 REMOTE SECTION NO. 2, TOP CONNECTOR 141, LOWER CONNECTOR 341 REMOTE SECTION NO. 3, TOP CONNECTOR 142, LOWER CONNECTOR 342 REMOTE SECTION NO. 4, TOP CONNECTOR 143, LOWER CONNECTOR 343 REMOTE SECTION NO.
Section 55 - Electrical System - Chapter 1 1 1 2 3 3 RT97K033 RT97K034 INCHING PEDAL 1. CONNECTOR NO. 50 - BOC SWITCH 2. CONNECTOR NO. 52 - CLUTCH POSITION POTENTIOMETER 55-1-16 3.
Section 55 - Electrical System - Chapter 1 1 ARMRST RIGHT HAND CONSOLE 1.
Section 55 - Electrical System - Chapter 1 1 RD98H143 LOWER FRONT CONSOLE 1. TO TRANSMISSION CONTROL LEVER 1 3 2 RD02H179 BOTTOM RH FRONT CORNER OF CAB 1. CONNECTOR NO. 60 - IN-LINE CONNECTOR (FRONT TO REAR HARNESS 2. BRAIDED GROUND STRAP 3.
Section 55 - Electrical System - Chapter 1 1 2 3 4 RD06B002 INSTRUMENTATION CLUSTER 1. INSTRUMENTATION CLUSTER 2. CONNECTOR NO. CN 1 3. CONNECTOR NO. CN 2 4. CONNECTOR NO. 380 1 RD05J085 TOP OF FUEL TANK 1. CONNECTOR NO.
Section 55 - Electrical System - Chapter 1 1 2 RD02H177 BRAKE VALVE SWITCH CONNECTIONS 1. RIGHT BRAKE SWITCH #1, CONNECTOR 47 2. LEFT BRAKE SWITCH #2, CONNECTOR 48 1 RD02H216 LEFT HAND SIDE OF ENGINE 1. AIR TO AIR TEMP SENSOR-CONNECTOR NO.
Section 55 - Electrical System - Chapter 1 1 2 RD05J139 REMOTE FENDER MOUNT SWITCHES 1. REMOTE HITCH SWITCHES - LEFT CONNECTOR NO. 313A, RIGHT NO. 313B 2. HYDRAULIC TOP LINK - LEFT CONNECTOR NO. 399, RIGHT NO. 401 2 3 4 1 RD06A176 ALTERNATOR 1. ALTERNATOR 2. REGULATOR 3. CONNECTOR NO. 77 - ALTERNATOR B+ 4. CONNECTOR NO. 85 - ALTERNATOR EXCITE (D+) 5. CONNECTOR NO.
Section 55 - Electrical System - Chapter 1 1 RD98E030 RIGHT HAND SIDE OF TRANSMISSION 1. CONNECTOR NO. 88 - TRANSMISSION FILTER RESTRICTION SENSOR 1 3 2 RD06A177 OPERATOR SEAT 1. CONNECTOR NO. 137 2. CONNECTOR NO. 51 3. CONNECTOR NO.
Section 55 - Electrical System - Chapter 1 1 2 RD98G022A TOP REAR OF TRANSMISSION 1. CONNECTOR NO. 145 - TO PTO SHAFT SPEED SENSOR 2. PTO SHAFT SPEED SENSOR 1 2 RD97K112 PTO SHAFT 1. CONNECTOR NO. 146 - TO PTO DUAL SPEED SENSOR 55-1-23 2.
Section 55 - Electrical System - Chapter 1 1 RD98E024 RIGHT HAND SIDE NEAR AXLE 1. CONNECTOR NO. 153 - TO RH DRAFT PIN 1 RD98E005 LEFT HAND SIDE NEAR AXLE 1. CONNECTOR NO.
Section 55 - Electrical System - Chapter 1 1 RD98E025 RIGHT HAND SIDE AT ROCKSHAFT 1. CONNECTOR NO.
Section 55 - Electrical System - Chapter 1 1 2 RT97K036 BRAKE PEDALS 1. CONNECTOR NO. 162 - LEFT BRAKE SWITCH 2. CONNECTOR NO.
Section 55 - Electrical System - Chapter 1 1 RD06A178 UNDER HOOD 1.
Section 55 - Electrical System - Chapter 1 1 RD02H178 NON-ELECTRONIC ENGINE 1. ENGINE OIL PRESSURE SWITCH (EMERGING MARKET) 1 RD02H220 ELECTRONIC ENGINE 1.
Section 55 - Electrical System - Chapter 1 1 2 RD02H223 NEAR A/C COMPRESSOR 1. CONNECTOR NO. 215 - ENGINE COOLANT TEMPERATURE SENSOR (ELECTRONIC ENGINE) 2. BLOCK HEATER (ALL ENGINES) 1 2 RD02H227 NON-ELECTRONIC ENGINE 1. INJECTION PUMP SOLENOID - CONNECTOR NO.214 2. CONNECTOR NO.
Section 55 - Electrical System - Chapter 1 1 2 RD02H217A LEFT SIDE OF ENGINE 1. REAR OF TIMING GEAR COVER 2 2. CONNECTOR NO. 246 - ENGINE SPEED SENSOR 1 RD06A186 LEFT SIDE OF ENGINE 1. INTAKE MANIFOLD AIR TEMP/BOOST PRESSURE- CONNECTOR NO. C4 2. AMBIANT AIR PRESSURE SENSOR - CONNECTOR NO.
Section 55 - Electrical System - Chapter 1 3 2 1 RD06A179 LEFT SIDE ELECTRONIC ENGINE 1. ENGINE CONTROLLER CONNECTOR J1 2. ENGINE CONTROL MODULE CONNECTOR NO. 256 3. ENGINE CONTROLLER POWER AND GROUND CONNECTOR NO. 204 1 RD06A185 AIR INTAKE 1.
Section 55 - Electrical System - Chapter 1 1 RD06B001 RIGHT SIDE OF FRONT CONSOLE 1. FOOT THROTTLE CONNECTOR NO. 256 1 2 RD06A172 GRID RELAY 1. GRID RELAY 2. FUSE NO.
Section 55 - Electrical System - Chapter 1 1 RD06B003 UNDER HOOD NEAR DISTRIBUTION BOX 1. PASSIVE TERMINATOR CONNECTOR NO. 175 NOTE: This photo is from TG !!! It is in same location on MX, but unsure if it works for both !! 3 1 4 2 RD06A182 REAR OF TRACTOR BELOW CONTROLLERS 1. IMPLEMENT RELAY CONNECTOT NO. 282 2. IMPLEMENT RELAY CONNECTOR NO. 283 55-1-33 3. RELAY FUSE 327M - 30 AMP 4.
Section 55 - Electrical System - Chapter 1 ELECTRICAL CONNECTORS 1S 631801C1 SOCKET HOUSING 631801C1 3M 294250A1 SOCKET HOUSING HEADLAMP HARNESS 294250A1 681801C1 CONNECTOR 3M - 294250A1 CONNECTOR 1S - 631801C1 RH SIDE HID LIGHT SEAT HEIGHT CAV WIRE NUMBER 1 S1 CAV CIRCUIT REFERENCE SWITCHED B+ WIRE CIRCUIT NUMBER REFERENCE A 738G SIDE LAMP B+ B 170G GROUND 3S SOCKET HOUSING CAB HARNESS 230227A1 2M 198714A1 SOCKET HOUSING CONNECTOR 2M - 198714A1 RH HEADLIGHT CAV 279658A1 WIRE CI
Section 55 - Electrical System - Chapter 1 4S 631801C1 SOCKET HOUSING 631801C1 6M 294250A1 SOCKET HOUSING HEADLAMP HARNESS 294250A1 681801C1 CAV CONNECTOR 4S - 631801C1 CONNECTOR 6M - 294250A1 SEAT COMPRESSOR HID CENTER LIGHT WIRE NUMBER 1 S4 CAV CIRCUIT REFERENCE GROUND 5M 294250A1 SOCKET HOUSING HEADLAMP HARNESS WIRE CIRCUIT NUMBER REFERENCE A 738F CENTER HID LIGHT B+ B 170H GROUND 6S 225316C1 SOCKET HOUSING 198435A1 CONNECTOR 5M - 294250A1 CONNECTOR 6S - 225316C1 LH SIDE HID L
Section 55 - Electrical System - Chapter 1 7M 409089A1 BLACK SOCKET HOUSING 8S 182077A1 SOCKET HOUSING 230227A1 CONNECTOR 8S - 182077A1 CONNECTOR 7M - 409089A1 SEAT HEATER POWER DISTRIBUTION CAV WIRE CIRCUIT NUMBER A 750B CAV REFERENCE WIRE CIRCUIT NUMBER REFERENCE FRONT HITCH POSITION A S15 HEATER B+ S20 HEATER GROUND B 602C ICU SHUT DOWN (FUEL) B C 728D LOW BEAM RELAY C S26 HEATER B+ D S29 HEATER GROUND D 89C START RELAY E 172C START OUTPUT F 792E CENTER/SIDE R
Section 55 - Electrical System - Chapter 1 9S 182077A1 SOCKET HOUSING 9F 225320C1 PIN HOUSING CONNECTOR 9S - 182077A1 9M 225319C1 BLACK SOCKET HOUSING HEATER CONTROL MODULE CAV 225320C1 CONNECTOR 9F - 225320C1 TURN SIGNAL SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE 1 20A 2 21A LEFT TURN SWITCH 3 22A RIGHT TURN SWITCH 4 23A HEADLIGHT SWITCH (B+) 5 24A HIGH BEAM 6 25A 7 26A HEADLIGHT DIPPING (B+) 8 27A GROUND TURN SIGNAL COMMON (B+) LOW BEAM CONNECTOR 9M -225319C1 TURN SIGNAL SWITC
Section 55 - Electrical System - Chapter 1 FLANGE 437550A1 10M - 437552A1 PIN HOUSING CAB HARNESS 10F - 437551A1 SOCKET HOUSING MAIN CHASSIS HARNESS 10F_10M.
Section 55 - Electrical System - Chapter 1 FLANGE 437550A1 10F - 437552A1 SOCKET HOUSING MAIN CHASSIS HARNESS 10M - 437551A1 PIN HOUSING CAB 10F_10M.
Section 55 - Electrical System - Chapter 1 FLANGE 437550A1 10F - 437551A1 SOCKET HOUSING MAIN CHASSIS HARNESS 10M- 437552A1 PIN HOUSING CAB 10F_10M.
Section 55 - Electrical System - Chapter 1 FLANGE 437550A1 10M - 437552A1 SOCKET HOUSING MAIN CHASSIS HARNESS 10F - 437551A1 437551A1 PIN HOUSING CAB 10F_10m.
Section 55 - Electrical System - Chapter 1 SOCKET HOUSING FRONT TO REAR HARNESS 225315C1 SOCKET HOUSING 225316C1 11M CONNECTOR 11S - 225316C1 BLACK SOCKET HOUSING CAB HARNESS 382391A1 SEAT SWITCH CAV 382391A1 CAV 1 CONNECTOR 11M - 382391A1 HEADLIGHT SWITCH WIRE CIRCUIT REFERENCE NUMBER 703A 2 751G 3 703A 703B REFERENCE 1 S12 SWITCH B+ 2 S13 PRESENCE SIGNAL SEAT SWITCH CAV HAZARD SIGNAL WIRE CIRCUIT NUMBER REFERENCE HAZARD LED 1 S7 SWITCH B+ ROAD LIGHTS 2 S9 PRESENCE SIGNAL 7
Section 55 - Electrical System - Chapter 1 13F PIN HOUSING ROOF HARNESS 179483A1 13M SOCKET HOUSING CAB HARNESS 196155A1 179483A1 CAV A CONNECTOR 13F - 179483A1 ROOF HARNESS WIRE CIRCUIT REFERENCE NUMBER 751D 751E B CAV LEFT TURN B+ A OPEN B CONNECTOR 13M - 196155A1 CAB HARNESS WIRE CIRCUIT REFERENCE NUMBER 751C LEFT ROOF HAZARD/TURN+ OPEN C 752D 752E RIGHT TURN B+ C 752C RIGHT ROOF HAZARD/TURN+ D 783D 783C A-POST WORKLIGHTS B+ D 783A A-POST WORKLIGHTS E 784B FRONT ROOF WORKLIGHT
Section 55 - Electrical System - Chapter 1 14F & 15F 16M & 17M PIN HOUSING LAMP 222136A1 SOCKET HOUSING ROOF HARNESS 245482C1 16F & 17F 14M & 15M PIN HOUSING WORKLAMP 245483C1 SOCKET HOUSING ROOF HARNESS 222135A1 245482C1 222135A1 136A1 CAV CONNECTOR 14M - 222135A1 RIGHT A-POST WORKLIGHT WIRE CIRCUIT REFERENCE NUMBER 1 783C B+ 2 178AE GROUND CAV CONNECTOR 14F - 222136A1 RIGHT A-POST WORKLIGHT WIRE CIRCUIT REFERENCE NUMBER 1 LAMP B+ 2 LAMP GROUND CAV 783B 2 178AD A 793C B+ B
Section 55 - Electrical System - Chapter 1 20F, 21F PIN HOUSING 225350C1 20M, 21M SOCKET HOUSING 225351C1 225350C1 350C1 CAV CONNECTOR 20F - 225350C1 RIGHT FENDER HARNESS WIRE CIRCUIT REFERENCE NUMBER CAV CONNECTOR 20M - 225351C1 RIGHT FENDER HARNESS WIRE CIRCUIT REFERENCE NUMBER 1 787 RIGHT WORKLIGHT B+ 1 787J 2 753 RIGHT TURN 2 754B RIGHT TURN 3 751 WIDE MARKER LIGHT 3 752L WIDE MARKER LIGHT 4 755 STOP LIGHT 4 755 C STOP LIGHT 5 750 RIGHT TAIL 5 750H RIGHT TAIL CAV CO
Section 55 - Electrical System - Chapter 1 18M SOCKET HOUSING ROOF HARNESS 239449A1 8S 182077A1 SOCKET HOUSING CAV 239449A1 CAV CONNECTOR 18M - 239449A1 RIGHT FRONT ROOF WORKLIGHT WIRE CIRCUIT REFERENCE NUMBER A 784C B+ B 178AH GROUND CONNECTOR 22F - 225320C1 FRONT HITCH LAMPS WIRE CIRCUIT REFERENCE NUMBER 1 OPEN 2 OPEN 3 738F 4 OPEN 5 6 WORKLAMPS OPEN 180F CHASSIS GROUND 7 OPEN 8 OPEN 22M 225320C1 SOCKET HOUSING CAV 25M 256342A1 SOCKET HOUSING CONNECTOR 22M - 225319C1 FRONT
Section 55 - Electrical System - Chapter 1 26F 86993701 SOCKET HOUSING CAV 27F 225315C1 PIN HOUSING CONNECTOR 26F - 86993701 FENDER HID BALLAST WIRE CIRCUIT REFERENCE NUMBER CAV CONNECTOR 27F - 225315C1 FENDER HID LIGHT WIRE CIRCUIT REFERENCE NUMBER 1 RED 1 RED 2 WHITE 2 BLACK 4 BLACK B+ GROUND 12162194 12162194 55-1-47
Section 55 - Electrical System - Chapter 1 29, 30, 31, 32, 33, 34, 36, 37, 38, 39 371614A1 SOCKET HOUSING ROOF HARNESS CAV CAV CONNECTOR 29M - 371614A1 ODD SOLENOID WIRE CIRCUIT REFERENCE NUMBER 1 201B) HIGH SIDE 2 580A LOW SIDE CAV 201C HIGH SIDE 2 582A LOW SIDE CAV 201D HIGH SIDE 2 584A LOW SIDE CAV 586A HIGH SIDE B 220B LOW SIDE CAV CONNECTOR 37M - 371614A1 MEDIUM SOLENOID WIRE CIRCUIT REFERENCE NUMBER 1 588A HIGH SIDE 2 220C LOW SIDE CAV 201N HIGH SIDE 2 590A LO
Section 55 - Electrical System - Chapter 1 40M AND 41M 182066A1 SOCKET HOUSING 40F AND 41F 182064A1 PIN HOUSING CAV A CAV A CONNECTOR 40F - 182064A1 RIGHT FENDER GROUND WIRE CIRCUIT REFERENCE NUMBER 174K CAV GROUND A CONNECTOR 41F - 182064A1 LEFT FENDER GROUND WIRE CIRCUIT REFERENCE NUMBER 174F CAV GROUND A CONNECTOR 40M - 182066A1 RIGHT FENDER GROUND WIRE CIRCUIT REFERENCE NUMBER 174 GROUND CONNECTOR 41M - 182066A1 LEFT FENDER GROUND WIRE CIRCUIT REFERENCE NUMBER 174 GROUND 44M 198456A1 SO
Section 55 - Electrical System - Chapter 1 49F SOCKET HOUSING FRONT TO REAR HARNESS 225315C1 49M SOCKET HOUSING 225316C1 47M 335461A1 SOCKET HOUSING 335461A1 225316C1 CONNECTOR 47M - 335461A1 RIGHT BRAKE PARK SOLENOID SWITCH #1 WIRE CAV CIRCUIT REFERENCE NUMBER A 561F PARK B+ B 567A TO SOLENOID CAV 1 567D PARK B+ 2 179BT GROUND CAV 48M 335461A1 SOCKET HOUSING 335461A1 CONNECTOR 48M - 335461A1 LEFT BRAKE PARK SOLENOID SWITCH #2 WIRE CAV CIRCUIT REFERENCE NUMBER A 561G PARK B+ B 567B
Section 55 - Electrical System - Chapter 1 50M 49MM 225316C1 SOCKET HOUSING SOCKET HOUSING 227429A1 225316C1 CAV 227429A1 CONNECTOR 49MM - 225316C1 PARK SOLENOID WIRE CIRCUIT REFERENCE NUMBER CAV CONNECTOR 50M - 227429A1 BOTTOM OF CLUTCH SWITCH WIRE CIRCUIT REFERENCE NUMBER 1 567G PARK B+ A 553B BOTTOM OF CLUTCH 2 179CA GROUND B 568A NOT NEUTRAL SIGNAL 55-1-51
Section 55 - Electrical System - Chapter 1 51M SOCKET HOUSING CAB HARNESS 223671A1 51F PIN HOUSING FNRP HARNESS 223672A1 CAV CONNECTOR 51F - 223672A1 FNRP SWITCH WIRE CIRCUIT REFERENCE NUMBER CAV CONNECTOR 51M - 223671A1 FNRP SWITCH WIRE CIRCUIT REFERENCE NUMBER 1 START INPUT 1 623A 2 START OUTPUT 2 172B START OUTPUT 3 RUN INPUT 3 550J RUN INPUT 4 FNRP - NOT PARK 4 511A FNRP - NOT PARK 5 FNRP-REVERSE 5 552B FNRP-REVERSE 6 FNRP-FORWARD 6 551D FNRP-FORWARD 7 FNRP-NOT NEUTR
Section 55 - Electrical System - Chapter 1 52M - 198550A1 53M SOCKET HOUSING 198550A1 SOCKET HOUSING 87410948, 198550A1 CAV A 223671A1 CONNECTOR 52M - 198550A1 ELECTRIC CLUTCH WIRE CIRCUIT REFERENCE NUMBER 557D CONNECTOR 53M - 87410948 TMF (TRACTOR MULTI-FUNCTION) CONTROLLER WIRE CAV CIRCUIT REFERENCE NUMBER CLUTCH POTENTIOMETER GROUND B 555D CLUTCH POSITION C 556D SUPPLY (8V DC) 55-1-53 1 900A INTERLOCKED SWITCHED B+ 2 900B INTERLOCKED SWITCHED B+ 3 900C 4 AUX1-TOP1 INTERLOCKED
Section 55 - Electrical System - Chapter 1 54M 55M SOCKET HOUSING 87410947, SOCKET HOUSING 87410948, 223671A1 CONNECTOR 54M - 87410947 J2 - TMF (TRACTOR MULTI-FUNCTION) CONTROLLER BLACK WIRE CAV CIRCUIT REFERENCE NUMBER CONNECTOR 55M - 87419488 TMF (TRACTOR MULTI-FUNCTION) CONTROLLER WIRE CAV CIRCUIT REFERENCE NUMBER 1 AUX6 - TOP2 EHR 6 RAISE SOL SINK 14 2 AUX3 - TOP2 EHR 3 RAISE SOL SINK 23 3 AUX5 - TOP 2 EHR 5 RAISE SOL SINK 24 512A EDC AUTO HITCH SW 4 AUX5 - BOT2 EHR 5 LOWER SOL S
Section 55 - Electrical System - Chapter 1 56M, 57M, 58M SOCKET HOUSING CONNECTOR 56M 87419489 TMF (TRACTOR MULTI-FUNCTION) CONTROLLER WIRE CAV CIRCUIT REFERENCE NUMBER 1 506A CONNECTOR 57M - 87410946 TMF (TRACTOR MULTI-FUNCTION) CONTROLLER WIRE CAV CIRCUIT REFERENCE NUMBER EDC POS POT HIGH SIDE CONNECTOR 58M - 87410949 TMF (TRACTOR MULTI-FUNCTION) CONTROLLER WIRE CAV CIRCUIT REFERENCE NUMBER 1 AUX1 - BOT2 EHR 1 LOWER SOL SINK 2 508A EDC POS POT LOW SIDE 3 AUX2 - BOT2 EHR 2 LOWER SOL SINK 4
Section 55 - Electrical System - Chapter 1 60F PIN HOUSING FRONT TO REAR HARNESS HDP26-24-31PT 60M SOCKET HOUSING CAB HARNESS HDP24-24-31ST 60F_60M.
Section 55 - Electrical System - Chapter 1 66M 66F SOCKET HOUSING FRONT TO REAR HARNESS 245484C1 PIN HOUSING FUEL SENDER 245485C1 64M 409086A1 BLACK SOCKET HOUSING 409086A1 CAV 245484C1 CONNECTOR 64M - 409086A1 SWITCHED POWER (BLACK CONN) WIRE CIRCUIT REFERENCE NUMBER A 620B UNSWITCHED B+ C 600B TO GROUND CAV A 234B FUEL SENDER 8V B 236B FUEL SENDER SIGNAL C 181M FUEL SENDER GROUND CAV 65M 409084A1 GRAY SOCKET HOUSING CONNECTOR 66M - 245484C1 FUEL SENDER WIRE CIRCUIT REFERENCE NUMBER
Section 55 - Electrical System - Chapter 1 68F 69F PIN HOUSING RADAR 245716C1 PIN HOUSING 245483C1 68M 69M SOCKET HOUSING FRONT TO REAR SOCKET HOUSING 245716C1 CAV 245482C1 CONNECTOR 68F - 245716C1 RADAR WIRE CIRCUIT REFERENCE NUMBER CONNECTOR 69F - 245483C1 WHEEL SPEED WIRE CIRCUIT REFERENCE NUMBER CAV A RADAR RADAR GROUND A SENSOR WHEEL SPEED SIGNAL B RADAR RADAR SIGNAL B SENSOR WHEEL SPEED GROUND C RADAR RADAR B+ D RADAR RADAR PRESENT CAV CONNECTOR 68M - 245715C1 RADAR W
Section 55 - Electrical System - Chapter 1 71M 73F PIN HOUSING 292548A1 SOCKET HOUSING 475075C1 71F SOCKET HOUSING 292549A1 RH99M024.
Section 55 - Electrical System - Chapter 1 75M 77F, 78F, 79F, 81F AND 81A PIN HOUSING ENGINE HARNESS 182068A1 RING TERMINAL 182068A1 CAV 200338.
Section 55 - Electrical System - Chapter 1 CAV 1 CONNECTOR 86F - 446658 ALTERNATOR EXCITE WIRE CIRCUIT REFERENCE NUMBER 121 D B+ 81F, 83F, 84F, 87F RING TERMINAL 200338.
Section 55 - Electrical System - Chapter 1 89M 91M FRONT TO REAR HARNESS 222315A1 SOCKET HOUSING 227728A1 89F 91F FRONT TO REAR HARNESS 222316A1 PIN HOUSING 227729A1 222135A1 CAV 1 2 CAV 1 2 227729A1 AND 728A1 CONNECTOR 89F - 225315C1 TRANSMISSION TEMP WIRE CIRCUIT REFERENCE NUMBER SENSOR SENSOR CAV TRANSMISSION OIL TEMPERATURE A 134C GROUND B 136C SWITCHED B+ ICU SENSOR GROUND C 135C UNSWITCHED B+ CONNECTOR 89M - 225316C1 TRANSMISSION TEMP WIRE CIRCUIT REFERENCE NUMBER 264B 181D C
Section 55 - Electrical System - Chapter 1 93F 95A AND 95B SOCKET HOUSING SOCKET HOUSING 292495A1 AND 292494A1 93M PIN HOUSING 12052833 RH99M016.
Section 55 - Electrical System - Chapter 1 98M SOCKET HOUSING 96F 245715C1 SOCKET HOUSING 96M 98F PIN HOUSING PIN HOUSING 12052833 245715A1 AND 716A1 CONNECTOR 96M - 298079A1 RIGHT FRONT SPEAKER WIRE CIRCUIT REFERENCE NUMBER CAV CAV CONNECTOR 98F - 245716C1 REAR WIPER MOTOR WIRE CIRCUIT REFERENCE NUMBER A 872B SPEAKER + A B 872A SPEAKER - B WIPER REAR WIPER LOW C WIPER REAR WIPER PARK D WIPER REAR WIPER BRAKE CONNECTOR 96F - 12052833 RIGHT FRONT SPEAKER WIRE CIRCUIT REFERENCE N
Section 55 - Electrical System - Chapter 1 104F, 105F, 106F, &107F 1/4 FLAG TERM. 100M.
Section 55 - Electrical System - Chapter 1 108M GRAY SOCKET HOUSING 110M 409090A1 END SOCKET HOUSING 429026A1 409089A1 CAV CONNECTOR 108M - 409090A1 ENGINE WIRE CIRCUIT REFERENCE NUMBER A OPEN B OPEN 429026A1 CAV CONNECTOR 110M - 87426882 ETHER SWITCH (EM ONLY) WIRE CIRCUIT REFERENCE NUMBER FUEL SHUTOFF 2 720A ETHER FUSE 744D POSITION LAMPS 3 641A TO ETHER SOLENOID 622A START RELAY C 456A D E F OPEN G OPEN H OPEN 111M SOCKET HOUSING CAB HARNESS 225351A1 109M GREEN SOCKET H
Section 55 - Electrical System - Chapter 1 112M.
Section 55 - Electrical System - Chapter 1 115M 118F SOCKET HOUSING ROOF HARNESS 245715C1 1/4 FLAG TERM.
Section 55 - Electrical System - Chapter 1 122M BLACK SOCKET HOUSING CAB HARNESS 382391A1 120F 1/4 FLAG TERM.
Section 55 - Electrical System - Chapter 1 124M 125M SOCKET HOUSING 245484C1 SOCKET HOUSING 245484C1 124F 125F PIN HOUSING 245485C1 PIN HOUSING 245485C1 245485C1 CAV A CONNECTOR 124F - 245485C1 BLOWER SPEED POT WIRE CIRCUIT REFERENCE NUMBER PLUG A B BLACK SIGNAL C BLACK TEMPERATURE CONTROL GROUND B 850B SIGNAL 803C TEMP CONTROL GROUND CONNECTOR 124M - 245484C1 BLOWER SPEED POT WIRE CIRCUIT REFERENCE NUMBER A B C CAV CAV OPEN BLACK BLACK CONNECTOR 125F - 245485C1 TEMP CONTROL POTEN
Section 55 - Electrical System - Chapter 1 126F 127F SOCKET HOUSING CAB HARNESS 449797C1 SOCKET HOUSING CAB HARNESS 449797C1 449797C1 449797C1 CONNECTOR 126F - 449797C1 STD A/C BLOWER SWITCH WIRE CIRCUIT REFERENCE NUMBER CAV 1 CAV CONNECTOR 127F - 449797C1 FRONT WIPER SWITCH WIRE CIRCUIT REFERENCE NUMBER OPEN 1 2 820D B+ 2 836A 836C BATTERY (B) 3 824B HIGH SPEED 3 833A 833C HIGH (H) 4 823B MEDIUM SPEED 4 832A 832C MEDIUM (M) 5 822B LOW SPEED 5 834A 834C LOW (L) 6 800B
Section 55 - Electrical System - Chapter 1 127M 129M SOCKET HOUSING CAB HARNESS 892136C1 SOCKET HOUSING CAB HARNESS 429026A1 449797C1 CAV 382391A1 CONNECTOR 127M - 892136C1 FRONT WIPER SWITCH WIRE CIRCUIT REFERENCE NUMBER 1 CAV CONNECTOR 129M - 429026A1 STROBE/BEACON WIRE CIRCUIT REFERENCE NUMBER OPEN 1 2 SWITCH B+ 2 821E SWITCH POWER 3 SWITCH HIGH SPEED 3 776A SIGNAL, BEACON/STROBE 4 SWITCH MEDIUM SPEED 4 OPEN 5 SWITCH LOW SPEED 5 OPEN 6 SWITCH A/C CLUTCH 6 128M BLUE
Section 55 - Electrical System - Chapter 1 131B 133M SOCKET HOUSING CAB HARNESS 279658A1 SOCKET HOUSING CAB HARNESS 225389C1 279658A1 223671A1 CONNECTOR 131B - 279658A1 CIGAR LIGHTER WIRE CIRCUIT REFERENCE NUMBER CAV A 821F CAV CIGAR LIGHTER B+ CONNECTOR 133M - 225389C1 SEAT POWER WIRE CIRCUIT REFERENCE NUMBER 1 73B SEAT POWER B+ (FEED) 2 73C SEAT POWER B+ (FEED) 3 177AC 131A 4 177AD SOCKET CAB HARNESS 5 73D 877291R1 6 303A SEAT SWITCH OPS RETURN 7 259A SEAT HEATER B+ 8 17
Section 55 - Electrical System - Chapter 1 133F 133FF SOCKET HOUSING CAB HARNESS 225388C1 SOCKET HOUSING CAB HARNESS 225388C1 687L95 CAV CONNECTOR 133F - 225388C1 SEAT POWER WIRE CIRCUIT REFERENCE NUMBER CONNECTOR 133FF - 225389C1 SEAT POWER WIRE CIRCUIT REFERENCE NUMBER CAV 1 73E 2 73F 1 S1 SEAT POWER B+ (FEED) 3 2 S2 SEAT POWER B+ (FEED) 4 177AG 73G SEAT POWER B+ (FEED) SEAT POWER B+ (FEED) SEAT GROUND SEAT GROUND 3 S3 SEAT GROUND 5 4 S4 SEAT GROUND 6 303C SEAT SWITCH OPS R
Section 55 - Electrical System - Chapter 1 135M 138A, 138B, AND 138C 225067C1 225402C1 SOCKET HOUSING CAB HARNESS 223671A1 CAV 200338.
Section 55 - Electrical System - Chapter 1 139F PIN HOUSING CAB HARNESS 179483A1 139MM SOCKET HOUSING HVAC ATC UNIT 196155A1 179483A1 CAV CONNECTOR 139F - 179483A1 HVAC WIRE CIRCUIT REFERENCE NUMBER A 800A AC CLUTCH FROM BLOWER SWITCH B 802A HVAC HIGH PRESSURE SWITCH OUT C 835A TO AC CLUTCH D 822A BLOWER LOW SPEED FROM SWITCH E 823A BLOWER MED SPEED FROM SWITCH F 178B CHASSIS GROUND G 824A BLOWER HIGH SPEED FROM SWITCH H 850A ATC BLOWER SIGNAL J 177F ATC CHASSIS GROUND K 82
Section 55 - Electrical System - Chapter 1 145F 140F, 141F, 142F, 143F, AND 144F PIN HOUSING 245483C1 SOCKET HOUSING AUX/PTO HARNESS 291718A1 145M SOCKET HOUSING 245482C1 RI99H129 CAV CONNECTOR 140F - 291718A1 AUX 1 MOTOR RAISE WIRE CIRCUIT REFERENCE NUMBER 1 AUX1 TOP1 B+ AUX 1 B RAISE 2 AUX1 TOP2 RETURN AUX 1 B RAISE CAV AUX2 TOP1 B+ AUX 2 B RAISE 2 AUX2 TOP2 RETURN AUX 2 B RAISE AUX3 TOP1 B+ AUX 3 B RAISE 2 AUX3 TOP2 RETURN AUX 3 B RAISE SENSOR PTO SHAFT SPEED B SENSOR SENDER
Section 55 - Electrical System - Chapter 1 147M 147F SOCKET HOUSING 182087A1 PIN HOUSING AUX/PTO HARNESS 182085A1 182085A1AND 87A1 CAV CONNECTOR 147F - 182085A1 TRAILER CONNECTOR WIRE CIRCUIT REFERENCE NUMBER CONNECTOR 147M - 182087A1 TRAILER CONNECTOR WIRE CIRCUIT REFERENCE NUMBER CAV A 787C WORK LIGHTS A 787S WORK LIGHTS B 751K LEFT TURN C 752J RIGHT TURN B 751S LEFT TURN C 752M RIGHT TURN D 755F STOP LIGHTS D 755G STOP LIGHTS E 750G TAIL LIGHTS E 750S TAIL LIGHTS F
Section 55 - Electrical System - Chapter 1 150M 151M SOCKET HOUSING AUX/PTO HARNESS 280451A1 150F 151F PIN HOUSING 280453A1 PIN HOUSING 225315C1 SOCKET HOUSING TRANSMISSION/ HITCH HARNESS 225316C1 280451A1 CAV 1 FEEDBACK #1 FEEDBACK SENSE 2 PLUGGED #1 FEEDBACK SOURCE 3 PLUGGED #2 FEEDBACK SENSE 4 FEEDBACK #2 FEEDBACK SOURCE 5 5V 6 GND CAV 225315C1 CONNECTOR 150F - 280453A1 IMPLEMENT POTENTIOMETER WIRE CIRCUIT REFERENCE NUMBER CAV 1 SOLENOID HITCH SOLENOID (B+) 2 SOLENOID HI
Section 55 - Electrical System - Chapter 1 153M SOCKET HOUSING TRANSMISSION/ HITCH HARNESS 225295C1 155M SOCKET HOUSING TRANSMISSION/HITCH HARNESS- 198550A1 153F PIN HOUSING 225294C1 225294C1 CAV CONNECTOR 153F - 225294C1 RIGHT HAND EDC PIN WIRE CIRCUIT REFERENCE NUMBER A SENSOR B SENSOR C SENSOR CAV 198550A1 CONNECTOR 155M - 198550A1 ROCKSHAFT POTENTIOMETER WIRE CIRCUIT REFERENCE NUMBER CAV GROUND A 506A HIGH SIGNAL B 507A SIGNAL +8V C 508A LOW CONNECTOR 153M - 225295C1 RIGHT HA
Section 55 - Electrical System - Chapter 1 160M 157F SOCKET HOUSING TRANSMISSION/HITCH HARNESS -225316C1 PIN HOUSING 225164C1 225316C1 225164C1 CONNECTOR 157F - 225164C1 IMPLEMENT AUXILIARY POWER WIRE CIRCUIT REFERENCE NUMBER CAV 1 142D CAV SWITCHED B+ 2 141D UNSWITCHED B+ 3 177AB GROUND CONNECTOR 160M - 225316C1 FWD SOLENOID WIRE CIRCUIT REFERENCE NUMBER 1 540A FWD SOL - HIGH (B+) 2 175D FWD CHASSIS GROUND 161F 158M SOCKET HOUSING CAB HARNESS -225253C1 SOCKET HOUSING TRANSMISSIO
Section 55 - Electrical System - Chapter 1 162M 163M SOCKET HOUSING CAB HARNESS - 227429A1 SOCKET HOUSING CAB HARNESS - 227429A1 227429A1 227429A1 CONNECTOR 162M - 227429A1 LEFT BRAKE WIRE CIRCUIT REFERENCE NUMBER CAV CONNECTOR 163M - 227429A1 RIGHT BRAKE WIRE CIRCUIT REFERENCE NUMBER CAV A 509B LEFT BRAKE SWITCH A 599D RIGHT BRAKE B+ B 599C LEFT BRAKE B+ B 510B RIGHT BRAKE SWITCH 162F 163F SOCKET HOUSING CAB HARNESS - 227430A1 SOCKET HOUSING CAB HARNESS - 227430A1 227429A1 CAV 22
Section 55 - Electrical System - Chapter 1 164M 166F SOCKET HOUSING CAB HARNESS - 225351C1 42913-2 RING TERMINAL 225351C1 200338.
Section 55 - Electrical System - Chapter 1 168M 170M SOCKET HOUSING SHELF HARNESS 227728A1 SOCKET HOUSING SHELF HARNESS 225295C1 168F PIN HOUSING EXTENSION HARNESS 227729A1 227729A1 225259C1 CONNECTOR 168F - 227729A1 AUXILIARY POWER #2 WIRE CIRCUIT REFERENCE NUMBER CAV CAV A 136J B 135J UNSWITCHED B+ B C 134J GROUND C SWITCHED B+ A CONNECTOR 168M - 227728A1 AUXILIARY POWER #2 WIRE CIRCUIT REFERENCE NUMBER CAV A 136E SWITCHED B+ B 135E UNSWITCHED B+ C 134E GROUND CONNECTOR 170
Section 55 - Electrical System - Chapter 1 171F SOCKET HOUSING CAB HARNESS - 877290R1 172F & 173F RING TERMINAL CAB HARNESS - 200338 171M SOCKET HOUSING CAB HARNESS - 877291R1 877291R1 CAV CONNECTOR 171F - 872290R1 RADAR WIRE CIRCUIT REFERENCE NUMBER A RADAR CLEAN GROUND B RADAR SIG FREQ TO ICU CAV 200338 CAV 1 CONNECTOR 171M - 877291R1 RADAR WIRE CIRCUIT REFERENCE NUMBER A 179T CLEAN GROUND B 199A 199B SIG FREQ TO ICU CONNECTOR 172F - 200338 CHASSIS GROUND WIRE CIRCUIT REFERENCE NUMBE
Section 55 - Electrical System - Chapter 1 178F 178M PIN HOUSING SOCKET HOUSING 227393A1 227392A1 175M SOCKET HOUSING 239451A1 225326C1 CAV CONNECTOR 175M - 239451A1 PASSIVE TERMINATOR WIRE CIRCUIT REFERENCE NUMBER 1 RED 2 YELLOW 3 BLACK CDB GROUND (TRACTOR) 4 GREEN CDB LOW (TRACTOR) 227393A1 CDB BATTERY (TRACTOR) CDB HIGH (TRACTOR) CAV A 832C HIGH B 833C LOW C 836C WASHER D 177AU GROUND E 831E BATTERY F 834C PARK CAV 55-1-86 CONNECTOR 178F - 227393A1 INTERMITTANT WI
Section 55 - Electrical System - Chapter 1 179F 181M 179M PIN HOUSING ORANGE SOCKET HOUSING 429028A1 SOCKET HOUSING 222136A1 222135A1 382391A1 CAV 222136A1 AND 135A1 1 CONNECTOR 179F - 222136A1 SELF CANCEL WIRE CIRCUIT REFERENCE NUMBER CAV 531C 531D SWITCH B+ 3 532A LOCK/UNLOCK 4 OPEN OPEN 1 R B+ 2 N GROUND 6 CONNECTOR 179M - 222135A1 SELF CANCEL WIRE CIRCUIT REFERENCE NUMBER 1 706E B+ 2 178AC GROUND OPEN 2 5 CAV CONNECTOR 181M - 429028A1 AXLE REGULATION SW WIRE CIRCU
Section 55 - Electrical System - Chapter 1 185M 188M SOCKET HOUSING SOCKET HOUSING 225295C1 245480C1 185F 188F PIN HOUSING PIN HOUSING 225294C1 245481C1 291718A1 CAV CONNECTOR 185F - 225294C1 FRONT AXLE POS SENSOR WIRE CIRCUIT REFERENCE NUMBER A 531F B+ B 179CL CLEAN GROUND C 544A SENSOR SIGNAL CAV 245480C1 CAV A CONNECTOR 185M - 225295C1 FRONT AXLE POS SENSOR WIRE CIRCUIT REFERENCE NUMBER A 543C B+ B 179BC CLEAN GROUND C 544C SENSOR SIGNAL CAV A 186M & 187M SOCKET HOUS
Section 55 - Electrical System - Chapter 1 192F 192M PIN HOUSING SOCKET HOUSING 280458A1 280456A1 RI00E014 CAV 1 CAV 280458A1 CONNECTOR 189F - AMP_327175 CLEAN GROUND WIRE CIRCUIT REFERENCE NUMBER 177A 174A 177B CAV CLEAN GND CONNECTOR 191F - SELF_CANCEL SELF CANCEL SENSOR WIRE CIRCUIT REFERENCE NUMBER 1 538C 2 179BK S1 SOL GND (RAISE) 3 357C S2 SOL B+ (LOWER) 4 179BL S2 SOL GND (LOWER) 5 542B LOWER LOCK SOL 6 546B LOWER LOCK SOL 541B UPPER LOCK SOL 548B UPPER LOCK SOL 20
Section 55 - Electrical System - Chapter 1 193M SOCKET HOUSING 291719A1 197M RING TERMINAL 222135A1 291719A1 CONNECTOR 193M - 291719A1 AXLE SENSOR WIRE CIRCUIT REFERENCE NUMBER CAV 1 179BC GROUND 2 543C OUTPUT 3 544C SUPPLY VOLTAGE CONNECTOR 197M - 222135A1 LEFT A-POST WORKLIGHT WIRE CIRCUIT REFERENCE NUMBER CAV 1 786E B+ 2 177AX GROUND RI00E014 CONNECTOR 195M - 239449A1 LEFT FRONT ROOF WORKLIGHT WIRE CIRCUIT REFERENCE NUMBER CAV A 784E B+ B 178AF GROUND 198M RING TERMINAL 222135
Section 55 - Electrical System - Chapter 1 201F RING TERMINAL 225072C1 198F 222136A1 200338.
Section 55 - Electrical System - Chapter 1 211M 205M SOCKET HOUSING 245482C1 211F PIN HOUSING 245483C1 RE97H023 CAV 245483C1 CONNECTOR 205M - 239451A1 PASSIVE TERMINATOR WIRE CIRCUIT REFERENCE NUMBER 1 GREEN CDB LOW (TRACTOR) 2 YELLOW CDB HIGH (TRACTOR) CAV A SWITCH B+ FROM ICU B SWITCH GROUND 291718A1 207M CAV SOCKET HOUSING 245488C1 CONNECTOR 211F - 245483C1 IMPLEMENT ICU WIRE CIRCUIT REFERENCE NUMBER CONNECTOR 211M - 245482C1 IMPLEMENT ICU WIRE CIRCUIT REFERENCE NUMBER A 285B
Section 55 - Electrical System - Chapter 1 213M SOCKET HOUSING FRONT TO REAR HARNESS - 877291R1 214M SOCKET HOUSING ENGINE HARNESS 411986A1 877291R1 CAV CONNECTOR 213M - 877291R1 REAR WASH MOTOR WIRE CIRCUIT REFERENCE NUMBER A 600G GROUND B 845C REAR WASH B+ 411988A1 CAV CONNECTOR 214M - 411986A1 FUEL SHUT OFF SOL (EM) WIRE CIRCUIT REFERENCE NUMBER A 456B SOL + B 604A SOL + C 600B SOL GROUND 215M SOCKET HOUSING SENSOR 225316C1 215F PIN HOUSING ENGINE HARNESS 225315C1 225315C1 CAV
Section 55 - Electrical System - Chapter 1 219F 216M SOCKET HOUSING ELOBAU 815 100 SOCKET HOUSING 198456A1 198456A1 CONNECTOR 216M - 198456A1 ENGINE OIL PRESS (EM) WIRE CIRCUIT REFERENCE NUMBER CAV A 181AA OIL GROUND B 255C OIL B+ C 256C OIL SIGNAL 219.
Section 55 - Electrical System - Chapter 1 220A, 220B, 220C, 220D, 220E, 220F, 220G, 220H AND 220J SOCKET RI00E016 CAV 1 CAV 1 CAV 1 CAV 1 CAV 1 CAV 1 CAV 1 CONNECTOR 220A - 1-4_FLAG UNIVERSAL SWITCH WIRE CIRCUIT REFERENCE NUMBER 20A CAV TURN SIGNAL COMMON 1 CONNECTOR 220B - 1-4_FLAG UNIVERSAL SWITCH WIRE CIRCUIT REFERENCE NUMBER 21A CAV TURN SIGNAL COMMON 1 CONNECTOR 220C - 1-4_FLAG UNIVERSAL SWITCH WIRE CIRCUIT REFERENCE NUMBER 22A TURN SIGNAL COMMON CONNECTOR 220D - 1-4_FLAG UNIVERSAL
Section 55 - Electrical System - Chapter 1 221F 222M 221M PIN HOUSING TURN INDICATORS SOCKET HOUSING TO CD CHANGER 379421A1 SOCKET HOUSING GHW 16182 221F 221M.
Section 55 - Electrical System - Chapter 1 223M 228M SOCKET HOUSING TO RADIO SOCKET HOUSING 426708A1 380431A1 375602A1 CAV 380431A1 CAV CONNECTOR 223M - 3804331A1 CD PLAYER WIRE CIRCUIT REFERENCE NUMBER 13 RED LEFT AUDIO 14 LIGHT GREEN E & C DATA 15 ORANGE 16 WHITE RIGHT AUDIO 17 CLEAR SHIELD GROUND 18 BLACK GROUND 19 BLACK 20 CONNECTOR 228M - 426708A1 LEFT STOP/TAIL LIGHT WIRE CIRCUIT REFERENCE NUMBER 1 174Z GROUND 2 753D TURN/HAZARD 3 750P TAIL 4 755L STOP 229F
Section 55 - Electrical System - Chapter 1 234F PIN HOUSING 225316A1 230M 230F SOCKET HOUSING 222316C1 PIN HOUSING 222315C1 234M SOCKET HOUSING 225315A1 222136A1 AND 135A1 CAV CONNECTOR 230F - 225315C1 LEFT REAR FENDER WORKLAMP WIRE CIRCUIT REFERENCE NUMBER 1 LAMP MARKER LIGHT B+ 2 LAMP GROUND CAV 222136A1 AND 135A1 CAV CONNECTOR 230M - 225316C1 LEFT REAR FENDER WORKLAMP WIRE CIRCUIT REFERENCE NUMBER 1 787 MARKER LIGHT B+ 2 174 GROUND 233M 375602A1 CAV CONNECTOR 233M - 426708A1 R
Section 55 - Electrical System - Chapter 1 235M 237F PIN HOUSING 222136A1 PIN HOUSING 222136A1 235F 237M SOCKET HOUSING 222135A1 SOCKET HOUSING 222135A1 222136A1 AND 135A1 222136A1 AND 135A1 A1 CAV CONNECTOR 235F - 225135C1 RIGHT FENDER REAR WORKLAMP WIRE CIRCUIT REFERENCE NUMBER 1 LAMP LEADS WORK LIGHT B+ 2 LAMP LEADS GROUND CAV CAV CONNECTOR 235M - 225136C1 RIGHT FENDER REAR WORKLAMP WIRE CIRCUIT REFERENCE NUMBER CONNECTOR 237F - 222136A1 RIGHT FENDER WIDE MARKER LIGHT WIRE CIRCUIT RE
Section 55 - Electrical System - Chapter 1 256M 255F SOCKET HOUSING 242580A1 144417A1 242580A1 144417A1 CAV CONNECTOR 255F - 144417A1 RELAY BLOCK WIRE CIRCUIT REFERENCE NUMBER A1 171B CHASSIS GROUND A2 160C RELAY IGNITION FEED A3 163B RELAY B+ A4 OPEN A5 162B CONTROLLER SW B+ B1 171C CHASSIS GROUND B2 160D RELAY IGNITION FEED B3 163C RELAY B+ B4 B5 162D CONTROLLER SW B+ 171A CHASSIS GROUND C2 160B RELAY IGNITION FEED C3 163A RELAY B+ C5 162A CONTROLLER SW B+ D1
Section 55 - Electrical System - Chapter 1 257F 258F WHITE SOCKET HOUSING CAB HARNESS GREEN SOCKET HOUSING CAB HARNESS 87426881 87426889 382391A1 CAV CONNECTOR 257F - 87426881 CRUISE, ON / OFF WIRE CIRCUIT REFERENCE NUMBER 382391A1 CAV CONNECTOR 258F - 87426889 CRUISE, INCREMENT / DECREMENT WIRE CIRCUIT REFERENCE NUMBER 1 OPEN 1 489A 2 OPEN 2 179BP 179BR DECREMENT SIGNAL 3 OPEN 3 358A 4 OPEN 4 OPEN CLEAN GROUND INCREMENT SIGNAL 5 179BR CLEAN GROUND 5 OPEN 6 547A ON/OFF
Section 55 - Electrical System - Chapter 1 261 FUSE BLOCK 144421A1 WIRE NUMBERS IDENTIFIED AS A “J” NUMBER, ARE JUMPER WIRES ON THE FUSE BLOCK 144421A1 FUSE BLOCK 261F - 144421A1 CAV WIRE NUMBER A1 765A A2 179AW A3 CAV WIRE NUMBER FUSE #28 C3 141A FUSE #13 CELCIUS/FAHRENHEIT GRD C4 101K FRONT/REAR AUX PWR (UNSW) C5 222B C6 103E FUSE #12 TRAILER AUXILIARY (SWITCHED) FUSE #26 C7 207A FUSE #11 SUSPENDED AXLE C8 101D CIGAR LIGHTER (UNSWITCHED) 195A FUSE #10 BLOWER CAB PRESSURE
Section 55 - Electrical System - Chapter 1 262 FUSE BLOCK 144421A1 WIRE NUMBERS IDENTIFIED AS A “J” NUMBER, ARE JUMPER WIRES ON THE FUSE BLOCK 144421A1 FUSE BLOCK 262F - 144421A1 CAV WIRE NUMBER A9 841C A10 JUMPER A11 831C A12 FUSE BLOCK 262F - 144421A1 CAV WIRE NUMBER C7 596A REAR WIPER/WASHER C8 JUMPER FUSE #51 C9 599E FUSE #38 102K FRONT WIPER/WASHER C10 200C PTO B1 820A FUSE #49 C11 203B FUSE #37 B2 103D HVAC BLOWER C12 JUMPER B3 136A FUSE #48 C13 900D B4 10
Section 55 - Electrical System - Chapter 1 263F RELAY BLOCK 144417A1 264F RELAY BLOCK 144417A1 CONNECTOR 263F - 144417A1 RELAY BLOCK CAV WIRE NUMBER CIRCUIT REFERENCE CONNECTOR 264F - 144417A1 RELAY BLOCK CAV WIRE NUMBER CIRCUIT REFERENCE A1 750K POS / HAZ COIL B+ A1 312D SWITCHED B+ A2 177AS COIL GROUND A2 177AT COIL GROUND A3 241A WORK LIGHTS INTERLOCK A3 195A UNSWITCHED B+ A4 789A ROTARY WORKLIGHTS A4 A5 OPEN OPEN A5 195B BLOWER B+ B1 558A PARK RELAY COIL B1 104B
Section 55 - Electrical System - Chapter 1 266MM 265F SOCKET HOUSING 239451A1 144417A1 239451A1 144417A1 CAV B1 CAV CONNECTOR 265F - 144417A1 RELAY BLOCK WIRE CIRCUIT REFERENCE NUMBER 731B EGRESS ON B2 177BE COIL GROUND B3 312E UNSWITCHED B+ B4 830A BLOWER SIGNAL B5 732A EGRESS SIGNAL ON D1 OPEN OPEN D2 177BD COIL GROUND D3 OPEN OPEN D4 OPEN OPEN D5 OPEN OPEN E1 OPEN OPEN E2 177BC COIL GROUND E3 OPEN OPEN E4 OPEN OPEN E5 OPEN OPEN F1 164C INTERLOCK ON
Section 55 - Electrical System - Chapter 1 269F PIN HOUSING 225164C1 225164C1 382391A1 CAV A CAV A CONNECTOR 267M - 631801C1 RECTIFIER ASSEMBLY WIRE CIRCUIT REFERENCE NUMBER 724A 724B CAV 1 HIGH BEAM DIMMING/INDICATOR CONNECTOR 267F - 739070C1 RECTIFIER ASSEMBLY WIRE CIRCUIT REFERENCE NUMBER 727D CONNECTOR 269F - 225164C1 TO AUXILIARY POWER CONNECTOR WIRE CIRCUIT REFERENCE NUMBER 142B SWITCHED B+ 2 141B UNSWITCHED B+ 3 177AF GROUND 270F PIN HOUSING 225164C1 HIGH BEAM DIMMING 225164C1 CA
Section 55 - Electrical System - Chapter 1 273M 273FF SOCKET HOUSING CAB HARNESS 223671A1 PIN HOUSING 223672A1 273F PIN HOUSING INTELLIVIEW II INSIDE CAB 223672A1 223671A1 CONNECTOR 273F - 223672A1 CAB/ ISO 11783 WIRE CIRCUIT REFERENCE NUMBER 223672A1 CONNECTOR 273FF - 223672A1 CAV WIRE NUMBER UNSWITCHED B+ 5 CDB-R59 CAN IMP B+ 2 RADAR SIGNAL 6 CDB-Y59 CAN IMP HIGH 3 SWITCHED B+ 7 CDB-BK59 CAN IMP GROUND CLEAN GROUND 8 CDB-DG59 CAN IMP LOW CAV 1 344E 4 179CB 5 RED 6 YELLOW
Section 55 - Electrical System - Chapter 1 276F 278MM 276M PIN HOUSING 182064A1 SOCKET HOUSING 239451A1 SOCKET HOUSING 182066A1 382391A1 382391A1 CAV 1 CAV 1 CONNECTOR 276F TO FNRP WIRE CIRCUIT REFERENCE NUMBER 522J CAV 1 REVERSE CONNECTOR 276M REVERSE WIRE CIRCUIT REFERENCE NUMBER 522AA REVERSE 55-1-108 CONNECTOR 278MM - 239451A1 TO ACTIVE TERMINATOR WIRE CIRCUIT REFERENCE NUMBER CAN-R48 CAN AUTO B+ 2 CAN-Y48 CAN AUTO HI 3 CAN-BK48 CAN AUTO GROUND 4 CAN-DG48 CAN AUTO LO
Section 55 - Electrical System - Chapter 1 278M 282M SOCKET HOUSING 239451A1 SOCKET HOUSING AMP 4-1437290-0 382391A1 CAV CONNECTOR 278M - 239451A1 TO ACTIVE TERMINATOR WIRE CIRCUIT REFERENCE NUMBER 282M.
Section 55 - Electrical System - Chapter 1 283M 287M SOCKET HOUSING 225316C1 SOCKET HOUSING 382391A1 225316C1 CONNECTOR 283M - 225316C1 BREAKAWAY WIRE CIRCUIT REFERENCE NUMBER CAV 1 137G ECU PWR 2 179CG ECU GND 382391A1 CONNECTOR 287M - 382391A1 MANUAL SWITCH 2 345B SW B+ 3 - AUTO/MAN 288M SOCKET HOUSING 239451A1 286M SOCKET HOUSING 225319C1 239451A1 CAV 225319C1 CAV CONNECTOR 286M - 225319C1 TASK CONTROLLER WIRE CIRCUIT REFERENCE NUMBER 1 344H 2 YELLOW ECU PWR CAN LO (IMP) 3
Section 55 - Electrical System - Chapter 1 290F SOCKET HOUSING 380841A1 290M PIN HOUSING 380842A1 380841A1 CAV CONNECTOR 290F - 380841A1 TO INSIDE AUTOGUIDANCE HARNESS WIRE CIRCUIT REFERENCE NUMBER CAV CONNECTOR 290M - 380842A1 TO OUTSIDE AUTOGUIDANCE HARNESS WIRE CIRCUIT REFERENCE NUMBER 5 421B PPS IN 5 421A PPS IN 6 419E S.V. SOURCE 6 419A S.V. SOURCE 8 410E S.V. RH SINK 8 410A S.V. RH SINK 7 9 411E S.V. LH SINK 9 411A S.V.
Section 55 - Electrical System - Chapter 1 291M 293M SOCKET HOUSING 323597A1 SOCKET HOUSING INSIDE CAB 310220A1 323597A1 CONNECTOR 291M - 279043A1 BREAKAWAY WIRE CIRCUIT REFERENCE NUMBER CAV 310220A1 CAV CONNECTOR 293M - 310220A1 INTELLIVIEW II POWER RELAY WIRE CIRCUIT REFERENCE NUMBER 1 407C CHASSIS GROUND 30 2 407B ECU GROUND 85 403A IMP POWER ACT 3 402A POWER 86 404A SWITCHED B+ 4 137D ECU POWER 87 402A UNSWITCHED B+ 5 - OPEN 6 - TBC POWER 7 - TBC RETURN 8 - CA
Section 55 - Electrical System - Chapter 1 294M 295M SOCKET HOUSING 223682A1 SOCKET HOUSING 223671A1 223671A1 CAV CONNECTOR 294M - 223682A1 TO ISO 11783 OUTSIDE HARNESS WIRE CIRCUIT REFERENCE NUMBER 223671A1 CAV CONNECTOR 295M - 223671A1 GPS ANTENNA RECEIVER WIRE CIRCUIT REFERENCE NUMBER 1 CAN IMP B+ 1 CAN-Y60 2 CAN IMP HI 2 413E RS232 RX 3 LOW ECU SW POWER 3 412E RS232TX 4 SWB+ 4 421E PPS IN 5 CLEAN GND 5 414E RS232 GROUND 6 WORKLIGHT B+ 6 OPEN CAN LO B 7 LEFT TURN
Section 55 - Electrical System - Chapter 1 297F 296F RING TERMIINAL PIN HOUSING 223682A1 200338 200338 CONNECTOR 297F - 200338 RING TERMINAL WIRE CIRCUIT REFERENCE NUMBER 223671A1 CAV CONNECTOR 296F - 223682A1 TO VT JUMPER WIRE CIRCUIT REFERENCE NUMBER 1 CDB-51R CDB IMP B+ 2 CDB-51Y CDB IMP HI 3 CDB-51BK CDB IMP GROUND 4 CDB-51DG CDB IMP LO 5 CDB-52R CDB IMP B+ 6 CDB-52Y CDB IMP HI 7 CDB-52BK CDB IMP GROUND 8 CDB-52DG CDB IMP LO 9 PLUG OPEN 10 344G SWITCHED B+ 11 17
Section 55 - Electrical System - Chapter 1 298F 299F PIN HOUSING PIN HOUSING 280453A1 277904A1 299M PIN HOUSING 277905A1 277905A1 AND 904A1 223672A1 CONNECTOR 298F - 280453A1 GPS ANTENNA WIRE CIRCUIT REFERENCE NUMBER CAV 1 CDB-37R CAV CAN BATT (IMP) 2 CDB-37Y CAN HI (IMP) 3 CDB-37BK CAN GND (IMP) 4 CDB-37DG CAN LOW (IMP) 5 PLUG OPEN 6 PLUG OPEN 1 414B RS232 GND 2 413B RS232 RX 3 412B RS232 TX 4 421B PPS IN CAV 298M PIN HOUSING 280453A1 223672A1 CAV CONNECTOR 298M -
Section 55 - Electrical System - Chapter 1 301F, 302F, 303F, AND 304F 313MA & 313MB SOCKET HOUSING REMOTE HITCH SWITCH HARNESS 1/4 FLAG TERM.
Section 55 - Electrical System - Chapter 1 315M 318M SOCKET HOUSING 225295C1 SOCKET HOUSING 245482C1 315F 318F PIN HOUSING PIN HOUSING 225294C1 245483C1 225294C1 CAV CONNECTOR 315F - 225294C1 REMOTE HITCH SWITCH WIRE CIRCUIT REFERENCE NUMBER A 526B B C CAV CAV CONNECTOR 318F - 245483C1 PNEUMATIC PARK SOLENOID WIRE CIRCUIT REFERENCE NUMBER RAISE REMOTE UP A 567F PARK BRAKE FEEDBACK 500E COMMON B+ B 179BV CLEAN GROUND 513B LOWER REMOTE DOWN CONNECTOR 315M - 225295C1 REMOTE HITCH
Section 55 - Electrical System - Chapter 1 325A & 325B AMP 41274-0 327M AND 328M 300518A1 RI00E015 CONNECTOR 325A - 41274-0 PNEUMATIC AIR SWITCH WIRE CIRCUIT REFERENCE NUMBER CAV 1 566C 300518A1 CAV B+ CONNECTOR 325B - 41274-0 PNEUMATIC AIR SWITCH WIRE CIRCUIT REFERENCE NUMBER CAV 1 179AB CONNECTOR 327M - 300518A1 INTELLIVIEW II FUSE WIRE CIRCUIT REFERENCE NUMBER GROUND 1 400B UNSWITCHED B+ 2 400C UNSWITCHED B+ CONNECTOR 328M - 300518A1 INTELLIVIEW II FUSE WIRE CIRCUIT REFERENCE NUMBER
Section 55 - Electrical System - Chapter 1 332M SOCKET HOUSING 332F PIN HOUSING 225326C1 225326C1 CAV CONNECTOR 332F - 225326C1 LEFT FRONT HITCH LAMPS WIRE CIRCUIT REFERENCE NUMBER 1 742B LOW BEAM B+ 2 743B HIGH BEAM B+ 3 744B PILOT 4 176D GROUND CAV CONNECTOR 332M - 239451C1 LEFT FRONT HITCH LAMPS WIRE CIRCUIT REFERENCE NUMBER 1 LAMP LOW BEAM B+ 2 LAMP HIGH BEAM B+ 3 LAMP PILOT 4 LAMP GROUND 55-1-119
Section 55 - Electrical System - Chapter 1 333M 333F PIN HOUSING SOCKET HOUSING HDP24-24-29PE HDP26-24-29SE 333M_333F CAV CONNECTOR 333M - 87426722 TO ENGINE HARNESS WIRE CIRCUIT REFERENCE NUMBER 1 204B 2 179AG 3 102P CAV CONNECTOR 333F - 87426768 TO CHASSIS HARNESS WIRE CIRCUIT REFERENCE NUMBER BATT B+ (ENG GOV) 1 204C BATT B+ (ENG GOV) ENGINE GOV GND 2 179AK ENGINE GOV GND SW B+ 3 102N SW B+ 4 722B HORN B+ 4 722C HORN B+ 5 223B ENG GOV B+ IG SW 5 223C ENG GOV B+ IG
Section 55 - Electrical System - Chapter 1 334M 334F PIN HOUSING SOCKET HOUSING HDP24-24-29PE HDP24-24-29PE 333M_333F CONNECTOR 334M - 225319C1 CONNECTOR 334F - 225320C1 CAV WIRE NUMBER 1 450B 2 641B ETHER SOLENOID B+ 2 641C ETHER SOLENOID B+ 3 181P AIR TO AIR GND 3 181W AIR TO AIR GND 4 453B ENG COOLANT TEMP INPUT 4 235C ENG COOLANT TEMP INPUT 5 454B ENG AIR INTAKE TEMP 5 240C ENG AIR INTAKE TEMP CIRCUIT REFERENCE ENGINE OIL PRESS +5V CAV WIRE NUMBER 1 255C CIRCUIT
Section 55 - Electrical System - Chapter 1 335M SOCKET HOUSING HDP24-24-31PE 335F PIN HOUSING HDP26-24-31SE CAV CONNECTOR 335F - 87426768 TO AUX HARNESS WIRE CIRCUIT REFERENCE NUMBER 1 501B 2 179CY 3 900F 4 179CW 7 599P POWER GROUND VF B+ POWER GROUND VH B+ 8 175M DIFF SOLENOID 9 174E PTO CLUTCH OUTPUT GND 10 175N CHASSIS GROUND 11 565F PNEUMATIC BRAKE B+ 15 510C RH BRAKE PEDAL SWITCH 16 702B BRAKE LIGHT RELAY 17 540B FWD SOLENOID SOURCE 18 216K ENGINE SPEED ALT W TERM
Section 55 - Electrical System - Chapter 1 336M 338F 338M SOCKET HOUSING PIN HOUSING SOCKET HOUSING 225316C1 225315C1 245482C1 336F PIN HOUSING 245483C1 245483C1 CAV CONNECTOR 336F - 245483C1 DUAL SPEED PTO WIRE CIRCUIT REFERENCE NUMBER 225315C1 CAV CONNECTOR 338F - 225315C1 BACKUP ALARM WIRE CIRCUIT REFERENCE NUMBER A SENSOR PTO SHAFT SPEED 1 571A ALARM POWER B SENSOR SENDER GROUND 2 174G ALARM GND CAV CONNECTOR 336M - 245482C1 DUAL SPEED PTO WIRE CIRCUIT REFERENCE NUMBER CAV
Section 55 - Electrical System - Chapter 1 340F, 341F, 342F, 343F AND 344F SOCKET HOUSING 291718A1 350M CNH 87410948 TYCO 3-1437290-7 291718A1 CAV CONNECTOR 340F - 291718A1 AUX 1 MOTOR LOWER WIRE CIRCUIT REFERENCE NUMBER 350M CAV CONNECTOR 350M - 3-1437290-7 TRANSMISSION CONTROLLER WIRE CIRCUIT REFERENCE NUMBER 1 AUX1 BOT1 B+ AUX 1 A LOWER 1 550B SWITCHED B+ 12V 2 AUX1 BOT2 RETURN AUX 1 A LOWER 2 550D SWITCHED B+ 12V 3 550H SWITCHED B+ 12V 4 558B PARK BRAKE CONTROL 5 586A MASTER
Section 55 - Electrical System - Chapter 1 351M CNH 87410946 353M CNH 87410949 TYCO 4-1437290-0 TYCO 3-1437290 SOCKET HOUSING SOCKET HOUSING 350M CAV 1 CONNECTOR 351M - 4-1437290-0 TRANSMISSION CONTROLLER WIRE CIRCUIT REFERENCE NUMBER 555A 2 350M CAV CONNECTOR 353M - 3-1437290-8 TRANSMISSION CONTROLLER WIRE CIRCUIT REFERENCE NUMBER MASTER CLUTCH SIGNAL 1 581A EVEN CLUTCH LOW SIDE OPEN 2 544A AXLE SENSOR SIGNAL RANGE PRESSURE SIGNAL 3 590A CREEP CLUTCH LOW SIDE 11 563A 12 552A R
Section 55 - Electrical System - Chapter 1 355M CNH 87410947 364M & 365M 222135A1 TYCO SOCKET HOUSING POLARITY 2 KEYING SOCKET HOUSING 4-1437290-0 350M CAV CONNECTOR 355M - 4-1437290-1 TRANSMISSION CONTROLLER WIRE CIRCUIT REFERENCE NUMBER CAV CONNECTOR 364M - 222135A1 STROBE/BEACON WIRE CIRCUIT REFERENCE NUMBER 1 776B STROBE/BEACON B+ 2 178Y GROUND 1 584A C5 - 6 CLUTCH LOW SIDE 2 585A REVERSE CLUTCH LOW SIDE 3 546A FSUS LOWER LOCK 4 589A HIGH CLUTCH LOW SIDE 5 201G REVERSE CLU
Section 55 - Electrical System - Chapter 1 367F 225326C1 372F 225067C1 350M CAV CONNECTOR 367F - 225326C1 TO ISO11783 ACTIVE TERM WIRE CIRCUIT REFERENCE NUMBER 1 CAN-R49 CAN AUTO B+ 2 CAN-Y49 CAN AUTO HI 3 CAN-BK49 CAN AUTO GND 4 CAN-DG49 CAN AUTO LO CAV 1 CONNECTOR 372F - 225067C1 HOT AIR UNSWITCHED B+ WIRE CIRCUIT REFERENCE NUMBER 270A HOT AIR B+ 373F 225067C1 369F 225067C1 CAV 1 CAV 1 CONNECTOR 369F - 225067C1 CLEAN GROUND WIRE CIRCUIT REFERENCE NUMBER 270C CONNECTOR 373F - 2250
Section 55 - Electrical System - Chapter 1 374M 245489C1 375M 197503A1 PIN HOUSING 350M CAV CONNECTOR 374M - 245489C1 TO STEERING POT JUMPER WIRE CIRCUIT REFERENCE NUMBER CAV A 417A STEERING POT SIG (1) B 422A STEERING POT SIG (2) C 417B STEERING POT CONTROLLER D 303D SEAT SW OPS RTN 303E SEAT SW OPS RTN TO CONTROLLER E F A 786A ROOF HID B+ B 177L ROOF HID GND C D E F OPEN G H 375F 196153A1 350M CAV CONNECTOR 375F - 196153A1 ROOF HID WORKLIGHTS WIRE CIRCUIT REFERENCE NUMBE
Section 55 - Electrical System - Chapter 1 377F 223672A1 379M 245488C1 PIN HOUSING 350M CAV 1 CONNECTOR 377F - 223672A1 TO CAB HARNESS WIRE CIRCUIT REFERENCE NUMBER CDB-Y51 2 CDB-DG51 3 CDB-R51 A 792A FENDER/BELTLINE LTS B 792J FENDER/BELTLINE LTS CAN HI (IMP) C 791A REAR WORKLIGHTS CAN LO (IMP) D 791C REAR WORKLIGHTS CAN B+ E 790A REAR WORKLIGHTS F 790E REAR WORKLIGHTS 4 CDB-BK51 CAN GROUND 5 CDB-Y52 CAN HI (TR) 6 CDB-DG52 CAN LO (TR) 7 OPEN 8 OPEN 9 OPEN 10
Section 55 - Electrical System - Chapter 1 386F 87428138 382F 225072C1 PIN HOUSING CAV 1 350M CONNECTOR 382F - 225072C1 INTAKE AIR HEATER COIL B+ WIRE CIRCUIT REFERENCE NUMBER 273C HOT AIR COIL RETURN CAV 1 383F 225072C1 CAV 1 273D CAN-R55 CAN BATT AUTO 2 145F SW B+ 3 420E CLEAN GND CAV CONNECTOR 383F - 225072C1 INTAKE AIR HEATER COIL B+ WIRE CIRCUIT REFERENCE NUMBER CONNECTOR 386F- 87428138 GPS RECEIVER WIRE CIRCUIT REFERENCE NUMBER 1 CONNECTOR 386M - 87428139 TO GPS RECEIVER WIRE CI
Section 55 - Electrical System - Chapter 1 387M 87428138 389F 276426A1 PIN HOUSING PIN HOUSING CAV 1 CONNECTOR 387M - 87428138 CAN SPL56 WIRE CIRCUIT REFERENCE NUMBER CAN-R61 CAV CONNECTOR 389F -276426A1 CAN SPL56 WIRE CIRCUIT REFERENCE NUMBER CAN B+ (IMP) 1 CAN-Y56 CAN HI (IMP) 2 OPEN 2 CAN-BK56 CAN GND (IMP) 3 OPEN 3 CAN-DG56 CAN LO (IMP) 388M 276426A1 PIN HOUSING CAV CAV CAN HI (IMP) 2 CAN GND (IMP) 3 CAN LO (IMP) 1 CAN-Y61 CAN HI (IMP) 2 CAN-BK61 CAN GND (IMP) 3 CAN
Section 55 - Electrical System - Chapter 1 391F 225315C1 CAV 395F 225350C1 CONNECTOR 391F -225315C1 TO CDB-SPL51 WIRE CIRCUIT REFERENCE NUMBER CAV CONNECTOR 395F -225350C1 ALT/COMP HARNESS WIRE CIRCUIT REFERENCE NUMBER 1 CAN R51 CDB AUTO B+ 1 835B A/C CLUTCH B+ 2 CAN-B51 CDB AUTO GND 2 810B A/C HI PRESSURE SW GND 3 802B A/C PRESS SW IN 4 179DB A/C COMP CLUTCH GND 5 121B ALT EXCITE B+ 6 216C ALT FREQ (W) 391M 225316C1 CAV CONNECTOR 391M -225316C1 TO CDB-SPL51 WIRE CIRCUIT REF
Section 55 - Electrical System - Chapter 1 395M 225351C1 CAV 1 CAV CONNECTOR 395M -225351C1 ALT/COMP HARNESS WIRE CIRCUIT REFERENCE NUMBER 1 835C CLUTCH B+ 2 179CL HI PRESSURE SW GND 3 802D HI PRESS 4 179CK A/C COMP GND 5 121E ALT EXCITE (D+) 6 126Y ALT FREQ (W) CAV 1 599W 2 PTO SW OUT (NC) 3 PTO SW OUT (NO) 4 957A EHR EXTEND 5 958A EHR RETRACT 6 B+ OPEN 3 OPEN 4 OPEN 5 957B REMOTE EHR NO 6 958B REMOTE EHR NC 1 B+ 599V 2 CAV CONNECTOR 396M -280451A1 LT FEND
Section 55 - Electrical System - Chapter 1 399F 291719A1 CAV 1 403M 87410948 CONNECTOR 399F - 291719A1 LT REMOTE LINK SW WIRE CIRCUIT REFERENCE NUMBER 399F REMOTE EHR NO 2 397E B+ 3 958E REMOTE EHR NC CAV 401M 291719A1 CAV CONNECTOR 401M -291719A1 RT REMOTE LINK SW WIRE CIRCUIT REFERENCE NUMBER 1 397D REMOTE EHR NO 2 599AC B+ 3 958D REMOTE EHR NC 55-1-134 CONNECTOR 403M -87410948 TO SWCD WIRE CIRCUIT REFERENCE NUMBER 1 CDB-Y51 CAN IMP HI 2 CDB-DG51 CAN IMP LO 3 966A ROTARY
Section 55 - Electrical System - Chapter 1 405F 8745344 CAV 1 2 407M 198459A1 CONNECTOR 405F- 87454344 HOME SWITCH WIRE CIRCUIT REFERENCE NUMBER 968A 179DF CAV SWCD HOME SWCD HOME GROUND 406F 87454342 CAV CONNECTOR 406F- 87454342 ESCAPE SWITCH WIRE CIRCUIT REFERENCE NUMBER CONNECTOR 407M- 198459A1 AUTOGUIDANCE CONTROLLER WIRE CIRCUIT REFERENCE NUMBER 1 179CP CLEAN GROUND 2 413A RS232 RX 3 CAN-Y51 6 986A AUTO MAN CAN HI (AUTO) 9 423B POWER GND 10 419A S. V.
Section 55 - Electrical System - Chapter 1 408F 280458A1 409F 182068A1 CONNECTOR 408F- 280458A1 TO CAB HARNESS WIRE CIRCUIT REFERENCE NUMBER CAV 1 CDB-Y57 CAN HI (TR) 2 CDB-DG57 CAN LO (TR) 3 345E TR SW B+ 4 420J CHASSIS GROUND 5 415A WHEEL SPEED 6 522D REVERSE 7 179CX CLEAN GROUND 8 CAV OPEN 408M 280456A1 CAV CONNECTOR 408M- 280456A1 TO INSIDE AUTOGUIDANCE HARNESS WIRE CIRCUIT REFERENCE NUMBER 1 CDB-Y CAN HI (TR) 2 CDB-DG CAN LO (TR) 3 971D TRACTOR SW B+ 4 177BE CH
Section 55 - Electrical System - Chapter 1 409M 182069A1 CAV 413M 244615A1 CONNECTOR 409M - 182069A1 TO ENGINE HARNESS WIRE CIRCUIT REFERENCE NUMBER A 722D HORN B+ B 723D HORN GROUND CAV CONNECTOR 410M- AMP_174922-2 SWCD ROTARY SWITCH WIRE CIRCUIT REFERENCE NUMBER 1 970C SWCD ENTER 2 179DJ SWCD ENTER GROUND 3 179DH SWCD GROUND 4 PLUG OPEN CAV 1 CAV 1 CAV CONNECTOR 413M- 244615A1 AUTOGUIDANCE CONTROLLER WIRE CIRCUIT REFERENCE NUMBER 1 424B RDL GROUND 2 412F RS232TX 5 CDB-Y
Section 55 - Electrical System - Chapter 1 414B 239451A1 CONNECTOR 430M - PACKARD-12059183 LEFT SIDE LIGHT WIRE CAV CIRCUIT REFERENCE NUMBER CONNECTOR 414B - 239451A1 SIDE WIPER MOTOR WIRE CIRCUIT REFERENCE NUMBER CAV 1 177R OPEN 2 971C SIDE WIPER LOW 3 973A SIDE WIPER PARK 4 972A SIDE WIPER BRAKE 738B B+ B 170D GROUND CONNECTOR 431M - PACKARD-12059183 CENTER LIGHT WIRE CAV CIRCUIT REFERENCE NUMBER A 738C B+ B 170F GROUND CONNECTOR 432M - PACKARD-12059183 RIGHT SIDE LIGHT WIRE CAV
Section 55 - Electrical System - Chapter 1 450M 182066A1 CAV 1 CN1 87410948 CONNECTOR 450M - 182066A1 FUEL SHUT OFF SOLENOID WIRE CIRCUIT REFERENCE NUMBER 456B FUEL SHUTOFF SOLENOID CAV 500M 225351C1 CAV CONNECTOR 500M -225351C1 TO STEERING POT WIRE CIRCUIT REFERENCE NUMBER CONNECTOR CN1 -87410948 INSTRUMENT CLUSTER WIRE CIRCUIT REFERENCE NUMBER 1 262A RADAR PRESENT 2 303A SEAT SWITCH 3 724A HIGH BEAM 5 727A LIGHT SWITCH 7 547A CRUISE ON/OFF 8 358A CRUISE INCREMENT 10 267D HYD
Section 55 - Electrical System - Chapter 1 CN2 87410949 CAV CONNECTOR CN2 -87410949 INSTRUMENT CLUSTER WIRE CIRCUIT REFERENCE NUMBER 1 121A ALT EXCITATION 2 203A KEYED B+ 3 202A UNKEYED B+ 4 183B CLEAN GND 5 808C BLOWER MOTOR CONTROL 6 731A EGRESS LIGHTING CONTROL 8 450A ENG OIL PRESS (EM TRACTORS) 10 181K SENSOR GROUND 13 452A FUEL RELAY SOL (EM) 14 655 BUZZER GROUND 19 489A CRUISE DECREMENT 20 656A BUZZER SIGNAL 21 234A FUEL LEVEL SUPPLY 23 267A TRANS FILTER 2
Section 55 - Electrical System - Chapter 1 ELECTRICAL SYSTEMS SCHEMATICS AND DIAGNOSTICS Power Distribution System Circuit Operation Power distribution consists of the following: 1. Unswitched battery power. Unswitched power is available at all times. The battery positive terminal is connected to the unswitched power bus from which all unswitched power circuits are energized.
Section 55 - Electrical System - Chapter 1 POWER DISTRIBUTION SYMPTOM CHART NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual. IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.
Section 55 - Electrical System - Chapter 1 Diagnostic Tests NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system. ! WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or park lock position.
Section 55 - Electrical System - Chapter 1 B - Controller Relay Test 1 Test Point Unplug the Controller relay from the relay base. Ignition switch in Run. Good Reading 12 volts If good reading, continue with next step. Possible Cause of Bad Reading Open circuit 163B(R) between controller relay terminal A3 and switched power bus. Check for 12 volts at controller relay base terminal A3. 2 Ignition switch in Run or Acc. Check for 12 volts at controller relay base terminal A2.
Section 55 - Electrical System - Chapter 1 AUDIO SYSTEM Audio System Circuit Operation The audio system is a four speaker AM/FM stereo with cassette. The audio system is energized by switched power. The audio system display is linked to the instrument panel light so that it dims when the instrument panel lights are dimmed. Audio System Circuit Troubleshooting Before troubleshooting the Audio system make sure that the following operating conditions are met: A. B. C. D. E.
Section 55 - Electrical System - Chapter 1 Symptom Noisy reception, FM only Possible Cause Reference/Test Antenna G - Antenna Test Audio unit If G - Antenna Test is good, audio unit is bad. Poor reception area Poor quality/distorted sound - one or more speakers Poor quality/distorted sound from all speakers No sound from speakers Audio speaker H - Speaker Resistance Test Substitute known good speaker(s). Circuit Perform relevant speaker circuit test(s).
Section 55 - Electrical System - Chapter 1 Audio System Diagnostic Tests NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual. IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.
Section 55 - Electrical System - Chapter 1 B - Left Front Speaker Circuit Test Test point 1 2 Good Reading Possible Cause of Bad Reading Open/short to ground in circuit 873B(O) between connectors 95B and 97F. Disconnect connector 95B from the radio, and connector 97F from the left front speaker. Measure resistance between radio connector 95B, terminal 13 and left front speaker connector 97F, terminal A.
Section 55 - Electrical System - Chapter 1 D - Right Rear Speaker Circuit Test 2 Test point Good Reading Possible Cause of Bad Reading Measure resistance between speaker connector 92F, terminal B and radio connector 95B, terminal 10. Less than 1 ohm Open/short to ground in circuit 874A(B) between connectors 95B and 92F(B). If good reading, right rear speaker wiring is okay.
Section 55 - Electrical System - Chapter 1 G - Antenna Test 2 Test point Good Reading Possible Cause of Bad Reading Measure resistance from antenna ground wire to chassis ground. Less than 1 ohm Open circuit between antenna and frame ground. Antenna is good. H - Speaker Resistance Test 1 Test point Good Reading Possible Cause of Bad Reading Disconnect suspect speaker electrical connector. Between 4 and 8 ohms Bad circuit in speaker.
Section 55 - Electrical System - Chapter 1 CHARGING SYSTEM Charging System Circuit Operation The alternator B+ terminal is connected to the battery via terminal 81F on the starter motor. The alternator is grounded by its mounting frame. Terminal 86 (D+) of the alternator receives field excitation voltage from connector CN2, terminal 1 of the Instrument cluster (ICU2). Charging system output is controlled by an integral voltage regulator/brush assembly. The regulator is set to 14.2 volt regulation.
Section 55 - Electrical System - Chapter 1 Charging System Symptom Chart NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual. IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.
Section 55 - Electrical System - Chapter 1 Charging System Diagnostic Tests NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual. IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.
Section 55 - Electrical System - Chapter 1 B - Excitation Circuit (D+) Test 1 Test point Good Reading Possible Cause of Bad Reading Ignition in Off position. Less than 1 ohm Disconnect wiring from alternator connector 86 (D+) and instrument cluster connector 61. Open 121E(Y) circuit between alternator and instrument cluster. If good reading, excitation circuit wiring is okay. Continue with next test point. Measure resistance between connector 86 and connector 61 terminal 1.
Section 55 - Electrical System - Chapter 1 C - RPM Circuit Test 1 Test point Good Reading Possible Cause of Bad Reading Ignition in Off position. Less than 1 ohm Open circuit in alternator rpm circuit. Disconnect alternator connector 85 and instrument cluster connector 61. If good reading, alternator rpm circuit wiring okay. Check all connectors for full installation, loose corroded, pushed out, or bent terminals.
Section 55 - Electrical System - Chapter 1 D - Instrumentation Cluster (ICU) Excitation Control Test 1 Test point Good Reading Possible Cause of Bad Reading Place transmission in PARK. Voltage varies between 12.8 and 14.5 volts in response to load applied. Instrument Cluster (ICU2). Start engine and set at 1000 rpm. Backprobing at Instrumentation Cluster (ICU2) connector CN2 terminal 1 and measure voltage. If good reading, excitation control circuit is operating properly.
Section 55 - Electrical System - Chapter 1 EXTERIOR LIGHTING SYSTEM Exterior Lighting System Circuit Operation • Exterior lighting consists of the following: • Headlights (high beam, low beam and center) • Turn signals front and rear • Tail lights • Left and right marker lights • Cab fender work lamps • Cab front roof work lamps • High intensity discharge lamp (optional) • Cab rear fender work lamps (optional) • Cab beltline work lamps (optional) • Cab rear roof work lamps (optional) • • • The various
Section 55 - Electrical System - Chapter 1 Exterior Lighting System Symptom Chart NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system. ! WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or park lock position.
Section 55 - Electrical System - Chapter 1 Work Lamp Switch Test 6 7 Test point Good Reading Possible Cause of Bad Reading Measure voltage at rotary switch connector 12, terminal HL. 12 volts Rotary switch Rotary switch in fourth position. 12 volts Measure voltage at rotary switch connector 12, terminal W. 8 9 If good reading, go to next test point. Rotary switch If good reading, go to next test point. Measure voltage at rotary switch connector 12, terminal HL.
Section 55 - Electrical System - Chapter 1 Electronic Flasher Test 5 Test point Good Reading Possible Cause of Bad Reading Headlight switch Off. 12 volts Universal switch in left turn position. If good reading, go to test point 10. Open circuit between electronic flasher and universal switch. Go to next test point. Measure voltage at electronic flasher connector 135 terminal 5. 6 7 8 9 10 Measure voltage at in-line connector 9 terminal 2.
Section 55 - Electrical System - Chapter 1 Electronic Flasher Test 15 Test point Good Reading Possible Cause of Bad Reading Universal switch in right turn position. Test light flashes. Electronic flasher. Backprobe electronic flasher connector 135 terminal 2 with test light. 16 Universal switch in left turn position. Backprobe electronic flasher connector 135 terminal 1 with test light. 17 Headlight switch in any position (except Off).
Section 55 - Electrical System - Chapter 1 Universal Switch Test 4 5 Test point Good Reading Possible Cause of Bad Reading Place universal switch in low beam position. Less than 1 ohm. Open circuit in universal switch. Measure resistance between terminals 220D and 220F. If good reading, go to next test point. Place universal switch in head lamp dipping position. Less than 1 ohm. Measure resistance between terminals 220E and 220G. 6 Open circuit in universal switch.
Section 55 - Electrical System - Chapter 1 INSTRUMENTATION AND WARNING SYSTEM Instrumentation and Warning System Circuit Troubleshooting Before troubleshooting the instrumentation and warning system make sure that the following operating conditions are met: 1. 2. 3. 4. The batteries are fully charged and all connections are clean and tight. Transmission in neutral or park. Check all connectors for full installation, loose, corroded, pushed out, or bent terminals.
Section 55 - Electrical System - Chapter 1 Instrumentation and Warning System Diagnostic Tests NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system ✎ ! WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or park lock position.
Section 55 - Electrical System - Chapter 1 B - Engine Coolant Temperature Sensor Circuit Test 1 Test point Good Reading Possible Cause of Bad Reading Remove electrical connector J1-6 from engine coolant temperature sensor. If good reading go to next test point. Open in circuit. Check continuity from J1-6 pin A to splice EC1. 2 Check continuity from Splice EC1 to Connector J1 pin 38. If good reading go to next test point. Open in circuit from Electronic Engine Controller.
Section 55 - Electrical System - Chapter 1 C - Engine Oil Pressure Sensor Circuit Test 1 Test point Good Reading Possible Cause of Bad Reading Remove electrical connector J1-8 from engine oil pressure sensor. If good reading go to next test point. Open in circuit. If good reading and Oil Pressure Sensor does not work, replace Oil Pressure Sensor. Open in circuit. Check continuity from J1-8 pin 1 to connector J1 pin 17.
Section 55 - Electrical System - Chapter 1 INTERIOR LIGHTING AND HORN SYSTEM Interior Lighting and Horn System Circuit Operation Interior lighting consists of a switchable dome light with door switch, a switchable map light, and a console light which operates in conjunction with the Instrument Cluster lighting. The dome light can be set to either come on when the door opens or it can be switched on with an integral switch. The power source is unswitched, so the dome light can be operated at any time.
Section 55 - Electrical System - Chapter 1 Interior Lighting and Horn System Symptom Chart NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system. ! WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or park lock position.
Section 55 - Electrical System - Chapter 1 A - Horn System Circuit Test 7 8 9 10 11 12 13 Test Point Good Reading Possible Cause of Bad Reading While pressing horn switch (on universal switch), measure resistance from horn connector 412B to ground. Less than 1 ohm Open in switched ground circuit from horn. While pressing horn switch, measure resistance from in-line connector 409 terminal B to ground.
Section 55 - Electrical System - Chapter 1 B - Dome Lamp and Switch Circuit Test 1 2 3 4 5 6 Test point Good Reading Possible Cause of Bad Reading Measure voltage at dome lamp connector 102. 12 volts Open in unswitched B+ circuit. If good reading, go to test point 6. Go to next test point. Measure voltage at in-line splice between dome lamp connector 102, and in-line connector 13 terminal V. 12 volts Open in unswitched B+ circuit. If good reading, repair open in 871C(R) circuit.
Section 55 - Electrical System - Chapter 1 C - Map Light Circuit Test 1 2 3 4 5 6 7 Test point Good Reading Possible Cause of Bad Reading Measure voltage at map light connector 170 terminal A. 12 volts Open in circuit from unswitched B+. If good reading, go to test point 6. Go to next test point. Measure voltage at splice SH3. 12 volts Open in circuit from unswitched B+. If good reading, repair open in 135G(R) circuit. Go to next test point.
Section 55 - Electrical System - Chapter 1 POWER MIRROR SYSTEM Power Mirror Circuit Operation Switched power is supplied to the power mirror switch from fuse #24. Power is supplied to the mirror switch connector 130. Chassis ground is supplied to the mirror switch connector 130. The mirror switch can be set to control either left or right mirrors. This action changes the contacts within the switch in order to operate either the left or the right mirror. Only one mirror can be operated at a time.
Section 55 - Electrical System - Chapter 1 Power Mirror System Symptom Chart NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual. IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.
Section 55 - Electrical System - Chapter 1 Symptom Right mirror, in/out inoperable Possible Cause Mirror Switch Reference/Test B - Power Mirror Switch Test, test points 1, 2, 3, 4, 11 and 12. Mirror Assembly E - Right Mirror Assembly Test, test points 1, 2, 5 and 6. Circuit between switch and mirror C - First Circuit Test, test points 5 and 6, and D - Second Circuit Test, test points 4 and 5.
Section 55 - Electrical System - Chapter 1 Power Mirror System Diagnostic Tests NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual. IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.
Section 55 - Electrical System - Chapter 1 B - Power Mirror Switch Test Test point 1 2 3 Good Reading Possible Cause of Bad Reading Ignition in Run position. 12 volts Open in circuit from switched B+. Measure voltage at power mirror switch connector 130 terminal 9. If good reading, go to next test point. Perform A - Power Mirror Switch Power and Ground Supply Test Measure resistance from power mirror switch. connector 130 terminal 3 to ground.
Section 55 - Electrical System - Chapter 1 B - Power Mirror Switch Test Test point 8 Hold mirror switch in OUT position. Measure voltage at power mirror switch connector 130 terminal 7. 9 Hold mirror switch in UP position. Measure voltage at power mirror switch connector 130 terminal 8. 10 Hold mirror switch in DOWN position. Measure voltage at power mirror switch connector 130 terminal 7. 11 Set mirror selector to Right mirror. Hold mirror switch in IN position.
Section 55 - Electrical System - Chapter 1 B - Power Mirror Switch Test Test point 15 Set mirror switch to control LEFT mirror. Hold mirror switch in IN position. Good Reading Less than 1 ohm Possible Cause of Bad Reading Open in power mirror switch. If good reading, go to next test point. Measure resistance from power mirror switch connector 130 terminal 7 to ground. 16 Hold mirror switch in OUT position. Measure resistance from power mirror switch connector 130 terminal 8 to ground.
Section 55 - Electrical System - Chapter 1 C - First Circuit Test (Mirror Switch Connector 130 to In-line Connector 111 Test point 1 Remove connector 130 from power mirror switch. Disconnect in-line connector 111M from inline connector 111F. Good Reading Continuity Possible Cause of Bad Reading Open in 275A(O) circuit. If good reading, go to next test point. Set DVOM to test continuity. Check for continuity between connector 111F terminal 1 and connector 130 terminal 8.
Section 55 - Electrical System - Chapter 1 D - Second Circuit Test (Mirror Assembly Connectors 112 and 113 to In-line Connector 111) Test point 1 Remove connector 112 from left mirror assembly. Disconnect in-line connector 111M from in-line connector 111F. Good Reading Continuity Possible Cause of Bad Reading Open in 949A(O) circuit. If good reading, go to next test point. Set DVOM to test continuity. Check for continuity between connector 111M terminal 1 and connector 112 terminal 3.
Section 55 - Electrical System - Chapter 1 E - Right Mirror Assembly Test Test point 1 Perform A - Power Mirror Switch Power and Ground Supply Test. Good Reading 12 volts If good reading, go to next test point. Possible Cause of Bad Reading Open circuit between connector 113 and mirror switch. Perform C - First Circuit Test, Ignition in Run position. test point 7, and Set mirror selector to Right mirror. D - Second Circuit Test, test point 6. Hold mirror switch in IN position.
Section 55 - Electrical System - Chapter 1 E - Right Mirror Assembly Test Test point 7 Hold mirror switch in UP position. Check for continuity from right mirror connector 113 terminal 2 to ground. 8 Hold mirror switch in DOWN position. Check for continuity from right mirror connector 113 terminal 3 to ground. Good Reading Continuity Possible Cause of Bad Reading Open in power mirror switch. If good reading, go to next test point. Open in power mirror switch.
Section 55 - Electrical System - Chapter 1 F - Left Mirror Assembly Test Test point 4 Hold Mirror switch in DOWN position. Measure voltage at terminal 2 of right mirror connector 112. 5 Good Reading 12 volts Possible Cause of Bad Reading Open in power mirror switch. If good reading, go to next test point. Ignition Off. Continuity Set DVOM to measure continuity. If good reading, go to next test point. Open in power mirror switch. Hold mirror switch in IN position.
Section 55 - Electrical System - Chapter 1 POWER SEAT SYSTEM Power Seat System Circuit Operation The seat system has a power seat height adjustment using an air motor adjustment. Additionally the seat has provision for seat and back cushion heating. The seat height is adjusted with air pressure controlled with a switch. The seat cushions are heated and controlled by a switch. The switch operates as follows: The seat heaters are OFF with the heater switch in the 0 position.
Section 55 - Electrical System - Chapter 1 Power Seat System Symptom Chart NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual. IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.
Section 55 - Electrical System - Chapter 1 Power Seat System Diagnostic Tests NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual. IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.
Section 55 - Electrical System - Chapter 1 A - Seat System Power and Ground Supply Test 10 11 12 Test Point Good Reading Possible Cause of Bad Reading Measure resistance from seat connector 133 terminal 3 to ground. Less than 1 ohm Open in circuit from seat connector 133 terminal 3 to ground. Measure resistance from seat connector 133 terminal 4 to ground. Less than 1 ohm Measure resistance from seat connector 133 terminal 8 to ground. Less than 1 ohm If good reading, go to next test point.
Section 55 - Electrical System - Chapter 1 B - Height Adjustment Circuit Test 6 Test point Good Reading Possible Cause of Bad Reading Check seat height adjustment power and grounds. If power and ground supplies okay, seat height adjust switch and air pump compressor circuits have continuity, but height adjustment does not operate, replace seat air pump compressor. Open in seat power and ground supply circuits. Perform A - Seat System Power and Ground Supply Test, test points 1, 2, 10, and 11.
Section 55 - Electrical System - Chapter 1 D - Heater Switch and Relay Power and Ground Supply Test 1 2 3 4 Test point Good Reading Possible Cause of Bad Reading Ignition in Run position. 12 volts Open in circuit from switched B+. Measure voltage at seat connector 133 terminal 7. If good reading, go to test point 4. Go to next test point. Measure voltage at fuse #29. 12 volts Open in circuit from switched B+. If good reading, repair open in 259A(R) circuit. Go to next test point.
Section 55 - Electrical System - Chapter 1 STARTING SYSTEM Starting System Circuit Operation Unswitched battery power, B+ is supplied through fuse #7 to the ignition switch connector 161. When the key is turned to the START position current is supplied to the FNRP Module connector 219. If the transmission is in neutral or park current flows to the buss box starter relay, and onto the intermediate starter relay which energizes the starter relay.
Section 55 - Electrical System - Chapter 1 Symptom Engine cranks slowly Possible Cause Starter motor Reference/Test F -Starter Motor Test, test points 3, 4 and 5. Starter motor continues to operate when key is released from START to RUN position Engine mechanical problem Refer to Engine Section in Service Manual. Ignition switch. B - Ignition Switch Test, and confirm that switch turns off when key is released.
Section 55 - Electrical System - Chapter 1 Starting System Diagnostic Tests NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual. IMPORTANT: DO NOT use a self-powered test light for any of these tests.
Section 55 - Electrical System - Chapter 1 B - Ignition Switch Test 4 Test point Good Reading Possible Cause of Bad Reading Ignition switch in Run position. Continuity Ignition switch. Check for continuity from connector 161 terminal 1 to terminal 6. 5 Ignition switch in Accessory position. Check for continuity from connector 161 terminal 1 to terminal 6. 6 Ignition switch in Off position. Check for continuity from connector 161 terminal 1 to terminals 2, 3, 4, 5, 6.
Section 55 - Electrical System - Chapter 1 C - FNRP Module Test 5 Test point Good Reading Possible Cause of Bad Reading Transmission control lever in Neutral. 12 volts Park/neutral position switch, or If good reading, FNRP module okay. FNRP module Measure voltage at FNRP module connector 219 terminal 2. NOTE: Before performing the starter relay test procedure - replace the starter relay with a known good relay. If tractor start troubleshooting is complete.
Section 55 - Electrical System - Chapter 1 E - Intermediate Starter Relay Test 1 Test Point Good Reading Possible Cause of Bad Reading Ignition switch in Start position. 12 volts Open in B+ circuit from starter relay. If good reading, go to test point 5. Go to next test point. 12 volts Open in B+ circuit from starter relay. If good reading, repair open in 622A(W) circuit. Perform D Starter Relay Test. Measure voltage at intermediate starter relay connector 78.
Section 55 - Electrical System - Chapter 1 F - Starter Motor Test 1 2 Test Point Good Reading Possible Cause of Bad Reading Measure voltage at terminal 81 of starter motor. 12 volts Open circuit between starter terminal 81 and battery positive terminal. Ignition switch in Start position. 12 volts Open in B+ circuit from starter relay. If good reading, go to test point 4. Go to next test point. 12 volts Open in B+ circuit. If good reading, repair open in 625A(W) circuit.
Section 55 - Electrical System - Chapter 1 WIPER/WASHER SYSTEM Wiper/Washer System Circuit Operation The wiper/washer system consists of two separate systems, front and rear. Each system has a two speed motor and a separate washer motor and reservoir. The two systems are energized by switched power. Wiper/Washer System Circuit Troubleshooting Before troubleshooting the Wiper/Washer system make sure that the following operating conditions are met: A.
Section 55 - Electrical System - Chapter 1 Wiper/Washer System Symptom Chart NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual. IMPORTANT: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.
Section 55 - Electrical System - Chapter 1 Wiper/Washer System Diagnostic Tests NOTE: • The batteries must be fully charged and all connections clean and tight. • Use a multimeter (DVOM) for these tests. • Check fuse 52 and circuit breaker 51. • Check Power Distribution section if fuse and circuit breaker are good. • For battery testing and service, see the battery section in the service manual. • Check all listed connectors for loose, damaged corroded or pushed out terminals.
Section 55 - Electrical System - Chapter 1 B - Rear Wiper System Power and Ground Supply Test 1 Test point Good Reading Possible Cause of Bad Reading Access connector 122 on rear wiper switch. Rear wiper switch power supply good. Go to next test point. Go to next test point. Ignition ON. Check for 12 volts at cavity 3 and 6. 2 Check for 12 volts at inline connector 13, cavity K. Go to next test point. Check inline splice if sent here by test point -1, bad reading.
Section 55 - Electrical System - Chapter 1 D - Rear Wiper/Washer Switch Test 1 Test point Good Reading Possible Cause of Bad Reading Key ON. Go to next test point. Go to test point G-3. Go to next test point. Go to test point G-9. Rear wiper/washer switch good. Go to test point H-1. Select low speed on rear wiper switch. Does rear wiper motor operate at low speed? 2 Turn rear wiper switch OFF. Does rear wiper PARK? 3 Operate rear washer switch.
Section 55 - Electrical System - Chapter 1 E - Front Wiper Motor Test Test point Good Reading Possible Cause of Bad Reading 7 Check for 12 volts at front wiper switch connector 127, cavity 4. Go to next test point. Confirm switch power supply, test point A-1. If power supply is good, replace switch. 8 Check for 12 volts at inline connector 13, cavity S. Go to next test point. Open circuit 832A (O). 9 Check for 12 volts at front wiper motor connector 115, cavity A.
Section 55 - Electrical System - Chapter 1 F - Front Washer Motor Test 5 Test point Good Reading Possible Cause of Bad Reading Disconnect front washer motor connector 212. Check for chassis ground at cavity A. Replace front washer motor. Open circuit to chassis ground 600H (O). G - Rear Wiper Motor Test 1 Test point Good Reading Possible Cause of Bad Reading Key ON. Go to next test point. Go to test point G-3. Wiper motor good. Go to test point G-6. Go to next test point.
Section 55 - Electrical System - Chapter 1 H - Rear Washer Motor Test Test point Good Reading Possible Cause of Bad Reading 1 Check for 12 volts at rear wiper/washer switch connector 122, cavity 3 & 6. Go to next test point. Confirm switch power supply, test point B-1. If power supply is good, replace switch. 2 Check for 12 volts at inline connector 10, cavity 82. Go to next test step. Open circuit 845A (O). 3 Check for 12 volts at rear washer motor connector 213, cavity B.
Section 55 Chapter 2 INSTRUMENTATION CONTROLLER FAULT CODES January, 2006
Section 55 - Electrical System, Controller - Chapter 2 TABLE OF CONTENTS FAULT CODE INST 1015 .............................................................................................................................. 55-2-4 FAULT CODE INST 3010 ............................................................................................................................... 55-2-6 FAULT CODE INST 3020 ..........................................................................................................
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 13052 ........................................................................................................................... 55-2-32 FAULT CODE INST 53001 ........................................................................................................................... 55-2-33 FAULT CODE INST 53005 ...........................................................................................................................
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 1015 Seat Switch Stuck Closed Cause: The switch is located in the seat cushion. The seat switch closes when the seat is sat in and opens when the operator gets up. If the switch is closed for over 24 engine hours, this fault code will be recorded. Possible failure mode: 1. Seat switch stuck closed. 2. Seat switch wiring circuit problems. Solution: Check the seat switch function.
Section 55 - Electrical System, Controller - Chapter 2 3. Check the wiring from the instrumentation controller to the seat switch connector C133 There should be continuity from cavity 23 of connector C61 to cavity 6 of connector C133. There should be 12 VDC power supply at the cavity 5 of connector C133. NOTE: Always inspect connector ends for damaged, bent or dislocated pins when troubleshooting. NOTE: See schematic section 67 on the schematic poster.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 3010 PTO Shaft Speed Sensor Failure Cause: The Data Bus signaled that the PTO shaft speed data is in error or not available from the AUX/HITCH/PTO controller. The instrumentation controller receives the signal from the AUX/HITCH/PTO controller. Possible failure modes: 1. The PTO shaft speed sensor failed in the AUX/HITCH/PTO controller (in most cases). 2. Software execution error in the AUX/HITCH/PTO controller (small chance).
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 3020 Engine Speed Sensor Failed in Engine Controller Cause: The Data Bus signaled that the engine speed data is in error or not available from the engine controller. Possible failure modes: 1. The engine speed sensor failed in the engine controller (most cases). 2. The engine controller is configured in the system where there is no engine controller. 3. Software execution error in the engine controller (small chance).
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 5011 Engine Oil Pressure Sensor Signal Too Low Cause: The engine oil pressure sensor signal voltage is out of range low (the signal was below 0.25 volts for 1 second). Possible failure modes: 1. Engine oil pressure sensor failed. 2. Engine oil pressure sensor wiring harness problems (open circuit, short to ground). 3. Instrument controller failure.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 10031 Controller Memory Error Cause: Controller memory error - loss of valid engine hours EEPROM checksum. Possible failure modes: Memory defect or intermittent controller. Solution: 1. When the valid engine hours are lost in the controller memory (EEPROM checksum), the controller will reset engine hour meter to 50000.0 hours to highlight the failure. It will continue counting the hours from that point. 2.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 10034 Controller Memory Error Cause: Controller memory error: loss of valid fuel table information. Possible failure modes: 1. Updated software without loading new fuel table. 2. Memory defect or intermittent controller. Solution: Use the service tool fuel update screen to load a new fuel table into the instrumentation controller. Clear the fault codes. NOTE: Updating software to a later version requires loading a new fuel table.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 10037 Controller Memory Error - Loss of Valid Implement Width Information Cause: Controller memory error: Loss of implement width information. Possible failure mode: 1. Intermittent controller - power supply or ground. 2. Controller memory defect. Solution: Verify power and ground to the controller. Adjust the implement width. 1. Make sure the controller has a good connection (CN-2) and the battery is properly grounded. 2.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 11011 Fuel Level Sensor Signal Too Low Cause: Fuel level sensor signal voltage out of range low (The signal was below 0.125 volts for 1 second). Possible failure mode: 1. Fuel level sensor failure. 2. Fuel level sensor wiring harness problems. 3. Instrument controller failure. Solution: Check the fuel sensor resistance and the wiring from the instrumentation controller to the fuel level sensor. 1.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 12011 Communication Lost With Armrest Controller Cause: Communication lost between the instrumentation controller and the armrest controller. Possible failure modes: 1. Bad connection between the instrumentation controller and the armrest controller. 2. Controller failure Solution: Make sure both the armrest controller and the instrument controller function properly. Check the data bus connections. 1.
Section 55 - Electrical System, Controller - Chapter 2 5. Use a multimeter to check the resistance on both can bus resistor terminators. The resistance at AUX/Hitch/ PTO controller connector C053 from pin 15 to 16 should be 120 ohms. The resistance at the engine end resistor terminator plug pin 1 to 2 should also be 120 ohms. 6. Split the Data Bus by disconnecting connector C333. Turn the key switch to OFF, then to ON. A. If none of the controllers come back on line, the problem is inside the cab.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 12043 Communication Lost With Data Bus and all Other Controllers Cause: The instrumentation controller has found that it cannot communicate with the Data Bus. Possible failure modes: 1. Data Bus is not powered. 2. Data Bus is shorted. 3. Passive terminator failed. Solution: Make sure the instrumentation controller is properly connected with the Data Bus. Check the Data Bus function. 1. Check the function of the instrument controller. A.
Section 55 - Electrical System, Controller - Chapter 2 A. If none of the controllers come back on line, the problem is inside the cab. Check the Data bus wiring in the cab for open circuits or shorts to ground. If the problem cannot be found in the wiring, disconnect each controller one at a time to determine if one of the controllers has failed. B. If all of the controllers except the engine controller come back online, the problem is the Data Bus external to the cab.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 12051 Communication Lost With Aux/Hitch/PTO Controller Cause: Communication lost between the instrumentation controller and the Aux/Hitch/PTO controller. Possible failure modes: 1. Bad connection between the instrumentation and Aux/Hitch/PTO controller. 2. Controller failure. Solution: Make sure both the Aux/Hitch/PTO controller and the instrumentation controller are functioning properly. Check the Data Bus connections. 1.
Section 55 - Electrical System, Controller - Chapter 2 A. If none of the controllers come back on line, the problem is inside the cab. Check the Data bus wiring in the cab for open circuits or shorts to ground. If the problem cannot be found in the wiring, disconnect each controller one at a time to determine if one of the controllers has failed. B. If all of the controllers except the engine controller come back online, the problem is the Data Bus external to the cab.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 12071 Communication Lost With Transmission Controller Cause: Comminution is lost between the instrumentation controller and the transmission controller. Possible failure mode: 1. Bad connection between instrumentation controller and transmission controller. 2. Controller failure. Solution: Make sure both the transmission controller and the instrumentation controller are functioning properly. Check the Data Bus connections. 1.
Section 55 - Electrical System, Controller - Chapter 2 A. If none of the controllers come back on line, the problem is inside the cab. Check the Data bus wiring in the cab for open circuits or shorts to ground. If the problem cannot be found in the wiring, disconnect each controller one at a time to determine if one of the controllers has failed. B. If all of the controllers except the engine controller come back online, the problem is the Data Bus external to the cab.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 12091 Communication Lost With Engine Controller Cause: Communication lost between the instrumentation controller and the engine controller. Possible failure modes: 1. Bad connection between the instrumentation controller and the engine controller. 2. Controller failure. Solution: Make sure both the engine controller and the instrumentation controller are functioning properly. Check the Data Bus connections. 1.
Section 55 - Electrical System, Controller - Chapter 2 5. Use a multimeter to check the resistance on both can bus resistor terminators. The resistance at AUX/Hitch/ PTO controller connector C053 from pin 15 to 16 should be 120 ohms. The resistance at the engine end resistor terminator plug pin 1 to 2 should also be 120 ohms. 6. Split the Data Bus by disconnecting connector C333. Turn the key switch to OFF, then to ON. A. If none of the controllers come back on line, the problem is inside the cab.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 12111 Communication Lost With ATC Controller Cause: The instrumentation controller has found that it cannot communicate with the ATC Controller. Possible failure modes: 1. Data Bus is not powered. 2. Data Bus is shorted. 3. Passive terminator failed. 4. Cab pressure blower relay failed. Solution: Replace the cab pressure blower relay with a known good relay. Replace the relay if fault code can now be erased.
Section 55 - Electrical System, Controller - Chapter 2 4. Use a multimeter to check the resistance on both can bus resistor terminators. The resistance at AUX/Hitch/ PTO controller connector C053 from pin 15 to 16 should be 120 ohms. The resistance at the engine end resistor terminator plug pin 1 to 2 should also be 120 ohms. 5. Split the Data Bus by disconnecting connector C333. Turn the key switch to OFF, then to ON. A. If none of the controllers come back on line, the problem is inside the cab.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 13010 Engine Coolant Temperature Sensor Failed in Engine Controller Cause: The Data Bus signaled that engine coolant temperature data is in error or not available from the engine controller. Possible failure modes: 1. Engine coolant temperature sensor failed in the engine controller. 2. The engine controller is configured into the instrumentation controller when there is no engine controller. 3.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 13011 Engine Coolant Temperature Sensor Signal Too Low Cause: Engine coolant temperature sensor voltage out of range low. Possible failure modes: 1. Engine coolant temperature sensor failed. 2. Engine coolant temperature sensor wiring harness problems (short to ground). 3. Instrument controller failure.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 13012 Engine Coolant Temperature Sensor Signal Too High Cause: Engine coolant temperature sensor voltage out of range high. Possible failure modes: 1. Engine coolant temperature sensor failed. 2. Engine coolant temperature sensor wiring harness problems (open circuit, short to power). 3. Instrument controller failure.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 13021 Transmission Oil Temperature Sensor Signal Too Low Cause: Transmission oil temperature sensor voltage out of range low. Possible failure modes: 1. Transmission oil temperature sensor failed. 2. Transmission oil temperature sensor wiring harness problems (short to ground). 3. Instrument controller failure.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 13022 Transmission Oil Temperature Sensor Signal Too High Cause: Transmission oil temperature sensor voltage out of range high. Possible failure modes: 1. Transmission oil temperature sensor failed. 2. Transmission oil temperature sensor wiring harness problems (open circuit, short to power). 3. Instrument controller failure.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 13040 Air Intake Temperature Sensor Failed in Engine Controller Cause: The Data Bus signaled that the air to air intake temperature data is in error or not available from the engine controller. Possible failure modes: 1. Air to air intake sensor failed in the engine controller. 2. The engine controller is configured in the instrumentation controller when there is no engine controller. 3.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 13051 Air To Air Intake Temperature Sensor Signal Too Low Cause: Air to air intake temperature sensor voltage out of range low. Possible failure modes: 1. Air to air intake oil temperature sensor failed. 2. Air to air intake oil temperature sensor wiring harness problems (short to ground). 3. Instrument controller failure.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 13052 Air To Air Intake Temperature Sensor Signal Too High Cause: Air to air intake temperature sensor voltage out of range high. Possible failure modes: 1. Air to air intake oil temperature sensor failed. 2. Air to air intake oil temperature sensor wiring harness problems (open circuit, short to power). 3. .Instrument controller failure.
Section 55 - Electrical System, Controller - Chapter 2 FAULT CODE INST 53001 Standard Instrumentation Configuration Is Incorrect Cause: This fault code is recorded if any controller is detected on the Data Bus but was not set to exist in the instrument controller configuration menu. Possible failure mode: 1. A controller is added to the Data Bus but the instrumentation controller is not recalibrated. 2. The standard instrumentation is calibrated without selecting all the controllers on the Data Bus.
Section 55 - Electrical System, Controller - Chapter 2 55-2-34
Section 55 Chapter 3 AUX / HITCH / PTO FAULT CODES TRACTOR MULTI FUNCTION (TMF) CONTROLLER January, 2006
Section 55 - Electrical System, Controller - Chapter 3 TABLE OF CONTENTS AUX/HITCH/PTO FAULT CODE 2 ................................................................................................................. 55-3-7 AUX/HITCH/PTO FAULT CODE 4 ................................................................................................................. 55-3-8 AUX/HITCH/PTO FAULT CODE 5 .................................................................................................................
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 43 ............................................................................................................. 55-3-32 AUX/HITCH/PTO FAULT CODE 44 ............................................................................................................. 55-3-32 AUX/HITCH/PTO FAULT CODE 45 .............................................................................................................
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 89 ............................................................................................................. 55-3-50 AUX/HITCH/PTO FAULT CODE 90 ............................................................................................................. 55-3-51 AUX/HITCH/PTO FAULT CODE 92 .............................................................................................................
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 133 ........................................................................................................... 55-3-72 AUX/HITCH/PTO FAULT CODE 134 ........................................................................................................... 55-3-73 AUX/HITCH/PTO FAULT CODE 135 ...........................................................................................................
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 166 ........................................................................................................... 55-3-96 AUX/HITCH/PTO FAULT CODE 167 .......................................................................................................... 55-3-97 AUX/HITCH/PTO FAULT CODE 168 ...........................................................................................................
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 2 Hitch Raise Solenoid Shorted To 12 Volts Cause: The hitch raise solenoid or its wiring is shorted to 12 volts. Possible failure modes: 1. Wiring from the hitch controller to the hitch raise solenoid shorted to 12 volts. 2. Hitch raise solenoid failure. Solution: Check the hitch raise solenoid resistance and the continuity from the hitch controller to the hitch raise solenoid. 1.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 4 Hitch Raise Solenoid Failed Open Or Shorted To Ground Cause: The hitch raise solenoid or its wiring has failed open or is shorted to ground. Possible failure modes: 1. Wiring from the hitch controller to the hitch raise solenoid has open circuit or short to ground. 2. Hitch raise solenoid failure. Solution: Check the hitch raise solenoid resistance and the continuity from the hitch controller to the hitch raise solenoid. 1.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 5 Hitch Lower Solenoid Shorted To 12 Volts Cause: The hitch lower solenoid or its wiring is shorted to 12 volts. Possible failure modes: 1. Wiring from the hitch controller to the hitch lower solenoid shorted to 12 volts. 2. Hitch lower solenoid failure. Solution: Check the hitch lower solenoid resistance and the continuity from the hitch controller to the hitch lower solenoid. 1.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 7 Hitch Raise/Lower Solenoids Circuit Failed Open, Or Short To Ground Possible failure mode: 1. Wiring problem from the hitch controller to the solenoids. 2. Both raise and lower solenoids failed. Solution: The chance for both raise and lower solenoids to fail at the same time is rare. If fault code hitch 4 exists, check the single solenoid resistance and its wiring harness.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 11 AUX/Hitch/PTO Controller is Disconnected from Can Bus Cause: AUX/Hitch/PTO controller has found that is cannot communicate with the Tractor Data Bus. Possible failure modes: 1. Tractor Data Bus does not have power or ground. 2. Tractor Data Bus is shorted to power or ground. 3. Resistor Terminator failed. 4. AUX/Hitch/PTO controller failed.
Section 55 - Electrical System, Controller - Chapter 3 4. Use a multimeter to check the resistance on both can bus resistor terminators. The resistance at AUX/Hitch/ PTO controller connector C053 from pin 15 to 16 should be 120 ohms. The resistance at the engine end resistor terminator plug pin 1 to 2 should also be 120 ohms. 5. Split the Data Bus by disconnecting connector C333. Turn the key switch to OFF, then to ON. A. If none of the controllers come back on line, the problem is inside the cab.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 12 Communication Lost With The Armrest Controller Cause: AUX/Hitch/PTO controller is not receiving or recognizing information from the armrest controller. Possible failure modes: 1. Bad connection between AUX/Hitch/PTO controller and the armrest controller. 2. Controller failure. Solution: Make sure both the armrest controller and the AUX/Hitch/PTO controller are functioning OK. Check the Data Bus connections. 1.
Section 55 - Electrical System, Controller - Chapter 3 A. If none of the controllers come back on line, the problem is inside the cab. Check the Data bus wiring in the cab for open circuits or shorts to ground. If the problem cannot be found in the wiring, disconnect each controller one at a time to determine if one of the controllers has failed. B. If all of the controllers except the engine controller come back online, the problem is the Data Bus external to the cab.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 15 5 Volt Reference is Below the Lower Voltage Limit Cause: The 5 volt reference voltage is monitored and is consistently less than 4.2 volts. Possible failure mode: 1. Short circuit to ground or an open circuit. 2. No power or ground to AUX/Hitch/PTO controller. Other low voltage fault codes will be recorded. Solution: 1. Check the power supply to the Tractor Data Bus. A. Check fuse #42. B.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 17 Hitch Position Command Potentiometer Failure Cause: The Data Bus signaled that the hitch position command potentiometer has failed. The hitch controller received the signal from the armrest controller. Possible failure modes: 1. The hitch position command potentiometer failed in the armrest controller (in most cases). 2. Software execution error in the armrest controller (small chance).
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 18 Rockshaft Position Potentiometer Is Outside Normal Operating Range Cause: The hitch rockshaft position potentiometer signal difference between the fully lowered and fully raised position is not within specifications. Possible failure modes: 1. Rock shaft potentiometer failed. 2. Wiring harness damage. 3. Potentiometer’s linkage problem. 4. Mechanical interference.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 19 Upper Limit Potentiometer Failure Cause: The Data Bus signaled that the upper limit potentiometer has failed. The hitch controller received the signal from the armrest controller. Possible failure modes: 1. The upper limit potentiometer failed in the armrest controller (in most cases). 2. Software execution error in the armrest controller (small chance).
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 22 Single Draft Pin Sensor Failed When Configured For One Draft Pin Sensor Cause: The hitch controller has detected a problem with the draft pin signal. Possible failure modes: 1. Draft pin failed. 2. Wiring problem from the hitch controller to the draft pin. If the problem is intermittent the draft function is disabled until the next engine start up.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 23 Both Draft Pins Failed Cause: Both draft pins failed when tractor is configured for two draft pins. Possible failure modes: 1. Draft pin failure. 2. Wiring problem. If the problem is intermittent, the draft function is disabled until the next engine start up. Solution: The chance for both draft pins to fail at the same time is rare. If fault code hitch 30 or hitch 31 exists, check the single pin function or its wiring.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 24 Communication Lost With The Instrument Controller Cause: The AUX/Hitch/PTO controller is not receiving or recognizing information from the instrumentation controller. Possible failure codes: 1. Bad connection between AUX/Hitch/PTO controller and the instrument controller. 2. Controller failure. Solution: Make sure both the instrument controller and the AUX/Hitch/PTO controller functioning OK. Check the Data Bus connections.
Section 55 - Electrical System, Controller - Chapter 3 A. If none of the controllers come back on line, the problem is inside the cab. Check the Data bus wiring in the cab for open circuits or shorts to ground. If the problem cannot be found in the wiring, disconnect each controller one at a time to determine if one of the controllers has failed. B. If all of the controllers except the engine controller come back online, the problem is the Data Bus external to the cab.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 26 Up/Down Fender Switch Failure Cause: Hitch UP/DOWN fender switch failure. Possible failure modes: 1. Both switches are pushed together. 2. Switch was pushed before engine start up. 3. Switch was pushed while tractor was moving. 4. Switch Up was pushed when the hitch is against the upper limit setting. 5. Switch Down was pushed when the hitch is against the lower limit setting.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 28 Travel Range Potentiometer Failure Cause: The Data Bus signaled that the travel range potentiometer has failed. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure modes: 1. The travel range potentiometer failed in the armrest controller (in most cases). 2. Software execution error in the armrest controller (small chance).
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 30 Right Draft Pin Voltage is Outside The Normal Operating Range Cause: During calibration, the ’No Load’ offset voltage is out of range for right draft pin. The draft control requires that the ’No load’ voltage is 3.00 +/- 0.05 volts to ensure the draft quality. The hitch controller will check it during calibration. Possible failure modes: 1. Right draft pin failed. 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 31 Left Draft Pin No Load Offset Voltage Outside Normal Range See 58 Cause: During calibration, the ’No Load’ offset voltage is outside normal range for left draft pin. The draft control requires that the ’No load’ voltage is 3.00 +/- 0.05 volts to ensure the draft quality. The hitch controller will check it during calibration. Possible failure modes: 1. Left draft pin failed. 2.
Section 55 - Electrical System, Controller - Chapter 3 c) At the draft pin side, measure the continuity of the pin circuit. The resistance should be 180 kohm across A and C and 18 kohm across B and C. NOTE: Always inspect connector ends for damaged, bent or dislocated pins when troubleshooting. NOTE: The resistances at the draft pin side are for reference only. Incorrect resistance means a bad pin but some bad pins may have correct resistances. NOTE: See schematic sections 51 and 52 on the schematic poster.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 32 Ground Speed Failure, Value Received From Data Bus Indicates Failure Condition Cause: The Data Bus signaled that the transmission speed sensor has failed. The AUX/Hitch/PTO controller received the signal from the instrumentation controller. Possible failure mode: 1. The transmission speed sensor failed (in most cases). 2. Software execution error in instrumentation controller (small chance).
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 33 Slip Set Switch Failure Cause: The Data Bus signaled that the slip set switch has failed. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure modes: 1. The slip set switch failed in the armrest controller (in most cases). 2. Software execution error in the armrest controller (small chance). Solution: The slip set switch is hard wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 35 Percent Slip Error Cause: The percent wheel slip is determined by the difference between the wheel speed and the ground speed. The AUX/ Hitch/PTO controller receives the information from the instrumentation controller through the Data Bus. Possible failure modes: 1. Wheel slip sensing (radar gun, wheel speed sensor) failed (in most cases). 2. Percent slip calculation failed in instrumentation controller (small chance).
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 37 The ARU reports EDC Transport Lock is Faulty or Not Available Cause: The armrest controller reports to the AUX/Hitch/PTO controller that the Electronic Draft Control transport lock is faulty or unavailable. The transport lock function control is built into the hitch drop rate control potentiometer. Possible failure modes: 1. The hitch drop rate control potentiometer failed. 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 42 Engine Speed Too Low For Hitch Lower Calibration Cause: For hitch lower calibration, the engine speed has to be above 1500 RPM. If the engine speed is lower than 1500 RPM during hitch lower calibration, this fault code is recorded. Solution: 1. Be sure the engine speed is above 1500 RPM and recalibrate the hitch.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 47 PWM Raise Threshold Is Too High During Calibration Cause: During calibration, PWM threshold to start hitch raising is above the limit (55%). Possible failure modes: 1. Raise solenoid coil resistance is too high. 2. Wire harness or connector problem between hitch raise solenoid and hitch controller. 3. Battery voltage is very low. 4. Hitch valve raise portion is stuck closed.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 50 Hitch Pot Signal Not Within Expected Range For Maximum Hitch Position Cause: During calibration full raise current out of range. Possible failure modes: 1. Raise solenoid coil resistance is to low. 2. Battery voltage is very high. Solution: Make sure the calibration procedure is correct. Then do the following for troubleshooting. 1. Test battery voltage and the alternator output voltage (must be less than 14.7 volts DC). 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 52 Hitch Lower Valve Threshold Is Too Low During Calibration Cause: During calibration, PWM threshold to start hitch lower is below the limit (6%). Possible failure modes: 1. Lower solenoid coil resistance is too low. 2. Battery voltage is very high. 3. Valve failure. Solution: Make sure the calibration procedure is correct. Then do the following for troubleshooting. 1.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 54 Hitch Position Is Not At Minimum Cause: During calibration, the hitch rockshaft position potentiometer signal at the fully lowered position is not within specifications. Possible failure modes: 1. Mechanical interference prevents hitch from moving fully down. 2. Rock shaft potentiometer failed. 3. Wiring harness damage. 4. Potentiometer’s linkage problem.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 55 Range Of The Hitch Position Is Not Within Specification Cause: During calibration, the hitch rockshaft position potentiometer signal difference between the fully lowered and fully raised position is not within specifications. Possible failure modes: 1. Rock shaft potentiometer failed. 2. Wiring harness damage. 3. Potentiometer’s shaft loose from the lever. 4. Mechanical interference.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 56 Ratio Of Position Command To Rockshaft Range Is Not Within Specification Cause: During calibration, the ratio of rockshaft position range to position command potentiometer range is not within specifications. Possible failure modes: 1. Rockshaft potentiometer has failed. 2. Rockshaft potentiometers shaft is loose from the lever. 3. Position command potentiometer failed at the arm controller. 4.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 57 Right Draft Pin No Load Offset Voltage Out Of Range Cause: During calibration, the ’No Load’ offset voltage is out of range for right draft pin. The draft control requires that the ’No load’ voltage is 3.00 +/- 0.05 volts to ensure the draft quality. The AUX/Hitch/PTO controller will check it during calibration. Possible failure modes: 1. Right draft pin failed. 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 58 Left Draft Pin No Load Offset Voltage Outside Normal Range Cause: During calibration, the ’No Load’ offset voltage is outside normal range for left draft pin. The draft control requires that the ’No load’ voltage is 3.00 +/- 0.05 volts to ensure the draft quality. The AUX/Hitch/PTO controller will check it during calibration. Possible failure modes: 1. Left draft pin failed. 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 59 ‘No Load’ Offset Voltage Out Of Range For Both Draft Pins Cause: During calibration, the ’No Load’ offset voltage is out of normal range for both draft pins. Possible failure mode: 1. Draft pin failure. 2. Wiring problem. Solution: The chance for both draft pins to fail at the same time is rare. If fault code AUX/Hitch/PTO 57 or AUX/Hitch/PTO 58 exists, check the single pin function or its wiring.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 61 AUX/Hitch/PTO Controller Requires Calibration Cause: The AUX/Hitch/PTO controller requires calibration. New controller requires calibration, or current software does not match with NVM. Solution: 1. Recalibrate the AUX/Hitch/PTO controller.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 64 8 Volt Reference is Below 7.2 Volts Cause: The 8 volt reference voltage is monitored and is consistently less than 7.2 volts. Possible failure mode: 1. Open circuit or short to ground. Solution: 1. Turn the key switch ON. Disconnect connector C057 on the AUX/Hitch/PTO controller. Use a multimeter to check the voltage from pin 25 and pin 31 on the controller to ground. A. It should read approximately 8 volts at both pins.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 66 12VF Voltage Supply is Below 8 Volts Possible failure mode: 1. Battery voltage is too low. 2. Alternator regulator malfunction. 3. The controller has a bad connection to power or is not grounded properly. Solution: Check for battery voltage, fuse #36, alternator regulator output, and the controller connection to power and ground. 1. Check for AUX/Hitch/PTO fault codes 65, 98 and 99.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 81 MFD Solenoid High Side Driver is Commanded On But No current Was Sensed Possible failure modes: 1. Valve solenoid coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: Check the valve solenoid resistance and the wiring from the AUX/Hitch/PTO controller to the valve solenoid. 1. Test the resistance of the valve solenoid at the valve connector C160. Disconnect connector C160.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 82 Diff Lock Solenoid High Side Driver is Commanded On But No Current Was Sensed Possible failure modes: 1. Valve solenoid coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: Check the valve solenoid resistance and the wiring from the AUX/Hitch/PTO controller to the valve solenoid. 1. Test the resistance of the valve solenoid at the valve connector C158.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 83 Brake Light Relay High Side Driver is Commanded On But No Current Was Sensed Possible failure modes: 1. Brake light relay coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: 1. Locate the brake light relay and replace with a known good relay. A. Erase the fault code. If the problem does not return troubleshooting is complete. B. Changing the relay made no difference.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 86 Wheel Slip Sensing Error In The Instrumentation Controller Cause: The percent slip is decided by the difference between the wheel speed and the ground speed. The AUX/Hitch/PTO controller receives the slip signal information from the instrumentation controller through the Data Bus. Possible failure mode: 1. Wheel slip sensing (radar gun, wheel speed sensor) failed (in most cases). 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 87 Ground Speed Signal Failed In The Instrumentation Controller Cause: The Data Bus signaled that the transmission speed sensor has failed. The AUX/Hitch/PTO controller received the signal from the instrumentation controller. Possible failure mode: 1. The transmission speed sensor failed (in most cases). 2. Software execution error in instrumentation controller (small chance).
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 88 Auto Differential Switch is Faulty Cause: The Data Bus signaled that the Diff lock switch has failed. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure mode: 1. The diff lock switch failed in the armrest controller (in most cases). 2. Software execution error in the armrest controller (small chance). Solution: The Diff lock switch is hard wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 90 Both Differential Lock Auto and On Switches are Active Cause: The Data Bus signaled that the difflock switches have failed. The PTO controller received the signal from the armrest controller. Possible failure mode: 1. The Diff lock switch failed in the armrest controller (in most cases). 2. Software execution error in the armrest controller (small chance).
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 93 Both Auto MFD and MFD On Switches are Active Cause: The Data Bus signaled that the MFD switches have failed. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure mode: 1. The MFD switch failed in the armrest controller (in most cases). 2. Software execution error in the armrest controller (small chance). Solution: The MFD switch is hard wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 98 12VD Voltage Supply is Below 8 Volts Possible failure mode: 1. Battery voltage is too low. 2. Alternator regulator malfunction. 3. The controller has a bad connection to power or is not grounded properly. Solution: Check for battery voltage, fuse #39, alternator regulator output, and the controller connection to power and ground. 1. Check for AUX/Hitch/PTO fault codes 65, 66 and 99.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 106 The AUX/Hitch/PTO Controller Has Received The Electro Hydraulic #5 Control Extend Switch Data In The Error State Cause: The Data Bus signaled that AUX 5 extend switch data (the 5th remote hydraulic valve control) is set to the error state. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure modes: 1. AUX 5 extend switch has failed in the armrest controller (in most cases). 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 108 Electro Hydraulic Remote #1 Lever Position Control Pot Data Is Set To The Error State Cause: The Data Bus signaled that AUX 1 lever potentiometer (the 1st remote hydraulic valve control) is set to the error state. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure modes: 1. AUX 1 lever potentiometer has failed in the armrest controller (in most cases). 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 110 Electro Hydraulic Remote #3 Lever Position Control Pot Data Is Set To The Error State Cause: The Data Bus signaled that AUX 3 lever potentiometer (the 3rd remote hydraulic valve control) is set to the error state. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure modes: 1. AUX 3 lever potentiometer has failed in the armrest controller (in most cases). 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 112 Electro Hydraulic Remote #1 Lever Flow Control Pot Data Is Set To The Error State Cause: The Data Bus signaled that AUX 1 flow limit potentiometer (the 1st variable flow control) is set to error state. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure modes: 1. AUX 1 flow limit potentiometer has failed in the armrest controller (in most cases). 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 113 Electro Hydraulic Remote #2 Lever Flow Control Pot Data Is Set To The Error State Cause: The Data Bus signaled that AUX 2 flow limit potentiometer (the 2nd variable flow control) is set to error state. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure modes: 1. AUX 2 flow limit potentiometer has failed in the armrest controller (in most cases). 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 114 Electro Hydraulic Remote #3 Lever Flow Control Pot Data Is Set To The Error State Cause: The Data Bus signaled that AUX 3 flow limit potentiometer (the 3rd variable flow control) is set to error state. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure modes: 1. AUX 3 flow limit potentiometer has failed in the armrest controller (in most cases). 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 115 Electro Hydraulic Remote #4 Lever Flow Control Pot Data Is Set To The Error State Cause: The Data Bus signaled that AUX 4 flow limit potentiometer (the 4th variable flow control) is set to error state. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure modes: 1. AUX 4 flow limit potentiometer has failed in the armrest controller (in most cases). 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 116 Electro Hydraulic Remote #5 Lever Flow Control Pot Data Is Set To The Error State Cause: The Data Bus signaled that AUX 5 flow limit potentiometer (the 5th variable flow control) is set to error state. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure modes: 1. AUX 5 flow limit potentiometer has failed in the armrest controller (in most cases). 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 120 Electro Hydraulic Remote Top Link Switch Is Stuck On Cause: The Data Bus signaled that the top link switches remain closed (ON). Possible failure mode: 1. A Top link switch failed (in most cases). 2. Software execution error in the AUX/Hitch/PTO controller (small chance). Solution: The top link switch is hard wired to the AUX/Hitch/PTO controller. 1.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 124 Aux #1 Driver is On And No Current Is Sensed, Retract /Lower Coil Open Or Shorted to Ground Possible failure modes: 1. Valve solenoid coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: Check the valve solenoid resistance and the wiring from the AUX/Hitch/PTO controller to the valve solenoid. 1. Test the resistance of the valve solenoid at the valve connector C340.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 125 Current Sensed When The Aux #1 Driver Is Off, Extend /Raise Coil Shorted to 12 Volts Cause: When the lever for this remote section is in Neutral, the controller should provide no voltage to the solenoid. If the controller senses voltage on the circuit, this fault code is recorded. Possible failure modes: 1. Damaged wiring resulting short to power. 2. Controller internal failure.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 126 Aux #1 Driver is On And No Current Is Sensed, Extend /Raise Coil Open Or Shorted to Ground Possible failure modes: 1. Valve solenoid coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: Check the valve solenoid resistance and the wiring from the AUX/Hitch/PTO controller to the valve solenoid. 1. Test the resistance of the valve solenoid at the valve connector C140.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 127 Current Sensed When The Aux #2 Driver Is Off, Retract /Lower Coil Shorted to 12 volts Cause: When the lever for this remote section is in Neutral, the controller should provide no voltage to the solenoid. If the controller senses voltage on the circuit, this fault code is recorded. Possible failure modes: 1. Damaged wiring resulting short to power. 2. Controller internal failure.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 128 Aux #2 Driver is On And No Current Is Sensed, Retract /Lower Coil Open Or Shorted to Ground Possible failure modes: 1. Valve solenoid coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: Check the valve solenoid resistance and the wiring from the AUX/Hitch/PTO controller to the valve solenoid. 1. Test the resistance of the valve solenoid at the valve connector C341.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 129 Current Sensed When The Aux #2 Driver Is Off, Extend /Raise Coil Shorted to 12 volts Cause: When the lever for this remote section is in Neutral, the controller should provide no voltage to the solenoid. If the controller senses voltage on the circuit, this fault code is recorded. Possible failure modes: 1. Damaged wiring resulting short to power. 2. Controller internal failure.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 130 Aux #2 Driver is On And No Current Is Sensed, Extend /Raise Coil Open Or Shorted to Ground Possible failure modes: 1. Valve solenoid coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: Check the valve solenoid resistance and the wiring from the AUX/Hitch/PTO controller to the valve solenoid. 1. Test the resistance of the valve solenoid at the valve connector C141.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 131 Current Sensed When The Aux #3 Driver Is Off, Retract /Lower Coil Shorted to 12 Volts Cause: When the lever for this remote section is in Neutral, the controller should provide no voltage to the solenoid. If the controller senses voltage on the circuit, this fault code is recorded. Possible failure modes: 1. Damaged wiring resulting short to power. 2. Controller internal failure.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 132 Aux #3 Driver is On And No Current Is Sensed, Retract /Lower Coil Open Or Shorted to Ground Possible failure modes: 1. Valve solenoid coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: Check the valve solenoid resistance and the wiring from the AUX/Hitch/PTO controller to the valve solenoid. 1. Test the resistance of the valve solenoid at the valve connector C342.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 133 Current Sensed When The Aux #3 Driver Is Off, Extend /Raise Coil Shorted to 12 Volts Cause: When the lever for this remote section is in Neutral, the controller should provide no voltage to the solenoid. If the controller senses voltage on the circuit, this fault code is recorded. Possible failure modes: 1. Damaged wiring resulting short to power. 2. Controller internal failure.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 134 Aux #3 Driver is On And No Current Is Sensed, Extend /Raise Coil Open Or Shorted to Ground Possible failure modes: 1. Valve solenoid coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: Check the valve solenoid resistance and the wiring from the AUX/Hitch/PTO controller to the valve solenoid. 1. Test the resistance of the valve solenoid at the valve connector C142.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 135 Current Sensed When The Aux #4 Driver Is Off, Retract /Lower Coil Shorted to 12 volts Cause: When the lever for this remote section is in Neutral, the controller should provide no voltage to the solenoid. If the controller senses voltage on the circuit, this fault code is recorded. Possible failure modes: 1. Damaged wiring resulting short to power. 2. Controller internal failure.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 136 Aux #4 Driver is On And No Current Is Sensed, Retract /Lower Coil Open Or Shorted to Ground Possible failure modes: 1. Valve solenoid coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: Check the valve solenoid resistance and the wiring from the AUX/Hitch/PTO controller to the valve solenoid. 1. Test the resistance of the valve solenoid at the valve connector C343.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 137 Current Sensed When The Aux #4 Driver Is Off, Extend /Raise Coil Shorted to 12 volts Cause: When the lever for this remote section is in Neutral, the controller should provide no voltage to the solenoid. If the controller senses voltage on the circuit, this fault code is recorded. Possible failure modes: 1. Damaged wiring resulting short to power. 2. Controller internal failure.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 138 Aux #4 Driver is On And No Current Is Sensed, Extend /Raise Coil Open Or Shorted to Ground Possible failure modes: 1. Valve solenoid coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: Check the valve solenoid resistance and the wiring from the AUX/Hitch/PTO controller to the valve solenoid. 1. Test the resistance of the valve solenoid at the valve connector C143.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 139 Current Sensed When The Aux #5 Driver Is Off, Retract /Lower Coil Shorted to 12 volts Cause: When the lever for this remote section is in Neutral, the controller should provide no voltage to the solenoid. If the controller senses voltage on the circuit, this fault code is recorded. Possible failure modes: 1. Damaged wiring resulting short to power. 2. Controller internal failure.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 140 Aux #5 Driver is On And No Current Is Sensed, Retract /Lower Coil Open Or Shorted to Ground Possible failure modes: 1. Valve solenoid coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: Check the valve solenoid resistance and the wiring from the AUX/Hitch/PTO controller to the valve solenoid. 1. Test the resistance of the valve solenoid at the valve connector C344.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 141 Current Sensed When The Aux #5 Driver Is Off, Extend /Raise Coil Shorted to 12 Volts Cause: When the lever for this remote section is in Neutral, the controller should provide no voltage to the solenoid. If the controller senses voltage on the circuit, this fault code is recorded. Possible failure modes: 1. Damaged wiring resulting short to power. 2. Controller internal failure.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 142 Aux #5 Driver is On And No Current Is Sensed, Extend /Raise Coil Open Or Shorted to Ground Possible failure modes: 1. Valve solenoid coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: Check the valve solenoid resistance and the wiring from the AUX/Hitch/PTO controller to the valve solenoid. 1. Test the resistance of the valve solenoid at the valve connector C144.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 147 Out Of Range Error High On The #1 Feedback Cause: The #1 section feedback voltage is greater than 4.5 volts. The AUX/Hitch/PTO controller generated this fault code. Possible failure modes: 1. Damaged wiring resulting short to power. 2. Controller internal failure. Solution: 1. Check the wiring from the AUX/Hitch/PTO controller back to scraper controls, or implement.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 149 Out Of Range Error High On The #2 Feedback Cause: The #2 section feedback voltage is greater than 4.5 volts Possible failure modes: 1. Damaged wiring resulting short to power. 2. Controller internal failure. Solution: 1. Check the wiring from the AUX/Hitch/PTO controller back to scraper controls, or implement. Check for damage, chaffed wires that could result in a short circuit to power. 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 151 No Data Transmission From ETC Is Received Cause: AUX/Hitch/PTO controller is not receiving data from Electronic Transmission Controller. Possible failure modes: 1. Tractor Data Bus does not have power or ground. 2. Tractor Data Bus is shorted to power or ground. 3. Resistor Terminator failed. 4. transmission controller failed. Solution: Make sure the transmission controller and Tractor Data Bus are functioning properly. 1.
Section 55 - Electrical System, Controller - Chapter 3 4. Use a multimeter to check the resistance on both can bus resistor terminators. The resistance at AUX/Hitch/ PTO controller connector C053 from pin 15 to 16 should be 120 ohms. The resistance at the engine end resistor terminator plug pin 1 to 2 should also be 120 ohms. A. If none of the controllers come back on line, the problem is inside the cab. Check the Data bus wiring in the cab for open circuits or shorts to ground.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 152 EHR Top Link Switch Short Cause: The Data Bus signaled that the top link switches remain closed (ON). The top link switch is hard wired to the AUX/ Hitch/PTO controller. Possible failure mode: 1. Operator depressed both retract and extend switch at same time. 2. Failed switch. Solution: 1. If both retract and extend were depressed at same time, erase fault code and continue operation. If not continue with step 2. 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 154 PTO Switch Interlock Cause: The Data Bus signaled that the PTO switch in cab and the PTO fender switch were both activated within 2 seconds. The PTO switches are hard wired to the AUX/Hitch/PTO controller. Possible failure mode: 1. Operator activated PTO switch in cab, second person activated PTO fender switch. 2. Failed switch. Solution: 1. Operate PTO from either cab, or remote fender switch.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 156 Auto PTO Switch Stuck On Condition Cause: The Data Bus signaled that Auto PTO switch is stuck ON. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure modes: 1. Bad Auto PTO switch. 2. Software execution error in the armrest controller (small chance). Solution: 3. Connect the service tool to the tractor Data Bus, do the following: Go to the Monitor screen by click the Monitor Icon.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 158 PTO Remote Fender Switch Open Cause: The Data Bus signaled that a PTO remote fender switch is stuck open. The PTO remote switches are hard wired to the AUX/Hitch/PTO controller. NOTE: AUX/Hitch/PTO fault code 159 may also be recorded. Possible failure modes: 1. Bad remote PTO switch. 2. Software execution error in the armrest controller (small chance). Solution: 1.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 160 PTO Clutch Is Slipping Excessively For The Duration Of 5 Seconds Or Longer Cause: The PTO controller monitors the PTO clutch input and output speed. This fault code is recorded when the difference of the input and output is beyond the limit. Possible failure mode: 1. PTO load too heavy. 2. PTO clutch pressure too low. 3. PTO speed sensor or its wiring harness failure. 4. Incorrect engine RPM signal from the alternator.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 161 PTO RPM Is Too High Cause: The PTO controller monitors the PTO clutch input and output speed. This fault code is recorded when the PTO controller has detected a PTO speed that is 20% higher than expected for more than 2 seconds. Possible failure modes: 1. PTO load is driving the PTO. 2. Wrong signal from the shaft speed sensor. 3. Incorrect alternator installed.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 162 Engine Speed Is Too Low For The PTO To Be In The On State Cause: The engine speed is at 0 RPM and the PTO is in the On state. Possible failure mode: 1. The engine has either stalled out, or has been shutdown. Solution: Determine the cause of the engine shutdown. Restart engine and erase fault code. Continue PTO operations.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 163 PTO Is Commanded Off But The PTO Speed Is Greater Than Zero Cause The PTO controller monitors the PTO clutch output speed. This fault code is recorded if the PTO controller has detected PTO shaft rotation when PTO is turned off for 45 seconds. Possible failure mode: 1. The PTO brake not functioning. 2. The clutch is not really turned off. 3. Implement attached to tractor had caused the PTO to turn. 4.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 164 The Software Has Not Detected PTO Shaft Speed For 3.6 Seconds Since The PTO Initial Fill Valve Was Commanded Cause: The PTO controller monitors the PTO clutch output speed. This fault code is triggered if the PTO controller does not detect PTO shaft rotation after engagement. Possible failure mode: 1. PTO shaft locked up by the implement. 2. PTO solenoid is not energized or spool stuck in the OFF position. 3.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 165 PTO Speed Is Detected When The PTO Is In The Off State Without Engine RPM Cause: The PTO controller monitors the PTO clutch output speed. This fault code is recorded if the PTO controller has detected PTO shaft rotation when engine is off. Possible failure mode: 1. Implement attached to tractor caused the PTO to turn. 2. PTO speed sensor or its wiring harness failure.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 166 PTO Driver Is On And No Current Is Sensed Possible failure modes: 1. PTO solenoid coil failed. 2. Damaged wiring. 3. Loose connector or bent pin. 4. Controller internal failure. Solution: Check the PTO solenoid resistance and the wiring from the AUX/Hitch/PTO controller to the PTO solenoid. 1. Test the resistance of the PTO solenoid at the valve connector C159. Disconnect connector C159.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 167 Current Sensed When PTO Driver Is Off Cause: When the PTO switch is OFF the controller should provide no voltage to the solenoid. If the controller senses voltage on the circuit, this fault code is recorded. Possible failure modes: 1. Damaged wiring resulting short to power. 2. Controller internal failure. Solution: 1.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 168 PTO Off Switch Data Is Set To The Error State Cause: The Data Bus signaled that PTO switch data is set to error state. The AUX/Hitch/PTO controller received the signal from the armrest controller. Possible failure modes: 1. Bad PTO switch. 2. Software execution error in the armrest controller (small chance). Solution: 1. Erase fault code. Continue PTO function and continue operation. Continue with next step if needed. 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 169 Both PTO On And Off Switches Are Simultaneously Off, One of the PTO Switches Is Shorted To Ground Cause: The PTO switches in armrest are both simultaneously off, one switch may be shorted to ground or a wire maybe open. The PTO switch in armrest is hard wired to AUX/Hitch/PTO controller. Possible failure mode: 1. The PTO on/off switch failed in the armrest controller (in most cases). 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 170 Both PTO On And Off Switches Are Simultaneously On, One of the PTO Switches Is Shorted To 12 Volts Cause: The PTO switches in armrest are both simultaneously on, one switch may be shorted to 12 volts. The PTO switch in armrest is hard wired to AUX/Hitch/PTO controller. Possible failure mode: 1. The PTO on/off switch failed in the armrest controller (in most cases). 2.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 171 PTO Software Fault Condition Detected Cause: The AUX/Hitch/PTO controller has flagged a PTO software fault condition. Solution: Calibrate the AUX/Hitch/PTO controller again. If the same fault code is logged after calibration, change the controller. Calibrate the AUX/Hitch/PTO controller again.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 173 PTO Solenoid Circuit Shorted To Ground When PTO Is In Off State Cause: The AUX/Hitch/PTO controller has detected a short to ground at PTO solenoid, when PTO is in OFF state. Possible failure mode: 1. The PTO clutch solenoid coil shorted to ground 2. PTO clutch solenoid wiring shorted to ground. Solution: Disconnect the PTO valve solenoid connector C159. 1. Check the wiring harness end pin 1 to ground.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 174 Current Flowing In The Sense Resistor When The High Side Was Off Cause: The sense resistor is an internal component in the AUX/Hitch/PTO controller. There should be no current flow in the sense resistor when the high side is off. Possible failure modes: 1. Bad AUX/Hitch/PTO controller. Solution: Replace AUX/Hitch/PTO controller.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 175 PTO Clutch Did Not Lock Up After 6 Seconds Of Clutch Motion Cause: The AUX/Hitch/PTO controller monitors the PTO clutch input and output speed. This fault code is recorded when the PTO does not reach lock up speed within 6 seconds of being turned on. Possible failure modes: 1. PTO load too heavy. 2. PTO clutch pressure too low. 3. PTO solenoid is not energized. 4. PTO speed sensor and its wiring harness failure. 5.
Section 55 - Electrical System, Controller - Chapter 3 5. Check the wiring harness to the PTO shaft speed sensor. Check the continuity from Pin 20 of connector C058 to Pin A of connector C145. Check the continuity from Pin B of connector C145 to the chassis ground. 6. Check the function of the PTO speed sensor. It should have resistance of about 3 K ohms. NOTE: Always inspect connector ends for damaged, bent or dislocated pins when troubleshooting.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 178 PTO Speed Sensor Has Been Changed Cause: The PTO speed sensor has been changed. Possible failure modes: 1. PTO clutch frequency is less than the PTO shaft size frequency. Solution: Calibrate the PTO speed configuration.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 179 PTO Is Configured As A Two Speed And No Shaft Size Frequency Was Detected When The PTO Was Switched On Cause: The module is receiving no frequency from the shaft size sensor when configured as a two speed PTO tractor. Possible failure mode: 1. The PTO system is equipped with only shaft speed sensor but configures as two speed system. 2. PTO shaft size sensor is not well connected or failed. 3.
Section 55 - Electrical System, Controller - Chapter 3 AUX/HITCH/PTO FAULT CODE 180 PTO Is Configured As A Single Speed And Shaft Size Frequency Was Detected When The PTO Was Switched On, Shaft Size Frequency Input Is Only Used For Two Speed PTO Cause: The module is receiving frequency from the shaft size sensor when configured as a single speed PTO tractor. Possible failure mode: 1. The PTO system is equipped with shaft size frequency but configures as single speed system. 2.
Section 55 Chapter 4 TRANSMISSION CONTROLLER FAULT CODES (INCLUDES SUSPENDED AXLE) January, 2006
Section 55 - Electrical System, Controller - Chapter 4 TABLE OF CONTENTS FAULT CODE TRANS 11 ............................................................................................................................... 55-4-5 FAULT CODE TRANS 12 ............................................................................................................................... 55-4-6 FAULT CODE TRANS 24 ............................................................................................................
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 82 ............................................................................................................................. 55-4-36 FAULT CODE TRANS 83 ............................................................................................................................. 55-4-36 FAULT CODE TRANS 103 ...........................................................................................................................
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 130 ........................................................................................................................... 55-4-60 FAULT CODE TRANS 131 ........................................................................................................................... 55-4-61 FAULT CODE TRANS 132 ...........................................................................................................................
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 11 Master Clutch Potentiometer Open Circuit or Short to Ground Cause: The transmission controller has detected that the clutch (inching) pedal potentiometer signal is out of range low. Possible failure mode: 1. The pedal position potentiometer failure. 2. Wire harness of the inching pedal potentiometer failed open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 12 Master Clutch Potentiometer Short to 12 Volts or Short to 5 Vreff Cause: The transmission controller has detected that the clutch (inching) pedal potentiometer signal is out of range high. Possible failure mode: 1. The pedal position potentiometer failed. 2. The wire harness of the inching pedal potentiometer is shorted to power.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 24 The Transmission Clutches Are Not Calibrated Cause: Transmission clutches have not been calibrated Solution: Clear the fault codes and perform the calibration procedure. If the fault code still appears after the calibration procedure is completed replace the Transmission controller.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 37 BOC switch open circuit or Neutral relay stuck open Cause: Fault code 37 is recorded when the clutch pedal position is above 30%, shuttle lever is in Forward or Reverse, and the controller does not detect +12V from bottom of clutch relay. Possible failure mode: 1. Neutral relay failure 2. Bottom of clutch switch failed open 3. No power supply to the Neutral Relay 4.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 38 Shuttled to reverse when no wheel speed signal Cause: This fault code will be recorded when the operator attempts to shuttle to reverse from 13 gear forward or higher and there is Fault code 77 (no transmission output RPM signal). Solution: Correct the no transmission output RPM signal fault following the trouble-shooting procedures for fault code 77. Otherwise, shift to forward or cycle the shuttle lever.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 47 Clutch Position Sensor Not Agree With BOC Switch Cause: The position sensor of the inching clutch pedal does not agree with the bottom of clutch (BOC) switch. Possible failure mode: 1. Mechanical misadjusted inching pedal, its position potentiometer, or BOC switch. 2. Bottom of clutch switch, its relay, or their wiring failure. 3. Inching pedal position potentiometer or its wiring failure.
Section 55 - Electrical System, Controller - Chapter 4 There should be continuity from pin 40 to chassis ground (resistance less than 3 ohms). If it does work as specified, replace the transmission controller. 5. Test the function of bottom of clutch switch, its relay and the wiring. NOTE: Always inspect connector ends for damaged, bent or dislocated pins when troubleshooting.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 48 BOC switch or Neutral relay short circuit Cause: Fault code 48 is recorded when the clutch pedal position is below 5%, shuttle lever is in Forward OR Reverse, and the controller detected +12V from bottom of clutch relay. Possible failure mode: 1. Neutral relay stuck closed 2. Bottom of clutch switch stuck closed 3. Wiring shorted to power. Solution: 1. Replace the Neutral relay (relay #6) with a known good relay.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 49 Auto Guidance Isolation Valve Driver Fault Cause: The high side driver has detected an open circuit, or is in thermal shutdown (short circuit). Possible failure mode: 1. Bad auto guidance solenoid. 2. Damaged wiring to auto guidance solenoid. Solution: 1. Disconnect the auto guidance solenoid valve connector C074. Use a multimeter to check the resistance of the coil. A good reading is 5 to 10 ohms.
Section 55 - Electrical System, Controller - Chapter 4 FAULT COE TRANS 50 Park Brake is powered off when in park Cause: The park brake is spring applied. It is hydraulically disengaged when 12 V is applied to the Park solenoid. Fault code 50 is recorded when the transmission controller turned the power off to the Park relay (in Park position) but sensed 12 v at the Park Brake coil. Possible failure mode: 1. Park relay stuck closed or shorted internally 2. Wiring shorted to power. Solution: 1.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 51 FNRP pod indicates forward OR reverse is on when Park is on Cause: If Park switch is off (indicating tractor is in Park) and either Forward or Reverse switch are in ON position (indicating tractor is in Forward or Reverse) at the same time, this fault code will be generated. Possible failure modes: 1. The transmission control (FNRP) pot failure 2.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 52 Park Brake is stuck on when commanded off Cause: The park brake is spring applied. It is hydraulically disengaged when 12 V is applied to the Park solenoid. Fault code 52 is recorded when the transmission controller turned the power on to the Park relay (Tractor shifted out of Park and powered off the Park brake) but sensed no power at the Park Brake coil. Possible failure mode: 1. Park relay stuck open or failed internally 2.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 53 5 Volt Reference Voltage Too High Cause: The transmission controller provides 5 volts to the FNRP pod and the Master clutch pedal pot through pin 16 and pin 17 of connector C351. The controller monitors the voltage at the two pins. If the voltage is higher than 5.8 volts, this fault code will be recorded. Possible failure modes: 1. Wiring harness shorted to power externally. 2. Internal problem with the transmission controller.
Section 55 - Electrical System, Controller - Chapter 4 If no problem can be found in steps 1 to 4, clear all the Trans fault codes. Disconnect connector 351, turn Key On, and check for fault 53 again. If fault code 53 appears again, it is an internal problem with the transmission controller. If fault code 53 does not appear any more, the problem must still be external. Repeat step 1 to 4.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 54 5 volt reference voltage too low Cause: The transmission controller provides 5 volt to the FNRP pod and the Master clutch pedal pot through pin 16 and pin 17 of connector C351. The controller monitors the voltage at the two pins. If the voltage is lower than 4.2 volts, this fault code will be recorded. Possible failure modes: 1. Wiring harness has shortage to ground. 2. Internal problem with the transmission controller.
Section 55 - Electrical System, Controller - Chapter 4 If fault code 54 appears again, it is an internal problem with the transmission controller. If fault code 54 does not appear any more, the problem must still be external. Repeat step 1 to 4.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 59 FNRP pod in illogical state (two position on at same time) Cause: If FNRP pot indicates two of the three positions (Neutral, Forward, and Reverse) are in ON position at the same time, the transmission controller will record this fault code. Possible failure modes: 1. The transmission control (FNRP) pot failure 2. Wiring harness problem from the transmission control (FNRP) pot to the transmission controller.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 60 FNRP pod in illogical state (in no position) Cause: If FNRP pot indicates not in neutral, not in forward, and not in reverse for 2.5 seconds, the transmission controller will record this fault code. Possible failure modes: For NH8: 1. The FNR lever may be stuck in between positions. For MU8: 1. The operator may be holding the lever up for too long. 2. The transmission control (FNRP) pot failure 3.
Section 55 - Electrical System, Controller - Chapter 4 Follow the wiring schematics. Conduct continuity checking (in a similar way to the way specified in step 2) between pins at each connectors. NOTE: Pay attention to bent pin, loose pin, wire damage, and any possible shortage between pins and wires FAULT CODE TRANS 66 FNRP Pod Forward switch is shorted to ground or open circuit Cause: If the Forward signal voltage from FNRP pot is detected too low, the transmission controller will record this fault code.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 67 FNRP Pod Forward switch is shorted to power Cause: If the Forward signal voltage from FNRP pot is detected too high, the transmission controller will record this fault code. Possible failure modes: 1. The transmission control (FNRP) pot failure 2. Wiring harness problem from the transmission control (FNRP) pot to the transmission controller.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 68 FNRP Pod Reverse switch is shorted to ground or open circuit Cause: If the Reverse signal voltage from FNRP pot is detected too low, the transmission controller will record this fault code. Possible failure modes: 1. The transmission control (FNRP) pot failure 2. Wiring harness problem from the transmission control (FNRP) pot to the transmission controller.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 69 FNRP Pod Reverse switch is shorted to power Cause: If the Reverse signal voltage from FNRP pot is detected too high, the transmission controller will record this fault code. Possible failure modes: 1. The transmission control (FNRP) pot failure 2. Wiring harness problem from the transmission control (FNRP) pot to the transmission controller.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 70 Battery voltage is too low for clutch solenoid operation Cause: The transmission controller monitors the power supply. If the voltage drops to 9 volts, this fault code will be recorded and transmission will shift to neutral. Possible failure modes: 1. Battery voltage low. 2. Alternator regulator malfunction. 3. The controller has a bad connection to power or is not grounded properly.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 73 Software is Out of Calibration Mode And Park Brake Request is Still Active. Cause: Transmission clutches are at maximum pressure and the park brake is ON. Possible failure modes: 1. Software issue. 2. Controller failed. Solution: Download latest software version for transmission controller. FAULT CODE TRANS 74 The Park Brake is Commanded ON and Gear is Engaged, But There is No Park Brake Request From Calibration.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 77 No signal from wheel speed sensor Cause: If the transmission controller detected the wheel speed sensor signal is too weak or does not exist, this fault code will be recorded. Possible failure modes: 1. Wheel speed sensor problem. 2. Wiring harness problem between the wheel speed sensor and the transmission controller.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 78 Transmission regulated pressure accumulator is discharged Cause: The transmission controller monitors the regulated system pressure. If the pressure drops below normal range during shifts, this fault code will be recorded. Possible failure modes: 1. Transmission regulated pressure accumulator is discharged (most likely). 2. Extensive internal clutch leaks (Rare case).
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 79 Engine RPM from the alternator is measured too high Cause: If the transmission controller detected the engine speed exceeds 3000 RPM, this fault code will be recorded. Possible failure modes: 1. Tractor was in over-speed condition, such as run down hill with load. 2. Faulty signal. Solution: The engine speed signal is from the W terminal of the alternator. The RPM is displayed on the ICU.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 80 wheel speed sensor is measured too high Cause: If the transmission controller detected the transmission output RPM (wheel speed sensor signal) is too high for the desired gear, this fault code will be recorded. Possible failure modes: 1. Tractor was in over-speed condition, such as run down hill with load. 2. Wheel speed sensor problem. 3. Wiring harness problem between the wheel speed sensor and the transmission controller.
Section 55 - Electrical System, Controller - Chapter 4 Take pin 34 out of connector 351 with all other part of harness connected, the signal from the wheel speed sensor can be checked. The signal from the wheel speed sensor is in sinusoidal form. The sensor has to be properly installed onto transmission (turn all way in) to give enough signal. With key ON, but tractor not moving, the signal will show around 2.5 V DC and almost 0 V AC.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 81 transmission clutches are slipping Cause: If the transmission controller detected the output speed is too low for gear selected, this fault code will be recorded. Possible failure mode: 1. Failed transmission speed sensor. 2. Solenoid mechanically not being turned ON (sticking). 3. Low hydraulic system pressure. 4. Leaking transmission clutch. 5. Failed master clutch. 6. Failed shaft in transmission.
Section 55 - Electrical System, Controller - Chapter 4 Locate the transmission speed sensor on top of the transmission. Disconnect connector C069 from the sensor. Inspect the connector. Clean the connection. Measure the sensor resistance between pin A and Pin B. The resistance should be around 3 k ohms at 20 degree Celsius. If the resistance is not in the specified range, replace the transmission speed sensor.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 82 Creep Clutch is not calibrated Cause: Creep Clutch is not calibrated Solution: Clear the fault codes and calibrate the Creep Clutch. FAULT CODE TRANS 83 Governor is off line CAN Bus Cause: Transmission controller has lost communication with engine controller. Solution: Check the engine and transmission controller connectors. Make sure the connectors are properly connected and that there are no broken wires or loose pins.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 103 Odd Clutch Solenoid Or Its Wiring Failed Open Or Shorted To Ground Possible failure mode: 1. The odd clutch solenoid coil failed open. 2. Odd clutch solenoid wiring failed open or shorted to ground. Solution: The transmission controller measures the current draw from the odd clutch solenoid circuit. If the current draw is lower than a limit, it means the circuit is open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 104 Even Clutch Solenoid Or Its Wiring Failed Open Or Shorted To Ground Possible failure mode: 1. The even clutch solenoid coil failed open. 2. Even clutch solenoid wiring failed open or shorted to ground. Solution: The transmission controller measures the current draw from the even clutch solenoid circuit. If the current draw is lower than a limit, it means the circuit is open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 105 C1-2 Clutch Solenoid Or Its Wiring Failed Open Or Shorted To Ground Possible failure mode: 1. The C1-2 clutch solenoid coil failed open. 2. C1-2 clutch solenoid wiring failed open or shorted to ground. Solution: The transmission controller measures the current draw from the C1-2 clutch solenoid circuit. If the current draw is lower than a limit, it means the circuit is open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 106 C3-4 Clutch Solenoid Or Its Wiring Failed Open Or Shorted To Ground Possible failure mode: 1. The C3-4 clutch solenoid coil failed open. 2. C3-4 clutch solenoid wiring failed open or shorted to ground. Solution: The transmission controller measures the current draw from the C3-4 clutch solenoid circuit. If the current draw is lower than a limit, it means the circuit is open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 107 C5-6 Clutch Solenoid Or Its Wiring Failed Open Or Shorted To Ground Possible failure mode: 1. The C5-6 clutch solenoid coil failed open. 2. C5-6 clutch solenoid wiring failed open or shorted to ground. Solution: The transmission controller measures the current draw from the C5-6 clutch solenoid circuit. If the current draw is lower than a limit, it means the circuit is open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 108 Master Clutch Solenoid Circuit Failed Open Or Shorted To Ground Possible failure mode: 1. The master clutch solenoid coil failed open. 2. Master clutch solenoid wiring failed open or shorted to ground. Solution: The transmission controller measures the current draw from the master clutch solenoid circuit. If the current draw is lower than a limit, it means the circuit is open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 109 Low clutch Solenoid Or Its Wiring Failed Open Or Shorted To Ground Possible failure mode: 1. The low clutch solenoid coil failed open. 2. Low clutch solenoid wiring failed open or shorted to ground. Solution: The transmission controller measures the current draw from the low clutch solenoid circuit. If the current draw is lower than a limit, it means the circuit is open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 110 Mid Clutch Solenoid Or Its Wiring Failed Open Or Shorted To Ground Possible failure mode: 1. The mid clutch solenoid coil failed open. 2. Mid clutch solenoid wiring failed open or shorted to ground. Solution: The transmission controller measures the current draw from the mid clutch solenoid circuit. If the current draw is lower than a limit, it means the circuit is open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 111 High Clutch Solenoid Or Its Wiring Failed Open Or Shorted To Ground Possible failure mode: 1. The high clutch solenoid coil failed open. 2. High clutch solenoid wiring failed open or shorted to ground. Solution: The transmission controller measures the current draw from the high clutch solenoid circuit. If the current draw is lower than a limit, it means the circuit is open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 112 Reverse Clutch Solenoid Circuit Failed Open Or Shorted To Ground Possible failure mode: 1. The reverse clutch solenoid coil failed open. 2. Reverse clutch solenoid wiring failed open or shorted to ground. Solution: The transmission controller measures the current draw from the reverse clutch solenoid circuit. If the current draw is lower than a limit, it means the circuit is open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 113 Creeper Clutch Solenoid Circuit Failed Open Or Shorted To Ground Possible failure mode: 1. The creeper clutch solenoid coil failed open. 2. Creeper clutch solenoid wiring failed open or shorted to ground. Solution: The transmission controller measures the current draw from the creeper clutch solenoid circuit. If the current draw is lower than a limit, it means the circuit is open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 114 Even Clutch Solenoid Coil Shorted Or Its Wiring Shorted To Power Cause: The transmission controller has turned Even clutch solenoid OFF but sensed current in the circuit. Possible failure mode: 1. The Even clutch solenoid coil shorted to power. 2. Even clutch solenoid wiring shorted to power. Solution: The transmission controller measures the current from the even clutch solenoid circuit.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 115 Odd Clutch Solenoid Coil Shorted Or Its Wiring Shorted To Power Cause: The transmission controller has turned odd clutch solenoid OFF but sensed current in the circuit. Possible failure mode: 1. The odd clutch solenoid coil shorted to power. 2. Odd clutch solenoid wiring shorted to power. Solution: The transmission controller measures the current from the odd clutch solenoid circuit.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 116 C1-2 Clutch Solenoid Coil Shorted Or Its Wiring Shorted To Power Cause: The transmission controller has turned C1-2 clutch solenoid OFF but sensed current in the circuit. Possible failure mode: 1. The C1-2 clutch solenoid coil shorted to power. 2. C1-2 clutch solenoid wiring shorted to power. Solution: The transmission controller measures the current from the C1-2 clutch solenoid circuit.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 117 C3-4 Clutch Solenoid Coil Shorted Or Its Wiring Shorted To Power Cause: The transmission controller has turned C3-4 clutch solenoid OFF but sensed current in the circuit. Possible failure mode: 1. The C3-4 clutch solenoid coil shorted to power. 2. C3-4 clutch solenoid wiring shorted to power. Solution: The transmission controller measures the current from the C3-4 clutch solenoid circuit.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 118 C5-6 Clutch Solenoid Coil Shorted Or Its Wiring Shorted To Power Cause: The transmission controller has turned C5-6 clutch solenoid OFF but sensed current in the circuit. Possible failure mode: 1. The C5-6 clutch solenoid coil shorted to power. 2. C5-6 clutch solenoid wiring shorted to power. Solution: The transmission controller measures the current from the C5-6 clutch solenoid circuit.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 119 Master Clutch Solenoid Coil Shorted Or Its Wiring Shorted To Power Cause: The transmission controller has turned master clutch solenoid OFF but sensed current in the circuit. Possible failure mode: 1. The master clutch solenoid coil shorted to power. 2. Master clutch solenoid wiring shorted to power. Solution: The transmission controller measures the current from the master clutch solenoid circuit.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 120 Low Clutch Solenoid Coil Shorted Or Its Wiring Shorted To Power Cause: The transmission controller has turned low clutch solenoid OFF but sensed current in the circuit. Possible failure mode: 1. The low clutch solenoid coil shorted to power. 2. Low clutch solenoid wiring shorted to power. Solution: The transmission controller measures the current from the low clutch solenoid circuit.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 121 Mid Clutch Solenoid Coil Shorted Or Its Wiring Shorted To Power Cause: The transmission controller has turned mid clutch solenoid OFF but sensed current in the circuit. Possible failure mode: 1. The mid clutch solenoid coil shorted to power. 2. Mid clutch solenoid wiring shorted to power. Solution: The transmission controller measures the current from the mid clutch solenoid circuit.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 122 High Clutch Solenoid Coil Shorted Or Its Wiring Shorted To Power Cause: The transmission controller has turned high clutch solenoid OFF but sensed current in the circuit. Possible failure mode: 1. The high clutch solenoid coil shorted to power. 2. High clutch solenoid wiring shorted to power. Solution: The transmission controller measures the current from the high clutch solenoid circuit.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 123 Reverse Clutch Solenoid Coil Shorted Or Its Wiring Shorted To Power Cause: The transmission controller has turned reverse clutch solenoid OFF but sensed current in the circuit. Possible failure mode: 1. The reverse clutch solenoid coil shorted to power. 2. Reverse clutch solenoid wiring shorted to power. Solution: The transmission controller measures the current from the reverse clutch solenoid circuit.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 124 Creeper Clutch Solenoid Coil Shorted Or Its Wiring Shorted To Power Cause: The transmission controller has turned creeper clutch solenoid OFF but sensed current in the circuit. Possible failure mode: 1. The creeper clutch solenoid coil shorted to power. 2. Creeper clutch solenoid wiring shorted to power. Solution: The transmission controller measures the current from the creeper clutch solenoid circuit.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 125 Odd Clutch is not calibrated Cause: Odd Clutch is not calibrated Solution: Clear the fault codes and calibrate the Odd Clutch. If the fault code still appears after the Odd clutch is properly calibrated, please contact TSG. FAULT CODE TRANS 126 Even Clutch is not calibrated Cause: Even Clutch is not calibrated Solution: Clear the fault codes and calibrate the Even Clutch.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 128 C3-4 Clutch is not calibrated Cause: C3-4 Clutch is not calibrated Solution: Clear the fault codes and calibrate the C3-4 Clutch. If the fault code still appears after the C3-4 clutch is properly calibrated, please contact TSG. FAULT CODE TRANS 129 C5-6 Clutch is not calibrated Cause: C5-6 Clutch is not calibrated Solution: Clear the fault codes and calibrate the C5-6 Clutch.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 131 Mid Range Clutch is not calibrated Cause: Mid Clutch is not calibrated Solution: Clear the fault codes and calibrate the Mid Clutch. If the fault code still appears after the Mid clutch is properly calibrated, please contact TSG. FAULT CODE TRANS 132 High Range Clutch is not calibrated Cause: High Clutch is not calibrated Solution: Clear the fault codes and calibrate the High Clutch.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 134 Master Clutch is not calibrated Cause: Master Clutch is not calibrated Solution: Clear the fault codes and calibrate the Master Clutch. If the fault code still appears after the Master clutch is properly calibrated, please contact TSG.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 135 Communication lost with the armrest controller Cause: Communication lost between transmission controller and armrest controller. Possible Failure modes: 1. Bad Can Bus connection between the transmission controller and armrest controller. 2. Controller failure. Solution: Make sure both the transmission controller and armrest controller are functioning OK. Check the Data Bus connections. 1.
Section 55 - Electrical System, Controller - Chapter 4 At cavity 16, the green wire, it should read from 2.2 to 2.5 volts. If the above checks are ok and all controllers came online, it means that the engine end resistor terminator and the data bus wiring are functioning correctly. The AUX/Hitch/PTO controller resistor terminator has most likely failed. Test the AUX/Hitch/PTO resistor terminator and replace if it has failed. 5. Use a multimeter to check the resistance on both can bus resistor terminators.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 136 Communication lost with the instrumentation controller Cause: Communication lost between transmission controller and instrumentation controller. Possible Failure modes: 1. Bad Can Bus connection between the transmission controller and instrumentation controller. 2. Controller failure. Solution: Make sure both the transmission controller and instrumentation controller are functioning OK. Check the Data Bus connections. 1.
Section 55 - Electrical System, Controller - Chapter 4 If the above checks are ok and all controllers came online, it means that the engine end resistor terminator and the data bus wiring are functioning correctly. The AUX/Hitch/PTO controller resistor terminator has most likely failed. Test the AUX/Hitch/PTO resistor terminator and replace if it has failed. 5. Use a multimeter to check the resistance on both can bus resistor terminators.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 137 Front Suspension upper lock solenoid circuit shorted or open circuit Cause: The transmission controller monitors the upper lock solenoid circuit. If the transmission controller detected open circuit or too much current draw in circuit, this fault code will be recorded. Possible failure mode: 1. The upper lock solenoid coil failed. 2. The upper lock solenoid wiring failed open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 138 Front Suspension Raise solenoid circuit shorted or open circuit Cause: The transmission controller monitors the Raise solenoid circuit. If the transmission controller detected open circuit or too much current draw in circuit, this fault code will be recorded. Possible failure mode: 1. The Raise solenoid coil failed. 2. The Raise solenoid wiring failed open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 139 Front Suspension Lower solenoid circuit shorted or open circuit Cause: The transmission controller monitors the Lower solenoid circuit. If the transmission controller detected open circuit or too much current draw in circuit, this fault code will be recorded. Possible failure mode: 1. The Lower solenoid coil failed. 2. The Lower solenoid wiring failed open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 140 front suspension position is above the expected absolute limit Cause: The transmission controller monitors the front axle potentiometer circuit. If the transmission controller detected the voltage is above 4.74 Volts, this fault code will be recorded. Possible failure mode: 1. The front suspension position is above the absolute limit. 2. The front axle position sensor failed. 3.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 141 front suspension position is below the expected absolute limit Cause: The transmission controller monitors the front axle potentiometer circuit. If the transmission controller detected the voltage is below 0.74 Volts, this fault code will be recorded. Possible failure mode: 1. The front suspension position is below the absolute limit. 2. The front axle position sensor failed. 3.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 142 Front suspension travel range has not been calibrated Cause: Front suspension travel range is not calibrated Solution: Clear the fault codes and calibrate the front suspension travel range. FAULT CODE TRANS 143 Front suspension position is above the upper suspension range Cause: The transmission controller monitors the front axle potentiometer circuit. If the transmission controller detected the voltage is 0.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 144 Front suspension position is below the lower suspension range Cause: The transmission controller monitors the front axle potentiometer circuit. If the transmission controller detected the voltage is 0.62 Volts below the mid calibrated point for 30 seconds, this fault code will be recorded. Solution: 1. Check if the front suspension position has been below the lower range for too long.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 145 Front Suspension lower lock solenoid circuit shorted or open circuit Cause: The transmission controller monitors the lower lock solenoid circuit. If the transmission controller detected open circuit or too much current draw in circuit, this fault code will be recorded. Possible failure mode: 1. The lower lock solenoid coil failed. 2. The lower lock solenoid wiring failed open or shorted to ground.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 147 Regulated system pressure below 290 PSI Cause: The transmission controller monitors the regulated system pressure. If the pressure drops below 290 PSI, this fault code will be recorded. Possible failure modes: 1. Transmission regulated pressure dropped. 2. Pressure sensor or its circuit has problem. Solution: 1. Check the transmission regulated pressure. See section 8001.
Section 55 - Electrical System, Controller - Chapter 4 The engaging of the transmission may cause sudden movement of the tractor. Execute extreme caution when engaging the tractor to avoid personal damage. Do the test only when the tractor can be moved safely. 4. Troubleshooting the system pressure sensor and its circuit. Clear fault codes. Disconnect the sensor at connector C044. Shorting pin C to pin A at the harness side and run the tractor. This fault code should not reappear.
Section 55 - Electrical System, Controller - Chapter 4 FAULT CODE TRANS 148 Backup alarm circuit shorted or open Cause: The transmission controller monitors the backup alarm circuit. If the transmission controller detected open circuit or too much current draw in the backup alarm circuit, this fault code will be recorded. Possible failure mode: 1. The backup alarm failed. 2. The backup alarm wiring failed open or shorted to ground. Solution: 1. Remove the controller cover from the rear of the tractor.
Section 55 - Electrical System, Controller - Chapter 4 55-4-78
Section 55 Chapter 5 ARMREST CONTROLLER FAULT CODES January, 2006
Section 55 - Electrical System, Controller - Chapter 5 TABLE OF CONTENTS FAULT CODE ARM 19 ................................................................................................................................... 55-5-4 FAULT CODE ARM 29 ................................................................................................................................... 55-5-5 FAULT CODE ARM 39 ..........................................................................................................
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 9011 ............................................................................................................................. 55-5-31 FAULT CODE ARM 9012 ............................................................................................................................. 55-5-31 FAULT CODE ARM 9013 .............................................................................................................................
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 19 The Throttle Lever Potentiometer Failure Cause: The throttle potentiometer has failed. (This fault code is for the tractors with electronically controlled engines only). Possible failure modes: 1. Potentiometer shorted or open. 2. External wiring damage. 3. Loose connector, bent or partially inserted pin. 4. Controller failure. Solution: The throttle lever potentiometer is hard wired to the armrest controller. 1.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 29 The 1st Remote Hydraulic Control Lever Potentiometer Failure Cause: The 1st remote valve lever potentiometer has failed. Possible failure modes: 1. Potentiometer shorted or open. 2. External wiring damage. 3. Loose connector, bent or partially inserted pin. 4. Controller failure. Solution: The 1st remote hydraulic control lever potentiometer (AUX 1 lever) is hard wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 39 The 2nd Remote Hydraulic Control Lever Potentiometer Failure Cause: The 2nd remote valve lever potentiometer has failed. Possible failure modes: 1. Potentiometer failed shorted or open. 2. External wiring damage. 3. Loose connector, bent or partially inserted pin. 4. Controller failure. Solution: The 2nd remote hydraulic control lever potentiometer (AUX 2 lever) is hard wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 49 The 3rd Remote Hydraulic Control Lever Potentiometer Failure Cause: The 3rd remote valve lever potentiometer has failed. Possible failure modes: 1. Potentiometer shorted or open. 2. External wiring damage. 3. Loose connector, bent or partially inserted pin. 4. Controller failure. Solution: The 3rd remote hydraulic control lever potentiometer (AUX 3 lever) is hard wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 59 The 4th Remote Hydraulic Control Lever Potentiometer Failure Cause: The 4th remote valve lever potentiometer has failed. Possible failure modes: 1. Potentiometer shorted or open. 2. External wiring damage. 3. Loose connector, bent or partially inserted pin. 4. Controller failure. Solution: The 4th remote hydraulic control lever potentiometer (AUX 4 lever) is hard wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 69 Hitch Position Control Lever Potentiometer Failure Cause: Hitch position potentiometer has failed. Possible failure modes: 1. Potentiometer shorted or open. 2. External wiring damage. 3. Loose connector, bent or partially inserted pin. 4. Controller failure. Solution: The hitch position control lever potentiometer is hard wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 79 Hitch Load Control Potentiometer Failure Cause: Hitch load potentiometer has failed. Possible failure modes: 1. Potentiometer shorted or open. 2. External wiring damage. 3. Loose connector, bent or partially inserted pin. 4. Controller failure. Solution: The hitch load control potentiometer is hard wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 89 The 1st Remote Hydraulic Flow Control Failure Cause: The 1st remote valve flow potentiometer has failed. Possible failure modes: 1. The remote hydraulic flow control potentiometer failed. 2. Bad connection between the armrest controller and the second panel. 3. Armrest controller failure. Solution: All controls on the second panel are built in as an integrated part with the second panel.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 99 The 2nd Remote Hydraulic Flow Control Failure Cause: The 2nd remote valve flow potentiometer has failed. Possible failure modes: 1. The remote hydraulic flow control potentiometer failed. 2. Bad connection between the armrest controller and the second panel. 3. Armrest controller failure. Solution: The 2nd remote hydraulic flow control potentiometer is mounted on the second panel and wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 109 The 3rd Remote Hydraulic Flow Control Failure Cause: The 3rd remote valve flow potentiometer has failed. Possible failure modes: 1. The remote hydraulic flow control potentiometer failed. 2. Bad connection between the armrest controller and the second panel. 3. Armrest controller failure. Solution: The 3rd remote hydraulic flow control potentiometer is mounted on the second panel and wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 119 The 4th Remote Hydraulic Flow Control Failure Cause: The 4th remote valve flow potentiometer has failed. Possible failure modes: 1. The remote hydraulic flow control potentiometer failed. 2. Bad connection between the armrest controller and the second panel. 3. Armrest controller failure. Solution: The 4th remote hydraulic flow control potentiometer is mounted on the second panel and wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 129 The 5th Remote Hydraulic Flow Control Potentiometer Failure Cause: The 5th remote valve flow potentiometer has failed. Possible failure modes: 1. Potentiometer shorted or open. 2. External wiring damage. 3. Loose connector, bent or partially inserted pin. 4. Controller failure. Solution: The 5th remote hydraulic flow control potentiometer (AUX 5 FLOW) is hard wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 139 The Remote Hydraulic Timer Control Failure Cause: The remote valve timer potentiometer has failed. Possible failure modes: 1. The remote hydraulic timer control potentiometer failed. 2. Bad connection between the armrest controller and the second panel. 3. Armrest controller failure. Solution: The remote hydraulic timer control potentiometer is mounted on the second panel and wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 149 The Hitch Upper Limit Control Failure Cause: Hitch upper limit potentiometer has failed. Possible failure modes: 1. The hitch upper limit control potentiometer failed. 2. Bad connection between the armrest controller and the second panel. 3. Armrest controller failure. Solution: The hitch upper limit control potentiometer is mounted on the second panel and wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 159 The Hitch Drop Rate Control Failure Cause: Hitch drop rate potentiometer has failed. Possible failure modes: 1. The hitch drop rate control potentiometer failed. 2. Bad connection between the armrest controller and the second panel. 3. Armrest controller failure. Solution: The hitch drop rate control potentiometer is mounted on the second panel and wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 169 The Hitch Travel Control Failure Cause: Hitch travel potentiometer has failed. Possible failure modes: 1. The hitch travel control potentiometer failed. 2. Bad connection between the armrest controller and the second panel. 3. Armrest controller failure. Solution: The hitch travel control potentiometer is mounted on the second panel and wired to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 1029 Remote Hydraulic Control Selection Switch 5 Failure Cause: This fault code is triggered when the extend and retract position are detected to be on at the same time. Possible failure modes: 1. Switch failed. 2. External wiring failure (damaged wires, loose connectors, or bent pins). 3. Armrest controller internal failure (power supply or signal sensing failed).
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 1039 PTO ON/OFF Control Switch Failure Cause: PTO ON/OFF control switch failure. Possible failure modes: 1. Switch failed. 2. External wiring failure (damaged wires, loose connectors, or bent pins). 3. Armrest controller internal failure (power supply or signal sensing failed). Solution: Monitor the switch status on the monitor screen of the service tool. Test the switch function, its wiring, and the function of the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 1049 Hitch UP/DOWN Switch Failure Cause: Hitch up/down switch failure. Possible failure modes: 1. The operator has been holding the switch between Up/Down positions for more than 2 seconds. 2. Switch failed. 3. External wiring failure (damaged wires, loose connectors, or bent pins). 4. Armrest controller internal failure (power supply or signal sensing failed). Solution: The ARMREST controller monitors the switch positions.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 1059 Slip Limit Switch Failure Cause: Slip limit switch failure. Possible failure modes: 1. Switch failed. 2. External wiring failure (damaged wires, loose connectors, bent pins). 3. Armrest controller internal failure (power supply or signal sensing failed). Solution: Monitor the switch status on the monitor screen of the service tool. Test the switch function, its wiring, and the function of the armrest controller. 1.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 1069 MFD Switch Failure Cause: MFD switch failure. Possible failure modes: 1. Switch failed. 2. External wiring failure (damaged wires, loose connectors, or bent pins). 3. Armrest controller internal failure (power supply or signal sensing failed). Solution: Monitor the switch status on the monitor screen of the service tool. Test the switch function, its wiring, and the function of the armrest controller. 1.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 1079 DIFF Lock Switch Failure Cause: DIFF LOCK switch failure. Possible failure modes: 1. Switch failed. 2. External wiring failure (damaged wires, loose connectors, or bent pins). 3. Armrest controller internal failure (power supply or signal sensing failed). Solution: Monitor the switch status on the monitor screen of the service tool. Test the switch function, its wiring, and the function of the armrest controller. 1.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 1089 Programmable Up/Down Switch Failure Cause: Programmable up/down switch failure. Possible failure modes: 1. Switch failed. 2. External wiring failure (damaged wires, loose connectors, or bent pins). 3. Armrest controller internal failure (power supply or signal sensing failed). Solution: Monitor the switch status on the monitor screen of the service tool.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 1099 Remote Set Switch Failure Possible failure modes: 1. Remote set switch failed. 2. Bad connection between the armrest controller and the second panel. 3. Armrest controller failure. Solution: The remote set switch is mounted on the second panel and wired to the armrest controller. The switch position information is broadcast over the Data Bus and can be monitored in the monitor screen of the service tool.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 1109 Hand Throttle Idle Validation Switch Failure Cause: Hand Throttle idle validation switch failure. Possible failure modes: 1. Switch Failed (shorted or open). 2. External wiring damage (shorted or open). 3. Bad connection (loose connector or bent pin). 4. Armrest controller has failed. Solution: Test the switch function, its wiring, and the function of the armrest controller. 1.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 1119 HTS Record/Play Switch Failure Cause: Both HTS RECORD and HTS PLAY circuits are detected to be closed at the same time. Possible failure modes: 1. HTS Record/Play switch failed. 2. Bad connection at the armrest controller. 3. Armrest controller failure. Solution: The HTS Record/Play switch is mounted on the second panel and wired directly to the armrest controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 1129 Invalid Configuration Implement Depth Control Switch Failure Cause: The implement depth control switch has failed. Possible failure modes: 1. Implement depth control switch failed. 2. Bad connection between the armrest controller and implement depth control switch. 3. Armrest controller failure. Solution: The implement depth control switch information is broadcast over the Tractor Data Bus.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 9011 Controller Memory Error Cause: Controller memory error: Loss of hitch position command calibration. Possible failure modes: Memory defect or intermittent controller. Solution: Make sure the controller has a good connection (C137) to the battery and is properly grounded. Shut down the tractor and restart. Calibrate the hitch menu in the armrest controller. If the same fault code appears again, replace the controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 9013 Controller Memory Error Cause: Controller failure: Loss of throttle calibration. Possible failure mode: Memory defect or intermittent controller. Solution: Make sure the controller has a good connection (C137) to the battery and is properly grounded. Shut down the tractor and restart. Calibrate the throttle menu in the armrest controller. If the same fault code appears again, replace the controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 9015 Controller Memory Error Cause: Controller failure: Loss of trans switches configuration. Possible failure mode: Memory defect or intermittent controller. Solution: Make sure the controller has a good connection (C137) to the battery and is properly grounded. Shut down the tractor and restart. Calibrate the TRANS menu in the armrest controller. If the same fault code appears again, replace the controller.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 9031 Hand Throttle Potentiometer Calibration Error Cause: Hand throttle potentiometer calibration results not acceptable. Possible failure mode: 1. Calibration was done incorrectly. 2. Hand throttle potentiometer or the lever out of the working range. 3. Memory defect or intermittent controller. Solution: Make sure the controller has a good connection (C137) to the battery and is properly grounded. 1. Shut down the tractor and restart.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 10091 Controller Internal Failure Cause: Controller internal failure: +5 V or +8 V regulator is out of range. Solution: Make sure the controller has a good connection (C137) to the battery and is properly grounded. Shut down the tractor and restart. Calibrate the armrest controller. If the same fault code appears again, replace the controller. NOTE: See schematic sections 47 and 48 on schematic poster.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 12013 Communication Lost With The Data Bus Cause: The armrest controller has found that it can not communicate with the Data Bus. Possible failure mode: 1. Data Bus is not powered. 2. Data Bus is shorted. 3. Passive terminator failed. Solution: Make sure the armrest controller is well connected to the Data Bus. Check the Data Bus function. 1.
Section 55 - Electrical System, Controller - Chapter 5 B. If all of the controllers except the engine controller come back online, the problem is the Data Bus external to the cab. Check the Data bus wiring outside of the cab for open circuits or shorts to ground. The Data bus can be split once again at connector C060 to determine which portion of the exterior Data bus wiring has the problem. If the problem cannot be found in the wiring, disconnect the engine controller to determine if it has failed.
Section 55 - Electrical System, Controller - Chapter 5 FAULT CODE ARM 12081 HTS Capability Message Not Received Cause: The armrest controller has found that it cannot communicate with the deluxe ICU (Instrument Cluster). Possible failure mode: 1. Instrument cluster not configured for HTS capability. 2. Data Bus is not powered. 2. Data Bus is shorted. 3. Passive terminator failed. Solution: Make sure the armrest controller is properly configured.
Section 55 - Electrical System, Controller - Chapter 5 B. If all of the controllers except the engine controller come back online, the problem is the Data Bus external to the cab. Check the Data bus wiring outside of the cab for open circuits or shorts to ground. The Data bus can be split once again at connector C060 to determine which portion of the exterior Data bus wiring has the problem. If the problem cannot be found in the wiring, disconnect the engine controller to determine if it has failed.
Section 55 - Electrical System, Controller - Chapter 5 55-5-40
Section 55 Chapter 6 ELECTRONIC CONTROLLER CONFIGURATION, CALIBRATION AND FAULT CODE RETRIEVAL January, 2006
Section 55 - Electrical System, Controller - Chapter 6 TABLE OF CONTENTS FAULT CODE RETRIEVAL .......................................................................................................................... 55-6-3 INSTRUMENTATION PROGRAMMING ...................................................................................................... 55-6-5 Radar Calibration ...................................................................................................................................
Section 55 - Electrical System, Controller - Chapter 6 FAULT CODE RETRIEVAL STEP 3 Controllers can be checked for fault codes at any time. Up to 10 fault codes can be stored in each controller. STEP 1 MD05F040 When the required controller is displayed, press the PROG key. If a controller is selected that is not on the Data Bus (does not exist), the display will read COMM ERR.
Section 55 - Electrical System, Controller - Chapter 6 STEP 5 STEP 7 MD05F041 MD05F003 To erase the fault codes from a controller, press and hold both the INCR and DECR keys for 10 seconds. Another controller can be selected at this time by using the INCR and DECR keys to scroll through the controller list as in Step 2. NOTE: All the fault codes for that controller will be erased. STEP 8 STEP 6 RD06A072 To exit the select controller screen, scroll until EXIT is displayed and press the PROG key.
Section 55 - Electrical System, Controller - Chapter 6 INSTRUMENTATION PROGRAMMING General Information Operation Setup The standard instrumentation controller must be configured/calibrated before any other controller. Tractor Standard instrumentation programming is perfor med through three levels. The first level, operation setup permits adjustment of display units and ti re radi us.
Section 55 - Electrical System, Controller - Chapter 6 STEP 3 STEP 5 MD05F005 MD05F007 The display will read CONFIG ICU with options, Operator Setup, Controller Config and Exit. The default will highlight Operator Setup. Press the PROG key. The display will show under the UNIT heading English and Metric. The last stored heading will be highlighted. The default setting is English. Display units can now be selected, either English or Metric, by using the INCR or DECR keys.
Section 55 - Electrical System, Controller - Chapter 6 STEP 7 STEP 9 MD05F010 MD0F012 The display will read TIRE RADIUS with the radius icon above the MANUAL or AUTO options. Use the INCR and DECR keys to select either MANUAL or AUTO format. Press the PROG key to enter the selected format. To use the AUTO format for determining tire radius the following preparations must be made: If MANUAL is selected, proceed to Step 8. If AUTO (automatic) is selected, proceed to Step 9. 2.
Section 55 - Electrical System, Controller - Chapter 6 STEP 10 STEP 12 MD05F013 MD05F015 When the AUTO format is selected in Step 9 the display will show the radius icon followed by AUTO. The next line reads *READY* and the bottom of the screen reads PRESS TO START. Press the DECR key when the front wheels touch the finish line. If successful the ICU will calibrate the tire radius, display and save the new value for 2 seconds before returning to the CONFIG ICU options screen.
Section 55 - Electrical System, Controller - Chapter 6 Radar Calibration STEP 13 STEP 14 MD05F016 MD05F017 After the Tire Radius has been completed the CONFIG ICU options screen is displayed. The display will show the radar icon and RADAR CAL. The next line shows MANUAL with the manual icon and the bottom line shows AUTO. Use the INCR and DECR keys to highlight either MANUAL or AUTO. Use the PROG key to enter the selected format.
Section 55 - Electrical System, Controller - Chapter 6 STEP 15 3. Turn the key switch OFF. Press and hold the PROG key for 3 seconds within the first 10 seconds of starting the engine. 4. The display will read CONFIG MENU. With ICU highlighted press the PROG key. 5. The display will show the CONFIG ICU options. Use the INCR or DECR keys to select Radar Cal and press the PROG key. 6. The display will show the radar icon followed by RADAR CAL.
Section 55 - Electrical System, Controller - Chapter 6 STEP 19 STEP 21 MD05F022 RD05G056 Press the DECR key when the front wheels touch the finish line. The CONFIG MENU is displayed. STEP 22 If successful, the ICU will calculate the new radar calibration and display *COMPLETE*. Press the PROG key to save the new value and return to the CONFIG ICU options screen.
Section 55 - Electrical System, Controller - Chapter 6 Controller Configuration STEP 25 NOTE: Configuration can only be entered within the first 10 seconds of turning the key switch to the ON position. STEP 24 MD05F025 3. Press the PROG key with INSTRUMENT on the display. The display will read CONFIG ICU, 1. Operator Setup, 2. Controller Config, and 3. Exit. (Instrumentation operation setup). Press the DECR key to highlight 2. Controller Config (Instrumentation controller configuration).
Section 55 - Electrical System, Controller - Chapter 6 Configuration/Calibration Mode STEP 27 STEP 26 MD05F174 Select between MANUAL or AUTO and press the PROG key. If AUTO was chosen, the system will go to Step 36. If MANUAL was chosen, the system will go to the next step. MD05F026 The display will read CONFIG ICU, 1. Tractor Model, 2. Fuel Tank, 3. Controller Config and 4. Exit. Use the INCR or DECR key to highlight 3. Controller Config and press the PROG key. STEP 28 NOTE: The 1.
Section 55 - Electrical System, Controller - Chapter 6 STEP 29 STEP 31 MD05F029 MD05F176 The bottom of the display will read ENGINE (engine controller). Press the INCR or DECR key to toggle between YES and NO. Select your choice and press the PROG key. The system will go to the next step. The bottom of the display will read ARM (armrest controller). Press the INCR or DECR key to select YES and press the PROG key, The system will go to the next step.
Section 55 - Electrical System, Controller - Chapter 6 STEP 33 STEP 35 MD05F032 RD06A075 The bottom of the display will read AUX (remote hydraulic controller). Press the INCR or DECR key to toggle between YES and NO. Select your choice and press the PROG key, The system will go to the next step. The bottom of the display will read PTO (AUX/ HITCH/PTO controller). Press the INCR or DECR key to toggle between YES and NO. Select your choice and press the PROG key, The system will go to the next step.
Section 55 - Electrical System, Controller - Chapter 6 STEP 37 RD05G056 The display will read CONFIG MENU. Press the INCR key. The display will read Exit. Press the PROG key to return to normal operation. STEP 38 C y c l e t h e key sw i t c h O F F, t h e n O N . C h e ck controllers for any fault codes. Erase the fault codes if any exist. IMPORTANT: The controller must be calibrated when moved from one tractor to another.
Section 55 - Electrical System, Controller - Chapter 6 INSTRUMENTATION DISPLAY SYMPTOM BASED FAULTS Instrumentation Display Will Not Illuminate When Key Is Turned On No Fault Code Meaning: The INST controller (display) is not to be powered or has failed. Possible failure mode: 1. Failed cab power relay - engine will run after starting. 2. Failed controller power relay - engine will stop after starting. 3. Failed key switch - engine will stop after starting. 4.
Section 55 - Electrical System, Controller - Chapter 6 STEP 5 - Check power at fuse 37 With the key switch on and the display not illuminate. Remove fuse 37 and check for 12 volts. -- OK - Go to Step 7. -- NOT OK - Go to Step 6. STEP 6 - Check controller relay (TMF/ICU controller relay #19) The controller relay (#19) is located in the fuse compartment behind the operator seat. Check relay ground supply wire. Turn key on. Check for power at Controller relay (#19) base.
Section 55 - Electrical System, Controller - Chapter 6 ARMREST CONTROLLER CONFIGURATION AND CALIBRATION General Information 4. AUX LEVER - (Remote hydraulic valve) This menu is used to tell the controller how many remote hydraulic valves are present on the tractor, and to record the voltage for the extend and retract position for each of the valve control levers. NOTE: The standard instrumentation controller must be calibrated before the armrest controller is calibrated.
Section 55 - Electrical System, Controller - Chapter 6 Entering Armrest Calibration Hitch Menu STEP 3 NOTE: Programming can only be entered within the first 10 seconds of turning the key switch to the ON position. To get to the armrest controller calibration main menu, do the following: STEP 1 MD05F097 Select the calibration option for the hitch control lever (if equipped). When the display reads ARM HITCH, press the PROG key. STEP 4 RD05G056 Turn the keys switch to the ON position.
Section 55 - Electrical System, Controller - Chapter 6 STEP 5 STEP 6 MD05F100 RD05F189 MD05F101 MD05F102 Press the PROG key. The display will read H Pos Dn. Move the hitch position lever to the full down position. An asterisk (*) will appear in the display when the potentiometer is in a valid range. Press the PROG key to record the voltage. The display will now read Draft or No Draft. There must be a hitch load command potentiometer in the armrest controller to select Draft.
Section 55 - Electrical System, Controller - Chapter 6 Throttle Menu STEP 9 STEP 7 MD05F105 The display will read lo idle. Move the throttle lever to the low idle. An asterisk (*) will appear in the display when the potentiometer is in a valid range. Press the PROG key to record the voltage. The display will now r e a d A R M T H R OT T L E . To ex i t t h e a r m r e s t calibration, go to Step 23. Press the DECR key and go to the next step to continue with the armrest calibration.
Section 55 - Electrical System, Controller - Chapter 6 Remote Valve Menu STEP 12 STEP 10 RD05F188. The display will read -XXXX hi flow. Turn the #1 flow potentiometer completely clockwise until the 1 appears in the first - position of the display. Press the PROG key. MD05F106 Select the calibration option for the remote hydraulic flow controls. When the display reads ARM AUX FLOW press the PROG key. STEP 13 STEP 11 The screen reads, ARM AUX FLOW. Press the DECR key to select AUX ARM LEVER.
Section 55 - Electrical System, Controller - Chapter 6 STEP 15 STEP 17 MD05F111 MD05F113 The display will read AUX EXT (extend). Move all the remote hydraulic levers to the full extend position (Rearward detent). If equipped with a fifth remote hydraulic section, press and release the fifth remote hydraulic control switch (momentary) in the extend direction (rearward). The display will read AUX RET (retract). Move all the remote hydraulic levers to the full retract position (First forward detent).
Section 55 - Electrical System, Controller - Chapter 6 ARM MFD ARM TRANS STEP 19 STEP 20 RD05F147 RD05F151 RD05F148 RD05F153 Select the software view option from the main menu. The display will read ARM MFD. Press the PROG key. The display will read YES MFD ? Press the INCR key to change to NO MFD ? if not equipped. Press the PROG key to exit the ARM MFD menu. Select the software view option from the main menu. The display will read ARM TRANS. Press the PROG key.
Section 55 - Electrical System, Controller - Chapter 6 View Menu STEP 22 STEP 21 MD05F117 MD05F115 MD05F115 The second part of the software code will now be shown. The display will read Ver#2 on the top and the software code on the bottom of the display. Press the PROG key to exit the view menu. The display will now read ARM VIEW. MD05116 Select the software view option from the main menu. The display will read ARM VIEW. Press the PROG key. The software is displayed in two par ts.
Section 55 - Electrical System, Controller - Chapter 6 Exit Calibration STEP 23 MD05F118 Use the DECR key to select the ARM EXIT menu and press the PROG key to exit armrest controller calibration. The display will now read CONFIG MENU. Press the INCR or DECR key until the display reads EXIT SET MENU. Press the PROG key to return to normal operation.
Section 55 - Electrical System, Controller - Chapter 6 TRANSMISSION CONTROLLER CONFIGURATION AND CALIBRATION Important General Information • • • Before star ting the transmission calibration pr oc e d ur e, c h e ck th e wi r i n g h a r n es s a n d components for damage or loose connections. Replace or repair any damaged par t as necessary. Before calibrating the transmission controller, be sure the Standard Instrumentation (ICU) and Armrest (ARM) controllers are calibrated.
Section 55 - Electrical System, Controller - Chapter 6 To access these menus: STEP 3 STEP 1 RD05F104 The display will read TRANS VIEW. Press DECR key. RD05G056 Push and hold the PROG key for two seconds within the first ten seconds after starting the tractor. A short beep will indicate that the program mode has been accessed and the display will read CONFIG MENU. STEP 4 STEP 2 RD05F125 The display will read TRANS SETUP. Press DECR key.
Section 55 - Electrical System, Controller - Chapter 6 STEP 5 STEP 7 RD05G004 RD06A079 The next display will be TRANS FSUS, but only if equipped with the Suspended Axle Option. Press DECR key. IMPORTANT: The TRANS ADJUST menu will only appear when the Electronic Service Tool (EST) is in use. Do Not enter this menu. Press the DECR key. The display will read TRANS ADJUST. Press the DECR key. STEP 8 STEP 6 RD05F134 The display will read TRANS EXIT. Press the PROG key to exit.
Section 55 - Electrical System, Controller - Chapter 6 Trans View Mode STEP 11 NOTE: Calibration can only be entered by pressing and holding the PROG key within the first 10 seconds of starting the tractor. NOTE: If any fault codes are recorded, they must be cleared before calibration is possible. Retrieve, record and clear any fault codes. See Fault Code Retrieval in this section. STEP 9 RD05F104 The display will read TRANS VIEW. Press the PROG key to enter the Transmission View Menus.
Section 55 - Electrical System, Controller - Chapter 6 STEP 14 STEP 16 RD05F179 RD05F105 The display will read EVEN mA. This displays the calibrated clutch current values in milliamps. Continue pushing the DECR key to display the calibrated clutch current values for C/O, C1, C3, C5, LOW, MID, HIGH, REV and MSTR clutch. The display will return to VIEW CLTCH. To display the next Transmission View Menu push the DECR key.
Section 55 - Electrical System, Controller - Chapter 6 STEP 18 STEP 20 RD05F109 RD05F110 The display will read ODD DEGC. The Calibration Clutch Temperature View Menu shows the clutch temp at which the calibration was performed. Push the DECR key. The Master Clutch temperature display reading is the final readout. Push the PROG key. NOTE: If you continue to push the DECR key the display will start through the menu again starting with the Odd clutch temp reading.
Section 55 - Electrical System, Controller - Chapter 6 STEP 22 STEP 25 RD05F111 RD05F113 The display will read OIL TEMP. Push the PROG key. The display will read VIEW PEDAL. The Clutch Pedal View Menu displays the position of the clutch. Push the PROG key. STEP 23 STEP 26 RD05F112 The display will read OIL DEGC. This is the actual transmission oil temperature. Pres the PROG key. RD05F114 STEP 24 The current pedal position is displayed, 100% for inching pedal up (top of clutch).
Section 55 - Electrical System, Controller - Chapter 6 STEP 28 STEP 31 RD05F113 RD05F118 The display will again read VIEW PEDAL. To display the next Transmission View Menu push the DECR key. The display will read VER#2. Version #2 is the engineering software version numbers. Push the PROG key. STEP 29 STEP 32 RD05F116 RD05F116 The display will read SW REVISION. This is the Software Revision View Menu. Push the PROG key. The display will again read SW REVISION.
Section 55 - Electrical System, Controller - Chapter 6 STEP 34 STEP 37 RD05F120 RD05F122 The display will read PRES KPA. This is the Transmission System Pressure. Push the PROG key. The display will read LOAD %. The engine load is displayed in percentage related to the engine torque. Push the PROG key. STEP 35 STEP 38 RD05F119 The display will again read PRES TRNSDCR. To display the next Transmission View Menu push the DECR key. RD05G009 The display will again read ENG LOAD.
Section 55 - Electrical System, Controller - Chapter 6 Trans Setup Mode STEP 42 NOTE: Calibration can only be entered by pressing and holding the PROG key within the first 10 seconds of starting the tractor. NOTE: If any fault codes are recorded, they must be cleared before calibration is possible. Retrieve, record and clear any fault codes. See Fault Code Retrieval in this section. STEP 40 RD05F104 The display will read TRANS VIEW. Press DECR key.
Section 55 - Electrical System, Controller - Chapter 6 STEP 44 STEP 48 RD05F126 RD05F131 The display will read CLTCH CAL. See the Clutch Calibration Procedure. To see the next setup menu press the DECR key. The display will read GEAR DEFAULT. See the Gear Default Mode in this section. Press DECR key. STEP 49 NOTE: The display will go directly to Step 48, GEAR DEFAULT, unless the Electronic Service Tool (EST) is in use. The display will read EXIT SETUP. Press PROG key to exit.
Section 55 - Electrical System, Controller - Chapter 6 Clutch Calibration Procedure STEP 51 NOTE: Calibration can only be entered by pressing and holding the PROG key within the first 10 seconds of starting the tractor. NOTE: If any fault codes are recorded, they must be cleared before calibration is possible. Retrieve, record and clear any fault codes.
Section 55 - Electrical System, Controller - Chapter 6 STEP 54 STEP 56 RD05F128 MD05F072 The display will read OIL DEGC. The transmission oil temp should be between 60 and 105 degrees C (140 to 221 degrees F). Push the PROG key. The display will read ENG RPM. Increase the engine RPM to 1100 to 1300 RPM. Push the PROG key. NOTE: If the program key is pushed when the RPM is not in the proper range The display will read CAL ABORTED. Pushing the PROG key again will display CAL EXIT.
Section 55 - Electrical System, Controller - Chapter 6 STEP 58 STEP 61 RD05F173 RD05F182 The display will read SHIFT TO FWD. Shift the transmission control lever to FWD. T h e d i s p l ay w i l l r e a d O d d m A . T h e t r a c t o r transmission controller will automatically run through the Odd clutch calibration procedure. ! WARNING: Since the valve calibration process involves engaging transmission clutches, this procedure should only be performed in open areas, free of obstructions.
Section 55 - Electrical System, Controller - Chapter 6 STEP 63 STEP 65 RD05F178 RD05G017 The display will read EVEN CLUTCH. Push the PROG key and the tractor transmission controller will automatically run through the Even clutch calibration procedure. The display will now read EXIT CAL. Push the prog key once. STEP 66 The display will read *EVEN mA when the Even clutch calibration is completed. Push the PROG key. Repeat this procedure to calibrate the C1, C3, C5, LOW, MID, HIGH, REV and MSTR clutch.
Section 55 - Electrical System, Controller - Chapter 6 Calibration Error Messages STEP 68 Listed below are calibration error messages that can appear during a calibration failure. POT OPEN CKT: Potentiometer open circuit or disconnected. POT HIGH VAL: Potentiometer is higher than safety value. POT SHRT CKT: Potentiometer short circuit. POT LOW VAL: Potentiometer is lower than safety value. RD05G056 Push and hold the PROG key for two seconds within the first ten seconds after starting the tractor.
Section 55 - Electrical System, Controller - Chapter 6 STEP 70 STEP 73 RD05F125 RD05F166 The display will read TRANS SETUP. Press the PROG key to enter the Transmission Setup Menus. The display will read SETUP FWD GEAR. Push the PROG key STEP 71 STEP 74 RD05F126 RD05F167 The display will read CLTCH CAL. Push the DECR key. The display will read *FWD GEAR# 7. Press the INCR key to increase the gear number, or press the DECR key to decrease the gear number.
Section 55 - Electrical System, Controller - Chapter 6 STEP 76 STEP 77 RD05F169 RD05F171 The display will read *REV GEAR# 2. Press the INCR key to increase the gear number, or press the DECR key to decrease the gear number. If no change is desired leave gear number as it is. Press the PROG key when desired gear number is set. The display will read EXIT SET GEAR. Press the PROG key to exit this menu.
Section 55 - Electrical System, Controller - Chapter 6 Front Suspension Installation Menu STEP 79 This menu allows the user to install, or remove the FSUS (Front Suspension). NOTE: This menu will only work when the Electronic Service Tool is in use. STEP 78 RD05F104 When the TRANS VIEW menu is displayed, push the DECR key. STEP 80 RD05G056 Push and hold the PROG key for two seconds within the first ten seconds after starting the tractor.
Section 55 - Electrical System, Controller - Chapter 6 STEP 81 STEP 83 RD05G041 RD05G012 The display will read DONE. After 1 second the display exits this menu. Press the DECR key multiple times until SETUP FSUS is displayed. Press the PROG key to enter the Menu. Front Suspension Menus STEP 82 The following menus are available for the Front Suspension. 1. FSUS CAL - This menu allows the user to Calibrate the Front Suspended axle. 2.
Section 55 - Electrical System, Controller - Chapter 6 Front Suspension Calibration STEP 85 NOTE: This menu will only work when the Electronic Service Tool is in use. STEP 84 RD05F104 When the TRANS VIEW menu is displayed, push the DECR key. STEP 86 RD05G056 Start the engine. Push and hold the PROG key for two seconds within the first ten seconds after starting the tractor. A short beep will indicate that the program mode has been accessed and the display will read CONFIG MENU.
Section 55 - Electrical System, Controller - Chapter 6 STEP 88 STEP 90 RD06A080 RD05G026 The display reads FSUS CAL. Press the PROG key to automatically start the calibration process. The Suspended Axle Switch lamp will flash on and off. When the calibration is completed the display will show FSUS Cal Done. NOTE: If the PROG key is pressed during the calibration the display will read CAL ABORTED. STEP 89 STEP 91 RD05G030 The display numbers (nnnn) will change as the calibration is in progress.
Section 55 - Electrical System, Controller - Chapter 6 STEP 92 RD05G047 Error Message Display Example.
Section 55 - Electrical System, Controller - Chapter 6 Front Suspension Demo STEP 94 The menu is accessed through the Trans Setup Menu. NOTE: This menu will only work when the Electronic Service Tool is in use. STEP 93 RD05F104 When the TRANS VIEW menu is displayed, push the DECR key. STEP 95 RD05G056 Start the engine. Push and hold the PROG key for two seconds within the first ten seconds after starting the tractor.
Section 55 - Electrical System, Controller - Chapter 6 Front Suspension Manual Menu STEP 97 NOTE: This menu will only work when the Electronic Service Tool is in use. STEP 99 RD05G038 Press the DECR key multiple times until FSUS DEMO is displayed. Press the PROG key. STEP 98 RD05G056 Start the engine. Push and hold the PROG key for two seconds within the first ten seconds after starting the tractor.
Section 55 - Electrical System, Controller - Chapter 6 STEP 100 STEP 103 RD05F104 RD05G028 When the TRANS VIEW menu is displayed, push the DECR key. Push the DECR key until the display reads FSUS Manual and then press the PROG key. STEP 101 STEP 104 RD05F125 RD05G030 The display will read TRANS SETUP. Press the DECR key. The display will read POS nnnn mV. This display is the front axle position sensor output voltage. Press the DECR key. STEP 102 RD05G019 The display will read TRANS FSUS.
Section 55 - Electrical System, Controller - Chapter 6 STEP 105 STEP 107 RD05G031 RD05G034 The display will read RAISE nnnn mV. Press and hold the Front Suspended Axle switch to raise the suspended axle. Release the switch to stop. Press the DECR key again. The display will read LOCK nnnn mV. Both the upper and lower lock solenoids are now powered ON. Press and hold the Front Suspended Axle switch to power OFF the lock solenoids.
Section 55 - Electrical System, Controller - Chapter 6 REMOTE (AUX) SYSTEM CALIBRATION Requirements For Calibration Aux Set Main Menu NOTE: AUX/HITCH/PTO controller is also referred to as Tractor Multi Function TMF Controller. Remote hydraulic calibration is performed through t h e p r o g r a m m a b l e d i s p l ay o n t h e s t a n d a r d instrumentation.
Section 55 - Electrical System, Controller - Chapter 6 STEP 3 To get to the aux set main menu, do the following: STEP 1 MD05F122 The display will read EDC MENU. Press the DECR key twice. RD05G056 Start the tractor. Push the PROG key and hold for two seconds within the first ten seconds. A short beep will indicate that the program mode has been accessed and the display will read CONFIG MENU. STEP 4 STEP 2 RD06A059 The display should read EHR MENU (Electro Hydraulic Remotes).
Section 55 - Electrical System, Controller - Chapter 6 Aux View Menu There are 5 main menu options in the EHR MENU: 1. AUX VIEW - This menu displays the software revision code and scraper configuration. STEP 1 2. AUX ADJUST - The adjustment menu offers the operator a means of tailoring the flow from a remote section to meet the needs of the job to be d o n e . T h e ex t e n d a n d r e t r a c t f l o w s a r e adjustable independently. 3.
Section 55 - Electrical System, Controller - Chapter 6 STEP 4 STEP 6 RD06A102 RD06A099 The screen will now read SCRPR OPTION. Press the PROG key. The display will now show how many scrapers are configured in the system. Press the DECR key. The AUX VIEW screen will now be displayed. Press the DECR key to display AUX ADJUST. NOTE: Scraper configuration is performed in the AUX SETUP menu. STEP 5 RD06A103 The display will now read EXIT VIEW. Press the PROG key.
Section 55 - Electrical System, Controller - Chapter 6 Aux Adjust Menu STEP 9 STEP 7 MD05F127A Press the PROG key for the section circuit of your choice. The current valve setting, which will be a number between -40 to +40 will be displayed. If the va lue di sp layed is in cr eas ed , the fl ow c ur ve associated with that valve will be shifted to the left. This res ul ts in a higher flow for a given flow potentiometer setting for that flow direction.
Section 55 - Electrical System, Controller - Chapter 6 Aux Setup Menu STEP 11 STEP 13 MD05F126A Press the PROG key to return to the valve section selection menu. Repeat these steps for other valve sections. RD06A128 With AUX SETUP on the display, push the PROG key. STEP 12 STEP 14 RD06A130 Press the INCR or DECR key to return to the EXIT screen. Press the PROG key.
Section 55 - Electrical System, Controller - Chapter 6 STEP 15 If any of these checks do not pass, the calibration will be exited with a message displayed of the fault. Selection of the INCR or DECR key will bring the main calibration menu back. If the checks pass, the present calibration values are set to a default value and the calibration process will begin. The sequence of calibration is sequential from valve section one through section five of the available sections.
Section 55 - Electrical System, Controller - Chapter 6 • Enable - lever not in neutral during pre-cal check. • Quit - During calibration, the lever of valve being STEP 17 calibrated was moved from neutral, INCR, Decr or PROG key was pushed. • • • • PSI - Feedback signal out of range low or high during pre-cal check. Cal Time - Pressure takes to long to drop during settling phase of calibration Cal Halt - Anytime a fault is associated with the section is detected.
Section 55 - Electrical System, Controller - Chapter 6 STEP 19 STEP 21 RD06A172 MD05F177A The first portion of calibration procedure is running. If no faults are displayed continue on to Step 21. The system will go automatically into the calibration process when the pre-calibration is completed. The screen will display each remote valve as it is calibrated and will automatically cycle through all remote valves in numeric order.
Section 55 - Electrical System, Controller - Chapter 6 HITCH SYSTEM CALIBRATION Setup Process Hitch Setup Main Menu Requirements For Calibration Hitch setup / calibration is perfor med from the programmable display on the standard monitor. NOTE: The standard instrumentation and armrest controllers must be calibrated before the hitch controller can be calibrated. NOTE: AUX/HITCH/PTO controller is also referred to as Tractor Multi Function TMF Controller.
Section 55 - Electrical System, Controller - Chapter 6 STEP 1 When the Electronic Draft Control (EDC) main menu is entered, the setup options include the following: 1. HITCH CAL - Capability to calibrate the hitch system. A. Calibration of systems configuration. B. Calibration of systems parameters 2. HITCH SETTINGS - Capability to set user settings of certain parameters. 3. HITCH VIEW - Capability to view information about the controller. 4. HITCH NVM- Allows the user to see stored calibration values.
Section 55 - Electrical System, Controller - Chapter 6 Hitch Calibration Menu STEP 4 NOTE: If any fault codes are recorded, they must be corrected before programming is possible. At this step, the controller is looking for the number of draft pins in the system. 1. If the hitch controller detects two draft pins, and the armrest controller is calibrated for draft, the hitch controller will assume there are two draft pins and go to Step 5. 2.
Section 55 - Electrical System, Controller - Chapter 6 STEP 5 STEP 6 The display will now read Cal Raise. This will allow you to calibrate the raise threshold of the hitch valve. 1. To calibrate the raise portion of the hitch valve, press the PROG key. The controller will start the raise calibration. Whenever current is applied to the coil, the display will change to xxx Raise mA, where “xxx” is the current value in mA.
Section 55 - Electrical System, Controller - Chapter 6 STEP 8 STEP 9 The display will now read Lower Limit ON. The system wants you to acknowledge that the hitch has reached the lower limit. 1. Push the “PROG” key to acknowledge that the hitch is at the lower limit. The system will then go to Step 10. MD05F050A The display will now read Cal Lower. This will allow you to calibrate the lower threshold of the hitch valve. 1. To calibrate the lower portion of the hitch valve, press the PROG key.
Section 55 - Electrical System, Controller - Chapter 6 STEP 10 STEP 11 If the display reads Cal Aborted. This means that the calibration process was aborted at some point. 1. Press the PROG key to return to the main menu. 2. There are several things that can cause the calibration to be aborted. A. The tractor starts moving. B. No engine speed. C. The operator aborted calibration. STEP 12 MD05F053A The display will now read Cal Done.
Section 55 - Electrical System, Controller - Chapter 6 Hitch Setting Menu STEP 14 Go to the Hitch Setting menu as shown under Hitch Setup Main Menu. The Hitch Setting Menu allows you to set certain performance parameters. The lower line of the display will read R/D Rate (raise/drop rate). The top line of the display will show the present user setting for this (either yes or no). If Yes is selected, the system will use the drop rate setting to set the raise rate.
Section 55 - Electrical System, Controller - Chapter 6 STEP 16 STEP 17 The lower line of the display will now read Hitch Up. This will allow you to choose the desired percentage of hitch travel that will be used to determine if the hitch is up for the Auto MFD and Auto Dif Lock functions. There are four choices: 60%, 70%, 80% and 90%. The default is 70%. The display will now read Done Settings. This i n d i c a t e s t h a t t h e u s e r s e t t i n g s h av e b e e n successfully programed.
Section 55 - Electrical System, Controller - Chapter 6 Hitch View Menu STEP 19 The Hitch View Menu allows the user to see different parameters of the system. It is used to monitor the hitch system for diagnostic purpose. The tractor should be running. STEP 18 RD06A089 Press the PROG key. The display will now read HITCH VIEW. Press DECR key to go to HITCH NVM, or to HITCH EXIT. STEP 20 RD06A089 Press the PROG key with HITCH VIEW on the display. Press the INCR or DECR key to scroll through the menu.
Section 55 - Electrical System, Controller - Chapter 6 Hitch NVM Menu STEP 23 The Hitch NVM Menu allows the user to see the calibration values that are stored. STEP 22 RD06A091 Press the PROG key. The display will now read HITCH NVM. Press DECR key to go to HITCH EXIT. RD06A091 STEP 24 Press the PROG key with HITCH NVM on the display. Press the INCR or DECR key to scroll through the menu. Hitch NVM menu: 1. PWMLT - Pulse Width Modulation threshold for lower valve 2.
Section 55 - Electrical System, Controller - Chapter 6 PTO SYSTEM CONFIGURATION General Information PTO Main Menu NOTE: The standard instrumentation and armrest controllers must be calibrated before the AUX/ HITCH/PTO controller can be configured. NOTE: Controller programming can only be entered within the first 10 seconds of turning the key switch to the on or run position. NOTE: AUX/HITCH/PTO controller is also referred to as Tractor Multi Function TMF Controller.
Section 55 - Electrical System, Controller - Chapter 6 PTO Speed Menu STEP 3 STEP 5 RD06A061 The display will read EDC MENU. Press the DECR key. RD06A111 The display will read PTO SPEED. Press the PROG key again. Use the INCR or DECR key to toggle between 1 and 2 and choose the number that applies to the number of PTO speeds that the tractor has. STEP 4 STEP 6 RD06A062 The display should read PTO MENU. Press the PROG key to enter the main menu for the PTO system.
Section 55 - Electrical System, Controller - Chapter 6 View Menu STEP 9 STEP 7 RD06A112 RD06A112 RD06A114 Press the PROG key. The display will read PTO VIEW. Press The DECR key and the display will read PTO EXIT. Pressing the PROG key will exit from PTO configuration. RD05F139A Press the DECR key. The menu will read PTO VIEW. Press the PROG key. The display will read SW 1. This is the first part of the software version number. STEP 8 RD05F140A Press the PROG key. The display will read SW 2.
Section 90 Chapter 1 PEDAL AND PEDAL SWITCH ADJUSTMENTS January, 2006
Section 90 - Cab, Hood, Seat - Chapter 1 TABLE OF CONTENTS INCHING PEDAL SWITCH ADJUSTMENT ................................................................................................... 90-1-3 BRAKE PEDAL ADJUSTMENTS ...................................................................................................................
Section 90 - Cab, Hood, Seat - Chapter 1 INCHING PEDAL SWITCH ADJUSTMENT 1 4 1 2 4 2 3 RT97K033 RT97K034 A. Install the switch (1) into the mounting bracket (2). B. Turn the switch into the bracket until the tip of the switch plunger (3) is even with the mounting bracket. C. Turn the switch an additional 2.3 turns so that the switch plunger protrudes from the bracket approximately 4.0 mm. D. Tighten the switch locking nuts (4) to secure the switch in position. Connect the switch to the wire harness.
Section 90 - Cab, Hood, Seat - Chapter 1 BRAKE PEDAL ADJUSTMENTS 1a 10 9 8 1 7 4 2 2 5 6 3 3 RI02K092 RI02K093 Brake Pedal Stop Adjustments A. Use the stop adjusting screw (1) to adjust the left brake pedal to the same height as the clutch pedal. Tighten the lock nut (2) when done. B. Adjust the right brake pedal to the same height as the left pedal. Be sure that the brake pedal lock (3) will engage the right pedal easily. Tighten the lock nut when done.
Section 90 Chapter 2 CAB RAISE / REMOVAL AND INSTALLATION January, 2006
Section 90 - Cab, Hood, Seat - Chapter 2 TABLE OF CONTENTS SPECIAL TORQUES ...................................................................................................................................... 90-2-3 SPECIAL TOOLS ........................................................................................................................................... 90-2-3 CAB RAISE PROCEDURE .................................................................................................................
Section 90 - Cab, Hood, Seat - Chapter 2 SPECIAL TORQUES Cab Mounting Bolt to Threaded Flat Plate ..................................................................... 47 to 61 Nm (35 to 45 lb. ft.) Cab Mounting Bolt Nut ........................................................................................... 190 to 244 Nm (140 to 180 lb. ft.
Section 90 - Cab, Hood, Seat - Chapter 2 CAB RAISE PROCEDURE STEP 1 STEP 3 3 3 4 1 2 RD02C070 RD02E069 Park the tractor on a hard, level surface. Put the transmission shift lever in PARK. Place blocks in front of and behind the rear wheels. Start the engine and fully raise the rear hitch. Turn off the engine and remove the key. Disconnect the negative (-) battery cable (1), first. Disconnect the positive (+) battery cable (2). Remove the three screws (3) securing the right front cab panel (4).
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 5 STEP 7 77-2 RD02F103 If equipped with rear fenders, remove the lower fender retaining bolt and spring nut from the right rear fender. Install the right rear cab raising bracket CAS2577-1 (from CAS2577 Cab Raising Bracket Kit) into the right rear cab support tube. STEP 6 STEP 8 1 RD02C143 RD02F104 Install a bolt (1), and a washer from the cab raising bracket kit through the slot in the raising bracket and the hole in the cab side panel.
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 9 STEP 12 1 2 77-23 76-0A Place one of the load bearings from CAS2577 under the rear cab raising bracket. Insert one of the longer threaded rods from the kit through the rear cab raising bracket, the load bearing, and the through hole in the cab suppor t bracket. Thread the rod through the raising bracket until the threads contact the load bearing.
Section 90 - Cab, Hood, Seat - Chapter 2 CAB LOWERING PROCEDURE STEP 14 STEP 16 75-13 77-23 Turn out the four threaded rods on the cab raising brackets in equal amounts to evenly lower the cab. Make sure the sleeves on the cab mounting bolts align with the holes in the cab support tubes. Begin lowering the tractor cab. Check for pinched cables, lines, or hoses. Fully lower the cab. Remove the threaded rod from the raising bracket. Remove the load bearing.
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 18 STEP 21 1 2 RD02F105 76-0A Install a new nut and the rear cab mount washer. Tighten the nut to a torque of 190 to 244 Nm (140 to 180 lb. ft.). Have an assistant hold the head of the bolt under the cab, if necessary. STEP 19 Remove the locking pin from bottom of the threaded rod on the front cab raising tool. Remove the threaded rod from the front cab upper raising bracket (1) and remove the bracket. Remove the load bearing.
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 23 STEP 25 1 1 76-33 RD05K002 Open the rear window. Install the two bolts securing the rear cab panel to the cab. Install the battery cover and tool box. Tighten the thumbscrews. STEP 24 STEP 26 4 4 3 2 1 RD02E069 RD02C070 Install the right panel (3). Install the three mounting screws (4) and tighten. Install the left panel and tighten the mounting screws.Install the positive (+) battery cable (1), first. Install the negative (-) battery cable (2).
Section 90 - Cab, Hood, Seat - Chapter 2 CAB REMOVAL STEP 27 STEP 28 RD02C070 RD05K002 Park the tractor on a hard, level surface. Put the transmission shift lever in PARK. Turn off the engine and remove the key. Place blocks in front of and behind the front wheels. Drain the radiator on a cold engine. Refer to the Operator’s Manual for cooling system capacity. Properly support the tractor and remove the rear wheels, if necessary.
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 30 STEP 32 2 1 1 RD02E064 RD02C162 Identify, tag, and remove the wiring harnesses on the two brake light switches (1) on the brake valve. Identify, tag, and remove the brake valve supply (1) and return line to sump (2). Cap the lines and open fittings. STEP 31 STEP 33 3 1 1 1 2 RD05M053 Identify, tag, and remove the four hydraulic hoses (1) and the steering sensing line (2) from the steering hand pump. Cap the lines and open fittings.
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 35 STEP 37 RD02C121 76-33 Remove the supply line to the left and right rear brake. Open the rear window. Remove the two bolts securing the rear cab panel to the cab. Remove the panel. STEP 36 STEP 38 2 1 2 1 1 RD02C124 Remove the electrical connector from the cab pressurization blower. NOTE: Fuel purposes. tank removed for RD05M054 Ta g a n d r e m ove a l l c o n n e c t or s ( 1 ) f r o m t h e controllers (2).
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 40 STEP 43 2 1 RD05M056 RD02E068 Disconnect the power cables (1) and remove the cab connector (2). Refer to the Air Conditioning Component Service section in this manual and evacuate the freon from the air-conditioning system at the capped line fittings (arrows) attached to the rear of the air conditioning compressor. STEP 41 STEP 44 2 1 RD05M057 Remove the ISO 11783 harness clamp (if equipped) at the rear of the cab.
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 45 STEP 48 101R-9A RD05M051 Remove the three mirror retaining bolts and the electrical plug, if equipped. Remove the mirrors. Remove the right and left side mount light (if equipped). STEP 46 STEP 49 RD02C139 RD05M052 Install CAS2529-1 front cab lifting brackets. Disconnect the right and left side light harness (if equipped).
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 51 STEP 53 2 1 3 RD02E274 RD02F026 Install the rear lifting bracket (1) and extension arm (2). Install the mounting nut (3) (not shown). Make sure the mounting bracket (1) is fully seated on the ROPS post. Tighten the nut. Repeat this step and the previous step on the opposite side of the cab. Remove the rear cab mount nut and washer on both sides of the cab.
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 55 STEP 57 RD02E272 RD02E067 Install CAS2531 cab lifting tool on the cab brackets. Make sure the chains do not bind against the roof or cab lenses. Lift the cab only high enough to gain access to the heater hoses and hydraulic trailer lines (if equipped). Remove the heater hoses at the cab HVAC box. STEP 58 Continue to lift the cab and remove from the tractor chassis. Carefully lower the cab onto suppor ts placed under the cab rails.
Section 90 - Cab, Hood, Seat - Chapter 2 CAB INSTALLATION STEP 59 STEP 61 RD02E272 RD02C155 Make sure the chains attached to cab lift tool CAS2531 do not bind against the roof or cab lenses. Raise the cab just high enough to clear all chassis components and move into place. Lower it so that it is slightly above the chassis. Properly support the cab. Lower the cab until the hydraulic trailer brake supply lines (if equipped) can be installed at the right rear side of the tractor.
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 63 STEP 65 RD02C143 RD02C121 Set the preload on the front cab isomounts using the procedure in the previous step. Install the front cab mount washer and nut. Tighten the nut to a torque of 190 to 244 Nm (140 to 180 lb. ft.) on both sides of the cab. Install the supply line to the left and right rear brake. Continue to lower the cab onto the tractor chassis, aligning the cab mount bolts with the holes in the cab frame.
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 68 STEP 71 RD02C133 RD05M051 Install the mirrors and the three mirror retaining bolts. Connect the electrical plug if equipped. If equipped, install the right and left side mounted field lights. STEP 72 STEP 69 RD02C132 RD02E104 Lubricate new O-rings with refrigerant oil, install on the A/C fittings at the firewall and tighten. Remove the upper bolt and swing the tractor rear warning lights up. Tighten the upper and lower bolts.
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 74 STEP 77 2 1 RD05M058 RD05M055 Install the fuel vent mounting clamp. Connect the cab power supply cable (1) and the ISO 11783 power cables (2) (if equipped). STEP 75 STEP 78 2 1 2 1 1 RD05M057 Install the ISO 11783 harness clamp (if equipped) RD05M054 Connect the wire harnesses (1) to the controllers (2). STEP 76 STEP 79 2 1 RD05M056 Install the cab power cables (1) and the wire connector (2) at the right rear of the cab.
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 80 STEP 83 1 RD05M060 RD02E064 Install the cab connector at the right hand front side of the cab. Use the identification tags to install the wiring harnesses on the two brake light switches (1). STEP 81 STEP 84 1 1 2 RD05M053 RD05M059 Use the identification tags to install the four hydraulic hoses (1) and the steering sensing line (2) to the steering hand pump. Connect the cab ground strap.
Section 90 - Cab, Hood, Seat - Chapter 2 STEP 85 STEP 86 2 2 1 4 3 RD02E069 RD02C070 Install the right panel (1). Install the three mounting screws (2) and tighten. Install the left panel and tighten the mounting screws. Install the positive (+) battery cable (3), first. Install the negative (-) battery cable (4). Install the rear wheels, if removed. Apply antiseize to the wheel hub bolts and tighten in a crossing pattern to a torque of 530 to 570 Nm (390 to 420 lb. ft.).
