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Section 35 - Hydraulic Systems, 3PT - Chapter 1

35-1-3

HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC

Introduction

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.

The purpose of this section is to show you how to find your
way around schematic circuit diagrams.

Circuit Diagrams

There are two types of circuit diagrams.

1. Cutaway Circuit Diagrams show the internal construction

of the components as well as the flow paths. By using
colors, shades or various patter ns in the lines and
p a s s a g e s , t h ey a r e a bl e t o s h o w m a n y d i f fe r e n t
conditions of flow and pressure. Cutaway diagrams take
c o n s i d e ra bl y l o n g e r t o p r o d u c e b e c a u s e o f t h e i r
complexity.

2. Schematic Circuit Diagrams the “shorthand” system of

the industry, are usually preferred for troubleshooting. A
schematic diagram is made up of simple geometric
symbols for the components and their controls and
connections.

Symbol Systems

There are several systems of symbols used when making
schematic diagrams. They are as follows:

I. S. O. = International Standards Organization

A. N. S. I. = American National Standards Institute

A. S. A. = American Standards Association

J. I. C. = Joint Industry Conference

A combination of these symbols are shown in this section.
There are differences between the symbols but there is
enough similarity so that if you understand the symbols in this
section you will be able to interpret other symbols as well.

Using Schematic Symbols

Reservoirs

A rectangle with the top removed represents a vented
reservoir. A rectangle with the top in place represents a
pressurized reservoir.

There are other schematic diagrams that show a slightly
different version of a pressurized reservoir, but the symbols
are similar and easily recognized. An oval with a short line on
top or a rectangle with curved sides represents a reservoir
that is pressurized.

Lines connected to the reservoir usually are drawn from the
top, regardless of where the actual connection is.

If the hydraulic line terminates below the fluid level, it is drawn
all the way to the bottom of the symbol.

710L8D

710L8B

VENTED RESERVOIR

PRESSURIZED RESERVOIR

710L8C

710L8A

PRESSURIZED RESERVOIR

PRESSURIZED RESERVOIR

710L8E

RETURN LINE ABOVE
THE OIL LEVEL

710L8F

SUCTION LINE OR RETURN LINE
BELOW THE OIL LEVEL

«
...
738
739
740
741
742
...
»

Содержание T8010

Страница 1: ...TALLATION 3001 10 HOOD REMOVAL SECTION 10 CHAPTER 3 HOOD REMOVAL 10 3 3 HOOD INSTALLATION 10 3 5 COOLING SYSTEM MODULE REMOVAL AND INSTALLATION SECTION 10 CHAPTER 4 COOLING MODULE REMOVAL 10 4 3 COOLING MODULE INSTALLATION 10 4 7 VISCOUS FAN DRIVE TEST SECTION 10 CHAPTER 5 REQUIRED TOOLS 10 5 3 DIAGNOSTIC PROCEDURE 10 5 4 FAN SPEED TEST 10 5 7 POWERSHIFT TRANSMISSION SYSTEM HOW IT WORKS AND TROUBL...

Страница 2: ...t and Mechanical Front Drive FWD Park Brake Assembly 21 6 7 Disassembly of the Master Clutch 21 6 12 Exploded View of the Master Clutch 21 6 14 Assembly of the Master Clutch 21 6 15 Disassembly of the Range Transmission Input Shaft 21 6 16 Exploded View of the Range Transmission Input Shaft 21 6 22 Assembly of the Range Transmission Input Shaft 21 6 23 Cross Section of Input Shaft 21 6 32 Disassem...

Страница 3: ... DRIVE CONTROL SYSTEM HOW IT WORKS SECTION 25 CHAPTER 1 FRONT WHEEL DRIVE FWD 25 1 3 ELECTRONIC FRONT WHEEL DRIVE FWD CONTROL 25 1 5 FRONT WHEEL DRIVE FWD CONTROL MODES 25 1 7 FRONT WHEEL DRIVE FWD FUNCTIONAL TESTS 25 1 8 TROUBLESHOOTING 25 1 10 DIFFERENTIAL LOCK CONTROL SYSTEM HOW IT WORKS SECTION 25 CHAPTER 2 DIFFERENTIAL LOCK 25 2 3 ELECTRONIC DIFFERENTIAL LOCK CONTROL 25 2 5 DIFFERENTIAL LOCK ...

Страница 4: ...RIER ASSEMBLY REMOVAL 25 8 3 DIFFERENTIAL DISASSEMBLY 25 8 4 Pinion Disassembly 25 8 8 DIFFERENTIAL ASSEMBLY 25 8 11 DIFFERENTIAL CARRIER ASSEMBLY 25 8 15 Pinion Position and Assembly 25 8 15 Shim Pack Thickness Chart 25 8 16 Setting The Pinion Depth 25 8 17 Adjusting Bearing Preload 25 8 20 DIFFERENTIAL INSTALLATION 25 8 22 Checking Backlash 25 8 23 Ring Gear and Pinion Tooth Pattern Interpretati...

Страница 5: ... CHAPTER 12 SPECIAL TORQUES 25 12 3 VERTICAL LINK DISASSEMBLY AND REPAIR 25 12 3 Vertical Link Removal 25 12 3 Roller Replacement 25 12 4 Articulation Bearing Removal and Installation 25 12 5 REAR AXLE AND PLANETARIES SECTION 27 CHAPTER 1 SPECIAL TOOLS 27 1 3 SPECIAL TORQUES 27 1 5 SPECIFICATIONS 27 1 5 GENERAL INFORMATION 27 1 5 REAR AXLE 27 1 6 AXLE HOUSING DISASSEMBLY 27 1 9 PLANETARY DISASSEMB...

Страница 6: ...5 SINGLE SPEED REVERSIBLE SHAFT PTO DRIVEN GEAR 31 2 39 Removal 31 2 39 Assembly 31 2 41 Reversible PTO Output Shaft Bearing Adjustment 31 2 43 SINGLE SPEED REVERSIBLE SHAFT PTO 31 2 45 Cross Section of PTO Output Shaft Assembly 31 2 45 BRAKE VALVE SECTION 33 CHAPTER 1 SPECIAL TORQUES 33 2 2 BRAKE VALVE 33 2 3 Removal 33 2 3 Disassembly 33 2 4 Assembly 33 2 6 Installation 33 2 8 BRAKE CYLINDERS SE...

Страница 7: ...E VALVE AND COUPLER SERVICE 35 4 3 REMOTE VALVE REMOVAL AND SERVICE 35 4 5 REMOTE COUPLERS 35 4 13 REMOTE HYDRAULIC SYSTEM HOW IT WORKS AND TROUBLESHOOTING SECTION 35 CHAPTER 5 REMOTE HYDRAULIC SYSTEM INTRODUCTION 35 5 3 REMOTE VALVE SYSTEM COMPONENTS 35 5 5 REMOTE VALVE SYSTEM CONTROLS 35 5 10 REMOTE VALVE OPERATION 35 5 14 REMOTE VALVE PROBLEMS AND WHERE TO LOOK 35 5 23 REMOTE VALVE PROPORTIONAL...

Страница 8: ...5 10 5 Assembly 35 10 7 Installation 35 10 9 HITCH CONTROL VALVE CROSS SECTION 35 10 11 TRACTOR HITCH SECTION 35 CHAPTER 11 SPECIAL TORQUES 35 11 3 TRACTOR HITCH 35 11 3 EDC PIN ASSEMBLY 35 11 20 POTENTIOMETER HITCH POSITION SENSOR 35 11 21 CAM SWAY LIMITER 35 11 23 CAM BUMPERS FOR DRAFT ARM 35 11 25 DRAWBAR HIGH VERTICAL CAPACITY 35 11 26 STEERING COLUMN AND STEERING HAND PUMP SECTION 41 CHAPTER ...

Страница 9: ... 131 50 1 25 ATC Fault Code 132 50 1 25 ATC Fault Code 133 50 1 26 ATC Fault Code 134 50 1 26 Locating System Problems Without Fault Codes 50 1 27 Controller Based Resistance Tests 50 1 27 ATC Controller Test Connector J8 Test Points 50 1 29 ATC Field Reported Symptoms Causes 50 1 32 Compressor And Clutch 50 1 33 Operational Check 50 1 33 Electrical Test 50 1 36 Compressor Clutch Control Circuit T...

Страница 10: ...BOX 50 1 59 STANDARD AIR CONDITIONING STD TROUBLESHOOTING 50 1 60 Standard A C Operation 50 1 61 Smart Pressure Switch Cycling System 50 1 61 Standard A C Controls and Their Function 50 1 62 Symptom Based Standard A C Troubleshooting 50 1 63 Standard Controller Test 50 1 65 Compressor And Clutch 50 1 67 Operational Check 50 1 67 Electrical Test Compressor Clutch 50 1 70 Clutch Relay Power Supply a...

Страница 11: ...ptoms 50 1 84 Evaporator Temperature Sensor and Circuit Test 50 1 84 Controller Power Ground And A C Switch 50 1 86 Background 50 1 86 Power and Ground Circuit 50 1 86 Possible Failure Modes 50 1 86 Controller Power Supply and Ground Test 50 1 86 A C Switch and Circuit Test 50 1 87 Cab Pressurizer Blower 50 1 88 Background 50 1 88 Power and Ground 50 1 88 Cab Pressurizer Blower Relay Power Supply ...

Страница 12: ...ting 50 2 59 A C SYSTEM COMPONENTS 50 2 60 Cab HVAC Box Components Automatic Temperature Control 50 2 60 Cab HVAC Components Standard Systems 50 2 62 Chassis Components 50 2 64 A C COMPRESSOR CLUTCH 50 2 65 Clutch Removal 50 2 65 Exploded View of Clutch 50 2 71 Compressor Clutch Replacement 50 2 71 A C COMPRESSOR 50 2 79 Oil Level Check or Adjustment 50 2 79 Compressor Removal 50 2 82 Compressor I...

Страница 13: ...ymptom Chart 55 1 145 Audio System Diagnostic Tests 55 1 147 CHARGING SYSTEM 55 1 151 Charging System Circuit Operation 55 1 151 Charging System Circuit Troubleshooting 55 1 151 Charging System Symptom Chart 55 1 152 Charging System Diagnostic Tests 55 1 153 EXTERIOR LIGHTING SYSTEM 55 1 157 Exterior Lighting System Circuit Operation 55 1 157 Exterior Lighting System Circuit Troubleshooting 55 1 1...

Страница 14: ...T CODE INST 1015 55 2 4 FAULT CODE INST 3010 55 2 6 FAULT CODE INST 3020 55 2 7 FAULT CODE INST 3022 55 2 7 FAULT CODE INST 5010 55 2 7 FAULT CODE INST 5011 55 2 8 FAULT CODE INST 10031 55 2 9 FAULT CODE INST 10032 55 2 9 FAULT CODE INST 10033 55 2 9 FAULT CODE INST 10034 55 2 10 FAULT CODE INST 10035 55 2 10 FAULT CODE INST 10036 55 2 10 FAULT CODE INST 10037 55 2 11 FAULT CODE INST 10038 55 2 11...

Страница 15: ... 29 AUX HITCH PTO FAULT CODE 34 55 3 29 AUX HITCH PTO FAULT CODE 35 55 3 30 AUX HITCH PTO FAULT CODE 37 55 3 31 AUX HITCH PTO FAULT CODE 41 55 3 31 AUX HITCH PTO FAULT CODE 42 55 3 32 AUX HITCH PTO FAULT CODE 43 55 3 32 AUX HITCH PTO FAULT CODE 44 55 3 32 AUX HITCH PTO FAULT CODE 45 55 3 32 AUX HITCH PTO FAULT CODE 47 55 3 33 AUX HITCH PTO FAULT CODE 48 55 3 33 AUX HITCH PTO FAULT CODE 50 55 3 34 ...

Страница 16: ...CH PTO FAULT CODE 127 55 3 66 AUX HITCH PTO FAULT CODE 128 55 3 67 AUX HITCH PTO FAULT CODE 129 55 3 68 AUX HITCH PTO FAULT CODE 130 55 3 69 AUX HITCH PTO FAULT CODE 131 55 3 70 AUX HITCH PTO FAULT CODE 132 55 3 71 AUX HITCH PTO FAULT CODE 133 55 3 72 AUX HITCH PTO FAULT CODE 134 55 3 73 AUX HITCH PTO FAULT CODE 135 55 3 74 AUX HITCH PTO FAULT CODE 136 55 3 75 AUX HITCH PTO FAULT CODE 137 55 3 76 ...

Страница 17: ...167 55 3 97 AUX HITCH PTO FAULT CODE 168 55 3 98 AUX HITCH PTO FAULT CODE 169 55 3 99 AUX HITCH PTO FAULT CODE 170 55 3 100 AUX HITCH PTO FAULT CODE 171 55 3 101 AUX HITCH PTO FAULT CODE 172 55 3 101 AUX HITCH PTO FAULT CODE 173 55 3 102 AUX HITCH PTO FAULT CODE 174 55 3 103 AUX HITCH PTO FAULT CODE 175 55 3 104 AUX HITCH PTO FAULT CODE 178 55 3 106 AUX HITCH PTO FAULT CODE 179 55 3 107 AUX HITCH ...

Страница 18: ...ULT CODE TRANS 77 55 4 29 FAULT CODE TRANS 78 55 4 30 FAULT CODE TRANS 79 55 4 31 FAULT CODE TRANS 80 55 4 32 FAULT CODE TRANS 81 55 4 34 FAULT CODE TRANS 82 55 4 36 FAULT CODE TRANS 83 55 4 36 FAULT CODE TRANS 103 55 4 37 FAULT CODE TRANS 104 55 4 38 FAULT CODE TRANS 105 55 4 39 FAULT CODE TRANS 106 55 4 40 FAULT CODE TRANS 107 55 4 41 FAULT CODE TRANS 108 55 4 42 FAULT CODE TRANS 109 55 4 43 FAU...

Страница 19: ...LT CODE TRANS 134 55 4 62 FAULT CODE TRANS 135 55 4 63 FAULT CODE TRANS 136 55 4 65 FAULT CODE TRANS 137 55 4 67 FAULT CODE TRANS 138 55 4 68 FAULT CODE TRANS 139 55 4 69 FAULT CODE TRANS 140 55 4 70 FAULT CODE TRANS 141 55 4 71 FAULT CODE TRANS 142 55 4 72 FAULT CODE TRANS 143 55 4 72 FAULT CODE TRANS 144 55 4 73 FAULT CODE TRANS 145 55 4 74 FAULT CODE TRANS 147 55 4 75 FAULT CODE TRANS 148 55 4 ...

Страница 20: ...LT CODE ARM 169 55 5 19 FAULT CODE ARM 1029 55 5 20 FAULT CODE ARM 1039 55 5 21 FAULT CODE ARM 1049 55 5 22 FAULT CODE ARM 1059 55 5 23 FAULT CODE ARM 1069 55 5 24 FAULT CODE ARM 1079 55 5 25 FAULT CODE ARM 1089 55 5 26 FAULT CODE ARM 1099 55 5 27 FAULT CODE ARM 1109 55 5 28 FAULT CODE ARM 1119 55 5 29 FAULT CODE ARM 1129 55 5 30 FAULT CODE ARM 8011 55 5 30 FAULT CODE ARM 9011 55 5 31 FAULT CODE A...

Страница 21: ...libration is Required 55 6 28 Clutch Calibration Procedure 55 6 39 Calibration Error Messages 55 6 43 Front Suspension Calibration 55 6 48 REMOTE AUX SYSTEM CALIBRATION 55 6 55 Aux Cal Menu 55 6 61 HITCH SYSTEM CALIBRATION 55 6 64 PTO SYSTEM CONFIGURATION 55 6 74 PEDAL AND PEDAL SWITCH ADJUSTMENTS SECTION 90 CHAPTER 1 TABLE OF CONTENTS 90 1 2 INCHING PEDAL SWITCH ADJUSTMENT 90 1 3 BRAKE PEDAL ADJU...

Страница 22: ...Section 00 Chapter 1 January 2006 STANDARD TORQUE SPECIFICATION ...

Страница 23: ...00 General Information Chapter 1 00 1 2 TABLE OF CONTENTS TORQUE SPECIFICATIONS METRIC HARDWARE 00 1 4 TORQUE SPECIFICATIONS STEEL HYDRAULIC FITTINGS 00 1 5 TORQUE SPECIFICATIONS STEEL HYDRAULIC FITTINGS 00 1 6 ...

Страница 24: ...5 8 inch 150 to 180 203 to 244 3 4 inch 270 to 324 366 to 439 7 8 inch 400 to 480 542 to 651 1 0 inch 580 to 696 787 to 944 1 1 8 inch 800 to 880 1085 to 1193 1 1 4 inch 1120 to 1240 1519 to 1681 1 3 8 inch 1460 to 1680 1980 to 2278 1 1 2 inch 1940 to 2200 2631 to 2983 Grade 8 Bolts Nuts and Studs Size Pound Inches Newton metres 1 4 inch 144 to 180 16 to 20 5 16 inch 288 to 348 33 to 39 3 8 inch 5...

Страница 25: ...hes Newton metres M4 24 to 36 3 to 4 M5 60 to 72 7 to 8 M6 96 to 108 11 to 12 M8 228 to 276 26 to 31 M10 456 to 540 52 to 61 Size Pound Feet Newton metres M12 66 to 79 90 to 107 M14 106 to 127 144 to 172 M16 160 to 200 217 to 271 M20 320 to 380 434 to 515 M24 500 to 600 675 to 815 M30 920 to 1100 1250 to 1500 M36 1600 to 1950 2175 to 2600 8 8 Grade 10 9 Bolts Nuts and Studs Size Pound Inches Newto...

Страница 26: ...7 8 12 210 to 250 285 to 338 Split Flange Mounting Bolts Size Pound Inches Newton metres 5 16 18 180 to 240 20 to 27 3 8 16 240 to 300 27 to 34 7 16 14 420 to 540 47 to 61 Size Pound Feet Newton metres 1 2 13 55 to 65 74 to 88 5 8 11 140 to 150 190 to 203 Tube OD Hose ID Thread Size Pound Inches Newton metres Straight Threads with O ring 1 4 inch 6 4 mm 7 16 20 144 to 228 16 to 26 5 16 inch 7 9 mm...

Страница 27: ...6 16 384 to 480 43 to 54 3 4 16 540 to 600 61 to 68 Thread Size Pound Feet Newton metres 10 5 8 inch 15 9 mm 1 14 552 to 672 62 to 76 7 8 14 60 to 65 81 to 88 Nom SAE Dash Size Tube OD Thread Size Pound Feet Newton metres 1 1 16 12 85 to 90 115 to 122 1 3 16 12 95 to 100 129 to 136 12 3 4 inch 19 0 mm 1 3 16 12 65 to 80 90 to 110 1 5 16 12 115 to 125 156 to 169 14 7 8 inch 22 2 mm 1 3 16 12 65 to ...

Страница 28: ...Section 00 Chapter 2 January 2006 SAFETY GENERALINFORMATION MAINTENANCE SCHEDULE ...

Страница 29: ...Section 00 General Information Chapter 2 00 2 2 TABLE OF CONTENTS SAFETY 00 2 3 GENERAL INFORMATION 00 2 5 LUBRICATION MAINTENANCE CHART 00 2 6 SYSTEM CAPACITIES 00 2 7 ...

Страница 30: ...490 WARNING This machine is for one operator no riders allowed M491A 201L95 WARNING Before starting engine study Operator s Manual safety messages Read all safety signs on machine Clear the area of other persons Learn and practice safe use of controls before operating It is your responsibility to understand and follow manufacturers instructions on machine operation service and to observe pertinent...

Страница 31: ... WARNING Use suitable floor service jacks or chain hoist to raise wheels or tracks off the floor Always block machine in placed with suitable safety stands M499 WARNING When servicing or repairing the machine Keep the shop floor and operator s compartment and steps free of oil water grease tools etc Use an oil absorbing material and or shop cloths as required Use safe practices at all times M500 W...

Страница 32: ...eplaced Needle Bearings Before you press needle bearings into a bore always remove any metal protrusions in the bore or the edge of the bore Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearing Gears Check all gears for excessive wear or damage Replace gears as necessary Oil Seals O rings and Gaskets Always install new oil seals O rings and ...

Страница 33: ... Hours Front Hitch If Equipped X Every 300 Hours Battery Water Level Note E X Engine Air Intake Hoses X Engine Oil And Filter X Front And Rear Wheel Bolt Torques X Front Weight And Rear Wheel Weight Bolt Torques X Front Axle And Rear Hitch Note A X Fuel Tank Drain Water X Differential And Planetary Oil Level Note B X Transmission Oil Pressure X Reversible 1000 RPM PTO Shaft Note D X Every 600 Hour...

Страница 34: ...er FWD Planetary Each 13 0 QtsB 14 0 QtsC 3 Pints 12 5 QtsD 14 0 QtsC 7 0 Pints 12 3 L 13 25 L 1 4 L 11 8 L 13 25 L 3 3 L 21 6 Pints 23 3 Pints 2 5 Pints 20 8 Pints 23 3 Pints 5 8 Pints Fuel Tank All 178 Gal 674L 148 Gal A Bolt quantity can be determined by observing the wheel ends B 25 pints New Holland Ambra Hypoide 140 Gear Oil SAE 85W140 plus 1 pint New Holland Limited Slip Additive B96606 for...

Страница 35: ...Section 00 General Information Chapter 2 00 2 8 This Page Left Blank ...

Страница 36: ...Section 10 Chapter 1 January 2006 ENGINE REMOVAL AND INSTALLATION ...

Страница 37: ...Section 10 Engine Chapter 1 10 1 2 TABLE OF CONTENTS ENGINE REMOVAL 10 1 3 ENGINE INSTALLATION 10 1 10 ...

Страница 38: ...ove the key Place blocks in front of and behind the rear wheels STEP 2 RD02E069 Remove the battery cover Disconnect the negative cable then the positive cable STEP 3 Remove the hood See Hood Removal Section in this Repair Manual STEP 4 Evacuate the A C system See A C Service Section in this Repair Manual STEP 5 Remove the cooling module See Cooling Module Section in this Repair Manual STEP 6 RD05N...

Страница 39: ... Disconnect the turbo to charge air cooler pipe 1 at the turbo 2 and remove STEP 10 RD05N104 Remove the starter cables STEP 11 RD05N105 Tag and remove the heater supply hose 1 and return hose 2 STEP 12 RD05N106 Disconnect the A C high pressure switch 1 Disconnect the A C compressor clutch harness 2 STEP 13 RD05N107 Remove and tag the alternator harness wires 1 2 2 1 1 2 ...

Страница 40: ...ow 2 pressure A C line Discard the O rings Cap all fittings STEP 16 RD05N110 Remove the air cleaner restriction switch harness STEP 17 RD05N136 Disconnect the coolant fill tube 1 at the deaeration tank hose 2 and the engine block 3 Remove the tube STEP 18 RD05N111 Loosen the air cleaner to turbo inlet hose clamp STEP 19 RD05N117 Disconnect the alternator wire harness connector This connector is lo...

Страница 41: ...1 and engine to deaeration tank air bleed hose 2 STEP 22 RD05N114 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 STEP 23 RD05N116 Disconnect the suspended axle position pot harness 1 if equipped Remove the engine ECM Electronic Control Module ...

Страница 42: ...sher hose and electrical connector 1 Repeat for the rear 2 if required STEP 26 RD05N120 Tag and remove the right 1 and left 2 brake switch connectors STEP 27 RD05N121 Properly support the hood deaeration tank mounting assembly STEP 28 RD05N122 Remove right rear support bracket bolt STEP 29 RD05N123 If installed remove the windshield step mounting bolts 1 and remove the step 2 2 1 2 1 1 2 ...

Страница 43: ...ise the assembly slightly to gain access to the main engine connector 1 and disconnect Continue to raise and remove from the engine STEP 33 RD05N127 Disconnect the high 1 and low 2 pressure A C lines STEP 34 RD05N128 Remove the hydraulic oil cooling lines STEP 35 RD05N129 Remove the two right rear tube hose air cleaner bracket assembly mounting bolts 1 2 ...

Страница 44: ...t mounting bolts 1 and spacer 2 STEP 39 RD05N133 Properly support the hose tube air cleaner support bracket assembly and remove from the engine STEP 40 RD05N135 RI02C011 Properly support the engine Place a small amount of tension on the hoist Remove the six engine mounting bolts Move the engine forward to disengage from the transmission Remove the engine from the front frame 1 2 ...

Страница 45: ...el dampener and slide into place Install the mounting bolts Tighten the two M20 bolts 1 to a torque of 430 to 485 Nm 315 to 355 lb ft Tighten the four M16 bolts 2 to a torque of 221 to 250 Nm 160 to 180 lb ft STEP 42 RD05N133 Set the hose tube air cleaner support bracket assembly in place on top of the engine STEP 43 RD05N132 Set the spacer 1 into place and install the mounting bolts 2 NOTE DO NOT...

Страница 46: ...this time STEP 46 RD05N130 Install the heat shield 1 Install and tighten mounting bolts 2 STEP 47 RD05N128 Install new O rings on the fittings and tighten the hydraulic cooling lines STEP 48 Rd05N127 Install new O rings on the fittings and tighten the A C lines STEP 49 RD05N121 Properly support the hood deaeration tank mounting assembly and set into place at the rear of the engine 2 1 ...

Страница 47: ...ng bolts and tighten to a torque of 310 to 380 Nm 230 to 280 lb ft STEP 52 RD05N124 Install the fuel supply hose STEP 53 RD05N123 If removed install the windshield step 1 and tighten the bolts 2 STEP 54 RD05N122 Install and tighten the right rear support bolt STEP 55 RD05N120 Install the right 1 and left 2 brake switch connectors 2 1 1 2 ...

Страница 48: ...gine grid heater power cable STEP 58 RD05N116 Install the throttle position connector 1 and the ECM power connector 2 If equipped connect the suspended axle position pot connector 3 STEP 59 RD05N134 Install a new O ring on the charge air cooler to intake manifold tube assembly Install the tube STEP 60 RD05N114 RD05N115 Install the bushing bolt 1 Install the clamp 2 Tighten all hardware 2 1 3 1 3 2...

Страница 49: ...the bracket and tighten the mounting nuts Make sure the alternator wire harness is installed between the air cleaner and mounting brackets STEP 63 RD05N111 Tighten the air cleaner to turbo hose clamp STEP 64 RD05N110 Install the air cleaner restriction switch connector STEP 65 RD05N117 Connect the alternator harness STEP 66 RD05N109 Install new O rings and tighten the A C compressor lines 2 1 1 2 ...

Страница 50: ...1 and the high pressure switch 2 connectors STEP 70 RD05N105 Install the heater out 1 and in 2 hoses STEP 71 RD05N104 Install the starter cables STEP 72 RD05N103 Install the turbo to charge air cooler pipe assembly 1 Install the clamp 2 NOTE Do not tighten clamp 2 until the cooling module has been installed This will allow alignment of the pipe with the charge air cooler connector 2 1 2 1 2 1 1 2 ...

Страница 51: ...he cooling module See Cooling Module Section in this Repair Manual 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 RD02E069 Install the positive cable Install the negative cable Install the battery cover NOTE Install all tie straps that were removed during disassembly STEP 80 Start the eng...

Страница 52: ...Section 10 Chapter 2 January 2006 FUEL TANK FUEL SENDER REMOVAL AND INSTALLATION ...

Страница 53: ...ction 10 Engine Chapter 2 10 2 2 TABLE OF CONTENTS SPECIAL TORQUES 10 2 3 FUEL TANK 10 2 3 General 10 2 3 Removal 10 2 3 Installation 10 2 7 FUEL LEVEL SENDER 10 2 10 Removal 10 2 10 Installation 10 2 11 ...

Страница 54: ...e following 1 Park the tractor on a hard level surface 2 Place the transmission control lever in PARK 3 Shut off the engine and remove the key 4 Put blocks in front of and in back of the rear wheels Removal STEP 2 95 12 Remove the six step mounting bolts 1 Move the steps away from the tractor STEP 3 4 25F Drain the fuel tank Fuel tank capacity is 674 L 178 gal 1 1 ...

Страница 55: ...ct the fuel level sending unit wire harness STEP 6 RD05K006 Remove the vent hose STEP 7 RD05K005 Loosen hose clamp 1 on fuel tank balance hose located under the transmission speed housing Remove the fuel injection system supply hose 2 STEP 8 95 24 Remove the pressure equalization hose at the front of the cab from the top left hand fuel tank STEP 9 95 15R Remove two bolts from each of the two lockd...

Страница 56: ... onto the support bracket STEP 11 RD05K008 Disconnect the fuel return line STEP 12 5 27 3 Remove the left tank STEP 13 RD05K007 Remove the fuel supply fitting 1 the fuel return fitting 2 vent fitting 3 and fuel sending unit cover 4 STEP 14 RD05K003 Remove the fuel sender 1 by placing a screwdriver under the head and prying up Remove the seal 2 Inspect for damage replace as necessary STEP 15 RD05K0...

Страница 57: ... the neck leading into tank STEP 18 5 20 Remove the two bolts from the lockdown plate on the right tank STEP 19 101R 23A Lift the right tank free of the support bracket and remove the tank IMPORTANT Be prepared to collect some fuel when the tank is removed STEP 20 RD02B107 If fuel tank support bracket needs to be removed properly support the bracket while removing the bolts 1 from the left and rig...

Страница 58: ...er of the seal with soap and install STEP 23 RD05K003 Lubricate the inside diameter of the seal 1 with soap and install the fuel sender 2 STEP 24 101R 19A Install the fuel tank onto the support brackets with enough room to attach fittings STEP 25 RD05K008 Install the fuel return line Push the fuel tank into position STEP 26 RD05K005 Connect the fuel injection system supply hose 1 and fuel tank bal...

Страница 59: ...n clamp STEP 29 RD05K006 Install the fuel vent hose 1 and reposition the hose clip STEP 30 101R 23A 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 31 5 20 Install and tighten the two bolts on the hold down plate STEP 32 RD02B106 Install t...

Страница 60: ...tall battery cover and toolbox 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 STEP 36 5 23 Position the wheels to the desired position on the rear axle ...

Страница 61: ...D05J085 Disconnect the fuel sender wire harness STEP 38 RD05J087 Remove the fuel sender cover bolts STEP 39 RD05J088 Pry the sender free of the fuel tank STEP 40 RD05K003 Remove the sender STEP 41 RD05K004 Remove the sender seal inspect for damage and replace if necessary ...

Страница 62: ...of the seal with soap and install STEP 43 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 STEP 45 RD05J085 Connect the fuel sender wire harness STEP 46 Install fuel and check sender for proper operation 2 1 ...

Страница 63: ...Section 10 Engine Chapter 2 10 2 12 ...

Страница 64: ...Section 10 Chapter 3 January 2006 HOOD REMOVAL INSTALLATION ...

Страница 65: ...Section 10 Engine Chapter 3 10 3 2 TABLE OF CONTENTS HOOD REMOVAL 10 3 3 HOOD INSTALLATION 10 3 5 ...

Страница 66: ...rface Put the transmission shift lever in PARK Place blocks in front of and behind the rear wheels STEP 2 RD05N001 Disconnect the hood light wire harness STEP 3 RD05N002 Disconnect horn wire harness STEP 4 RD05N003 Remove the windshield washer nozzle hose STEP 5 RD05J075 Remove the hood lanyard and fully raise the hood STEP 6 RD05N004 Properly support the hood ...

Страница 67: ...ach hood strut STEP 8 RD05N007 Remove the hood struts STEP 9 RD05N008 Remove the locking bracket STEP 10 RD05N009 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 1 2 ...

Страница 68: ...aise and set into place STEP 12 RD05N009 Align the hood bracket 1 with the hood support rod 2 and slide forward into place STEP 13 Rd05N004 Raise the hood STEP 14 RD05N008 Install the locking bracket STEP 15 RD05N007 Install the hood support struts STEP 16 RD05N006 Install the safety pin in each strut and lock in place 1 2 ...

Страница 69: ...the hood STEP 18 RD05J074 Clip the hood lanyard to the support bracket STEP 19 RD05N003 Install the windshield washer nozzle supply hose STEP 20 RD05N002 Connect the horn wire harness STEP 21 RD05N001 Connect the hood lights wire harness STEP 22 RD02C070 Remove all wheel blocks ...

Страница 70: ...Section 10 Chapter 4 January 2006 COOLING SYSTEM MODULE REMOVAL AND INSTALLATION ...

Страница 71: ...Section 10 Engine Chapter 4 10 4 2 TABLE OF CONTENTS COOLING MODULE REMOVAL 10 4 3 COOLING MODULE INSTALLATION 10 4 7 ...

Страница 72: ...cuate the system STEP 4 RD05N013 Drain the engine coolant into a suitable clean container Radiator drain is located on the right side of the front frame RD05N014 Remove the air scoop hose bracket 1 mounting bolt 2 and mounting nut 3 Remove the bracket Remove the hose clamps 4 NOTE In the following steps the hood has been removed for photographic purposes WARNING Check and service cooling system ac...

Страница 73: ...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 RD05N017 Remove the swing latch locking pin 1 Remove the mounting lock nuts 2 STEP 8 RD05N018 Place a piece of cardboard or other suitable padding on top of the air cleaner Carefully lift the condenser from its mounting and place it on the padding as show Continue wi...

Страница 74: ...hose 3 Discard the O ring STEP 10 RD05N020 Remove the A C dryer inlet hose Discard the O ring STEP 11 RD05N021 Remove the air bleed 1 and upper radiator 2 hoses STEP 12 RD05N022 Remove the radiator outlet lower pipe at the engine Discard the gasket STEP 13 RD05N023 Remove the lower charge air cooler hose STEP 14 RD05N024 Remove the upper charge air cooler hose 2 3 1 2 1 ...

Страница 75: ...N026 Properly support the cooling assembly STEP 18 RD05N028 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 IMPORTANT DO NOT bend the fan blades too far as damage to the fan may occur STEP 19 RD05N029 Move the cooling assembly out far enough to gain e...

Страница 76: ... the radiator drain hose STEP 22 RD05N028 Lower the assembly into position until the shroud 1 clears the fan 2 STEP 23 RD05N027 Install the module mounting bolts 1 and tighten to a torque of 90 to 107 Nm 66 to 79 lb ft STEP 24 RD05N023 Install the lower charge air cooler hose and tighten the clamp STEP 25 RD05N024 Install the upper charge air cooler hose and tighten the clamp 1 2 1 1 ...

Страница 77: ...e clamp Install the air bleed hose and clamp 2 Do the following step if the A C condenser was not removed STEP 28 RD05N018 RD05N017 Lift the condenser from the padding and place on the mounting studs 1 Install the locking nuts 2 Do not over tighten the nuts allow condenser to swing freely Install the locking pin 3 STEP 29 RD05N020 Install a new O ring on the A C dryer inlet hose and tighten the fi...

Страница 78: ... line and tighten the fitting 1 Install the support clamp 2 STEP 32 Rd05N016 Install a new O ring on the upper hydraulic cooler hose 1 and tighten the fitting STEP 33 RD05N015 Install the air cleaner scoop and install new plastic fasteners 1 Lower fastener not shown STEP 34 RD05N014 Install hose clamps 1 bracket 2 and mounting hardware 3 STEP 35 RD05N012 If required recharge the A C system See A C...

Страница 79: ...ycol 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 STEP 37 RD05N011 Install the left 1 and right side panels If necessary top off coolant in the recovery bottle 2 STEP 38 RD02C070 Remove wheel blocks 1 2 ...

Страница 80: ...Section 10 Chapter 5 January 2006 VISCOUS FAN DRIVE TEST ...

Страница 81: ...Section 10 Engine Chapter 5 10 5 2 TABLE OF CONTENTS REQUIRED TOOLS 10 5 3 DIAGNOSTIC PROCEDURE 10 5 4 FAN SPEED TEST 10 5 7 ...

Страница 82: ...ction 10 Engine Chapter 5 10 5 3 REQUIRED TOOLS Digital Photo Tachometer OEM1057A or Equivalent Digital Thermometer with Probe 380001301 OR Digital Multimeter with Air Probe Equivalent OEM1057A 380001301 ...

Страница 83: ... 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 STEP 2 Check the torque of the fan driven pulley bolts 20 22 lb ft 27 30 Nm STEP 3 Check the torque of the fan drive pulley 148 lb ft 200 Nm RD03C013 RD03C014 RH02J056 ...

Страница 84: ...l resistance If the fan rotates with strong or non uniform resistance replace the fan drive NOTE Fan resistance must result from the internal drive not from interference with a non rotating part STEP 7 There should be minimal forward rearward play in the fan drive Grasp the center of the blade assembly and attempt to move the drive forward and rearward If there is more than 1 16 inch 1 6 mm play i...

Страница 85: ...ash 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 Do NOT aim the low pressure wash directly at the fan bi metal drive while cleaning STEP 9 Check that the cooling system is filled to the proper level and with the corre...

Страница 86: ...the engine and operate until the thermostat opens then turn the engine OFF NOTE The A C system and the heater valve should remain closed throughout this test STEP 11 Place a piece of reflective tape 1 from the Digital Photo Tachometer Kit on the engine side of the fan blade Install the tape near the outside edge of the blade the left corner of the blade as viewed from the left side of the tractor ...

Страница 87: ...aft Increase engine speed until fan drive shaft speed reaches 2200 rpm on all models with 40 KPH transmission or 2500 rpm on all models with 50 KPH transmission NOTE Fan drive shaft speed is not the same as engine speed Fan drive to engine speed ratio is 1 1 1 on all 40 KPH transmission models and 1 25 1 on all 50 KPH models Lock the throttle at this RPM This establishes the fan drive shaft test R...

Страница 88: ...hile recording temperatures and fan RPM STEP 18 1 Replace the viscous fan drive if 50 KPH Transmissions If the fan fails to reach 2125 RPM or higher at least 85 of the test RPM at 200 220 F 93 3 104 4 C coolant temperature AND air temperature at the fan drive exceeds 195 F 90 6 C 40 KPH Transmissions If the fan fails to reach 1870 RPM or higher at least 85 of the test RPM at 200 220 F 93 3 104 4 C...

Страница 89: ...5 10 5 10 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 ...

Страница 90: ...Section 21 Chapter 1 January 2006 POWERSHIFT TRANSMISSION SYSTEM How It Works and Troubleshooting ...

Страница 91: ...DISTRIBUTION TUBES 21 1 8 POWERSHIFT TRANSMISSION CLUTCH LAYOUT 21 1 10 POWERSHIFT VALVE CLUTCH ENGAGEMENTS 21 1 11 POWER FLOW FORWARD SPEEDS 21 1 12 POWER FLOW REVERSE SPEEDS 21 1 30 POWER FLOW FORWARD CREEPER DRIVE SPEEDS 21 1 34 POWER FLOW REVERSE CREEPER DRIVE SPEEDS 21 1 40 INCHING VALVE OPERATION 21 1 42 INSTRUMENTATION CLUSTER TRANSMISSION LEAKAGE CHECK 21 1 46 MASTER CLUTCH PRESSURE CHECK ...

Страница 92: ...R PROGRAMMABLE DISPLAY AND CONTROLLER TRANSMISSION SPEED SENSOR TRANSMISSION CONTROL VALVE SPEED TRANSMISSION CONTROL VALVE RANGE TRANSMISSION CONTROL VALVE ODD EVEN INCHING VALVE TRANSMISSION CONTROL LEVER FNRP PRIORITY REGULATOR VALVE SUPPLY TO OTHER REGULATED CIRCUITS ENGINE SPEED SENSOR SEAT SWITCH ENGINE CONTROLLER F W D 1 3 5 R L O W M E D H I G H O D D E V E N P A R K C R E E P M C SYSTEM P...

Страница 93: ...ntroller will display any system faults or fault code information through the programmable display When a fault occurs a 3 second continuous audible alarm will sound The audible alarm will stop after 3 seconds Once the fault has been corrected depress the Reset button on the programmable display to clear the fault NOTE The following warning is of a critical nature and the tractor engine should be ...

Страница 94: ...LS RH05J060 RD05J155 1 THROTTLE HAND LEVER 6 GEAR SHIFT UP BUTTON 2 TRANSMISSION CONTROL LEVER 7 GEAR SHIFT DOWN BUTTON 3 CREEPER CONTROL SWITCH IF EQUIPPED 8 PARK BUTTON ACTIVATE IN NEUTRAL 4 FWD CONTROL SWITCH 9 SHUTTLE SHIFT CONTROL BUTTON 5 DIFF LOCK SWITCH 1 2 3 4 5 6 7 8 9 ...

Страница 95: ...ame SM_1_col Template Date 2001_03_06 Alt to hide template information Alt to display template information TRANSMISSION SYSTEM COMPONENTS RI02E087 and 088 1 2 3 4 5 7 8 9 14 14 28 25 20 27 26 6 15 16 9 17 19 18 6 ...

Страница 96: ...CH TEST PORT 5 PARK BRAKE SOLENOID 20 POWERSHIFT VALVE SPEED 6 PTO DIFF LOCK VALVE 21 C1 CLUTCH SOLENOID 7 PRIORITY REGULATOR VALVE 22 C3 CLUTCH SOLENOID 8 REGULATED PRESSURE TO POWERSHIFT VALVES 23 C5 CLUTCH SOLENOID 9 POWERSHIFT VALVE RANGE 24 REVERSE SOLENOID 10 FWD SOLENOID 25 SYSTEM PRESSURE TRANSDUCER 11 LOW CLUTCH SOLENOID 26 TO PARK BRAKE 12 MID CLUTCH SOLENOID 27 PARK BRAKE PUMP 13 HIGH C...

Страница 97: ...TION TUBE 4 SPEED C5 CLUTCH DISTRIBUTION TUBE 16 EVEN CLUTCH DISTRIBUTION TUBE 5 SPEED REVERSE CLUTCH DISTRIBUTION TUBE 17 SPEED INPUT SHAFT BEARING CAGE 6 RANGE INPUT SHAFT BEARING CAGE 18 SPEED COUNTERSHAFT BEARING CAGE 7 CREEPER CLUTCH SUPPLY 19 MASTER CLUTCH SOLENOID 8 MASTER CLUTCH SPEED OUT AND RANGE INPUT LUBE 20 ODD EVEN POWERSHIFT MOUNTING PLATE 9 HIGH CLUTCH DISTRIBUTION TUBE 21 INCHING ...

Страница 98: ...Section 21 Transmission Drivelines Chapter 1 21 1 9 RH98C089 Top Rear View 1 2 3 4 5 19 20 16 15 14 18 21 13 22 10 11 8 9 ...

Страница 99: ...zed DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION FWD CLUTCH SPRING ENGAGED HYDRAULIC PUMP DRIVE GEAR CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 ...

Страница 100: ...EUTRAL X X PARK 1 X X X X 2 X X X X 3 X X X X 4 X X X X 5 X X X X 6 X X X X 7 X X X X 8 X X X X 9 X X X X 10 X X X X 11 X X X X 12 X X X X 13 X X X X 14 X X X X 15 X X X X 16 X X X X 17 X X X X 18 X X X X 19 X X X X REV 1 X X X X REV 2 X X X X REV 3 X X X X REV 4 X X X X CR1 X X X X CR2 X X X X CR3 X X X X CR4 X X X X CR5 X X X X CR6 X X X X RCR 1 X X X X RCR 2 X X X X ...

Страница 101: ... is transmitted across the range transmission input shaft to the low range drive gear Power then flows to the low range clutch pack gear across the range countershaft to the constant mesh gear set Power flow is delivered to the opinion shaft by this constant mesh gear set in all speeds SECOND GEAR As the operator selects second speed with the gear selection switch the odd speed clutch is disengage...

Страница 102: ...NPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER...

Страница 103: ...e odd speed clutch the countershaft the third speed clutch across the output shaft to the master clutch Power flow through the range transmission is the same for speeds one through six FOURTH GEAR As the operator selects fourth speed the odd speed clutch is disengaged and the even speed clutch is engaged Power then flows from the speed transmission input shaft through the even speed clutch the cou...

Страница 104: ...NPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER...

Страница 105: ...odd speed clutch the countershaft the fifth speed clutch and across the output shaft to the master clutch Power flow through the range transmission is the same for speeds one through six SIX GEAR As the operator selects sixth speed the odd speed clutch is disengaged and the even speed clutch is engaged Power then flows from the speed transmission input shaft through the even speed clutch the count...

Страница 106: ...NPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER...

Страница 107: ...r clutch With the master clutch engaged power is transmitted across the range transmission input shaft to the medium range clutch Power then flows to the range countershaft driven gear across the countershaft to the constant mesh gear set Power flow is delivered to the pinion shaft by the constant mesh gear set in all speeds EIGHTH GEAR As the operator selects eighth speed the odd speed clutch is ...

Страница 108: ...NPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER...

Страница 109: ...eed clutch the countershaft the third speed clutch and across the output shaft to the master clutch Power flow through the range transmission is the same for speeds seven through twelve TENTH GEAR As the operator selects tenth speed the odd speed clutch is disengaged and the even speed clutch is engaged Power then flows from the speed transmission input shaft through the even speed clutch the coun...

Страница 110: ...NPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER...

Страница 111: ... clutch the countershaft the fifth speed clutch and across the output shaft to the master clutch Power flow through the range transmission is the same for speeds seven through twelve TWELFTH GEAR As the operator selects twelfth speed the odd speed clutch is disengaged and the even speed clutch is engaged Power then flows from the speed transmission input shaft through the even speed clutch and the...

Страница 112: ...INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTE...

Страница 113: ...r clutch With the master clutch engaged power is transmitted across the range transmission input shaft to the high range clutch Power then flows to the range countershaft driven gear across the countershaft to the constant mesh gear set Power flow is delivered to the pinion shaft by the constant mesh gear set in all speeds FOURTEENTH GEAR As the operator selects fourteenth speed the odd speed clut...

Страница 114: ...INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTE...

Страница 115: ...clutch the countershaft the third speed clutch and across the output shaft to the master clutch Power flow through the range transmission is the same for speeds thirteen through twelve SIXTEENTH GEAR As the operator selects sixteenth speed the odd speed clutch is disengaged and the even speed clutch is engaged Power then flows from the speed transmission input shaft through the even speed clutch t...

Страница 116: ...INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTE...

Страница 117: ...utch the countershaft the third speed clutch and across the output shaft to the master clutch Power flow through the range transmission is the same for speeds thirteen through eighteen EIGHTEENTH GEAR As the operator selects eighteenth speed the odd speed clutch is disengaged and the even speed clutch is engaged Power then flows from the speed transmission input shaft through the even speed clutch...

Страница 118: ...INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTE...

Страница 119: ...reverse rotation compared to the forward gear rotation With the master clutch engaged power is transmitted across the range transmission input shaft to the low range drive gear Power then flows to the low range clutch pack gear and across the range countershaft to the constant mesh gear set Power flow is delivered to the pinion shaft by this constant mesh gear set in all speeds SECOND REVERSE GEAR...

Страница 120: ...D INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUN...

Страница 121: ...t and everything rearward of the pinion shaft to reverse rotation in contrast to the forward gear rotation With the master clutch engaged power is transmitted across the range transmission input shaft to the medium range clutch pack Power then flows to the medium range driven gear on the range countershaft across to the constant mesh gear set driving the pinion shaft FOURTH REVERSE GEAR As the ope...

Страница 122: ...D INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUN...

Страница 123: ...constant mesh gear set and the clutch pack across the output shaft to the master clutch With the master clutch engaged power is transmitted across the range transmission input shaft to the low range drive gear Power then flows to the low range clutch pack gear and across the range countershaft to the constant mesh gear set Power flow is delivered to the pinion shaft by this constant mesh gear set ...

Страница 124: ... SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED...

Страница 125: ...rd creep FOURTH CREEP GEAR As the operator selects fourth creep speed he simultaneously disengages the fifth speed clutch and the low range clutch and engages the first speed clutch and the medium range clutch Power then flows from the speed transmission input shaft through the creep speed clutch on the countershaft to the first speed clutch on the output shaft across the master clutch With the ma...

Страница 126: ... SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED...

Страница 127: ...the master clutch Power flow through the range transmission is the same for speeds fourth creep through sixth creep SIXTH CREEP GEAR As the operator selects sixth 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 on t...

Страница 128: ... SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Inactive Clutches Pressurized Clutches Non Torque Transmitting Parts Torque Transmitting Parts RT98A064 DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED...

Страница 129: ...haft power is transmitted through the low range drive gear low range driven gear and clutch to the constant mesh gear set and pinion shaft CREEPER REVERSE SECOND GEAR CR2 As the operator selects creeper second reverse speed he simultaneously disengages and locks out the odd even speed clutch packs He also engages the creep speed clutch pack the reverse clutch pack and medium clutch pack Power then...

Страница 130: ...FF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER DROP BOX MASTER CLUTCH HI MID RANGE INPUT SHAFT 1 2 3 4 5 6 REV SPEED OUTPUT SHAFT POWER TAKE OFF SHAFT SPEED INPUT SHAFT LOW RANGE COUNTER SHAFT SPEED COUNTER SHAFT ODD EVEN FINAL DRIVE PINION PUMP DRIVE GEAR FWD CLUTCH SPRING ENGAGED CREEPER KEY Ina...

Страница 131: ...rate the operating range of the clutch pedal Cal Valve Used to calibrate the fill current of the master clutch and detect the presence of the optional creeper transmission The fill current is the current required to just fill the clutch with oil without conducting torque through the clutch 2 3 4 5 6 7 8 9 1 10 1 PORTING TO MASTER CLUTCH 6 PRELOAD SPRING 2 INCHING VALVE BODY 7 INNER MODULATOR SPRIN...

Страница 132: ...g valve PCC solenoid When the inching pedal is fully depressed there is no current supplied to the inching valve PCC solenoid 1 PORTING TO MASTER CLUTCH 6 PRELOAD SPRING 2 INCHING VALVE BODY 7 INNER MODULATOR SPRING 3 MODULATOR SPOOL 8 PISTON CENTER PIN 4 REGULATED PRESSURE SUPPLY 9 MODULATOR PISTON ASSEMBLY 5 PROPORTIONAL CURRENT CONTROL SOLENOID 10 CHECK VALVE 2 4 3 5 6 7 8 9 1 10 REGULATED PRES...

Страница 133: ...the modulator spool The inner modulator spring force begins to shift the modulator spool As the modulator spool shifts upward it simultaneously blocks the master clutch return and opens the master clutch supply to the inlet regulated supply At the same time the inlet regulated supply is also ported through a cross drilled and end drilled holes to the top of the modulator spool The balance between ...

Страница 134: ...spring but through direct contact from the ramp area on the modulator piston assembly The modulator spool has now moved far enough to allow full regulated pressure from the valve inlet to be applied to the master clutch 1 PORTING TO MASTER CLUTCH 6 PRELOAD SPRING 2 INCHING VALVE BODY 7 INNER MODULATOR SPRING 3 MODULATOR SPOOL 8 PISTON CENTER PIN 4 REGULATED PRESSURE SUPPLY 9 MODULATOR PISTON ASSEM...

Страница 135: ...order is set by the operator The TRANS OIL TEMP and TRANS SYS PRESURE screens could or could not be together depending on setup Operate the engine at 1500 RPM until the transmission temperature displayed on the instrumentation reads at least 49 C 120 F Press the INCR as required to display the TRANS SYS PRESSURE screen With the engine at 1500 RPM record the transmission system pressure with all hy...

Страница 136: ...WD switch in the ON position Select 1st gear with the Gear selection switch Move the transmission control lever to forward Release the inching pedal Shift through the gears and record the valve manifold pressures below NOTE Valve manifold pressures will momentarily drop and quickly recover pressure as each shift is completed Shift back to 1st gear and move the transmission control lever to reverse...

Страница 137: ...age Low pressure for Speeds 1 3 5 7 9 11 13 15 17 R1 and R3 Indicates Odd Clutch Leakage Low pressure for Speeds 2 4 6 8 10 12 14 16 18 R2 and R4 Indicates Even Clutch Leakage Low pressure for Speeds 1 2 3 4 5 6 R1 and R2 Indicates Low Range Clutch Leakage Low pressure for Speeds 7 8 9 10 11 12 R3 and R4 Indicates Mid Range Clutch Leakage Low pressure for Speeds 13 14 15 16 17 and 18 Indicates Hig...

Страница 138: ...ection switch select gear number 1 Press and hold the inching pedal to the floor Place the transmission control lever in forward As the inching pedal is slowly let up the gauge reading should gradually increase Once the pedal is fully up and the tractor is moving forward the gauge reading should be 325 to 355 PSI 22 4 to 24 4 bar A If the master clutch pressure reading is low perform the Regulated...

Страница 139: ...ulator piston Both must move freely within the valve bore See Inching Valve Operation in this section and the Transmission Control Valves and Inching Valve s ec tio n o f th is m anua l for disassembly Master clutch is leaking see Range Transmission including FWD Clutch Park Brake section of this manual ...

Страница 140: ...Section 21 Chapter 2 January 2006 FRONT FRAME TO SPEED TRANSMISSION SPLIT ...

Страница 141: ...Section 21 Transmission Drivelines Chapter 2 21 2 2 TABLE OF CONTENTS SPECIAL TOOLS 21 2 3 SPECIAL TORQUES 21 2 3 FRONT FRAME TO SPEED TRANSMISSION SPLIT 21 2 4 ...

Страница 142: ...rame To Speed Transmission Front End Housing M16 Bolts 251 to 280 Nm 185 to 205 lb ft M20 Bolts 430 to 485 Nm 315 to 355 lb ft 1 6 3 4 5 2 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 ...

Страница 143: ...front of the rear wheels 6 Remove the front weights and weight bracket 7 Evacuate the A C system See A C Section in this Service Manual 8 See the FWD drive shaft removal information and remove the FWD drive shaft 9 Drain the engine cooling system into a clean container NOTE Cooling capacity is approximately 24 7 liters 6 5 gallons STEP 2 RD02E069 Disconnect the negative 1 and positive 2 battery ca...

Страница 144: ... 7 RD05N128 Disconnect the A C lines at the firewall and cap the fittings STEP 8 RD05N128 Disconnect the hydraulic cooling lines at the fittings located at the rear of the engine STEP 9 RD06A166 Tag and remove the steering return hoses 1 and brake switch connectors 2 STEP 10 RD06A167 If equipped remove and cap the FWD differential lock hydraulic supply 1 and return line 2 2 1 2 1 ...

Страница 145: ...ulic hoses 2 STEP 12 RD05N128 If required remove the windshield step STEP 13 RD05N124 Remove the fuel supply 1 and return 2 hoses Remove the return hose at the fuel cooler STEP 14 RD02C175 Position the front splitting stand 17 526A 1 as shown Properly support the transmission speed housing with jack 2 Place jack stands not shown under the speed housing for added support and safety 1 1 1 1 2 2 1 2 ...

Страница 146: ...Install an alignment dowel on each side Remove the remaining five bolts on each side STEP 16 RD02C174 Remove the two top inside bolts STEP 17 RD02C177 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 1 ...

Страница 147: ...3 NOTE It may be necessary to rotate the flywheel by turning the engine crankshaft dampener to align the flywheel splines with the input shaft STEP 19 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 STEP 20 RD02C174 Ins...

Страница 148: ... all the bolts to the values shown STEP 21 RD05N124 Install the fuel supply 1 and return 2 lines STEP 22 RD05N123 If required install the windshield step STEP 23 RD06A169 RD06A168 If equipped install the suspended front axle hydraulic fittings 1 and electrical connectors 2 STEP 24 RD06A167 If equipped install the FWD differential lock hydraulic hoses Replace O rings as needed 1 2 2 2 2 2 2 2 2 2 1...

Страница 149: ...TEP 26 RD05N128 Install new O ring and install the hydraulic cooling hoses STEP 27 RD05N127 Install new O ring and install the A C lines STEP 28 RD05N126 Connect the main electrical connector STEP 29 RD05N119 If equipped install the rear windshield washer hose STEP 30 RD05N105 Install the heater supply 1 and return 2 hoses 1 2 1 2 ...

Страница 150: ...aft See FWD drive shaft removal and installation information 3 Recharge the A C system See A C Section in this Service Manual 4 If required install the front weight bracket and weights 5 Remove the blocks from the wheels STEP 33 RD02E069 Connect the positive 1 negative 2 and battery cables STEP 34 When tractor assembly is complete run the tractor and check for hydraulic leaks Check the fluid level...

Страница 151: ...Section 21 Transmission Drivelines Chapter 2 21 2 12 This Page Left Blank ...

Страница 152: ...Section 21 Chapter 3 January 2006 SPEED TO RANGE TRANSMISSION SPLIT ...

Страница 153: ...Section 21 Transmission Drivelines Chapter 3 2 TABLE OF CONTENTS SPECIAL TOOLS 21 3 3 SPECIAL TORQUES 21 3 3 SPEED TO RANGE TRANSMISSION SPLIT 21 3 4 Removal 21 3 4 Installation 21 3 7 ...

Страница 154: ... 232 to 262 Nm 171 to 193 lb ft 20 mm X 80 mm 3 15 in 220 to 250 Nm 162 to 184 lb ft 24 mm 430 to 486 Nm 317 to 358 lb ft 5 7 3 6 1 4 2 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 ...

Страница 155: ...he procedure in the Tilt and Fixed Hoods section of this manual 7 Remove the cab following the procedure in the Cab Raise Removal and Installation section of this manual 8 Remove the fuel tanks following the procedure in the Fuel Tank Fuel Sender Removal and Installation section of this manual 9 Remove the MFD drive shaft following the procedure in the MFD Drive Shaft section of this manual STEP 2...

Страница 156: ...gnment on assembly NOTE The exhaust stack does not have to be removed for this split but removal does simplify the task NOTE Rear wheels removed for photographic purposes NOTE Tag and identify all lines before removing them throughout this procedure STEP 4 RD02C165 Disconnect the wire harness from the speed powershift valve solenoids STEP 5 RD02C166 Remove the clamp bar 1 over the hydraulic lines ...

Страница 157: ...smission and install a guide stud on each side STEP 10 RD02C171 Move the speed and range transmissions apart a few inches Check to be sure no lines are connected across the split Push on the front wheels and continue to move the speed and range transmissions apart 1 STEERING SENSING AND SUPPLY LINES 4 REGULATED PRESSURE SUPPLY LINE 2 REGULATED SUPPLY JUMPER TUBE 5 OIL COOLER RETURN LINE 3 MFD DIFF...

Страница 158: ...ge It may be necessary to rotate the drive shaft yoke end of the MFD shaft 2 rotate the engine crankshaft dampener not shown and to remove the side cover plate and rotate the gear 3 to align all the shaft splines STEP 12 Rd02C170 Install and partially tighten the 10 bolts STEP 13 BOLTPAT4 1 220 to 250 Nm 162 to 184 lb ft 80 mm 3 15 in long bolt 2 232 to 262 Nm 171 to 193 lb ft 3 430 to 486 Nm 317 ...

Страница 159: ...peed radar on to the transmission housing and connect to the wire harness STEP 17 RD02C166 Connect the removed tagged lines Position the lines in the retaining bracket and install the clamp bar 1 STEP 18 RD02C165 Connect the wire harness to the speed powershift valve solenoids 1 ODD EVEN VALVE RETURN LINE 3 OIL COOLER SUPPLY LINE 2 FILTER TEMP SENDING WIRE 4 STEERING RETURN LINE 1 STEERING SENSING...

Страница 160: ...riveshaft 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 7 Remove the blocks from the wheels STEP 22 When tractor assembly is complete run the tractor and check for ...

Страница 161: ...Section 21 Transmission Drivelines Chapter 3 10 This Page Left Blank ...

Страница 162: ...Section 21 Chapter 4 January 2006 SPEED TRANSMISSION ...

Страница 163: ...AL TORQUES 21 4 4 TROUBLESHOOTING AFTER SPEED TRANSMISSION REPAIR 21 4 4 SPECIAL TOOLS 21 4 5 SPEED TRANSMISSION WITH CREEP OPTION 21 4 6 ASSEMBLING THE COUNTERSHAFT WITH CREEPER SPEED CLUTCH 21 4 14 TRANSMISSION ASSEMBLY WITH CREEP OPTION 21 4 78 TRANSMISSION ASSEMBLY WITHOUT CREEP OPTION 21 4 80 ...

Страница 164: ...3 PICTORIAL INDEX SPEED TRANSMISSION 85L94A 8 6 5 3 4 9 10 1 2 7 1 1ST SPEED CLUTCH 4 OUTPUT SHAFT 7 CREEPER SPEED CLUTCH 9 ODD SPEED CLUTCH 2 5TH SPEED CLUTCH 5 INPUT SHAFT 10 3RD SPEED CLUTCH 3 REVERSE SPEED CLUTCH 6 COUNTERSHAFT 8 EVEN SPEED CLUTCH ...

Страница 165: ...ft Mounting Bolts for Speed Transmission Housing Through Speed Housing Front Flange into Drop Box 16 mm grade 8 8 plain 234 to 260 Nm 173 to 192 lb ft Through Speed Housing Rear Flange into Range Housing 16 mm grade 10 9 plated 220 to 250 Nm 162 to 185 lb ft 16 mm grade 8 8 plain 232 to 262 Nm 171 to 193 lb ft 20 mm grade 10 9 plated 430 to 486 Nm 317 to 359 lb ft TROUBLESHOOTING AFTER SPEED TRANS...

Страница 166: ...tand CAS10431 CAS19031 Compression Plate with 6 Tangs and 2 Capscrews CAS1903 1 first used on Page 12 CAS 1903 2 Compression Plate CAS 1903 2 first used on Page 12 T98826 Compression Sleeve with Notch CAS1903 3 first used on Page 10 CAS1903 4 Centering Sleeve CAS1903 4 first used on Page 52 CAS1903 5 Compression Sleeve CAS 1903 5 first used on Page 37 1 2 3 ...

Страница 167: ...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 NOTE Use Steps 4 through 6 for transmission equipped with the creep option Use Steps 8 through 11 for transmissions without the creep option STEP 4 51L91 Make support blocks as follows 1 Use suitable material to make two ...

Страница 168: ...s shown above 4 Slowly lower the transmission housing until the bearing support cover is fully seated on the support blocks NOTE Be sure the blocks are in the correct position on the support cover 5 Reach under the housing and remove the two remaining support cover retaining bolts that were tightened only finger tight STEP 6 18 11 18 14 Slowly raise the transmission housing leaving the bearing sup...

Страница 169: ...he transmission housing on the engine stand turn the housing so the cover is in the upright position 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 STEP 9 25 26 Place strap around input shaft Raise input shaft and remove countershaft STEP 10 25 20 Remove output shaft STEP 11 25 14 Remove input shaf...

Страница 170: ...m the shaft STEP 13 T95238 Use a hydraulic press to remove the front bearing cone and the creeper driven gear NOTE The front needle thrust bearing and two bearing thrust washers will come off with the front bearing cone STEP 14 T95239 Remove the caged needle bearing STEP 15 A11511 Remove the rear needle thrust bearing and the two bearing thrust washers ...

Страница 171: ...e over the ends of the snap ring 3 Compress the Belleville washers with a hydraulic press and remove the snap ring NOTE See Steps 27 through 30 for an alternative method for removing the snap ring STEP 17 RD05M015 Remove eight Belleville washers Note the orientation of the washers for later installation STEP 18 RD05M014 Remove the lube management ring STEP 19 RD05M013 Remove the last Belleville wa...

Страница 172: ...ng from inside the clutch plate carrier STEP 23 40 33 Remove the backing plate friction plates separator plates and reaction plate thicker than separator plate from the clutch carrier STEP 24 T95251 Remove the spacer STEP 25 T95252 Remove the 2nd 4th 6th speed driven gear and steel ball STEP 26 T95256 Turn the shaft over and use a hydraulic press to remove the rear bearing cone 1st 2nd speed drive...

Страница 173: ...emove the snap ring STEP 28 DBR01 Turn the shaft over and use a hydraulic press to remove the 3rd 4th speed driver gear and the 1st 3rd 5th speed driven gear Remove the two steel balls 1 COUNTERSHAFT 3 1ST 3RD 5TH DRIVEN GEAR 2 3RD 4TH DRIVER GEAR 4 SUPPORT PRESS 1 2 4 3 ...

Страница 174: ...5 Install the compression plate CAS 1903 2 over the piston return Belleville washers The counterbore of the plate must go over the Belleville washers STEP 30 T95546 Install the compression plate CAS 1903 1 with the two cap screws and six tangs inside the clutch carrier The tangs on the plate must engage the snap ring groove inside the carrier STEP 31 T95547 Compress the Belleville washers by tight...

Страница 175: ...STON 31 THRUST WASHER 2 PLUG 12 BOLT M10 X 25 22 SEPERATOR DISC 32 THRUST BEARING 3 STEEL BALL 13 SEAL RING 23 FRICTION DESC 33 GEAR 4 PINION GEAR DRIVEN 39T 14 PINION GEAR DRIVEN 37T 24 SEPERATOR DISC 34 NEEDLE BEARING 5 PINION GEAR DRIVE 34TP 15 SPACER 25 CLUTCH DISC 35 THRUST WASHER 6 SNAP RING 16 CARRIER 26 SNAP RING 36 THRUST BEARING 7 PINION GEAR DRIVE 29T 17 SEAL RING 27 CIRCLIP 37 BEARING ...

Страница 176: ... 5th speed driven gear in a bearing oven for 3 to 4 hours at a temperature of 350 to 370 F 177 to 187 C NOTE Do not heat the gear beyond a temperature of 375 F 190 C 3 Install the gear over the shaft engaging the ball and seat against the shaft shoulder 4 Apply petroleum jelly to the second steel ball 4 and install into the shaft hole for 3rd 4th speed driver gear 1 2 3 A DIMENSION 2 1 1ST 2ND DRI...

Страница 177: ...3 to 4 hours at a temperature of 350 to 370 F 177 to 187 C NOTE Do not heat the gear beyond a temperature of 375 F 190 C 10 Install the gear 1 over the shaft engaging the ball and seat against the shaft shoulder STEP 35 A11504 Install the bearing cone over the shaft with the larger OD end of the bearing seated against the gear Press the bearing on the inner race to properly seat the bearing on the...

Страница 178: ...ier against a wood block to remove the clutch piston STEP 40 T95278 40 35 Remove and replace teflon ring and O ring as follows 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 detail_b 1 PISTON 2 TEFLON RING 3 O RING 1 2 3 ...

Страница 179: ... into the carrier with the flat side of the piston facing down Push the piston into the carrier by hand STEP 43 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 A10876 Install a new friction plate NOTE Dip all friction plates in clean transmission fluid ...

Страница 180: ...the backing plate The flat side of the plate must be facing down STEP 47 A10879 Install the snap ring STEP 48 AA11505 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 NOTE Be sure the oil holes in the shaft and carrier are aligned before proceeding STEP 49 A11507 Install the carrier reta...

Страница 181: ...t Belleville washers STEP 53 A11501 1 Install the snap ring on the shaft 2 Install the compression sleeve CAS1903 3 with the notch over the shaft 3 Use a hydraulic press to compress the Belleville washers 4 Install the snap ring in the groove STEP 54 A11511 Install the needle thrust bearing and the two bearing thrust washers The needle thrust bearing must be between the two bearing thrust washers ...

Страница 182: ... the gear hub when all the friction plates are engaged on the hub STEP 58 A11513 Install the needle thrust bearing and the two bearing thrust washers The needle thrust bearing must be between the two bearing thrust washers STEP 59 A11514 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 STEP 60 T95237 I...

Страница 183: ...21 4 22 Countershaft with Creep 85L94A 8 6 5 3 4 9 10 1 2 7 1 1ST SPEED CLUTCH 4 OUTPUT SHAFT 7 CREEPER SPEED CLUTCH 9 ODD SPEED CLUTCH 2 5TH SPEED CLUTCH 5 INPUT SHAFT 10 3RD SPEED CLUTCH 3 REVERSE SPEED CLUTCH 6 COUNTERSHAFT 8 EVEN SPEED CLUTCH ...

Страница 184: ...TEEL BALL 9 PINION DRIVE GEAR 29T 13 CAGE 2 SNAP RING 6 PINION DRIVEN GR 37T 10 SHIM 14 BOLT M10 X 25 3 PINION DRIVE GEAR 34T 7 BEARING 11 BEARING 4 PINION DRIVEN GR 37T 8 BEARING CONE 12 BEARING CONE 1 2 4 3 5 6 1 1ST 2ND SPEED DRIVER GEAR 3 2ND 4TH 6TH SPEED DRIVEN GEAR 5 1ST 3RD 5TH SPEED DRIVEN GEAR 2 3RD 4TH SPEED DRIVER GEAR 4 REAR BEARING CONE 6 FRONT BEARING CONE ...

Страница 185: ...e the five seal rings from the speed input shaft STEP 63 T95301a Use a bearing puller to remove the rear bearing cone STEP 64 T95303a Remove the spacer STEP 65 T95305a Remove the two snap rings STEP 66 T95306a Remove the spacer STEP 67 T95307a Remove the two bearing thrust washers and the needle thrust bearing ...

Страница 186: ...69 T95309a Remove the caged needle bearing STEP 70 T95310a Remove the two bearing thrust washers and the needle thrust bearing STEP 71 T95311a Remove the snap ring STEP 72 T95312a Remove the backing plate STEP 73 T95313a Remove the friction plates separator plates and the reaction plate thicker than separator plate ...

Страница 187: ...0 Non Creep Transmission Use a bearing puller to remove the gear and front bearing cone STEP 76 T95316 Use a bearing puller to remove the creeper gear if equipped STEP 77 T95317 Remove the snap ring STEP 78 A11538 Remove the two bearing thrust washers and the needle thrust bearing STEP 79 T95319 Remove the 2nd 4th 6th speed drive gear ...

Страница 188: ...eedle bearing STEP 81 T95321 Remove the spacer STEP 82 T95322 Remove the second caged needle bearing STEP 83 A11532 Remove the snap ring STEP 84 A11531 Remove the backing plate STEP 85 T95325 Remove the friction plates separator plates and the reaction plate thicker than separator plate ...

Страница 189: ... be over the ends of the snap ring Compress the Belleville washers with a hydraulic press and remove the snap ring from both sides of the clutch plate carrier STEP 88 T95331 Remove the piston return Belleville washers and lube management ring from each side of the clutch plate carrier IMPORTANT Note orientation of Belleville washers and lube management ring for later installation STEP 89 T95332a R...

Страница 190: ...ake sure that these marks are aligned These marks will be used to align the 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 STEP 91 T95333 Press the splined front end of the shaft so that the shaft moves through the clutch plate carrier 1 MARK ON FACE OF CARRIER 2 MARK ON FRONT END OF...

Страница 191: ...d Input Shaft Assembly With Creep Speed Or 50 KPH Transmission RI05M069M 6 5 4 3 2 1 13 14 12 11 10 8 9 7 18 22 20 19 18 9 17 16 15 30 29 28 27 26 25 24 23 21 31 29 30 31 32 9 33 9 32 16 15 34 23 24 25 26 27 9 18 18 19 28 38 9 37 15 36 35 16 44 43 41 42 41 39 ...

Страница 192: ...l the teflon ring over the O ring 1 COIL PIN 10 THRUST WASHER 19 LUBE RING 28 SEAL 37 SPACER 2 SHAFT 11 THRUST BEARING 20 SHAFT 29 O RING 38 BEARING 3 BOLT M10 X 10 12 PINION GEAR 37T 21 PLUG 30 PISTON 39 BEARING CUP 4 BOLT M12 X 40 13 NEEDLE BEARING 22 SEAL 31 SEAL 40 SHIM 5 CARRIER 14 SPACER 23 SNAP RING 32 O RING 41 CAGE 6 BEARING CUP 15 THRUST WASHER 24 CLUTCH DISC 33 CARRIER 42 TUBE 7 BEARING...

Страница 193: ...he front to retain the rear side of the clutch plate carrier STEP 96 468L72 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 1 MARK ON FACE OF CARRIER 2 MARK ON FRONT END OF SHAFT 1 2 ...

Страница 194: ... the carrier until the carrier is seated against the snap ring 3 Check to be sure that all the oil holes in the shaft and carrier are aligned NOTE Be sure marks are properly aligned for correct timing STEP 98 T95341 Turn the shaft over and install the carrier retaining ring STEP 99 A11519 Install a clutch piston into each side of the carrier The flat side of the piston must be down Push the piston...

Страница 195: ...eve CAS 1903 4 over the shaft STEP 104 A11525 Install the snap ring as follows 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 NOTE The smaller OD side of the sleeve must be facing up STEP 105 A11526 Install the compression sleeve CAS1903 3 with the notch over the shaft U...

Страница 196: ...n fluid STEP 108 A11530 Install a separator plate Install the remaining six new friction plates and five separator plates alternating the plates STEP 109 A11531 Install the backing plate The flat side of the plate must face down STEP 110 A11532 Install the snap ring STEP 111 A11537 Install the two bearing thrust washers and the needle thrust bearing The needle thrust bearing must be between the tw...

Страница 197: ... Slight oscillation of the gear will help with the installation The splined hub of the gear must engage all the friction plates STEP 114 A11535 Install a caged needle bearing into the gear hub STEP 115 A11536 Install a spacer into the gear hub STEP 116 A11535 Install another caged needle bearing into the gear hub NOTE The top of the second needle bearing cage will be aligned with the top of the ge...

Страница 198: ...rust washer STEP 119 T95362 Install the creeper speed gear if equipped The longer hub of the gear must face down STEP 120 T95363 Press the creeper speed gear into position STEP 121 A11516 Install the bearing cone on the shaft The larger OD end of the bearing cone must face down Press the bearing on the inner race to properly seat the bearing on the shaft STEP 122 RD05M004 Turn the shaft over and i...

Страница 199: ...e concave side is facing down STEP 125 A11540a Install the snap ring over the shaft STEP 126 A11541a 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 127 A11542 Install snap ring as follows 1 Install the compression sleeve CAS1903 3 with the notch over the shaft 2 Use a hydraulic press to ...

Страница 200: ...the plates STEP 129 T95312a Install the backing plate The flat side of the plate must face down STEP 130 A11543 Install the snap ring STEP 131 A11544 Install the two bearing thrust washers and the needle thrust bearing The needle thrust bearing must be between the two thrust washers STEP 132 A11545 Install a new seal ring on the 1st 3rd 5th speed drive gear Align the friction plate teeth Install t...

Страница 201: ...e bearing into the gear hub NOTE The top of the needle bearing cage will be aligned with the top of the gear hub when all the friction plates are engaged with the splined hub of the gear STEP 135 A11547a 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 136 A11551A Install the first spacer STEP 13...

Страница 202: ... the second spacer 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 STEP 140 T95300a Install five new seal rings on the end of the input shaft ...

Страница 203: ...d Input Shaft 385L7 2 1 3 4 8 9 7 6 5 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 REAR BEARING CONE ...

Страница 204: ... puller to remove the front bearing cone and the reverse driven gear from the shaft STEP 143 T95389 Remove the two bearing thrust washers and the needle thrust bearing STEP 144 T95391 Remove the reverse driven gear STEP 145 A11638 Remove the caged needle bearing and nylon spacer STEP 146 A11555 Remove the two bearing thrust washers and the needle thrust bearing ...

Страница 205: ...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 STEP 150 RD05M010 Remove one piston return Belleville washers STEP 151 RD05M011 Remove the lube management ring STEP 152 RD05M012 Remove eight Belleville washers NOTE Record oreintation of Belleville was...

Страница 206: ...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 STEP 154 A11559 Remove the clutch plate carrier from the shaft STEP 155 A11560 Remove the snap ring from the clutch plate carrier STEP 156 A11561 Remove the backing plate friction plates separator plates and reaction plate 1 MARK ON FACE OF CARRIER...

Страница 207: ...t be over the ends of the snap ring Compress the Belleville washers with a hydraulic press and remove the snap ring STEP 158 RD05M010 Remove one piston return Belleville washer STEP 159 RD05M011 Remove the lube management ring STEP 160 RD05M012 Remove eight Belleville washers STEP 161 T95429 Remove the snap ring STEP 162 T95430 Remove the two bearing thrust washers and the needle thrust bearing ...

Страница 208: ...move the 5th 6th speed driven gear STEP 164 T95432 Remove the caged needle bearing STEP 165 T95433a Remove the thrust washer STEP 166 T95434 Remove the 3rd 4th speed driven gear STEP 167 T95435 Remove the thrust washer spacer STEP 168 T95436 Remove the caged needle bearing ...

Страница 209: ...ll 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 2 Compress the Belleville washers with a hydraulic press and remove the snap ring 3 Remove the Belleville washers and lube management ring 4 Note orientation of Belleville washers and lube management ring for later installation STEP 173 A1156...

Страница 210: ...461 Remove the backing plate friction plates and separator plates STEP 177 T95469 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 STEP 178 T95471 Remove the piston return Belleville washers and lube manage...

Страница 211: ...nd 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 STEP 180 T95476 Press the splined rear end of the shaft so the shaft moves through the clutch plate carrier 1 MARK ON CARRIER FACE 2 MARK ON SHAFT FRONT 1 2 ...

Страница 212: ...1 22 23 24 22 23 21 10 9 11 12 13 15 14 19 29 28 27 26 25 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 PISTON 27 THRUST WASHER 4 SEAL 12 RETAINER RING 20 O RING 28 THRUST BEARING 5 RING 13 CLUTCH DISC 21 SEAL 29 BEARING CONE 6 THRUST WASHER 14 FRICTION PLATE 22 O RING 30 BEARING CUP 7 NEEDLE BEARING 15 SEPERA...

Страница 213: ...2 17 19 16 18 19 20 17 6 9 13 8 12 10 11 15 2 5 3 7 4 1 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 O RING 27 SHIM 4 PINION 39T 12 RETAINER RING 20 CARRIER 28 CAGE 5 THRUST WASHER 13 BELLEVILLE SPRING 21 PINION 44T 29 BOLT M10 X25MM 6 THRUST BEARING 14 LUBE RING 22 NEEDLE BEARING 7 RING 15 PISTON 23 ...

Страница 214: ... open STEP 182 T95479 Hit the clutch carrier against a wood block to remove the clutch pistons STEP 183 T95337 Replace the teflon ring and O ring on the piston and carrier as follows 40 35 1 Install the O ring in the groove 2 Install the teflon ring over the O ring STEP 184 T95497 Install the snap ring into the third groove in the shaft down from the rear end of the shaft 1 PLUG 1 1 ...

Страница 215: ...ws 1 Install the front end of the rear clutch plate carrier over the rear end of the shaft 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 Press the carrier down on the shaft until the carrier is again...

Страница 216: ...de STEP 190 Rd05M007 Install the first piston return Belleville washer The concave side of the washer must be facing down STEP 191 Rd05M008 Install the lube management ring STEP 192 RD05M009 Install the second Belleville washer The concave side of the washer must be facing up Install the remaining seven Belleville washers alternating the position of the washers until the last washer with the conca...

Страница 217: ... rest on top of the snap ring NOTE The smaller OD side of the sleeve must be facing up STEP 195 A11574 Install the sleeves and snap ring as follows 1 Install the compression sleeve with the notch over the shaft 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 se...

Страница 218: ...78 Install the remaining 10 separator plates and 10 friction plates alternating the plates STEP 199 A11579 Install the backing plate The flat side of the plate must face down STEP 200 A11580 Install the snap ring STEP 201 A11581 Install the needle thrust bearing and the two bearing thrust washers The needle thrust bearing must be between the two bearing thrust washers ...

Страница 219: ... the gear will help with the installation The splined hub of the gear must engage all the friction plates STEP 203 A11583 Install a caged needle bearing into the gear hub STEP 204 A11584 Install the two bearing thrust washers and the needle thrust bearing The needle thrust bearing must be between the two bearing thrust washers STEP 205 A11585 Install the bearing on the shaft with larger OD side of...

Страница 220: ...08 A11593 Install the second Belleville washer NOTE The concave side of the washer must be facing up Install the remaining seven Belleville washers alternating the position of the washers until the last washer has the concave side facing down STEP 209 A11595 1 Install the snap ring over the shaft 2 Install the Belleville washer compression sleeve CAS1903 5 over the shaft and on top of the snap rin...

Страница 221: ...the snap ring is seated properly in the groove STEP 211 A11598 Install a separator plate NOTE 1st and 3rd clutch does not use a reaction plate thicker than separator plate STEP 212 A11599 Install a new friction plate NOTE Dip all friction plates in clean transmission fluid STEP 213 A11600 Install the remaining 8 separator plates and 8 friction plates alternating the plates STEP 214 A11590 Install ...

Страница 222: ...ust washers STEP 217 A11602 Install the 3rd 4th speed driven gear as follows 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 STEP 218 A1160...

Страница 223: ... 221 A11606 Install another caged needle bearing STEP 222 A11607 Install a new seal ring on the 5th 6th speed gear Install the gear on the shaft NOTE The splined hub of the gear must be facing up STEP 223 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 1 ...

Страница 224: ...g the position of the washers until the last washer concave side is facing up STEP 226 RD05M011 Install the lube management ring STEP 227 RD05M010 Install final washer with concave facing upward STEP 228 T95424 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 STEP 229 T95499 Install the Belleville washer compression ...

Страница 225: ...nap ring will be pushed into position in the groove 3 Verify that the snap ring is seated properly in the groove STEP 231 T95415 Put the clutch pack retaining ring on top of the gear STEP 232 T95416 Install the backing plate over the gear NOTE The flat side of the place must be facing up STEP 233 T95417 Install a new friction plate NOTE Dip all friction plates in clean transmission fluid STEP 234 ...

Страница 226: ...separator plate over the gear STEP 237 T95337 40 35 Install the teflon and O rings as follows 1 Hit the clutch carrier against a wood block to remove the clutch pistons 2 Replace the teflon ring and O ring on the carrier and piston 3 Install the O ring in the groove 4 Install the teflon ring over the O ring STEP 238 A11609 Apply petroleum jelly to the teflon rings and install the 5th clutch piston...

Страница 227: ...the shaft before pushing the carrier down on the shaft NOTE Aligning the marks will align the oil holes in the shaft with the oil holes in the carrier 3 Align the separator plate tabs with the slots in the carrier 4 Use a press if necessary to carefully push the carrier down on the shaft 5 Check to be sure that the oil holes in the shaft and carrier are aligned Look through the oil hole in the car...

Страница 228: ... small that it goes through the hole in the compression tool 2 Use a hydraulic press to press the carrier snap ring into the groove 3 Verify that the snap ring is seated properly in the groove STEP 244 T95411 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 STEP 245 A...

Страница 229: ... facing upward STEP 249 A11614 Install snap ring and Belleville washer compression sleeve as follows 1 Install a centering sleeve CAS1903 4 over the shaft 2 Install the snap ring over the centering sleeve 3 Install the Belleville washer compression sleeve CAS1903 5 on top of the snap ring STEP 250 A11615 Install snap ring as follows 1 Install the compression sleeve CAS1903 3 with the notch over th...

Страница 230: ...d STEP 253 T95400 Install a separator plate Install the remaining 6 new friction plates and 5 separator plates alternating the plates and plates STEP 254 T95395 Install the backing plate The flat side must be facing down STEP 255 T95393 Install the snap ring STEP 256 T95394 Install the needle thrust bearing and the two bearing thrust washers NOTE The needle thrust bearing must be between the two b...

Страница 231: ...on NOTE The splined hub of the gear must engage all the friction plates STEP 258 A11617 Install the spacer in the gear hub Install the caged needle bearing into the gear hub STEP 259 T95389 Install the needle thrust bearing and the two bearing thrust washers NOTE The needle thrust bearing must be between the two bearing thrust washers STEP 260 A11552 Install the front bearing cone with the smaller...

Страница 232: ... 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 REVERSE SPEED DRIVEN GEAR ...

Страница 233: ...ve the clutch plates in the odd gear clutch 3 Replace the seal rings on the clutch piston if the clutch plates do not move STEP 264 T95510A Check the even gear clutch piston operation as follows 1 Install the tip of the air gun into the hole in the fourth groove from the rear of the input shaft 2 The air pressure will move the clutch plates in the even gear clutch 3 Replace the seal rings on the c...

Страница 234: ... 1 Install the tip of the air gun into the oil hole in the second groove from the rear of the output shaft The air pressure will move the clutch plates in the 1st gear clutch 2 Replace the seals on the clutch piston if the clutch plates do not move STEP 268 T95514 Check 3rd gear clutch piston operation as follows 1 Install the tip of the air gun into the oil hole in the third groove from the rear ...

Страница 235: ...12 11 9 8 1 10 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 FRONT BEARING CAGE WITHOUT CREEP SPEED 8 INPUT SHAFT REAR BEARING CAGE ...

Страница 236: ...ousing surface STEP 270 A11622 Press the bearing cup out of the rear output shaft bearing cage if the bearing cone on the output shaft has been replaced STEP 271 A11621 Press a new bearing cup into the cage until the cup is fully seated STEP 272 T95482 Use a puller to remove the bearing cup from the rear countershaft bearing cage if the bearing cone on the countershaft has been replaced STEP 273 A...

Страница 237: ...lly seated STEP 276 CVR901 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 NOTE Support cover shown for creep option STEP 277 A11618 Press the new cup into the bearing support until the cup is fully seated NOTE Replacement of ...

Страница 238: ...21 4 77 STEP 278 23 13 Install the rear bearing shim packs that were removed during disassembly and the rear bearing cages Do not fully tighten the bolts STEP 279 T95515 Remove all foreign material from the speed transmission housing front flange ...

Страница 239: ...the rear of the speed housing Use a suitable hoist and slowly and carefully lower the housing over the shaft assemblies until the shaft bearing cones are seated in the cups STEP 282 886L0 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 2 Turn the housing up right and insta...

Страница 240: ...Section 21 Transmission Drivelines Chapter 4 21 4 79 Shafts in Speed Transmission 85L94 1 OUTPUT SHAFT ASSEMBLY 2 INPUT SHAFT ASSEMBLY 3 COUNTERSHAFT ASSEMBLY 1 2 3 ...

Страница 241: ...tall the input shaft STEP 284 25 20 Install the output shaft STEP 285 25 26 Install the countershaft as follows 1 Raise the input shaft approximately 44 mm 1 3 4 inches 2 Install the countershaft until the gears of the countershaft are in mesh with the gears of the input shaft 3 Lower both the countershaft and input shaft into position STEP 286 25 32 Install the bearing support cover and bolts Tig...

Страница 242: ...aring cage The bolts must be loose 3 Rotate the shaft a minimum of 12 revolutions while tightening the bolts 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 STEP 289 SCH308 Do the following 1 Measure the shim gap clearance between the rear bea...

Страница 243: ...ack thickness Select a measured shim pack having a thickness within 0 001 inch 0 025 mm of the desired value STEP 291 SCH310 Install the measured shim pack and the rear bearing cage Tighten the bolts to a torque of 54 to 61 Nm 40 to 45 lb ft STEP 292 SCH311 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 spee...

Страница 244: ...Section 21 Chapter 5 January 2006 RANGE TRANSMISSION TO REAR FRAME SPLIT ...

Страница 245: ...Section 21 Transmission Drivelines Chapter 5 21 5 2 TABLE OF CONTENTS SPECIAL TOOLS 21 5 3 SPECIAL TORQUES 21 5 3 RANGE TRANSMISSION TO REAR FRAME SPLIT 21 5 4 Disassembly 21 5 4 Assembly 21 5 7 ...

Страница 246: ...r Frame Bolts M16 x 60 mm 232 to 262 Nm 171 to 193 lb ft M16 x 80 mm 220 to 250 Nm 162 to 184 lb ft M16 x 110 mm 220 to 250 Nm 162 to 184 lb ft 1 6 3 4 5 2 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 ...

Страница 247: ...s 6 See the cab removal information and remove the cab 7 See the fuel tank removal information and remove the fuel tank 8 Drain the transmission fluid into a clean container NOTE The transmission capacity is approximately 172 liters 45 gallons STEP 2 RD02C181 RD02C180 Position the splitting stand 17 526A 1 adapter plates 2 and jack stands 3 as shown above Position rear housing handler 17 527 4 and...

Страница 248: ... connector STEP 5 RD02C184 Disconnect the draft pin connector 1 LH and RH side and the transmission sump temperature sender connector 2 STEP 6 RD02C185 Disconnect the wire harness from the PTO 1 and MFD 2 solenoids STEP 7 RD02C186 Remove the two lines 1 from the trailer brake valve if equipped Remove the two lines 2 from the steering priority valve 2 1 1 1 2 ...

Страница 249: ...ansmission Move the snap ring out of the groove and forward on the shaft STEP 11 RD02C193 Remove the top bolts STEP 12 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 STEP 13 RD02C196 Separate the rear housing from the range housing As the rear housing is moved rearward move the snap ring and ge...

Страница 250: ...nstall the constant mesh gear 1 spacer 2 and snap ring 3 onto the shaft Continue to move the rear housing forward while moving the snap ring along the shaft until it is seated in the groove in the shaft STEP 16 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 ...

Страница 251: ...from the cover and cover mounting flange Apply a bead of Loctite Gasket Eliminator 515 down the center of the flange and around each bolt hole Install the cover and seven bolts Tighten all bolts to a torque of 54 to 61 Nm 40 to 45 lb ft STEP 20 RD02C188 Install tube removed from the remote valve STEP 21 RD02C197 Move the wire harness 1 and controllers back in position Connect the remote auxiliary ...

Страница 252: ...d the transmission sump temperature sender connector 2 to the wire harness STEP 25 RD02C183 Connect the hitch position sensor to the wire harness STEP 26 RD02C182 Install the hitch position sensor cover and tighten the bolts STEP 27 91S17 If not already done install all removed drain plugs in the transmission STEP 28 RD02C181 Remove the rear handler front splitting stand and jack stands 2 1 ...

Страница 253: ...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 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 ...

Страница 254: ...Section 21 Chapter 6 January 2006 RANGE TRANSMISSION ...

Страница 255: ...Shaft 21 6 22 Assembly of the Range Transmission Input Shaft 21 6 23 Cross Section of Input Shaft 21 6 32 Disassembly of the Range Transmission Countershaft 21 6 33 Exploded View of the Range Transmission Countershaft 21 6 37 Assembly of the Range Transmission Countershaft 21 6 38 Front Wheel Drive FWD Emergency Brake Disassembly 21 6 45 Exploded View of FWD and Emergency Brake 21 6 51 Assembly of...

Страница 256: ... Housing Front Bearing Support Cover Mounting Bolts 90 to 107 Nm 66 to 79 lb ft Range Transmission Housing to Rear Frame Mounting Bolts 232 to 262 Nm 171 to 194 lb ft Range Transmission Access Cover Mounting Bolts 54 to 61 Nm 40 to 45 lb ft Lubrication Manifold Mounting Bolts 52 to 61 Nm 38 to 45 lb ft Hydraulic Pump Assembly Mounting Bolts 52 to 61 Nm 38 to 45 lb ft Problem Probable Cause Tractor...

Страница 257: ...6 and Mounting Plate 17 52 14 C1903H3 Compression Sleeve with notch CAS1903 3 C1903H5 Compression Sleeve without notch CAS1903 5 CAS 2358 Compression Sleeve with notch CAS2602 RI05f022 Compression Sleeve with notches 380002454 1 17 52 14 MOUNTING PLATE 3 CAS 10431 ENGINE MOUNTING STAND 2 17 52 16 MOUNTING BRACKETS SET OF 2 1 2 3 ...

Страница 258: ...tion 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 STEP 2 RD05K013 Remove the speed sensor STEP 3 RD05K015 Remove range valve body STEP 4 12S9CUR4 Remove valve body plate STEP 5 12S15 Remove feeder tubes STEP 6 15S18 Remove the large internal snap ring from the master cl...

Страница 259: ...d 9 separator plates STEP 10 A22306 Enlarged View A22306CU Mark the master clutch for reassembly Remove the snap ring that fastens the master clutch to the range input shaft IMPORTANT The master clutch must be aligned properly with the input shaft STEP 11 15S30 Remove the master clutch carrier assembly including master clutch piston and return springs 1 ALIGNMENT MARK 1 1 ...

Страница 260: ...rive FWD Park Brake Assembly STEP 12 15S33 Remove the lubrication tube from the input shaft bearing cage STEP 13 16S1 Remove the master clutch carrier rear retaining ring from the input shaft STEP 14 16S4 Remove the mounting bolts from the input shaft bearing cage STEP 15 16S9 Remove the input shaft bearing cage ...

Страница 261: ...sembly STEP 17 16S15 Remove the mounting bolts from the countershaft bearing cage STEP 18 16S18 Remove the countershaft bearing cage and pump drive gear assembly STEP 19 16S21 Remove the shims for the countershaft bearing cage Keep the shims together with the bearing cage STEP 20 16S24 Remove the mounting bolts from the front bearing support cover STEP 21 16S27 Remove the front bearing support cov...

Страница 262: ...ange 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 STEP 23 A22321 Remove the input shaft ...

Страница 263: ...TEP 25 RD05K012 Remove the supply tube 1 and fitting 2 for the FWD clutch pack STEP 26 RD05K014 Remove the jumper tube for the emergency brake Repeat for the FWD STEP 27 A22326 Remove the FWD lube supply tube from the rear of the FWD emergency brake input shaft STEP 28 A22328 Remove the six FWD emergency brake rear flange mounting bolts 1 2 ...

Страница 264: ...Section 21 Transmission Drivelines Chapter 6 21 6 11 STEP 29 RD05K017 Properly support the FWD emergency brake assembly STEP 30 RD05K018 Carefully lift the assembly from the range housing ...

Страница 265: ...Use a bridge and hydraulic press to compress the spring retainer plate Remove the snap ring from the clutch carrier STEP 32 A22348 Release the press and remove the spring retainer plate STEP 33 A22347 Remove the 16 springs from the clutch piston STEP 34 A22346 Remove the piston from the clutch carrier ...

Страница 266: ... remove both the seals and the O rings beneath them 3 Replace the O rings and seals 4 Lightly lubricate with petroleum jelly STEP 36 248L7 Check the clutch springs with a spring compression tester The springs must have the following specifications Free Length 35 82 mm 1 410 inches Compressed to 23 12 mm 0 910 inch 111 25 N 25 lb NOTE Do not compress these springs beyond 23 12 mm 0 910 inch ...

Страница 267: ...ed View of the Master Clutch 31L94R 1 SEAL 9 SNAP RING 2 HUB 10 SPRING RETAINER 3 SEAL 11 SPRING 4 BACKING PLATE 12 PISTON 5 SNAP RING 13 CLUTCH CARRIER 6 SNAP RING 14 SEALS 7 FRICTION PLATE 15 O RINGS 8 SEPARATOR PLATE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 15 15 ...

Страница 268: ...ated seals STEP 38 A22347 Install the 16 springs STEP 39 A22348 Install the spring retainer plate Be sure the spring locators in the plate engage each spring STEP 40 A22350 Use a bridge and hydraulic press to compress the springs Install the snap ring in the groove in the clutch carrier NOTE The assembly of the master clutch is continued after the master clutch is installed onto the range input sh...

Страница 269: ... the four seal rings on the front of the shaft 1 STEP 42 T95697 Use a puller to remove the low range drive gear and front bearing cone STEP 43 T95702 Use a puller to remove the medium range clutch pack assembly STEP 44 A10871 Remove the snap ring from the clutch pack assembly STEP 45 40S33 Turn the assembly over and remove the friction separator and backing plates 1 ...

Страница 270: ...to compress the Belleville springs Move the snap ring out of the groove in the shaft STEP 48 T95713 Remove the compression sleeve and the snap ring STEP 49 RD05K110 Remove one piston return Belleville spring STEP 50 RD05K109 Remove the lube management ring STEP 51 RD05K108 Remove eight piston return Belleville springs NOTE Mark the orientation of the Belleville springs and lube management ring for...

Страница 271: ...s STEP 53 A10910 Remove the snap ring for the bearing thrust washers and needle thrust bearing STEP 54 T95718 Remove the two bearing thrust washers and the needle thrust bearing STEP 55 T95719 Remove the medium range drive gear STEP 56 T95720 Remove the caged needle bearing STEP 57 T95721R Remove the thrust washer ...

Страница 272: ...8 Remove the two bearing thrust washers and the needle thrust bearing STEP 62 A10884 Remove the piston return Belleville springs as follows 1 Install a compression sleeve with the notch CAS1903 3 over the piston return Belleville springs for removing the snap ring 2 Position the opening in the compression sleeve over the ends of the snap ring 3 Compress the Belleville springs with a press 4 Remove...

Страница 273: ...RD05K110 Remove the final Belleville spring NOTE Mark the orientation of the Belleville springs and lube management ring for proper reinstallation STEP 66 A10888 Use a puller to remove the rear bearing cone STEP 67 A10889 Remove the snap ring and remove the high range clutch pack assembly from the shaft STEP 68 A10871 Remove the snap ring from the clutch pack assembly ...

Страница 274: ...Section 21 Transmission Drivelines Chapter 6 21 6 21 STEP 69 40S33 Turn the assembly over and remove the friction and separator plates STEP 70 A10891 Remove the snap ring ...

Страница 275: ...36 19 21 25 13 22 26 23 Exploded View of the Range Transmission Input Shaft 1 SHAFT ASSEMBLY 10 THRUST BEARING 19 O RING 28 BEARING 2 PLUG 11 SNAP RING 20 SEAL RING 29 BEARING CONE 3 SEAL RING 12 CLUTCH DISC 21 O RING 30 SUPPORT 4 THRUST WASHER 13 SEPARATOR DISC 22 SEAL RING 31 BOLT M12 X 50 5 RING 14 FRICTION DISC 23 O RING 32 SHIM 6 MEDIUM RANGE GEAR 15 CIRCLIP 24 CARRIER 33 CAGE 7 HIGH RANGE GE...

Страница 276: ...p ring for the high range clutch plate carrier into the second groove on the shaft STEP 73 T95277 Hit the high range clutch plate carrier against a wooden block to remove the clutch piston STEP 74 T95278 40S35 Install the teflon ring and O ring as follows 1 Replace the teflon ring and O ring from the carrier 1 and piston 2 2 Install the O ring in the groove 3 Install the teflon ring over the O rin...

Страница 277: ...on must face down Push the piston into the carrier by hand STEP 77 Repeat above Steps for the medium range clutch plate carrier STEP 78 A10875 Install a separator plate STEP 79 A10876 Install a new friction plate NOTE Dip all friction plates in clean transmission fluid STEP 80 A10877 Install a separator plate Install the remaining 10 friction plates and 9 separator plates alternating the plates ...

Страница 278: ... clutch pack It will be assembled on the shaft STEP 83 A10889 Install the high range clutch pack assembly as shown 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 A10917 Install the bearing on the shaft with the larger OD end of the bearing facing down Press the bearing into place to be sure that it is properl...

Страница 279: ...springs alternating the position of the springs until the last washer with the concave side is facing down STEP 87 A10899 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 88 A10900 Install the snap ring as follows 1 Install the compression sleeve with the notch CAS1903 3 2 Use a hydraul...

Страница 280: ... be between the two bearing thrust washers STEP 91 A10905 Align the gear teeth on all the friction plates STEP 92 A10904 Install a new seal ring on the hub of the high range drive gear STEP 93 A10906 Install the high range drive gear The teeth on the gear hub align with the friction plates Slight oscillation of the drive gear will help with the installation STEP 94 A10907 Install the caged needle ...

Страница 281: ...w seal ring on the medium range drive gear Install the gear The hub of the gear must be facing up STEP 99 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 STEP 100 A10910 Install the snap ring for the bearing thrust washers and needle thrust bearing The ring goes into the lowest of the th...

Страница 282: ...acing up the second facing down Continue to alternate STEP 103 RD05K109 Install the lube management ring STEP 104 RD05K110 Install the final Belleville spring concave side down STEP 105 A10911 Install the retaining ring onto the shaft along with the Belleville washer compression sleeve Use tool CAS1903 5 STEP 106 A10912 Install the compression sleeve with the notch CAS1903 3 over the shaft Use a h...

Страница 283: ... ring on top of the gear STEP 109 T95709 Install the backing plate The flat side of the plate must be facing up STEP 110 T95707 Install a friction plate NOTE Dip all friction plates in clean transmission fluid STEP 111 T95708 Install a separator plate Install the remaining 10 friction plates and 10 separator plates alternating the plates Whenever the clutch pack has been disassembled new friction ...

Страница 284: ...le in the shaft must be aligned with the hole in the carrier STEP 113 A10916 Turn the shaft assembly over and move the snap ring into the groove in the carrier STEP 114 T95699 Install the low range drive gear STEP 115 A10920 Install the bearing cone with the larger outside diameter OD side of the bearing cone facing down Press the bearing with approximately 22250 N 5000 lb of force to compress the...

Страница 285: ...new seal rings 1 on the front end of the shaft Cross Section of Input Shaft 11L94R2 1 1 2 3 4 5 6 7 1 REAR BEARING CONE 5 FRONT BEARING CONE 2 HIGH RANGE DRIVE GEAR 6 MEDIUM RANGE CLUTCH PLATE CARRIER 3 MEDIUM RANGE DRIVE GEAR 7 HIGH RANGE CLUTCH PLATE CARRIER 4 LOW RANGE DRIVE GEAR ...

Страница 286: ...ft on a clean work bench STEP 118 T95749 Use a puller to remove the constant mesh gear and the rear bearing cone STEP 119 T95750 Remove the gear spacer STEP 120 T95751 Remove the high range driven gear STEP 121 T95752 Remove the medium range driven gear from the carrier STEP 122 A10921 Remove the snap ring for the medium range driven gear ...

Страница 287: ...ove the front bearing cone and front bearing cone spacer STEP 125 A10925 Remove the two bearing thrust washers and the needle thrust bearing STEP 126 A10926 Remove the four seal rings from the hub on the gear two rings in each of two grooves STEP 127 A10928 Turn the low range driven gear and clutch plate carrier over and remove the snap ring STEP 128 A10929 Carefully turn the assembly over and rem...

Страница 288: ...132 T95774 Remove the two bearing thrust washers and the needle thrust bearing STEP 133 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 2 Position the opening in the compression sleeve over the ends of the snap ring 3 Compress the Belleville washers with a press and remove the snap ring ...

Страница 289: ... Remove three piston return Belleville washers STEP 136 RD05M017 Remove the lube oil management ring STEP 137 RD05M018 Remove eight piston return Belleville washers NOTE Mark the orientation of the Belleville springs and lube management ring for proper reinstallation STEP 138 T95783 Use a puller to remove the roller bearing from the rear end of the shaft ...

Страница 290: ... 30 GEAR 54T 5 PINION GEAR 39T 18 FRICTION DISC 31 RING 6 PINION GEAR 25T 19 SEPARATOR DISC 32 SEAL RING 7 SPACER 20 SEPARATOR DISC THICKER 33 SPACER 8 PINION 23T 21 THRUST BEARING 34 BEARING 9 BEARING 22 THRUST WASHER 35 BEARING CONE 10 BEARING CONE 23 PISTON 36 SHIM 11 BELLEVILLE SPRING 24 O RING 37 CAGE 12 LUBE RING 25 SEAL RING 38 PLUG 13 THRUST WASHER 26 NEEDLE BEARING 39 BOLT M10 X 30 3 31 3...

Страница 291: ...9 T95782 498L7 Make sure that all the oil passages in the shaft are open STEP 140 A10937 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 20 64 mm 0 81 INCH ...

Страница 292: ...he two bearing thrust washers The needle bearing must be between the two bearing thrust washers STEP 145 T95777 Install the snap ring onto the shaft STEP 146 A10939 Install the snap ring and Belleville washers as follows 1 Install the compression sleeve with the notch CAS1903 3 over the shaft and snap ring see Special Tools in this section 2 Position the opening in the compression sleeve over the ...

Страница 293: ...range driven gear Install the gear on the shaft STEP 149 T95751 Install the high range driven gear STEP 150 T95750 Install the gear spacer STEP 151 A10949 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 NOTE Do not press on the bearing cage 1 1 ...

Страница 294: ...shers STEP 153 40S18 Remove the clutch piston from the clutch plate carrier If necessary hit the low range driven gear and clutch plate carrier against a wooden block to remove the clutch piston STEP 154 40S24 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 STEP 155 41S3 Put petroleum jelly...

Страница 295: ... be down Push the piston into the carrier by hand STEP 157 40S29 CTRINGS Install two new seal rings in each groove on the hub of the gear STEP 158 A10932 Install the reaction plate thicker separator plate STEP 159 A10933 Install a new friction plate NOTE Dip all friction plates in clean transmission fluid 1 TEFLON RING 2 CAST IRON RINGS 1 1 2 ...

Страница 296: ...late facing down STEP 162 A10936 Install the snap ring into the groove on the carrier STEP 163 T95785R2 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 friction plate teeth Slight oscillation of the low range driven gear will help with the installation Be sure the hub passes thro...

Страница 297: ...n the two bearing thrust washers STEP 166 A10943 Install the bearing spacer STEP 167 A10945 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 NOTE Be sure the tool used to press the bearing does not contact the end of the shaft Do not press on the bearing cage ...

Страница 298: ...for proper reassembly Remove the three clips Repeat for the opposite side STEP 170 RD05K021 Remove the FWD clutch assembly 1 from the gear can weldment 2 STEP 171 RD05K040 Compress the Belleville springs using Tool 380002454 and release the retaining ring Release the tool and remove retaining ring and locking ring STEP 172 RD05K076 Note the orientation of the Belleville springs and remove STEP 173...

Страница 299: ...scard STEP 176 RD05K069 Remove the separator plate STEP 177 RD05K070 Remove the friction plate Continue until all friction and separator plates are removed NOTE When replacing separator and friction plates they have to be replaced as complete assemblies STEP 178 RD05K071 Remove the backing plate and mark for proper reassembly STEP 179 RD05K029 Remove the hub seal and discard ...

Страница 300: ...re NOT serviced STEP 182 RD05K033 Remove the three shaft seals and discard STEP 183 Rd05K034 Remove the retaining ring for the emergency brake clutch assembly IMPORTANT Mark the shaft and hub 1 for proper reassembly STEP 184 RD05K035 Place a puller over the shaft assembly and using the two threaded holes in the emergency brake hub assembly install two bolts 1 as shown and pull the assembly from th...

Страница 301: ... Remove the separator plate STEP 189 RD05K038 Remove the friction plate Continue to remove all friction and separator plates There is a total of six separator and six friction plates NOTE When replacing separator and friction plates they have to be replaced as complete assemblies STEP 190 RD05K042 Remove the backing plate STEP 191 R05K053 Remove the seal from the piston and discard ...

Страница 302: ...emove the seal backing O ring and discard STEP 193 RD05K051 Remove the seal from the emergency hub STEP 194 RD05K052 Remove the O ring from the emergency hub STEP 195 RD05K077 Remove bearing retainer ring 1 from the shaft STEP 196 RD05K079 Remove the spacer and shim pack 1 ...

Страница 303: ... as damage to the shaft may occur IMPORTANT Mark the bearing for location If bearing is to be reused it MUST be reinstalled with the same bearing cup STEP 198 RD05K044 Remove the second bearing from the shaft IMPORTANT Mark the bearing for location If bearing is to be reused it MUST be reinstalled with the same bearing cup STEP 199 RD05K045 Using a soft drift 1 remove the bearing cup 2 STEP 200 RD...

Страница 304: ...BRAKE HUB 3 BOLT HEX HD M12 X 50 MM 14 SHIM PACK 25 HUB EMERGENCY BRAKE 4 TUBE FWD 15 SPACER FWD CLUTCH BEARING 26 RING RETAINER EMERGENCY BRAKE HUB ASSY 5 SHIELD UPPER HALF 16 RING RETAINER 27 PLATE SEPARATOR 6 SHIELD LOWER HALF 17 RING RETAINER 28 PLATE FRICTION 7 SCREW SOC HD M8 X 16 MM 18 SPACER IF REQUIRED 29 PLATE BACKING 8 U CLIP FWD SHIELD 19 SPRING BELLEVILLE EMERGENCY BRAKE AND FWD 30 RI...

Страница 305: ...nants before reassembly STEP 202 RD05K047 Install snap rings STEP 203 RD05K048 Install new bearing cup in gear can weldment STEP 204 RD05K049 Press cup into place IMPORTANT DO NOT overpress cup against the snap ring STEP 205 RD05K050 Press the second bearing cup into the weldment IMPORTANT DO NOT overpress cup against the snap ring ...

Страница 306: ...r the shaft and place the second bearing onto the shaft STEP 208 RD05K082 Set Bearing Preload As Follows 1 Attach a spring scale to one of the holes in the gear can weldment 1 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 STEP 209 RD05K079 Install the spacer and shim pack STEP 210 RD05K077 Install the retai...

Страница 307: ...bearing failure STEP 212 RD05K084 Check the shaft end play 1 Place a dial indicator on the shaft 2 Carefully pry up between the FWD gear and shaft flange 3 Shaft end play 0 089 mm 0035 inch 0 064 mm 0025 inch 4 Add or subtract shims as needed 5 Recheck end play if shims are changed NOTE Do not install seals at this time STEP 213 RD05K062 Install the retainer ring STEP 214 RD05K064 Install a backin...

Страница 308: ... greater than 29 0 MM use one spring spacer 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 Remove piston spacers friction plates and backing plate from the hub NOTE If spring spacer is needed it will be placed between the Belleville springs and the retainer ring during assembly STEP 219 RD05K086 From a length of 4 inch ID 1 4 ...

Страница 309: ...ainer ring in the upper ring grove 2 not shown STEP 222 RD05K030 Lubricate a new O ring 1 with petroleum jelly and install in the seal ring groove 2 STEP 223 RD05K029 Lubricate a new seal with petroleum jelly and install Use care not to overstretch the seal STEP 224 RD05K058 Lubricate a new O ring 1 and seal 2 with petroleum jelly and install in the piston seal grove 3 DO NOT overstretch the seal ...

Страница 310: ...nstall 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 Once all spacers and friction plates are installed rotate the hub in one direction ONLY to get maximum separator and friction plate spline clearance This wil...

Страница 311: ...en the Belleville springs and the retainer ring during assembly STEP 232 RD05K023 Install the five Belleville springs over the shaft as shown IMPORTANT Belleville springs must be aliened and centered so that they do not catch on the shaft when they are compressed STEP 233 RD05K022 Place the spring spacer s if required locking ring 1 and retaining ring 2 over the shaft STEP 234 RD05K040 Center Tool...

Страница 312: ... pipe make sure each end is cut square STEP 237 RD05K093 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 STEP 238 RD05K105 Lubricate with petroleum jelly and install a new O ring 1 and seal 2 in the seal ring groove 3 of the park brake hub STEP 239 RD05K058 Lubricate a new O ring 1 and seal 2 with petroleum jelly an...

Страница 313: ...he PVC pipe STEP 242 RD05K095 Install the backing plate Make sure the wide cutout 1 is facing downward STEP 243 RD05K096 Install a friction plate STEP 244 RD05K097 Install a separator plate Alternate separator and friction plates until all six separator and six friction plates are installed NOTE Once all spacers and friction plates are installed rotate the hub in one direction ONLY to get maximum ...

Страница 314: ...e FWD assembly and install STEP 247 RD05K0101 Place the spacer s if required and retainer ring on top of the Belleville springs IMPORTANT Belleville springs must be aligned and centered so that they do not catch on the shaft when they are compressed STEP 248 RD05K102 Compress the Belleville springs using Tool 380002454 and install the retainer ring IMPORTANT Make sure retainer ring is fully seated...

Страница 315: ...e emergency brake assembly make sure the oil supply holes 1 are properly aligned with the oil supply holes 2 in the shaft STEP 251 RD05K104 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 252 RD05K073 Continue to lower the hub until it is fully seated into the weldment STEP 253 RD05K034 Install the emergency b...

Страница 316: ...amage the friction plate tabs and shaft seals STEP 256 RD05K019 Place the two halves of the shield together making sure the marks are aligned Install the retaining clips Repeat for the opposite side STEP 257 RD05K020 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 258 RD05K018 Properly support the FWD Park b...

Страница 317: ...t hole as shown in the following step STEP 260 RD05K063 Once the alignment pin 1 is properly aligned install the six mounting bolts Tighten bolts to a torque of 101 to 113 Nm 78 to 84 lb ft Install the FWD lube fitting 2 if removed STEP 261 A22327 Install the FWD lube tube at the shaft end and to fitting in top of range casting STEP 262 16S35 Install a new O ring on each end of the jumper tube lub...

Страница 318: ... is excessive leakage at the seals and will have to be replaced STEP 264 RD05K012 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 24 1 Bar 2413 kPa Because of design there will be some leakage in the FWD clutch pack pressure will not hold If there is excessive leakage cannot pump up press...

Страница 319: ...4 8 14 7 6 5 9 11 17 10 12 16 15 2 1 3 1 SHIMS 7 FRONT BEARING CUP 13 PLUG 2 FRONT BEARING CUP 8 SHIM 14 HEATER 3 INPUT SHAFT BEARING CAGE 9 FRONT BEARING SUPPORT COVER 15 COVER 4 HYDRAULIC PUMP DRIVE GEAR 10 COVER 16 NEEDLE BEARING 5 ROLLER BEARING 11 RANGE TRANSMISSION HOUSING 17 PLUG 6 COUNTERSHAFT BEARING CAGE 12 BEVEL PINION CONSTANT MESH GEAR ...

Страница 320: ... the range transmission housing if required Drive a new bearing cage into the bore The bearing cage must be centered in the bore STEP 266 T95672 Use a puller to remove the rear bearing cups from the range transmission housing STEP 267 T95673 Drive new bearing cups into the bores until the cups are seated against the housing shoulder STEP 268 40S10 Use a puller to remove the bearing cup from the ra...

Страница 321: ...put shaft bearing cage STEP 271 T95883R 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 272 T95884R Remove the hydraulic pump drive gear STEP 273 T95885R Use a puller to remove the bearing cup from the range transmission...

Страница 322: ... STEP 276 T95888 Drive the roller bearing out of the gear The gear retaining snap ring from Step 217 will come out with the roller bearing STEP 277 T95889 Install a new seal ring inside the gear STEP 278 T95890 Install the gear retaining snap ring inside the gear and over the hub The flat side of the snap ring must be facing down STEP 279 T95891R Press a new ball bearing inside the gear until the ...

Страница 323: ...the snap ring into the groove in the bearing cage 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 A22321 Apply petroleum jelly to the seal ring on the rear end of the range transmission input shaft Install the range transmission input shaft into the housing Make sure that the rear bearing...

Страница 324: ...er down over the dowel pins in the range housing STEP 285 16S24 Install and tighten the support cover bolts to a torque of 90 to 107 Nm 66 to 79 lb ft STEP 286 16S21 Place the original shims over the end of the range transmission countershaft STEP 287 16S17 Install the countershaft front bearing cage Install the mounting bolts to a torque of 54 to 61 Nm 40 to 45 lb ft STEP 288 16S12 Apply petroleu...

Страница 325: ...Section 21 Transmission Drivelines Chapter 6 21 6 72 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 ...

Страница 326: ...using to lift a gear on the shaft The end play must be 0 025 to 0 127 mm 0 001 to 0 005 inches for the input shaft 2 and 0 013 to 0 102 mm 0 0005 to 0 004 inches for the countershaft 1 If the end play is not within 0 025 to 0 127 mm 0 001 to 0 005 inches for the input shaft add or remove shims to get a correct reading If the end play for the countershaft is not within 0 013 to 0 102 mm 0 0005 to 0...

Страница 327: ...using STEP 294 15S30 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 NOTE The master clutch carrier assembly must be indexed correctly on the input shaft ...

Страница 328: ...the clutch to the input shaft according to the mark made in Step 8 STEP 296 A22302 Install a new seal ring into the hub assembly Lubricate the seal ring with petroleum jelly STEP 297 15S24 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 STEP 298 A22304CR Install a separator plate into the master clutch ...

Страница 329: ...s in clean transmission fluid before installation STEP 300 A22298CR Install the clutch backing plate STEP 301 A22297CR Install the snap ring into the master clutch carrier STEP 302 12S15 Install new O ring on the feeder tubes and lubricate with petroleum jelly Install the feeder tubes STEP 303 12S9CUR4 Install a new gasket and install the range shift valve adapter plate STEP 304 RD05K015 Install a...

Страница 330: ...Section 21 Chapter 7 January 2006 TRANSMISSION CONTROL VALVES AND INCHING VALVE ...

Страница 331: ...tion 21 Transmission Drivelines Chapter 7 21 7 2 TABLE OF CONTENTS SPECIAL TORQUES 21 7 3 POWERSHIFT TRANSMISSION CONTROL VALVES 21 7 3 TRANSMISSION CONTROL VALVE CONFIGURATION 21 7 4 INCHING VALVE 21 7 15 ...

Страница 332: ...gured for three different applications Speed Transmission Control Valve 1 Odd Even Transmission Control Valve 2 and Range Transmission Control Valve 3 The function of this basic valves is determined by its location on the transmission how it is connected hydraulically and number of solenoids The odd even and range valve can be removed after raising the cab See the Cab Raise Removal and Installatio...

Страница 333: ...n housing adjacent to the valve body to eliminate any contamination TRANSMISSION OPTIONS SPEED TRANSMISSION CONTROL VALVE ODD EVEN TRANSMISSION CONTROL VALVE RANGE TRANSMISSION CONTROL VALVE NAO WITHOUT FWD WITHOUT CREEP FIGURE 1 FIGURE 4 FIGURE 3 NAO WITHOUT FWD WITH CREEP FIGURE 1 FIGURE 2 FIGURE 3 NAO WITH FWD WITHOUT CREEP FIGURE 1 FIGURE 4 FIGURE 2 NAO WITH FWD WITH CREEP FIGURE 1 FIGURE 2 FI...

Страница 334: ... with Four Solenoids This type of control valve is used with these transmission configurations Speed control valve for all tractor configurations RI02E100 1 VALVE BODY 5 COVER PLATE 2 PWM SOLENOID 6 PLUG 3 O RINGS 7 MOUNTING BOLT 4 GASKET 8 PRESSURE SENSOR SPEED VALVE ONLY 1 5 3 8 4 6 2 7 ...

Страница 335: ...lenoids This type of control valve is used with these transmission configurations Range control valve with FWD Odd Even control valve with NA park and creep RI02E099 1 VALVE BODY 6 PLUG 2 PWM SOLENOID 7 MOUNTING BOLT 3 O RINGS 8 SOLENOID 4 GASKET 9 SOLENOID CARTRIDGE 5 COVER PLATE 3 7 4 2 5 3 10 9 6 1 ...

Страница 336: ...mission Control Valve with Three Solenoids and Plug This type of control valve is used with these transmission configurations Range control valve without FWD RI02E096 7 4 2 5 3 6 6 1 3 1 VALVE BODY 5 COVER PLATE 2 PWM SOLENOID 6 PLUG 3 O RINGS 7 MOUNTING BOLT 4 GASKET ...

Страница 337: ...Three Solenoids and Plug This type of control valve is used with these transmission configurations Odd even control valve with NA park without creep RI02E097 1 VALVE BODY 6 PLUG 2 PWM SOLENOID 7 MOUNTING BOLT 3 O RINGS 8 SOLENOID 4 GASKET 9 SOLENOID CARTRIDG 5 COVER PLATE 7 4 2 5 3 6 6 1 3 9 8 ...

Страница 338: ...Two Solenoids Check Valve and Plug This type of control valve is used with this transmission configuration Odd even control valve with Euro park without creep RI02E095 1 VALVE BODY 6 PLUG 2 PWM SOLENOID 7 MOUNTING BOLT 3 O RINGS 8 CHECK VALVE 4 GASKET 9 BALL 5 COVER PLATE 1 5 3 7 4 6 8 2 3 6 9 ...

Страница 339: ...ith Three Solenoids and Check Valve This type of control valve is used with this transmission configuration Odd even control valve with Euro park with creep RI02E098 1 VALVE BODY 6 PLUG 2 PWM SOLENOID 7 MOUNTING BOLT 3 O RINGS 8 CHECK VALVE 4 GASKET 9 BALL 5 COVER PLATE 1 5 3 7 1 6 8 2 3 6 9 ...

Страница 340: ...ors to the solenoids and pressure sensor 1 and disconnect 2 Remove the valve supply tube 2 3 Remove the valve retaining bolts valve body and gasket Discard the gasket STEP 3 RD02E275 Remove the odd even transmission control valve as follows 1 Tag and disconnect the park lock and if equipped the FWD tubes 1 Tag and disconnect the regulated pressure tubes 2 2 Tag and disconnect the solenoid wires 3 ...

Страница 341: ...ensor See Figure 1 Transmission Control Valve with Four Solenoids for pressure sensor location STEP 5 RD02E221 Place the valve on a clean surface STEP 6 RD02E222 Remove the park lock solenoid nut and coil and cartridge Remove and discard the O rings STEP 7 RD02E223 Remove the solenoid cover plate Remove the solenoid assembly and discard the O rings STEP 8 Repeat for the remaining solenoids ...

Страница 342: ...l the solenoid into the valve body Repeat for the remaining solenoids Install the cover plate and retaining bolts Tighten the bolts to a torque of 6 to 8 Nm 4 to 6 lb ft STEP 10 RD02E222 Install new O rings on the cartridge Install the cartridge into the valve body Tighten to a torque of 19 to 25 Nm 14 to 18 lb ft Install new O rings on the coil and install the coil onto the cartridge Tighten the ...

Страница 343: ...ission control valve as follows 1 Install a new gasket and the valve 2 Tighten the M8 socket head mounting bolts 4 to a torque of 27 to 32 Nm 20 to 24 lb ft 3 Connect the wire harness to the solenoids 2 4 Connect the regulated pressure tube 2 Connect the park lock and if equipped the FWD tubes 1 STEP 13 RD02E276 Install the speed transmission valve as follows 1 Install a new gasket and the valve 2...

Страница 344: ... RD02E274 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 Remove the mounting bolts 3 range valve and gasket Discard the gasket 4 Tag and remove the hydraulic tubes from the inching valve 5 Disconnect the wire harness from the inching valve solenoid 6 Remove four attaching bolts for the inchin...

Страница 345: ... 16 56 34 Place the inching valve on a clean work surface Remove plug STEP 17 57 6 Remove nut two O rings and coil from the solenoid assembly STEP 18 57 10 Remove solenoid cartridge NOTE The solenoid cartridge is not designed to be disassembled STEP 19 57 13 Remove plug ...

Страница 346: ...1 Transmission Drivelines Chapter 7 21 7 17 STEP 20 57 19 Remove the plug STEP 21 54 33 Remove the plug spring and modulator spool assembly NOTE Parts of the modulator spool assembly are not serviced separately ...

Страница 347: ... 9 7 9 8 11 13 35 22 25 24 26 27 23 5 4 12 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 SOCKET BOLT ...

Страница 348: ... lb ft STEP 24 56 34 Install a new O ring on the plug Install plug Tighten the plug to a torque of 34 to 54 Nm 25 to 40 lb ft STEP 25 57 19 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 26 57 16 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 27 57 28 Install new ...

Страница 349: ...ching 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 Install a new gasket on top of the inching valve and install the range transmission control valve Install the M8 socket head bolts 3 and tighten to a torque of 27 to 32 Nm 20 to 24 lb ft 3 Connect the Hydraulic tubes to the inching val...

Страница 350: ...21 7 21 Inching Valve Cross Section 302171AA WMF 1 VALVE BODY 7 SPRING 2 PLUG 8 SPRING 3 SOLENOID 9 PLUG 4 INCHING SPOOL 10 INCHING MODULATOR SPOOL ASSEMBLY 5 BALL 11 MODULATOR ASSEMBLY PISTON 6 RETAINING SLEEVE 12 PLUG 1 2 3 4 5 6 7 11 8 10 9 12 ...

Страница 351: ...Section 21 Transmission Drivelines Chapter 7 21 7 22 This Page Left Blank ...

Страница 352: ...Section 21 Chapter 8 January 2006 REAR FRAME ...

Страница 353: ...ERENTIAL 21 8 4 Removal 21 8 4 Disassembly 21 8 10 PINION SHAFT 21 8 14 Removal and Disassembly 21 8 14 Assembly and Installation 21 8 16 DIFFERENTIAL ASSEMBLY 21 8 24 DIFFERENTIAL INSTALLATION 21 8 29 ADJUSTING THE DIFFERENTIAL PRELOAD 21 8 35 ADJUSTING THE RING AND PINION BACKLASH 21 8 37 BEVEL PINION AND GEAR TOOTH CONTACT CHECK 21 8 38 ...

Страница 354: ...and Pinion Backlash 0 179 to 0 279 mm 0 007 to 0 011 inch Pinion Shaft End Play 0 013 to 0 102 mm 0 0005 to 0 004 inch Ring and Pinion Nominal Setting Distance 33 92 mm 1 335 inch SPECIAL TORQUES Right Hand RH Retainer Initial 11 Nm 100 lb inch Bearing Retainer Final Phosphate Coated with Oiled Threads 235 to 260 Nm 173 to 195 lb ft Pinion Shaft Assembly Mounting Bolts 101 7 to 112 5 Nm 75 to 83 l...

Страница 355: ...Hydraulic Systems and Troubleshooting in this manual and remove the following 1 Supply line from PFC piston pump to remote valve 2 Signal line to compensator 3 PTO lube supply 4 Bevel gear lube tube 5 Remote valve return line 6 Regulated supply to PTO valve 7 Difflock supply tube STEP 6 Disconnect the hydraulic lines to the hitch lift cylinders NOTE If the pinion shaft must be serviced the power t...

Страница 356: ... to the hitch lift cylinder as follows 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 STEP 11 76 6a Remove the bolt and locking flag plate in the upper end of the hitch lift cylinder both sides STEP 12 35 24 Secure the rockshaft assembly as fo...

Страница 357: ...cylinders If the cylinders are removed first there may be excessive travel of the rockshaft which would damage the sensor STEP 14 36s17 Remove the nut from the link assembly STEP 15 36s34b Remove pin and free the upper end of the hitch lift cylinder STEP 16 36s28b Remove the bolt locking flag plate pin and free the lower end of the hitch lift cylinder Remove the cylinder STEP 17 36s8 Hold the left...

Страница 358: ... on tractor the tie rod may be disassembled by sliding tie rod through the chain support hole in the disc Position the wheels as necessary STEP 20 35 30 Remove the split ring retainers from both ends of the rockshaft STEP 21 35 21 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...

Страница 359: ... and rear cab bracket to the rear frame STEP 25 28s22r Remove the rear frame top cover and set aside STEP 26 T98138 Remove the differential lock supply line from the differential STEP 27 69RS13 Remove the rear frame cover and the PTO clutch assembly Refer to PTO Assembly Single and Dual Speeds in this manual STEP 28 T98213 Remove the differential lube line from the rear frame NOTE Bevel pinion mus...

Страница 360: ...ve the LH bearing retainer shims from the rear frame and tag for location STEP 32 T98187 Remove the RH bearing retainer from the housing STEP 33 T98200 Remove the right hand bearing retainer shims from the housing and tag for location STEP 34 T98204 Remove and set up the differential assembly as follows 1 Remove the differential assembly from the rear frame 2 Place the differential assembly on a c...

Страница 361: ... bolt Carefully turn the assembly over Remove the nut and bolt STEP 36 T98149 Remove the differential cover from the housing STEP 37 88 28A Remove the thrust washer from the cover STEP 38 T98151 Remove the differential lock separator and friction plates from the housing STEP 39 T98153 Remove the bevel lock side gear and six dowel pins from the housing STEP 40 T98156 Apply compressed air to the dif...

Страница 362: ...ing bolts from the housing STEP 43 R98159 Insert an M8 bolt into the short pinion shaft hole STEP 44 T98160 Remove each short pinion shaft from the housing STEP 45 T98161 Remove the short spacers from the housing STEP 46 T98162 Remove the short shaft pinion gears from the housing Remove the thrust ring and needle bearings from both short shaft pinion gears ...

Страница 363: ...ng shaft from the housing STEP 49 T98165 Remove the long spacer from the housing STEP 50 T98166 Remove the long pinion shaft gears from the housing Remove the thrust ring and needle bearings from both long shaft pinion gears STEP 51 T98167 Remove the thrust washers from the housing STEP 52 T98168 Remove the bevel side gear from the housing ...

Страница 364: ...ing cup from the housing STEP 55 T98171 Remove the bearing cup from the differential cover STEP 56 T98205 Remove the oil seal from each bearing retainer STEP 57 RD98C192 Remove the seal ring and the bearing cone from the right hand bearing retainer STEP 58 T98174 Remove the seal ring and the bearing cone from the left hand bearing retainer ...

Страница 365: ...lts STEP 61 T95912 Install two aligning dowels through the bearing cage and into the rear frame Remove the pinion shaft assembly from the rear frame STEP 62 T95913 Remove the shims from the bearing cage Use a micrometer to measure all the shims and record the shim pack size STEP 63 T95915 Remove the front pinion shaft snap ring Press on the bearing cone race if it blocks removal of the snap ring S...

Страница 366: ...against the gear will clear the press STEP 66 T95917 Press the bearing cone from the pinion shaft STEP 67 T95921 Remove the front bearing cup from the bearing cage STEP 68 T95925 Remove the inner snap ring from the bearing cage STEP 69 T95923 Remove the rear bearing cup from the bearing cage STEP 70 T95919 Be sure the hole in the button of the pinion shaft is open ...

Страница 367: ...TE All parts marked with remain in the range transmission 1 RING GEAR 8 BEARING CAGE 2 PINION SHAFT 9 SNAP RING 3 CUP PLUG WITH HOLE 10 SPACER 4 BEARING CONE 11 CONSTANT MESH GEAR 5 BEARING CUP 12 SHIM RING 6 SNAP RING 13 BEARING CONE 7 SHIM 14 BEARING CUP 1 4 3 2 5 6 7 8 9 10 11 12 13 14 ...

Страница 368: ...ove STEP 73 T95922 Press the front bearing cup into the bearing cage until seated against the snap ring STEP 74 88 33A Press the bearing cone on the pinion shaft until seated against the gear STEP 75 T95928 Install the bearing cage over the shaft and bearing STEP 76 T95929 Press the front bearing on the pinion shaft and into the bearing cup as you turn the bearing cage to help seat the bearing ...

Страница 369: ...ust 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 It may be necessary to make calculations to determine the force to use with your ram See How to Determine Ram Pressure below 1060L9 Determine pinion shaft bearing end play as follows 1 Mount the bearing cage in a vise 2 Attach a dial in...

Страница 370: ... 3 574 sq inch EXAMPLE Find the pressure gauge reading for the specified minimum and maximum lb ft force rising a ram with 3 528 sq inch effective area Minimum pressure gauge reading PSI 2090 lb 591 PSI 3 534 sq inch Maximum pressure gauge reading PSI 2610 lb 738 PSI 3 528 sq inch STEP 80 1061L9 Determine correct dimension as follows 1 The reference number etched on the end of the pinion shaft is ...

Страница 371: ...he pinion shaft assembly without any shims Install and tighten retaining bolts to a torque of 102 to 113 Nm 75 to 83 lb ft STEP 82 T98212 Install the pinion shaft depth setting tool CAS1902 1 into the differential bearing retainer bores so the bar is centered on the pinion shaft ...

Страница 372: ...E BEARING 43 PIN 55 PLATE 2 HOUSING 12 WASHER 22 RING 33 CUP BEARING 44 SEAL 56 PLATE 3 PIN 13 SHAFT 23 CONE BEARING 34 RETAINER 45 RING 57 TUBE 4 RING 14 SHAFT 25 CUP BEARING 35 PIN 46 BOLT 58 O RING 7 GEAR 15 BOLT 29 COVER 36 SEAL 50 PISTON 8 GEAR 19 SPACER 30 WASHER 40 RING 10 THRUST WASHER 20 SPACER 31 BOLT 41 RETAINER ...

Страница 373: ...d dimension calculated in Step 80 Example 034 14 mm Desired Dimension 33 82 mm Measured Dimension 0 32 mm Shim Pack Size 4 Shims are available in the following sizes 0 003 0 004 0 005 and 0 012 inches 0 076 0 10 0 13 and 0 30 mm STEP 84 T95912 Remove the pinion shaft assembly from the housing STEP 85 T95913 Select the correct shim pack determined in Step 83 within 0 03 mm 0 001 inch Install the sh...

Страница 374: ...ion Drivelines Chapter 8 21 8 23 STEP 87 T95912 Place the pinion shaft assembly on the housing STEP 88 T95911 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 ...

Страница 375: ...etainer STEP 90 RR98C045 Install the seal rings on both the RH and LH retainer Make sure the ends of the ring lock together STEP 91 T98206 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 STEP 92 RD98C188 Install a new O ring lubricated with petroluem jelly on the pinion sha...

Страница 376: ...fferential housing so the washer tabs enter the cavities in the housing STEP 96 T98168 Install the standard side gear in the housing so the gear teeth face away from the thrust washer STEP 97 T98167 Apply petroleum jelly to the four thrust washers Install two washers for the long pinion shaft so the tabs 1 enter the cavities 2 in the housing The long shaft does not use locking bolts STEP 98 T98208...

Страница 377: ...the thrust washers STEP 101 T98165 Install the long spacer into the housing cavity STEP 102 T98164 Install the long pinion shaft into the housing bore without locking bolts holes and through the long spacer STEP 103 T98163 Install the remaining two thrust washers into the housing so that the washer tabs enter the cavities in the housing STEP 104 T98162 Install the two remaining pinon gears into th...

Страница 378: ...nd into the hole in the long spacer and long pinion shaft Keep the locking bolt hole of the short shaft aligned with the bolt hole in the housing STEP 107 T98155 Install the short pinion shaft locking bolts through the housing into the shafts STEP 108 RD98C189 Install the differential lock piston in the housing STEP 109 T98154 Install the six dowel pins into the housing STEP 110 T98153 Install the...

Страница 379: ...l mesh with the locking side gear STEP 113 T98151 Alternate the separator and friction plates until you have a total of three friction plates and four separator plates in the housing STEP 114 T98172 Install the bearing cup into the differential cover until seated against the cover STEP 115 88 28A Apply grease to the larger thrust washer and install the washer on the cover so the tabs enter the cov...

Страница 380: ... the ends of the rings are locked together STEP 118 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 T98204 Install the differential lifting tool onto the differential STEP 120 T98214 Install the differential into the rear frame with the ring gear to the left hand side IMPORTANT The pinion shaft must not be assembled into...

Страница 381: ...see Adjusting Differential Preload beginning at Step 148 4 Make sure that the lube passages in the rear frame align with the proper hole in each shim see Step 122 STEP 123 T98193 Install bearing retainers as follows 1 Align the lube passage on the rear frame housing with the lube passage in the bearing retainer shown 2 Install the bearing retainers on the rear frame housing 3 Gradually and evenly ...

Страница 382: ...ert the other rockshaft pin STEP 127 35 30 Insert new split washer retainers at the ends of both rockshaft pins STEP 128 36s1 Install the tie rod as follows 1 Place one washer and retainer in place on the end tie rod with the nut 2 Insert the end of the tie rod without the washer and retainer through the centers of the rockshaft pins 3 Attach the split rings washer and retainer to the end projecti...

Страница 383: ...ghten to a torque of 62 to 80 Nm 46 to 59 lb ft NOTE Refer to Tractor Hitch in this manual for details about adjusting the hitch support system STEP 132 36s17 Install the nut for the rockshaft sensor link assembly Torque to 18 to 23 Nm 14 to 17 lb ft STEP 133 36s28b Install the hitch lift cylinder as follows 1 Pins must be clean and free of dirt grease oil and anti seize compound etc 2 Position a ...

Страница 384: ...70 lb ft STEP 136 27s12b Connect the hydraulic lines to the top and bottom of the hitch cylinder Repeat for the other hitch lift cylinder STEP 137 26s27cu Install the vertical lift links as follows 1 Pin must be clean and free of oil grease anti seize 2 Refer to the view in Step 10 if necessary to assemble the vertical lift link for proper orientation of swivels and flags 3 Place a hitch swivel pi...

Страница 385: ...1 91s16 Install and tighten the rear frame drain plug in the housing 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 STEP 144 Install the axle shafts and planetaries on the tractor STEP 145 Connect the range...

Страница 386: ...ng gear when the pinion assembly is in place or with the ring gear when the pinion assembly is removed If no adjustment is necessary go to Step 156 for the differential rolling torque check STEP 150 T98194 Install the LH bearing retainer assembly on the rear frame without shims STEP 151 T98143 Tighten the three retainer mounting bolts to a torque of 235 to 260 Nm 173 to 192 lb ft STEP 152 T98187 I...

Страница 387: ...al assembly 2 Loosen the RH carrier bolts evenly until they are finger tight 3 Tighten the RH carrier bolts equally and evenly until a rolling torque of 5 Nm 45 lb inch is reached NOTE Do not tighten beyond this point STEP 155 T98198 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...

Страница 388: ... 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 To decrease the rolling torque add approximat...

Страница 389: ...to the other Moving a 0 254 mm 0 010 inch shim from one side to the other will change the backlash approximately 0 169 mm 0 0067 inch STEP 161 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...

Страница 390: ...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 244L0 1 RING BEVEL GEAR 3 BEVEL GEAR 2 BEVEL PINION IN TO CORRECT PATTERN A 4 BEVEL PINION IN TO CORRECT PATTERN B 1 2 4 3 ...

Страница 391: ...Section 21 Transmission Drivelines Chapter 8 21 8 40 RH98C093 3 2 1 4 1 DIFFERENTIAL LOCK ASSEMBLY 3 DRIVE PINION SHAFT 2 RING GEAR 4 DIFFERENTIAL ASSEMBLY ...

Страница 392: ...Section 21 Chapter 9 January 2006 HYDRAULIC PUMP DRIVE ...

Страница 393: ...ection 21 Transmission Drivelines Chapter 9 21 9 2 TABLE OF CONTENTS SPECIAL TORQUES 21 9 3 SPECIFICATIONS 21 9 3 PUMP DRIVE 21 9 3 Removal 21 9 3 Disassembly 21 9 4 Assembly 21 9 7 Installation 21 9 12 ...

Страница 394: ...nd the hydraulic PFC piston pump 3 from the hydraulic pump drive 4 Refer to the PFC Piston Pump section of this manual for transmission filter base and PFC piston pump removal NOTE Provide open access to the pump drive by blocking the front wheels and properly supporting the rear axle Loosen the six wheel bushing bolts and move the wheel outward on the axle STEP 2 RD02D023 Remove the three hydraul...

Страница 395: ...Remove the bearing cup from the bearing cage STEP 7 RP98B048 Remove the shims from the pump drive housing STEP 8 RP98B049 Mark the gear positions and remove the drive gear assembly from the pump drive housing STEP 9 T94753 Remove the idler gear bolt and washer from the pump drive housing STEP 10 T94764 Install a slide hammer on the idler gear shaft ...

Страница 396: ...751 Remove the idler gear assembly from the pump drive housing STEP 13 T94750 Drive one of the bearings from the idler gear Discard the bearing STEP 14 T94749 Remove the spacer from the idler gear STEP 15 T94748 Press the other bearing from the idler gear Discard the bearing STEP 16 T94747 Remove the two snap rings from the idler gear ...

Страница 397: ...Section 21 Transmission Drivelines Chapter 9 21 9 6 STEP 17 RP98B051 Remove the front and rear bearing cone from the driven gear shaft using a bearing puller or a press and collet ...

Страница 398: ...es Chapter 9 21 9 7 Assembly SCRH98A5 1 PUMP DRIVE HOUSING 7 BEARING CUP 2 IDLER SHAFT 8 BEARING CONE 3 BEARING 9 DRIVEN GEAR 4 SPACER 10 SHIM 5 RETAINING RING 11 O RING 6 IDLER GEAR 12 BEARING CAGE 7 8 9 8 7 10 11 12 1 2 3 4 5 6 5 3 ...

Страница 399: ... into the grooves of the idler gear STEP 20 T94748 Press a new bearing into the idler gear until it rests solidly against the snap ring STEP 21 T94749 Install the spacer on top of the bearing in the idler gear Install a new spacer if damaged or worn STEP 22 T94750 Press the other new bearing into the idler gear until it rests solidly against the snap ring STEP 23 T94751 Install the idler gear asse...

Страница 400: ... 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 Turn the shaft while tightening the bolts to help seat the bearings Check all bolt torques Tighten again if necessary STEP 28 RR98B003 Determine required shim pack size as follows 1 Measure the gap between the bearing cage and the pump drive housing at each bolt 2 If t...

Страница 401: ...new O ring with petroleum jelly Install the O ring on the bearing cage STEP 31 RP98B048 Install the shim pack determined in Step 28 on the bearing cage mounting surface of the pump drive housing STEP 32 RP98B083 Install the bearing cage on the pump drive housing STEP 33 RR98B005 Tighten the bearing cage bolts to a torque of 55 to 60 Nm 41 to 44 lb ft ...

Страница 402: ...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 If needed adjust the shim pack to get the correct end play ...

Страница 403: ...ilter and base 3 Refer to the PFC Piston Pump and Hydraulic Filter section in this manual Install the charge pump and filter 4 Refer to the Charge Pump section in this manual When installing the charge pump it will be necessary to loosen the clamps on the rubber charge pump suction hose and pry up on the hose to provide needed clearance for the suction flange O ring STEP 39 RD02D023 Connect the hy...

Страница 404: ...Section 25 Chapter 1 January 2006 FRONT WHEEL DRIVE FWD CONTROL SYSTEM How It Works ...

Страница 405: ...nt Axle Chapter 1 25 1 2 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 25 1 7 FRONT WHEEL DRIVE FWD FUNCTIONAL TESTS 25 1 8 TROUBLESHOOTING 25 1 10 ...

Страница 406: ...y reading appropriate fault codes through the instrument cluster display or with the service tool Refer to fault code section for a complete list of fault codes related to the PTO FWD and Differential Lock system IMPORTANT To activate the FWD clutch pack the solenoid valve is de energized The clutch pack is applied mechanically by means of Belleville springs WARNING These tractors are equipped wit...

Страница 407: ...Section 25 Four Wheel Drive Front Axle Chapter 1 25 1 4 RI02E086 1 FWD SOLENOID 2 POWERSHIFT VALVE RANGE 1 2 ...

Страница 408: ...or 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 Diagnostic and programming information are communicated between the PTO controller and the Instrument Cluster Unit ...

Страница 409: ...Section 25 Four Wheel Drive Front Axle Chapter 1 25 1 6 RH05J060 1 FRONT WHEEL DRIVE FWD SWITCH 1 ...

Страница 410: ...energized The clutch pack is applied mechanically by means of Belleville springs RH05J067 Automatic FWD Control When the FWD switch is placed in the Automatic position the FWD will be activated solenoid deactivated unless the following conditions are applicable 1 Operating with the hitch position control lever down and the hitch is raised with the UP DOWN switch End of Row Feature deactivates FWD ...

Страница 411: ...cled Check operational indicator AUTO Disengaged Hitch is UP with UP DOWN switch Position lever in down position Except Both brake pedals are pressed Except When slip is above 15 Engaged Hitch DOWN with UP DOWN switch Position lever in down position Except When speed is in excess of 10 MPH Except When one brake is pressed and slip is below 15 Engaged Hitch UP with UP DOWN switch Position lever in ...

Страница 412: ...ve The solenoid is controlled by an armrest mounted rocker switch The armrest controller communicates via Data Bus with the PTO controller supplying current to deactivate the FWD clutch based on commands from the operator FWD switch and signals supplied to it from the brake pedal switches true ground speed circuit hitch position control system and transmission speed signal circuit The FWD is a spr...

Страница 413: ...ons for excessive resistance Place the FWD switch in the manual ON position Check for 12 VDC at FWD valve coil C If 12 VDC is not available to the coil the electrical circuit is functioning properly D If 12 VDC is found troubleshoot the FWD electrical circuit 3 Check wires 540B R and175D BK ground 4 Check all connections for excessive resistance 4 Start and run the engine A Press the INCR or DECR ...

Страница 414: ...functioning correctly Check fault codes controller and data bus function 3 Place the FWD switch in the ON position Check for 12 VDC at FWD valve coil A If 12 VDC is not available to the coil the electrical circuit is functioning properly B If 12 VDC found troubleshoot the FWD electrical circuit 1 Check wires 540B R and 175D BK ground 2 Check all connections for excessive resistance Place the FWD s...

Страница 415: ...ting regulated pressure hydraulically released clutch 4 Any interruption in the electrical control power coil energized to release clutch 5 Both brakes are applied automatic FWD operation For these reasons the following service procedures must be utilized Before rotating the rear wheels of an FWD equipped tractor when using engine power with the rear wheels raised off the ground one of the followi...

Страница 416: ...Section 25 Chapter 2 January 2006 DIFFERENTIAL LOCK CONTROL SYSTEM How It Works ...

Страница 417: ... OF CONTENTS DIFFERENTIAL LOCK 25 2 3 ELECTRONIC DIFFERENTIAL LOCK CONTROL 25 2 5 DIFFERENTIAL LOCK CONTROL MODES 25 2 7 DIFFERENTIAL LOCK CONTROL 25 2 8 DIFFERENTIAL LOCK FUNCTIONAL TESTS 25 2 9 TROUBLESHOOTING 25 2 12 PTO DIFFERENTIAL LOCK VALVE CIRCUIT 25 2 15 ...

Страница 418: ...ston in the differential carrier housing As the piston extends friction discs and separator plates are locked together The separator plates are pinned to the differential carrier while the friction plates are splined to the left differential side gear When the differential lock is applied the clutch pack locks causing the left side gear to rotate with the differential carrier This eliminates all d...

Страница 419: ...Section 25 Four Wheel Drive Front Axle Chapter 2 25 2 4 RI02E086 1 PTO DIFF LOCK VALVE 2 DIFF LOCK CLUTCH SOLENOID 1 2 ...

Страница 420: ...m Rest Control Module then relayed to the PTO controller via the Data Bus Transmission speed and true ground speed signals are sent to the instrument Cluster Unit ICU then relayed to the PTO controller Diagnostic and programming information are communicated between the PTO controller and the Instrument Control Unit ICU by way of the Data Bus Operational Modes The differential lock system operates ...

Страница 421: ...Section 25 Four Wheel Drive Front Axle Chapter 2 25 2 6 RD05J060 1 DIFFERENTIAL LOCK SWITCH 1 ...

Страница 422: ...vated manually Automatic Differential Lock Control When the differential lock switch is placed in the Automatic position A symbol the differential lock will be activated differential symbol will be illuminated on the tractor monitor unless the following conditions are applicable 1 Operating with the hitch position control lever down and the hitch is raised with the UP DOWN switch End of Row Featur...

Страница 423: ...O CONTROL CAN TRANSCEIVER MICRO CONTROLLER MFD DIFF LOCK CONTROL LH BRAKE PEDAL SWITCH RH BRAKE PEDAL SWITCH CLEAN GROUND IMPLEMENT BRAKE LIGHTS TRACTOR BRAKE LIGHTS BRAKE LIGHT RELAY RANGE TRANSMISSION HOUSING MFD VALVE MFD CLUTCH REAR FRAME HOUSING DIFF LOCK VALVE DIFF LOCK CLUTCH AUX HITCH PTO CONTROL MODULE TMF TRUE GROUND SPEED SENSOR TRANSMISSION SPEED SENSOR DIFF L SWITCH MFD SWITCH PTO SWI...

Страница 424: ... or both brake pedals is pushed the differential lock light will go out and the differential lock will be deactivated AUTO Disengaged As hitch raises and reaches upper 30 of travel lever down switch NOTE If slippage is above 15 the differential lock will engage or stay engaged Disengaged As travel speed exceeds 10 MPH NOTE If slippage is above 15 the differential lock will engage or stay engaged D...

Страница 425: ...ng components of the PTO valve are involved in the differential lock system Solenoid Cartridge Valve The solenoid is controlled by an armrest mounted rocker switch The armrest controller communicates via the Data Bus with the PTO controller The PTO controller supplies current to the differential lock valve to activate the differential lock clutch based on commands from the operator differential lo...

Страница 426: ...rted to the transmission housing and the differential lock clutch will disengage NOTE It is not possible to disengage the differential lock with the switch control Pushing either brake pedal will deactivate the differential lock The differential lock switch has three 3 positions The mid switch position is OFF when the differential lock is deactivated The same switch position is ON when the differe...

Страница 427: ...esistance Apply the brakes this will deactivate the differential lock Check for 12 VDC at differential lock valve coil C If 12 VDC is available to the coil the differential lock electrical circuit is not functioning properly 1 Check left and right brake switches D If 12 VDC is not found the differential lock electrical circuit is functioning properly 4 Start and run the engine A Press the INCR or ...

Страница 428: ...ressure 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 The clutch pack locks causing the left side gear to rotate with the differential carrier eliminating differential action RH98H056 DIFFERENTIAL LOCK CLUTCH ASSEMBLY ...

Страница 429: ...functioning correctly Check fault codes controller and data bus function 3 Place the differential lock switch in the ON position Check for 12 VDC at differential lock valve coil A If 12 VDC is available to the coil the differential lock electrical circuit is functioning properly B If 12 VDC is not found troubleshoot the differential lock electrical circuit 1 Check wires 530A R and 175E BK ground 2...

Страница 430: ...pter 2 25 2 15 PTO DIFFERENTIAL LOCK VALVE CIRCUIT RH02A059 NOTE Refer to Differential Lock electrical schematic diagram BEVEL PIN LUBE DIFF LOCK SOLENOID REGULATED SUPPLY PTO CLUTCH LUBE DIFFERENTIAL LOCK PISTON PTO CLUTCH PISTON PTO SOLENOID ...

Страница 431: ...Section 25 Four Wheel Drive Front Axle Chapter 2 25 2 16 This Page Left Blank ...

Страница 432: ...Section 25 Chapter 3 January 2006 FWD OUTPUT SHAFT ...

Страница 433: ... Four Wheel Drive Front Axle Chapter 3 25 3 2 TABLE OF CONTENTS SPECIAL TORQUES 25 3 3 FWD OUTPUT SHAFT 25 3 4 FWD Output Shaft Removal 25 3 4 FWD Output Shaft Disassembly 25 3 5 FWD Output Shaft Assembly 25 3 9 ...

Страница 434: ...nt Axle Chapter 3 25 3 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 ...

Страница 435: ...e speed transmission into a suitable clean container STEP 3 RD02H172 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 Properly support the drive shaft Refer to the information in this manual for the drive shaft removal procedure Remove the four bolts 3 from the pinion yoke and the...

Страница 436: ... the output shaft bearing cage STEP 5 11S21 Remove FWD shaft and bearing cage from drop box FWD Output Shaft Disassembly STEP 6 108RS4 Place the FWD output shaft in a vise and remove the yoke retaining bolt STEP 7 108RS7 Remove the yoke retaining bolt washer and the shim s NOTE Keep the shims with the yoke ...

Страница 437: ...5 3 6 STEP 8 108RS10 Remove and discard the O ring STEP 9 108RS16 Remove the yoke from the output shaft spline STEP 10 108RS22 Remove and discard the oil seal STEP 11 108RS28 Remove the internal retaining ring STEP 12 108RS23 Remove the bearing spacer ...

Страница 438: ...llows 1 Rest the bottom of the drive shaft on a wooden block 2 Hold the bearing cage 3 Tap downward on the ears of the bearing cage in a crossing pattern 4 Remove the front bearing cup 5 Remove the bearing cage STEP 15 2940CUP1 Remove the rear bearing cup from the bearing cage as shown in drawing above STEP 16 109RS17 Press the front bearing cone from the output shaft STEP 17 109RS22 Remove the ex...

Страница 439: ...Section 25 Four Wheel Drive Front Axle Chapter 3 25 3 8 STEP 18 109RS28 Press the rear bearing cone from output shaft STEP 19 109RS11 Remove and discard the O ring from bearing cage ...

Страница 440: ... FWD Output Shaft Assembly 2940FUL2 1 SEAL 8 BEARING SPACER 2 YOKE 9 O RING 3 WASHER 10 SHIMS 4 BOLT 11 EXTERNAL RETAINING RING 5 SHIMS 12 BEARING CONE 6 O RING 13 BEARING CUP 7 INTERNAL RETAINING RING 14 BEARING CAGE 14 13 12 11 10 9 8 7 6 5 4 3 2 1 13 12 ...

Страница 441: ...stall a new rear bearing cone just below the external retaining ring groove STEP 22 109S22 Install a new external retaining ring and press the rear bearing cone against the retaining ring STEP 23 109RS31 Install a new front bearing cone on the output shaft Press the front bearing cone against the external retaining ring STEP 24 2940CUP2 Press a new rear bearing cup into the bearing cage ...

Страница 442: ... cup face to the top edge of the internal retaining ring groove in the bearing cage Subtract 0 27 MM 0 011 inch for bearing end play 5 This will be the total shim spacer and internal retaining ring dimension required Select shims that with the spacer and the internal retaining ring will equal the dimension to within 0 25 MM 0 010 inch Refer to Step 14 to remove the front bearing cup from the beari...

Страница 443: ...ove the output shaft from the bearing cage and repeat Steps 25 and 26 to obtain the proper measurement STEP 28 108RS19 Lubricate the inner diameter of the FWD output shaft seal with clean hydraulic oil Install the oil seal The seal must be installed 8 5 MM 0 335 inch below the surface of the bearing cage STEP 29 108RS16 Install the yoke on the output shaft spline STEP 30 108RS11 Lubricate a new O ...

Страница 444: ...ce 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 STEP 34 11S21 Install the FWD output shaft and bearing cage into the housing IMPORTANT The output shaft engages a needl...

Страница 445: ...lts to a torque of 375 to 485 Nm 276 to 358 lb ft STEP 36 RD02H173 RD02H172 Install the FWD drive shaft and the drive shaft protector Refer to the installation procedure contained in this manual Properly support the drive shaft Tighten the drive shaft retaining bolts 1 to a torque of 58 to 64 Nm 43 to 47 lb ft Install the drive shaft protector pins 2 using the position marks on the drive shaft pro...

Страница 446: ...mission with hydraulic oil STEP 38 96RS28A 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 ...

Страница 447: ...Section 25 Four Wheel Drive Front Axle Chapter 3 25 3 16 This Page Left Blank ...

Страница 448: ...Section 25 Chapter 4 January 2006 FWD DRIVE SHAFT ...

Страница 449: ...Section 25 Four Wheel Drive Front Axle Chapter 4 25 4 2 TABLE OF CONTENTS SPECIAL TORQUES 25 4 3 FWD DRIVE SHAFT 25 4 4 ...

Страница 450: ...Section 25 Four Wheel Drive Front Axle Chapter 4 25 4 3 SPECIAL TORQUES Drive Shaft Retaining Bolts 58 to 64 Nm 43 to 47 lb ft ...

Страница 451: ...nd the rear wheels STEP 2 RD02H166 Mark the position of the sleeve on the drive shaft cover 1 Remove the plastic pin 2 Slide the cover toward the transmission STEP 3 RD06A007 Remove the suspended front axle hoses 1 if equipped Remove the steering hoses 2 right side shown from the drive shaft cover STEP 4 RD02H169 Mark the drive shaft to pinion yoke 1 Support the drive shaft Remove the four drive s...

Страница 452: ... yolks Remove the four drive shaft to transmission yoke retaining bolts Remove the drive shaft STEP 7 RD02H191 Place the drive shaft 1 on V blocks 2 Position a dial indicator 3 over the drive shaft Turn the drive shaft one complete revolution to check for straightness Replace the drive shaft if necessary 2 2 1 3 ...

Страница 453: ...ighten bolts in a crossing pattern until the yoke is fully seated STEP 9 RD02H154 Slide the cover over the drive shaft STEP 10 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 STEP 11 RD02H166 Move the position marks 1 made on the drive shaft cover and sleeve until the holes...

Страница 454: ... if equipped to the steering hoses STEP 13 96RS28A 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 2 1 ...

Страница 455: ...Section 25 Four Wheel Drive Front Axle Chapter 4 25 4 8 ...

Страница 456: ...Section 25 Chapter 5 January 2006 SUSPENDED FWD AXLE SYSTEM How It Works and Troubleshooting ...

Страница 457: ... Chapter 5 25 5 2 TABLE OF CONTENTS SUSPENDED FWD AXLE OPERATION 25 5 3 SUSPENDED MFD AXLE CALIBRATION MODE 25 5 9 ERROR TABLE 25 5 11 SUSPENDED FWD AXLE MANUAL OPERATION MODE TEST MODE 25 5 13 SUSPENDED FWD AXLE DEMONSTRATION MODE 25 5 16 ...

Страница 458: ...ly turn on or off With the system turned off the axle will be locked in position until the tractor reaches 12 km h 7 5 mph at 12 km h 7 5 mph the system will switch to the auto mode for roading This can only be overridden with the Electronic Service Tool EST connected and the DEMO mode accessed through the ICU See demonstration instructions in this section This will allow the operator to experienc...

Страница 459: ...ator maintain the axle position When the axle hits a small 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 and orifice 9 to the accumulator Oil moving into the accumulator against the nitrogen charge absorbs the shock to the axle No oil passes to tank it is stopped at check valve 14 check in unload v...

Страница 460: ...bsorb excess oil will pass through lock out valve 4 then through relief valve 7 to tank Returning the axle to its original position will require additional oil to the system since some was lost to sump When the potentiometer signals the controller that the axle has moved out of the mid point band for more than 0 1 second the controller will energize the raise solenoid 1 and maintain current to bot...

Страница 461: ...ONTROL VALVE 1 RAISE SOLENOID COLOR CODE RED 6 PUMP SUPPLY 2 LOWER SOLENOID COLOR CODE GREEN 7 LOAD SENSE SIGNAL 3 PISTON SIDE LOCKOUT SOLENOID COLOR CODE YELLOW 8 TANK 4 ROD SIDE LOCKOUT SOLENOID COLOR CODE BLUE 9 TO ACCUMMULATOR 5 UNLOAD VALVE 10 CONTROL VALVE BODY 1 2 4 3 5 6 7 9 8 10 ...

Страница 462: ... CODE GREEN 9 PISTON END SUPPLY TO SUSPENSION CYLINDER 3 PISTON SIDE LOCKOUT SOLENOID COLOR CODE YELLOW 10 LEFT SUSPENSION CYLINDER 4 ROD SIDE LOCKOUT SOLENOID COLOR CODE BLUE 11 RIGHT SUSPENSION CYLINDER 5 UNLOAD VALVE 12 SUPPLY HOSE 6 TO ACCUMMULATOR 13 RETURN TO TANK HOSE 7 ACCUMMULATOR 14 SIGNAL LINE HOSE 2 3 1 TOP VIEW REAR TOP VIEW FRONT 4 5 9 8 6 7 10 11 12 13 ...

Страница 463: ...ID COLOR CODE GREEN 9 PISTON END SUPPLY TO SUSPENSION CYLINDER 3 PISTON SIDE LOCKOUT SOLENOID COLOR CODE YELLOW 10 LEFT SUSPENSION CYLINDER 4 ROD SIDE LOCKOUT SOLENOID COLOR CODE BLUE 11 RIGHT SUSPENSION CYLINDER 5 UNLOAD VALVE 12 SUPPLY HOSE 6 TO ACCUMMULATOR 13 RETURN TO TANK HOSE 7 ACCUMMULATOR 14 SIGNAL LINE HOSE SIDE VIEW REAR SIDE VIEW FRONT 12 13 14 11 ...

Страница 464: ...ting the tractor A short beep will indicate that the program mode has been accessed and the display will read CONFIG MENU STEP 2 RD06A022 Push the DECR key until Transmission is highlighted Press the PROG key STEP 3 RD06A023 The display will read TRANS VIEW STEP 4 RD06A024 Push the DECR key until the display reads TRANS FSUS STEP 5 RD06A025 Press the PROG key and the display reads Fsus Cal ...

Страница 465: ...ost completed an asterik will appear on the display STEP 8 RD06A028 Seconds later the display will read FSUS Cal Done and the lamp will stop flashing NOTE If the display reads Cal Failed continue with Step 10 STEP 9 RD06A029 Press the DECR key until the display reads Exit Fsus Press the PROG key to exit calibration Exit out of the calibration menu If there are any calibration errors they will appe...

Страница 466: ...er installation and adjust as necessary Change potentiometer Pot Shrt Ckt Front axle potentiometer short circuit Automatic Calibration Procedure will not work Check wire harness Check the position sensor ground circuit Check connector 193 pin 1 to ground Change potentiometer Pot Low Val Front axle potentiometer threshold is lower than set limit Check potentiometer and adjust as necessary Change po...

Страница 467: ...uring lowering command in the Automatic Calibration Procedure Check unload solenoid GREEN harness Check suspension mechanics Check hydraulic pressure Disconnect Implement Slow to min Suspension unable to reach minimum height within 25 seconds Check unload solenoid GREEN installation Check hydraulic pressure Disconnect Implement Not Cal Unable to calibrate suspension Check suspension mechanics Chec...

Страница 468: ...work when the tractor is stationary The manual mode operation is useful to verify that the valves and potentiometer are working and installed correctly In the manual mode the system valves can be used to raise lower or unlock the front suspension RD05J033 To enable the front suspension Manual mode STEP 1 RD06A021 Push and hold the PROG key for two seconds within the first ten seconds after startin...

Страница 469: ...monitoring the front suspension position sensor STEP 7 RD06A031 Next use the DECR key until the display reads Raise nnnnn mV The nnnnn reading is the millivolt reading for the position sensor output 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 STEP 8 RD06A032 The display will...

Страница 470: ...ot the raise and lower lockout circuits Use a multimeter to check the voltage at the lockout solenoids Release the rocker switch and both lockout solenoids will be energized again Press the DECR key STEP 10 RD06A034 The display will read Exit Manual Press the PROG key STEP 11 RD06A030 The display will read Fus Manual Press the DECR key STEP 12 RD06A035 Press the DECR key until Exit Fsus is display...

Страница 471: ... 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 2 RD06A022 Push the DECR key until Transmission is highlighted Press the PROG key STEP 3 RD06A023 The display will read TRANS VIEW STEP 4 RD06A024 Push the DECR key until the display reads TRANS FSUS STEP 5 RD06A0...

Страница 472: ... RD06A038 Press the DECR key The display will read Demo On STEP 9 RD06A039 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 10 RD06A040 Press the PROG key Press the DECR key until the display reads Demo Off Next press the PROG The display will read Exit Dem...

Страница 473: ...ter 5 25 5 18 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 ...

Страница 474: ...Section 25 Chapter 6 January 2006 SUSPENDED FWD AXLE REMOVAL ...

Страница 475: ...Section 25 Four Wheel Drive Front Axle Chapter 6 25 6 2 TABLE OF CONTENTS SUSPENDED FWD AXLE 25 6 3 Removal 25 6 3 Installation 25 6 5 ...

Страница 476: ...emoval 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 Remove the front fenders if equipped Remove the front wheels STEP 2 RD02K103 Tag and remove right and left steering lines 1 if equipped tag and remove the hydraulic differential lock supply and return lines not shown STEP 3 RD02K100 The axle position senso...

Страница 477: ...aining plate 3 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 Place a jack under the center of the axle to help keep it level Remove the pivot pin and thrust washers STEP 7 RD02K101 Remove the jack Lower the axle and remove from the tractor 2 3 1 ...

Страница 478: ...r and lift into place Once in place install a jack under the center of the axle and level STEP 10 RD02K114 RI02K095 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 STEP 11 RD02K115 Install the pivot pin locking plate and bolts Torque bolts to 59 to 105 Nm 44 to 78 lb ft 2 1 ...

Страница 479: ...9 Connect the axle sensing connector STEP 14 RD02K103 Connect the right and left steering lines 1 If equipped connect the hydraulic differential lock supply and return lines not shown 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 2 1 1 ...

Страница 480: ...Section 25 Chapter 7 January 2006 SUPERSTEER AXLE REMOVAL AND INSTALLATION ...

Страница 481: ...Section 25 Four Wheel Drive Front Axle Chapter 7 25 7 2 TABLE OF CONTENTS SPECIAL TORQUES 25 7 3 SPECIAL TOOLS 25 7 3 FRONT AXLE REMOVAL 25 7 4 FRONT AXLE INSTALLATION 25 7 7 ...

Страница 482: ... Tie Rod Support Plate Retaining Bolt 300 to 550 Nm 225 to 405 lb ft Tie Rod End Castle Nut 373 Nm 275 lb ft Tie Rod End Adjusting Nut 373 to 441 Nm 275 to 325 lb ft Front Weight Bracket Bolt 662 to 851 Nm 488 to 627 lb ft Front Wheel Stud Nut 385 to 425 Nm 285 to 315 lb ft Front Drive Shaft Bolts 58 to 64 Nm 43 to 47 lb ft SPECIAL TOOLS RH02D006 17 527 REAR HOUSING HANDLER ...

Страница 483: ...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 Mark the position of the drive shaft protector Remove the plastic drive shaft protector pin and discard Slide the drive shaft protector from the drive shaft STEP 4 RD02B153 Mark the alignment of the transmission output flange and the d...

Страница 484: ...tags to mark the hoses Remove the cylinder supply hoses 1 from each cylinder Remove the two front axle differential lock hoses 2 from the axle cover if equipped STEP 8 RD02B159 Use proper lifting equipment to support the front weight bracket Remove the four retaining bolts and the weight bracket STEP 9 RD02C014 Properly support the front axle for removal using 17 527 rear housing handler STEP 10 R...

Страница 485: ...Remove the three axle side plate retaining bolts from both sides of the axle STEP 12 RD02C015 Remove the front pivot pin bolt STEP 13 RD02C011 Remove the pivot pin and the front and rear pivot arm shims STEP 14 RD02C026 Lower the front axle and remove from under the tractor ...

Страница 486: ... the pivot pin with grease Install the front and rear pivot arm shims and the pivot pin STEP 17 RD02C017 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 18 RD02C015 Install the front pivot pin bolt 1 Tighten the bolt to a torque of ...

Страница 487: ... to 441 Nm 275 to 325 lb ft STEP 20 RD02B159 Use proper lifting equipment to install the front weight bracket Tighten the four retaining bolts to a torque of 662 to 851 Nm 488 to 627 lb ft STEP 21 RD02B158 Using the identification tags from the disassembly procedure install and tighten the cylinder supply hose 1 to each cylinder Install and tighten the two front axle differential lock hoses 2 to t...

Страница 488: ...e drive shaft at the front axle pinion flange using the alignment marks Tighten the drive shaft bolts to a torque of 58 to 64 Nm 43 to 47 lb ft STEP 25 RD02B151 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 tra...

Страница 489: ...Section 25 Four Wheel Drive Front Axle Chapter 7 25 7 10 ...

Страница 490: ...Section 25 Chapter 8 January 2006 LIMITED SLIP FWD DIFFERENTIAL ...

Страница 491: ... 20 to 50 lb inch Differential Assembly Rolling Torque without input seal 2 83 to 5 65 Nm 25 to 50 lb ft Differential Ring Gear Backlash 10 Stud Wheel End Axle 0 127 to 0 254 mm 0 005 to 0 010 inch 12 Stud Wheel End Axle 0 127 to 0 203 mm 0 005 to 0 008 inch SPECIAL TORQUES Differential Adjusting Ring 85 to 115 lb ft 115 to 156 Nm Differential Adjusting Ring Clip Bolts 27 to 40 Nm 20 to 30 lb ft D...

Страница 492: ...lower carrier housing bolt 1 Note the location before bolt removal Remove the bolts and washers that hold the differential carrier to the axle housing 21 mm socket STEP 3 RR98K029 Support the differential carrier with a chain or lift strap and hoist Carefully pry the differential carrier from the axle housing When lifting the carrier assembly out of the axle assembly make certain the carrier does ...

Страница 493: ...ers and ring clips from the bearing caps 13 mm socket or wrench STEP 7 RR98K045 Remove bearing cap retaining bolts and washer 24 mm or 15 16 inch socket STEP 8 RR98K015 RR98K016 Remove the bearing caps and adjusting rings STEP 9 RR98K047 Lift and remove the differential assembly from the carrier Remove the differential bearing cups from the bearing cones Note which side each cup originates from ...

Страница 494: ...rawhide or plastic hammer to separate the gear from the housing half STEP 12 RR98K228 Mark the housing halves for reassembly Also mark the end of the cross shaft that is nearest the housing mark for reassembly STEP 13 RR98K017 Place shop towels over and between the vise jaws This will prevent possible damage to the axle shaft Place one of the axle shafts into the vise with the spline end extending...

Страница 495: ...it collet and remove the bearing cone from the differential housing half STEP 16 RR99K230 Remove the differential housing half STEP 17 RR99K231 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 18 RR99K223 Remove the dished disc STEP 19 RR99K234 Remove the side gear ...

Страница 496: ...he pinion mate cross shaft the pinion mate gears and thrust washers STEP 22 RR99K237 Remove the side gear STEP 23 RR99K238 Remove the dished disc the separator plated and friction discs NOTE If reused make sure the discs and plates are kept in the same order for reassembly STEP 24 RR98K031 Install a split collet and remove the bearing cone from the differential gear housing half ...

Страница 497: ...t reassembly 1 5 16 inch socket STEP 26 T98483 Remove end yoke If yoke or flange shows wear in the seal contract area if should be replaced STEP 27 RR98K012 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 RR98K019 Remove the pinion by tapping with a rawhide hammer Support the pinion to prevent it from falling a...

Страница 498: ...haft must be replaced as matched set STEP 29 RR98K020 Remove the pinion seal with a puller as shown DISCARD SEAL Replace with new seal during reassembly Also remove bearing cone and outer pinion oil slinger STEP 30 T98492 Remove the spacer from the pinion shaft as shown STEP 31 T98490 Remove pinion adjustment shims from the pinion shaft STEP 32 RR98K039 Remove the inner bearing cup NOTE Shims are ...

Страница 499: ...r bore STEP 35 RR98K036 Install a split collet and press the bearing cone off of the pinion shaft NOTE It is recommended that whenever bearings are removed they are to be replaced with new ones regardless of hours NOTE If replacement of a damaged bearing cup or cone is necessary the cup and cone must be replaced as a set WARNING Do not allow the shaft to fall It can strike legs or feet and may cau...

Страница 500: ...o all the disc and plate friction surfaces NOTE Make sure the discs and plates are kept in the same order as disassembly 1 BEARING CUP 2 BEARING CONE 3 RING GEAR BOLT 4 HOUSING HALF 5 DIFFERENTIAL RING GEAR 6 DISHED DISC 7 FRICTION DISCS 8 SEPARATOR PLATES 9 SIDE GEAR 10 PINION GEAR 4 PINION MATES 11 CROSS SHAFT 1 12 DIFFERENTIAL CASE SCREW 13 ADJUSTING RING 14 THRUST WASHER 2 2 3 4 4 5 6 6 7 8 8 ...

Страница 501: ...ousing The convex side of the disc must be up so the ID of the disc makes contact with the side gear that is installed next STEP 40 RR99K237 Apply grease to the shoulder of the side gear then install the side gear in dished disc in the flanged housing half STEP 41 RR98K025 Lubricate the pinion mate gear ID s Install the pinion mate gears and thrust washers NOTE Make sure the shafts are installed i...

Страница 502: ...ear shoulder STEP 44 RR99K231 Apply friction modifier B91246 to all the discs and plate friction surfaces NOTE Make sure the discs and plates are kept in the same order as disassembly STEP 45 RI03B005 Be sure the plates are arranged for installation as follows 3 Plates in board side 1 Discs 1 Plate 1 Disc 1 Plate 1 Disc 1 Plate 1 Disc 1 Plate 1 Disc ...

Страница 503: ...ine up on the case halves Refer to the alignment marks made prior to disassembly Install eight 8 new differential case screws Tighten to a torque of 122 to 135 Nm 90 to 100 lb ft STEP 47 RR98K035 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 NOTE Make sure the disc...

Страница 504: ...s and setting pinion distance NOTE On the pinion there is etched either a zero 0 or plus or minus number This indicates the best running position for each gear set The dimension is set by shimming behind the inner pinion bearing cup 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 PINION SHAFT POSITION SHIM...

Страница 505: ... 0 003 0 002 0 001 0 0 007 0 006 0 005 0 004 0 003 0 002 0 001 0 0 001 0 006 0 005 0 004 0 003 0 002 0 001 0 0 001 0 002 0 005 0 004 0 003 0 002 0 001 0 0 001 0 002 0 003 0 004 0 003 0 002 0 001 0 0 001 0 002 0 003 0 004 0 003 0 002 0 001 0 0 001 0 002 0 003 0 004 0 005 0 002 0 001 0 0 001 0 002 0 003 0 004 0 005 0 006 0 001 0 0 001 0 002 0 003 0 004 0 005 0 006 0 007 0 0 001 0 002 0 003 0 004 0 0...

Страница 506: ...0 through 64 to assemble tool to differential housing STEP 51 T98516 Install the Handle FNH 00401 or 380001132 and Threaded Shaft FNH 00402 or 380001133 into the carrier housing STEP 52 T98517 Install Aligning Disc FNH 00405 or 380001136 and the Gauge Disc FNH 00403 or 380001134 STEP 53 T98518 Install Gauge Block FNH 00404 or 380001135 and finger tighten to hold the gauge assembly and bearing cone...

Страница 507: ... 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 0 127 mm 0 ...

Страница 508: ...e Front Axle Chapter 8 25 8 19 STEP 60 T98491 Install the proper amount of shims STEP 61 T98513 Install the inner bearing cup STEP 62 RR98K037 Assemble inner bearing cone on pinion Drive bearing onto pinion using suitable press ...

Страница 509: ...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 NOTE Typically a change of 0 001 inch will change rolling torque 15 lb inch 1 To increase the torque adjust the 0 070 inch shim pack to remove a small amount of thickness For example replace a 0 015 inch shim with a 0 014 inch shim Repeat torque check procedure 2 To decrease the torque a...

Страница 510: ...inion Seal Installer FNH 00419 or 380001111 to install a new pinion shaft oil seal Install the seal with the lip towards the pinion shaft STEP 69 T98534 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 70 T98530 Tighten the pinion nut to a torque of 326 to 406 Nm 240 to 300 lb ft 1 5 16 inch sock...

Страница 511: ...e bearing Installed opposite the adjusting ring would clamp against the bearing cage restricting movement STEP 73 RR98K015 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 NOTE Make sure the match marked bearing cap and match marked leg o...

Страница 512: ...dicator face Move the ring gear in the opposite direction until it contacts the pinion gear and observe the dial face The reading should be 0 127 to 0 254 mm 0 005 to 0 010 inch for 10 stud wheel end axle or 0 127 mm to 0 203 mm 0 005 to 0 008 inch for 12 stud wheel end axle Check the backlash at three different locations around the gear There should be no more than 0 06 mm 0 003 inch variation be...

Страница 513: ...hould be 5 to 10 lb inch higher than the torque you had when setting pinion shaft bearing preload 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 STEP 79 T98561 Tighten all of the bearing cap bolts to a torque of 240 to 270 Nm 180 to 200 lb ft ...

Страница 514: ...the range of 0 05 mm 0 002 inch to 0 10 mm 0 004 inch until correct pattern has been obtained When a change in backlash is required backlash should be changed approximately 1 1 2 times the amount needed to bring the gears into specification For example if the backlash needed to be changed by 0 10 mm 0 004 inch the adjusting rings should be moved so that the backlash changes by 0 15 mm 0 006 inch a...

Страница 515: ...d Pattern moves slightly higher and toward heel Reverse Pattern moves higher and toward heel 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 4 A thinner pinion position shim with the ...

Страница 516: ...er assembly into the axle housing Apply Loctite 271 to all bolt threads prior to installation Install the hose clamp on the lower bolt 1 from where it was removed Install washers and bolts and tighten to a torque of 135 to 155 Nm 100 to 115 lb ft STEP 83 Assemble axle shafts and wheel end components following procedures shown in axle disassembly information STEP 84 Clean drain plugs and install in...

Страница 517: ...Section 25 Four Wheel Drive Front Axle Chapter 8 25 8 28 ...

Страница 518: ...Section 25 Chapter 9 January 2006 LOCKING FWD DIFFERENTIAL ...

Страница 519: ...THE FRONT DIFFERENTIAL CARRIER ASSEMBLY 25 9 4 REMOVAL OF THE FRONT DIFFERENTIAL FROM THE CARRIER HOUSING 25 9 5 DISASSEMBLY OF THE DIFFERENTIAL 25 9 7 PINION DISASSEMBLY 25 9 9 ASSEMBLY OF THE DIFFERENTIAL 25 9 12 DIFFERENTIAL CARRIER ASSEMBLY 25 9 16 SETTING THE PINION DEPTH 25 9 18 ADJUSTING BEARING PRELOAD 25 9 21 DIFFERENTIAL INSTALLATION 25 9 23 ...

Страница 520: ...ential Adjusting Ring Clip Bolts 27 to 40 Nm 20 to 30 lb ft Differential Bearing Cap Bolts 240 to 270 Nm 180 to 200 lb ft Differential Front Ring Gear Bolts 163 to 190 Nm 120 to 140 lb ft Differential Housing Bolts 122 to 135 Nm 90 to 100 lb ft Differential Pinion Shaft Nut 10 Bolt 325 to 406 Nm 240 to 300 lb ft Differential Pinion Shaft Nut 12 Bolt 460 to 542 Nm 340 to 400 lb ft Seal Retainer Soc...

Страница 521: ... from the tractor NOTE Do not alter the tie rod adjustment STEP 3 RD02K001 RD02K002 Remove the differential lock supply and return hoses and remove the fittings 1 from the differential carrier Remove the bolts and washers that hold the differential carrier to the axle housing 21 mm socket STEP 4 RR98K029 Support the differential carrier with a chain or lift strap and hoist Carefully pry the differ...

Страница 522: ... surface STEP 7 RD06A138 Remove the three socket head screws from the seal retainer 3 mm Allen wrench STEP 8 RD06A139 Remove the bolt and washer locking the adjusting nut in place STEP 9 RD06A140 Remove the seal retainer STEP 10 RD06A141 Mark the bearing cap STEP 11 RD06A142 Remove bearing cap retaining bolts and washers then remove bearing cap 24 mm or 15 16 inch socket ...

Страница 523: ...ark the opposite bearing cap 1 Remove the bolt and adjusting ring retaining cup 2 STEP 14 RD06A145 Remove the bolts washers bearing cap and adjusting ring STEP 15 RD06A146 Remove the differential from the carrier STEP 16 RD06A147 Remove the bearing cup Repeat for the opposite side STEP 17 RD06A148 Remove the seal 1 2 ...

Страница 524: ...06A151 Remove the piston 1 from the cap half of the case 2 STEP 20 RD06A152 Remove the outer 1 and inner 2 seal rings from the piston and discard the seals STEP 21 RD06A153 Remove the seal rings from the shaft STEP 22 RD06A154 Remove the thrust washer STEP 23 RD06A155 Remove the separator and friction plates NOTE Separator and friction plates are replaced as complete assemblies 2 1 2 1 ...

Страница 525: ...the pinon mate cross shaft pinon mates pinon gears and thrust washer Mark the assembly 1 so that it can be reinstalled in the same position during reassembly STEP 27 RR99K236 Separate the pinion mate cross shaft pinion mate gears and thrust washers STEP 28 RD02H199 RD02H232 Remove the bearing cone from the flange half case and cap half case if replacement is required 1 ...

Страница 526: ...g and being damaged 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 be used later in reassembly Do not damage the shims If the shims are damaged replace with new ones shims are available in thicknesses of 0 003 inch 0 005 inch 0 010 inch and 0 030 inch N...

Страница 527: ...justment shims from the pinion shaft STEP 36 RR98K039 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 37 T98491 Remove inner bearing adjustment shims ...

Страница 528: ...stall a split collet and press the bearing cone off of the pinion shaft NOTE It is recommended that whenever bearings are removed they are to be replaced with new ones regardless of hours NOTE If replacement of a damaged bearing cup or cone is necessary the cup and cone must be replaced as a set WARNING Do not allow the shaft to fall It can strike legs or feet and may cause serious injury Gear tee...

Страница 529: ... SEAL RETAINER 21 DIFF THRUSTWASHER 4 OUTER SEAL RING 13 SOCKER HEAD SCREW 22 GEAR 5 INNER SEAL RING 14 SEPERATOR PLATE 23 CASE FLANGE HALF 6 PISTON 15 FRICTION PLATE 24 BOLT 7 SEAL 16 CLUTCH HOUSING 25 SEAL 8 BEARING CONE 17 THRUST WASHER 26 ADJUSTING RING 9 BEARING CUP 18 DIFFEERENTIAL GEAR 27 PLUG 28 SIDE GEAR 3 5 6 4 2 1 7 8 9 11 26 13 10 12 10 9 18 17 22 23 24 25 8 17 16 14 15 21 20 19 27 28 ...

Страница 530: ...lder of the side gear then install side gear into the flange half case 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 NOTE Make sure the cross shaft is installed in the same order as disassembly Refer to the alignment marks STEP 40 RD06A157 Refer to the alignment marks Place the clutch housing onto the fla...

Страница 531: ...pply friction modifier B91246 to all the disc and plate friction surfaces NOTE If reinstalling make sure the discs and plates are kept in the same order as disassembly IMPORTANT When installing the friction plates make sure the gaps 3 in the teeth are all aligned STEP 43 RD05A154 Install the thrust washer STEP 44 RD06A153 Install new seal rings STEP 45 RD06A152 Lubricate with petroleum jelly and i...

Страница 532: ...e piston to avoid damaging the seal rings STEP 47 RD06A165 Clean the mounting bolts and install Loctite 242 to the threads STEP 48 RD06H149 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 STEP 49 RD06A148 Install a new seal STEP 50 RD06A147 Install the bearing cup 1 2 1 ...

Страница 533: ...etting pinion distance NOTE On the pinion there is etched either a zero 0 or plus or minus number This indicates the best running position for each gear set The dimension is set by shimming behind the inner pinion bearing cup 4 5 6 7 8 9 10 9 8 11 12 13 1 2 3 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 B...

Страница 534: ... 0 003 0 002 0 001 0 0 007 0 006 0 005 0 004 0 003 0 002 0 001 0 0 001 0 006 0 005 0 004 0 003 0 002 0 001 0 0 001 0 002 0 005 0 004 0 003 0 002 0 001 0 0 001 0 002 0 003 0 004 0 003 0 002 0 001 0 0 001 0 002 0 003 0 004 0 003 0 002 0 001 0 0 001 0 002 0 003 0 004 0 005 0 002 0 001 0 0 001 0 002 0 003 0 004 0 005 0 006 0 001 0 0 001 0 002 0 003 0 004 0 005 0 006 0 007 0 0 001 0 002 0 003 0 004 0 0...

Страница 535: ... as shown above Follow Steps 50 through 54 to assemble tool to differential housing STEP 50 T98516 Install the Handle CAS 1898 1 and Threaded Shaft CAS 1898 2 into the carrier housing STEP 51 T98517 Install Aligning Disc CAS 1898 5 and the Gauge Disc CAS 1898 3 STEP 52 T98518 Install Gauge Block CAS 1898 4 and finger tighten to hold the gauge assembly and bearing cones in position STEP 53 T98519 I...

Страница 536: ...ount shown from the measurement taken in Step 55 The remainder is your shim pack thickness If the pinion shaft has a marking add the amount shown to the measurement taken in Step 55 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 0 127 mm 0 005 inch 0 25 mm 0 010 inch Ac...

Страница 537: ...ection 25 Four Wheel Drive Front Axle Chapter 9 25 9 20 STEP 60 T98513 Install the inner bearing cup STEP 61 RR98K037 Assemble inner bearing cone on pinion Drive bearing onto pinion using suitable press ...

Страница 538: ...TEP 62 T98610 Install the pinion into the carrier Install a shim pack of 0 070 inch on the pinion shaft STEP 63 T98528 Use the Companion Flange Installer CAS 1898 8 to push the yoke onto the shaft STEP 64 T98530 Torque the pinion nut to 326 to 406 Nm 240 to 300 lb ft 1 5 16 inch socket ...

Страница 539: ...e shim pack to add a small amount of thickness For example replace a 0 014 inch shim with a 0 015 inch shim Repeat torque check procedure NOTE Shim kits contain the following size shims 0 010 inch 0 014 inch 0 015 inch 0 016 inch 0 018 inch 0 020 inch 0 021 inch 0 022 inch 0 023 inch and 0 030 inch STEP 66 RR98K043 Remove nut and end yoke Apply Permatex D to the housing face and to the outer diame...

Страница 540: ...te the adjusting ring would clamp against the bearing cage restricting movement NOTE Right hand adjusting ring shown STEP 70 RD02J019 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 NOTE Make sure the match marked bearing cap and match m...

Страница 541: ...0 to 30 lb ft Tighten all of the bearing cap bolts to a torque of 240 to 270 Nm 180 to 200 lb ft Tighten adjusting nut A to a torque of 75 to 88 Nm 55 to 65 lb ft with the differential locknut wrench tool Which will result in a bearing preload of 1 13 to 2 26 Nm 10 to 20 lb inch When measured through the pinion will read 2 5 to 5 lb inch more than the original pinion torque setting Install the bol...

Страница 542: ...m 0 005 to 0 010 inch for 10 stud wheel end axle or 0 127 mm to 0 203 mm 0 005 to 0 008 inch for 12 stud wheel end axle Check the backlash at three different locations around the gear There should be no more than 0 06 mm 0 003 inch variation between readings A reading larger than 0 008 to 0 010 inch is corrected by moving ring gear closer to pinion A reading smaller than 0 005 inch is corrected by...

Страница 543: ... 05 mm 0 002 inch to 0 10 mm 0 004 inch until correct pattern has been obtained When a change in backlash is required backlash should be changed approximately 1 1 2 times the amount needed to bring the gears into specification For example if the backlash needed to be changed by 0 10 mm 0 004 inch the adjusting rings should be moved so that the backlash changes by 0 15 mm 0 006 inch as a starting p...

Страница 544: ...d Pattern moves slightly higher and toward heel Reverse Pattern moves higher and toward heel 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 4 A thinner pinion position shim with the ...

Страница 545: ...al lock supply and return fittings Install the carrier assembly into the axle housing Coat all bolt threads with Loctite 271 prior to installation Install washers and bolts and tighten to a torque of 135 to 155 Nm 100 to 115 lb ft STEP 79 Assemble axle shafts and wheel end components following procedures shown in the FWD Planetary Hub Steering Knuckle and Axle Drive Shaft Section of this Service M...

Страница 546: ...Section 25 Chapter 10 January 2006 FWD PLANETARY HUB STEERING KNUCKLE AND AXLE DRIVE SHAFT ...

Страница 547: ...OOLS 25 10 3 PLANETARY HUB DISASSEMBLY 25 10 4 STEERING KNUCKLE AND KINGPIN DISASSEMBLY 25 10 9 AXLE DRIVE SHAFT DISASSEMBLY 25 10 13 AXLE SHAFT ASSEMBLY 25 10 14 KINGPIN ASSEMBLY 25 10 16 STEERING KNUCKLE ASSEMBLY 25 10 20 PLANETARY HUB ASSEMBLY 25 10 24 Ten Bolt Axle Only 25 10 29 Twelve Bolt Axle Only 25 10 33 All Axles 25 10 38 ...

Страница 548: ...ft Steering Cylinder Socket End Clamp Nut 95 to 108 Nm 70 to 80 lb ft Steering Cylinder Tapered Socket Stud Nut 272 Nm 200 lb ft Drain Fill Plugs 38 to 41Nm 28 to 30 lb ft Tie Rod Tapered Socket Stud Nut 372 Nm 275 lb ft Tie Rod Tube Nut 374 to 442 Nm 276 to 326 lb ft Rolling Torque of Kingpin Bearings 34 to 74 Nm 25 to 55 lb ft Rolling Torque of Planetary Hub Bearings 11 4 to 16 Nm 100 to 140 lb ...

Страница 549: ...plug to release any internal axle pressure Remove the axle drain plug 1 Drain the axle oil into a suitable clean container STEP 4 RR98K083 Before draining the oil from the planetary hub position the hub cover so the planetary hub drain fill plug 1 is at the highest position Make sure the axle fill plug has been loosened to release any internal axle pressure Loosen the planetary hub plug and rotate...

Страница 550: ... RR98K087 Remove the planetary gear pins by threading a suitable bolt into the pin and prying up on the bolt head STEP 8 RR98K089 Remove the thrust washers from the top of the planetary gear STEP 9 RR98K088 Remove the planetary gear through the center opening of the gear plate Remove the upper level of needle bearings in the planetary gear Remove the spacer and the lower level of needle bearings I...

Страница 551: ...ar shaft from the yoke retaining ring NOTE Remove the thrust washer on the planetary gear shaft for tractors equipped with ten bolt hubs STEP 13 RR98K093 Remove the eight retaining plate bolts Discard the bolts NOTE NEW BOLTS need to be installed during reassembly STEP 14 RR98K094 Remove the retaining plate and shims Slide the planetary ring gear assembly off the splines of the steering knuckle Th...

Страница 552: ... STEP 16 RR098K097 Twelve bolt hub Remove the oil seal and the inner planetary hub bearing cone from the planetary hub STEP 17 RD05J1172 Twelve bolt Remove the dust seal STEP 18 RD05J177 Ten bolt Remove the bearing STEP 19 RD05J1172 Ten bolt hub Remove the oil seal NOTE Seal may separate when hub is removed STEP 20 RR98K082 Remove damaged wheel studs as needed ...

Страница 553: ...ver to remove the outer planetary hub bearing cup STEP 23 RR98K101 Remove the wire retaining ring 3 and remove the gear hub STEP 24 RR98K103 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 Repeat the preceding procedure for the opposite planetary hub if necessary 1 ...

Страница 554: ...et end STEP 27 RR98K10 Loosen do not remove the steering cylinder socket end nut STEP 28 RR98K108 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 STEP 29 RR98K109 With the slotted nut in place on the steering cylinder socket end unseat the steering cylinder socket end from the s...

Страница 555: ...erly support the steering knuckle to retain the position of the upper king pin bearing cap when it is removed STEP 32 RR98K111 Remove the three upper king pin bearing cap bolts STEP 33 RR98K112 Remove the upper king pin bearing cap 1 and the shims 2 STEP 34 RR98K114 Install lifting eyes and properly support the steering knuckle Remove the lower king pin bearing cap and shims STEP 35 RR98K115 Remov...

Страница 556: ...ring cap STEP 39 RR99K247 RR99K249 Use a suitable puller 1 or a blind hole puller to remove the upper king pin bearing outer ring 2 from the axle housing 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 A new grease retainer plate will be required for assembly Use the same procedure for the removal of the lower ki...

Страница 557: ... shaft seals with a slide hammer and a suitable puller STEP 41 RR98K062 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 ...

Страница 558: ... 45 RD02J016 Place the universal joint cap in a vise Use a lever to remove the cap from the yoke STEP 46 RD02J030 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 Remove and disass...

Страница 559: ...Four Wheel Drive Front Axle Chapter 10 25 10 14 AXLE SHAFT ASSEMBLY RI02H044 1 AXLE SHAFT 5 YOKE INNER SEAL 2 UNIVERSAL JOINT 6 RETAINING RING 3 RETAINING RING 7 YOKE 4 YOKE 8 YOKE OUTER VSEAL 1 2 2 3 3 4 5 7 8 6 ...

Страница 560: ...the seal facing away from the yoke STEP 50 RD02J014 Install new universal joints by reversing the disassembly procedure Use a press to seat the universal bearing caps into the axle shaft yokes and the centering yoke STEP 51 RD02J015 Press the universal joint cap below the retaining ring groove and install the retaining ring Repeat this procedure for each universal joint cap STEP 52 Repeat the asse...

Страница 561: ...ng until it bottoms in the axle housing STEP 54 RR98K063 Use seal installers to install new inner and outer axle shaft oil seals NOTE The outer oil seal is installed flush with the axle housing 2 3 4 5 6 7 8 1 2 4 3 1 UPPER KINGPIN GREASE SEAL 2 KINGPIN BEARING INNER RING 3 KINGPIN BEARING OUTER RING 4 GREASE RETAINING PLATE 5 AXLE SHAFT BUSHING 6 AXLE SHAFT INNER OIL SEAL 7 AXLE SHAFT OUTER OIL S...

Страница 562: ...meter 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 STEP 57 RR99K251 Apply Loctite 515 to the bottom face of axle housing bore Install the grease retaining plate so that the grease cavity is belo...

Страница 563: ...aring cap by using the outer ring as the installer STEP 60 RR99K252 Use a bearing installer to install the king pin outer ring into the axle housing STEP 61 RR99K253 Make sure the outer ring is fully seated in the housing Apply a layer of grease to the bearing surface STEP 62 RR99K256 Lubricate the inner diameter of a new king pin seal with grease Position the new king pin oil seal in the axle hou...

Страница 564: ...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 ...

Страница 565: ...66 RR98K117 Use a bushing installer to press the bushing in flush with the machined bore in the knuckle Wipe away the excess Loctite 609 1 2 3 4 5 6 7 8 9 10 11 12 13 12 14 15 4 1 PLANETARY GEAR SHAFT SEAL 2 PLANETARY GEAR SHAFT BUSHING 3 NUT 4 COTTER PIN 5 STEERING CYLINDER 6 WHEEL STOP 7 CLEVIS PIN 8 STEERING CYLINDER SOCKET END 9 TIE ROD SOCKET END 10 WASHER 11 UPPER KINGPIN BEARING CAP 12 SHIM...

Страница 566: ...ower king pin bearing cap WITHOUT shims 3 Install the upper king pin bearing cap WITHOUT shims 4 Tighten all bolts to a torque of 156 to 170 Nm 115 to 125 lb ft DO NOT rotate the steering knuckle STEP 69 RR99K244 Remove the king pin bearing caps after verifying that the bearings are fully seated and install the king pin shims NOTE The same thickness king pin shims can be used on top and bottom to ...

Страница 567: ...ns evenly Repeat the procedure until the torque required to rotate the steering knuckle is within the specification When the final adjustments are complete apply antiseize lubricant to the king pin bore of the steering knuckle Lubricate the king pin through the grease fitting on the kingpin bearing cap Repeat the installation procedure for the opposite steering knuckle if removed STEP 72 RR98K130 ...

Страница 568: ... 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 STEP 75 RR98K105 Use the identifying mark made during disassembly to position the wheel stop Install the wheel stop 1 the clevis locking pin 2 and the clevis retaining pin 3 Install the ...

Страница 569: ...WASHER 3 PLANETARY HUB SEAL 12 PLANETARY RING GEAR 21 GEAR 4 BEARING CONE 13 THRUST WASHER 10 BOLT HUB ONLY 22 PIN 5 BEARING CUP 14 SHIM 23 NEEDLE BEARING 6 DUST SEAL TWELVE BOLT ONLY 15 RETAINING PLATE 24 SPACER 7 STUD 16 BOLT 25 HUB RETAINING BOLT 8 PLANETARY HUB 17 PLANETARY GEAR SHAFT 26 PLUG 9 NUT 18 BUTTON 1 20 12 11 23 23 22 21 24 26 25 19 20 15 17 13 18 14 10 1 7 9 3 2 5 4 5 8 4 16 13 6 ...

Страница 570: ...ry gear hub 1 in the planetary ring gear 2 Install the wire retaining ring 3 in the ring gear groove STEP 78 RD02J038 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 Use a suitable bearing cup installer to install the outer bearing cup in the hub STEP 79 RR98K125 Turn the planetary hub over Lubricate the inn...

Страница 571: ...rea STEP 82 RD05J175 Clean the bolt holes in the steering knuckle with a tap and Loctite Safety Solvent STEP 83 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 84 RD05J174 Thoroughly clean the steering knuckle STEP 85 RD05J179 Install the bearing and LIGHTLY coat the bearing with a light multipurpose oil 1 ...

Страница 572: ...d 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 If only the hub oil seal has been replaced reuse all removed shims if not damaged and check the rolling torque of the planetary hub to make sure it is within the specification NOTE The rolling torque of the planetary hub bearings m...

Страница 573: ...Install the spanner plate Rotate the hub several times in both directions to set the bearings STEP 93 RD05J184 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 94 RD05J185 Once the rolling torque has be established remove the spanner plate STEP 95 RD05J182 Remove the retaining ...

Страница 574: ... Ten Bolt Axle Only STEP 98 RD04D227 RD04D228 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 ...

Страница 575: ...stall the flanged tool with threaded rod onto the spindle end face Using four of the retainer plate mounting bolts secure the tool as shown STEP 102 RD04D233 Install the seal driver tool over the pilot tool so that it is resting on the seal STEP 103 RD04D234 Install the thrust bearing 1 flat washer 2 and nut 2 onto the threaded rod STEP 104 RD04D235 Use a wrench to tighten the nut 1 2 3 ...

Страница 576: ... a normal condition STEP 106 GRAPHIC_ID_NUMBER Once the seal is installed use both hands to rotate the outer portion of the seal The seal should turn but may require some effort STEP 107 RD04D238 Remove all the installation tools except the for the flanged tool 1 Install the bearing cone onto the spindle STEP 108 RD04D239 Apply a THIN film of oil on the OD of the seal Spread the oil evenly around ...

Страница 577: ...the bolts provided STEP 112 RD04D243 Use a hoist or other suitable means and lift the hub with mounted alignment tools and align with the spindle STEP 113 RD04D245 Push the hub by hand onto the spindle until contact with the seal is made The threaded rod should be exposed STEP 114 RD04D246 Install a washer and nut onto the threaded rod STEP 115 RD04D247 Tighten until a noticeable increase in torqu...

Страница 578: ...roximately 1 MM between the spindle and the hub Make sure that the hub can be rotated by hand Twelve Bolt Axle Only STEP 117 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 ...

Страница 579: ...s the dust seal into place STEP 121 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 STEP 122 RD05J195 Place the hub in a suitable vise STEP 123 RD05J194 Thoroughly clean and dry the seal counterbore STEP 124 RD05J196 Apply a thin bead of Loctite 680 to the seal counterbore 1 2 1 ...

Страница 580: ...J193 Install the threaded rod STEP 127 RD05J197 Set the inboard bearing into the hub cone STEP 128 RD05J198 While holding the bearing 1 set the oil seal 2 into place STEP 129 RD05J199 Place the seal driver over the threaded rod STEP 130 RD05J200 Install a washer and nut and hand tighten Make sure the seal driver 1 is centered on the seal 2 2 1 1 2 ...

Страница 581: ...re the seal in the bore Once seal is seated in the bore remove the installation tools STEP 133 RD02M029 Inspect the seal 1 to make sure it is fully seated in the bore Remove the hub from the vise STEP 134 RD05M030 Bolt the seal installation adapter over the end of the steering knuckle STEP 135 RD05M031 Place the installation hub on the wheel hub STEP 136 RD05M032 Bolt the spanner plate 1 to the sp...

Страница 582: ... light multipurpose oil to oil seal sealing area of the steering knuckle or to the ID of the hub seal STEP 139 RD05M035 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 STEP 140 RD05M039 Install a washer 1 driver bearing 2 and nut 3 ...

Страница 583: ... the shoulder 1 of the seal installation tool is bottomed against the hub 2 Remove the seal installation tool All Axles STEP 142 RD05M041 Install the planetary gear hub and bearing STEP 143 RD05M042 Place the shim pack 1 on the retaining plate 2 and apply a bead of Loctite 271 to the new bolts 1 2 2 1 ...

Страница 584: ...er on the planetary gear shaft before installing the gear shaft STEP 146 RD02J002 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 Make sure the retaining ring in the spline of the outer yoke of the axle shaft if fully engaged in the ring grove on the sun gear shaft STEP 147 RD02J001 RD02J002 Swivel the steeri...

Страница 585: ...STEP 150 RD05M044 Install the wire retaining ring 1 in the planetary hub 2 ring grove STEP 151 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 STEP 152 RR98K090 RR98K088 Install the lower thrust washers 1 and the planetary gear 2 through the ce...

Страница 586: ...tor to the planetary hub cover STEP 156 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 Install the axle drain plug Tighten the plug to a torque of 38 to 41 Nm 28 to 30 lb ft STEP 158 RR98K074 Remove the axle fill plug located on the front of the axle housing Add...

Страница 587: ...nutes recheck the oil level Tighten the planetary fill plug to a torque of 38 to 41 Nm 28 to 30 lb ft STEP 160 98RS8A Properly support and install the front tires STEP 161 96RS34A Install the front fenders if equipped Remove the wheel blocks in front of and behind the rear wheels Make sure the transmission lever is in PARK Start the tractor and check the operation of the FWD axle and the planetary...

Страница 588: ...Section 25 Chapter 11 January 2006 SUSPENSION FWD AXLE ...

Страница 589: ...r bolt for cylinder mounting pin 27 to 30 Nm 20 to 22 lb ft Shoulder bolt for upper cradle swing arm pin 41 to 45 Nm 30 to 33 lb ft Retaining plate bolts 58 to 64 Nm 43 to 47 lb ft Sensor to mounting bracket screws 4 to 4 5 Nm 36 to 40 lb in Link to sensor shaft nut 20 to 25 5 Nm 180 to 200 lb in Sensor mounting bracket to axle housing bolts 22 to 24 Nm 16 to 18 lb ft Ball joint to axle housing 19...

Страница 590: ...rollover and falls that could cause damage or injury IMPORTANT Carelessness and inattention on the part of the technicians or others working on or around this axle can create an increased risk of injury STEP 1 RD02M104 Disassembly of the following parts is from location B STEP 2 RD02M001 Remove the angle sensor linkage from the sensor STEP 3 RD02M002 Remove the angle sensor linkage from the axle S...

Страница 591: ...2M009 Loosen the set screw 1 and remove the sensor shaft STEP 8 RD02M010 Inspect the bushing for wear or damage Replace the bushing if necessary STEP 9 RD02M104 Disassembly of the following parts is from location O STEP 10 RD02M013 Install a slide hammer into the swing arm cradle pin STEP 11 RD02M016 Move the pin out a small amount and remove the dowel pin 1 O ...

Страница 592: ...arm cradle pin STEP 13 RD02M105 RD02M017 Remove the two shoulder bolts from location C STEP 14 RD02M105 The following parts are removed from locations D and E STEP 15 RD02M018 Remove the snap ring from the cylinder pins STEP 16 RD02M019 Install a slide hammer into the cylinder pin C C E D D E ...

Страница 593: ... 17 RD02M020 Slide the pin partially out Do not let the spacer fall out STEP 18 RD02M021 Remove the pin and spacer STEP 19 RD02M104 RD02M105 The following parts are removed from location G and H STEP 20 RD02M022 Remove the five bolts from each retaining plate G H ...

Страница 594: ... 11 7 STEP 21 RD02M023 Remove both retaining plates STEP 22 RD02M024 Remove and discard the O rings STEP 23 RD02M025 Loosen and remove the shoulder bolt STEP 24 RD02M027 Install a slide hammer into the upper swing arm pin STEP 25 RD02M028 Remove the pin ...

Страница 595: ...and carefully lift the cradle off the axle assembly STEP 28 RD02M030 Remove the snap ring from the lower suspension swing arm STEP 29 RD02M031 Use a magnet and remove the lower swing arm thrust washer Note that there is a dowel pin in the shaft STEP 30 RD02M032 Use a puller to remove the lower swing arm pin Be sure to catch the dowel pin when removing the puller A K J A J K ...

Страница 596: ... swing arm thrust washer Note that there is a dowel pin in the shaft STEP 33 RD02M035 Use a puller to remove the upper swing arm pin Be sure to catch the dowel pin when removing the puller STEP 34 RD02M036 Remove the upper pin STEP 35 RD02M037 Remove the snap ring from the suspension cradle STEP 36 RD02M038 Remove and discard the seals from both sides NOTE Seals are different sizes ...

Страница 597: ...wing arm Carefully remove the swing arm from the axle assembly STEP 39 RD02M041 Install a strap securely to the upper swing arm and remove the arm IMPORTANT Be sure the axle housing is secure to prevent injury STEP 40 RD02M104 The following parts are removed from locations E and L STEP 41 RD02 M042 Remove the snap rings from the cylinder mounting pins STEP 42 RD02M043 Remove the cylinders E L ...

Страница 598: ...ylinder must be replaced if either is present STEP 44 RD02M045 Remove the shoulder bolts from the cylinder mounting pins STEP 45 RD02M046 Use a puller or slide hammer and remove the mounting pins from the housing STEP 46 RD02M047 Remove the seals from the housing Inspect the bores for damage STEP 47 RD02M048 Remove the thrust washers STEP 48 RD02M049 Use a driver and remove the bushing from the bo...

Страница 599: ...Section 25 Four Wheel Drive Front Axle Chapter 11 25 11 12 STEP 49 RD02M050 Remove the seals from the upper swing arm STEP 50 RD02M051 Use a driver to remove the bushings from the swing arm bores ...

Страница 600: ...RI02M063 16 6 3 17 13 7 16 10 16 5 17 3 4 15 14 5 1 5 3 16 5 6 8 11 6 2 6 13 9 9 3 12 3 10 9 1 8 16 19 3 18 21 20 1 CRADLE 8 AXLE PIN 15 PLATE 2 BEARING 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 RH CYLINDER 19 SENSOR 6 SEAL 13 PIN 20 CONNECTING LINK 7 LOWER SWING LINK 14 O RING 21 SET SCREW ...

Страница 601: ...53 RD02M053 Use an appropriate driver and install the bushing until it is flush with the bore STEP 54 RD02M055 Apply grease to the counter bore Install the thrust washer STEP 55 RD02M056 Apply Loctite 609 to the new seal case Install an appropriate driver STEP 56 RD02M057 Install the seal into the bore Be sure that the thrust washer does not obstruct the seal when installing the seal E L ...

Страница 602: ...g pin into the bore STEP 59 RD02M060 Install the shoulder bolt Tighten to a torque of 27 to 30 Nm 20 to 22 lb ft STEP 60 RD02M104 The following parts are assembled in locations A and O STEP 61 RD02M062 Apply Loctite 609 to the OD of the new bushing STEP 62 RD02M063 Place the cradle on a press Press the bushing into the bore using appropriate drivers A O ...

Страница 603: ...h are different sizes STEP 65 RD02M067 Install the seal squarely in the bore Use an appropriate seal driver and seat the seal Repeat the procedure for the other side STEP 66 RD02M068 Apply grease to the pin STEP 67 RD02M069 Install the pin into the housing Align the bolt hole in the pin with the shoulder bolt bore in the housing STEP 68 RD02M070 Install the shoulder bolt into the pin ...

Страница 604: ...e of 27 to 30 Nm 20 to 22 lb ft STEP 70 RD02M072 Install the cylinder spacer on to the pin STEP 71 RD02M073 Install the lift cylinders STEP 72 RD02M074 Install the snap rings STEP 73 RD02M105 The following parts are assembled at locations A I and K STEP 74 RD02M075 Install the grease fitting into the cradle A I K ...

Страница 605: ...ders can be installed onto the pins STEP 76 RD02M042 Install the snap ring onto the cylinder pins STEP 77 RD02M077 Place the bearing on an appropriate driver Apply Loctite 609 to the OD of the bearing STEP 78 RD02M078 Install the bushing into the bore STEP 79 RD02M079 Apply Loctite to a new seal case STEP 80 RD02M080 Use an appropriate driver and install the new seal into the bore ...

Страница 606: ... grease to the swing arm pins STEP 82 RD02M082 Align the cradle and upper swing arm and install the pin STEP 83 RD02M083 Align the dowel pin slot STEP 84 RD02M084 Install the dowel pin STEP 85 RD02M085 Continue to drive the pin until seated STEP 86 RD02M086 Install the thrust washer ...

Страница 607: ...ign the bolt hole in the pin with the shoulder bolt bore in the housing STEP 89 RD02M026 Install the shoulder bolt into the pin STEP 90 RD02M025 Tighten the shoulder bolt to a torque of 41 to 45 Nm 30 to 33 lb ft STEP 91 RD02M024 Install a new O ring in the receiver groove STEP 92 RD02M023 Apply Anti Seize to the end of the pin Install the retaining plate ...

Страница 608: ...Nm 43 to 47 lb ft STEP 94 RD02M104 The following parts are assembled at locations J N and O STEP 95 RD02M090 Move the lower swing arm assembly into position STEP 96 RD02M091 Install the lower swing arm pins STEP 97 RD02M093 Install the dowel pin Drive the pion in until seated STEP 98 RD02M949 Install the thrust washer J O N ...

Страница 609: ...ll the snap ring STEP 100 RD02M096 Apply grease to the ID of the bearing STEP 101 RD02M097 Apply grease to the lower swing arm cradle pin STEP 102 RD02M098 Install the pin STEP 103 RD02M099 Align the dowel pin slot STEP 104 RD02M014 Install the dowel pin Drive the pin in until seated ...

Страница 610: ...washer STEP 106 RD02M100 Install the snap ring STEP 107 RD02M010 Install the bushing into the sensor housing STEP 108 RD02M009 Install the sensor shaft STEP 109 RD02M008 Align the set screw with the flat on the shaft Tighten the screw STEP 110 RD02M007 Install the sensor onto the mounting bracket ...

Страница 611: ...22 5 Nm 180 to 200 lb in STEP 113 RD02M003 Install the bracket on the housing Tighten the bolts to a torque of 22 to 24 Nm 16 to 18 lb ft STEP 114 RD02M002 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 115 RD02M001 With the unit in the collapsed position install remaining ball joint onto the...

Страница 612: ...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 STEP 117 RD02M103 When adjustment is complete tighten the sensor screws to a torque of 4 to 4 5 Nm 36 to 40 lb in NOTE The axle must be calibrated after installing onto the tractor See calibration information in the Suspension...

Страница 613: ...Section 25 Four Wheel Drive Front Axle Chapter 11 25 11 26 ...

Страница 614: ...Section 25 Chapter 12 January 2006 SUPERSTEER AXLE VERTICAL CONTROL LINKAGE ...

Страница 615: ...pter 12 25 12 2 TABLE OF CONTENTS SPECIAL TORQUES 25 12 3 VERTICAL LINK DISASSEMBLY AND REPAIR 25 12 3 Vertical Link Removal 25 12 3 Roller Replacement 25 12 4 Articulation Bearing Removal and Installation 25 12 5 Vertical Link Assembly 25 12 6 ...

Страница 616: ... removal and service refer to the Chapter for your axle in this manual Vertical Link Removal STEP 3 RD02K003 With the axle removed from the tractor support the vertical link assembly 1 with a lift strap and hoist Remove the two bolts and washers 2 from the retainer plate 3 and remove the vertical link assembly 1 and retainer plate 3 from the axle NOTE Support the retainer plate 3 when removing the...

Страница 617: ...le links and vertical link if required Roller Replacement STEP 7 RD02K009 RH02K003 If the rollers need replaced remove the two M20 x 70 mm socket head screws and remove the roller pin washers and roller Remove the roller from the pin and install a new roller on the pin if required Install the roller pin washers and roller to the frame with the two M20 x 70 mm socket head screws Torque the screws t...

Страница 618: ... RD02K010 Support the bottom of the front axle rear support 1 to keep it from falling when the retaining ring 4 is removed 1 Remove the dust cap retainer ring 2 2 Remove the dust cap 3 3 Remove the retaining ring 4 4 Lower the front axle rear support 1 just enough to remove the bearing spacer 5 and the bearing 6 5 Install the bearing 6 and bearing spacer 5 6 Raise the front axle rear support 1 and...

Страница 619: ...st be on each side of the axle links 2 STEP 13 RD02K003 RH02K002 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 Slip the axle links 5 over the linkage pins 3 and install another 55 5 x 88 x 3 mm washer 4 onto the linkage pin 3 Install the retainer plate 2 and retain with the two M24 x 355 mm hex head bolts and...

Страница 620: ...Section 27 Chapter 1 January 2006 REAR AXLE AND PLANETARIES ...

Страница 621: ...REAR AXLE 27 1 6 AXLE HOUSING DISASSEMBLY 27 1 9 PLANETARY DISASSEMBLY 27 1 11 DIFFERENTIAL CARRIER SEAL REPLACEMENT 27 1 13 PLANETARY ASSEMBLY THREE PIN 27 1 14 PLANETARY ASSEMBLY FOUR PIN 27 1 15 AXLE HOUSING ASSEMBLY 27 1 18 HOW TO DETERMINE RAM PRESSURE 27 1 23 AXLE INSTALLATION 27 1 26 AXLE SEAL WEAR SLEEVE INSTALLATION 4 Inch Axle Only 27 1 30 ...

Страница 622: ...pter 1 27 1 3 SPECIAL TOOLS RH02D122 Rear Housing Handler 17 527 RH02D123 Pushing Bridge 89 525 18 RH02D124 Brake Disc Alignment Tool 89 581 5 CAS2601 Alignment Guide Pins studs CAS2601 RD02E109 Cab Raising Bracket Kit CAS2577 ...

Страница 623: ...Set with 30 Ton Ram CAS10030 T82109 Bushing Bearing And Seal Driver Set CAS 10387 Tool Organizer Board CAS10390 T82108 Universal Driver Set 1 2 Inch To 4 1 2 Inch Diameter CAS10388 T82107 Universal Driver Set 3 1 16 Inch To 4 1 2 Inch Diameter CAS10389 ...

Страница 624: ...ning After cleaning dry and lubricate all parts Clean oil passages with compressed air Inspection Visually inspect all parts when disassembled Replace all parts that have wear or damage The replacement of parts as necessary will prevent early failure Gears Check all gears for wear and damage Replace worn or damaged gears Oil Seals O rings And Gaskets Always install new oil seals O rings and gasket...

Страница 625: ...he fluid from the transmission housing 3 Remove the drain plug from under the axle housings and remove the fluid NOTE The transmission holds approximately 174 liters 46 gallons of oil STEP 2 13S23 Move the rear housing handler CAS17 527 into position under the tractor STEP 3 13S29 Raise the front lift of the rear housing handler Turn the rear threaded rods until the rear frame is supported ...

Страница 626: ...ke sure that no wires or hydraulic lines are pinched Lower the cab and remove the cab jacking bolt 1 STEP 7 RD02F104 Remove the cab mounting bolt 1 from the cab mount Lifting bracket 2 can be left in place STEP 8 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 STEP 9 RD06A003 Remove a bolt from fro...

Страница 627: ...ange sealant by hitting the axle end with a soft faced mallet NOTE The following steps show three gear planetary the four gear will be similar STEP 11 T97973 Remove the ring gear from the axle housing STEP 12 T97974 Remove the retaining ring from the axle shaft STEP 13 T97975 Use a sling and hoist to remove the planetary assembly from the axle STEP 14 87S23 Remove the sun gear from the brake discs...

Страница 628: ... to relieve pressure on the retaining ring before removing retaining ring from shaft STEP 16 T97980 Remove the thrust ring from the axle shaft STEP 17 T97981 Remove the shims from the axle shaft STEP 18 T97984 Install a pulling bridge and a 30 ton ram on the axle housing Press the axle assembly out of the axle housing STEP 19 T97985 Remove the seal and if equipped the wear sleeve from the axle sha...

Страница 629: ...n 4 in axles from the axle bushing STEP 22 T97991 Use a puller to remove the bushing from the axle shaft NOTE Remove the O ring from the inside diameter of the bushing on 115 mm 4 5 in diameter axle STEP 23 T97994 Use a puller to remove the inner bearing cup from the axle housing STEP 24 T97997 Use a puller to remove the outer bearing cup from the axle housing ...

Страница 630: ...again make marks so that the gears are assembled in their original location in the gear carrier STEP 26 T97999 Drive the roll pin into the planet gear shaft STEP 27 T98002 Remove the planet gear shaft from the planetary gear carrier STEP 28 T98003 Remove the planetary gear and bearing assembly from the gear carrier ...

Страница 631: ... the thrust washer and needle bearings from one side of the planet gear STEP 30 RD98C194 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 ...

Страница 632: ...r 1 27 1 13 DIFFERENTIAL CARRIER SEAL REPLACEMENT STEP 32 T98027 Remove the seal from the differential carrier STEP 33 T98028 Use a driver to install a new seal until the seal is flush with the surface of the differential carrier ...

Страница 633: ...xle Chapter 1 27 1 14 PLANETARY ASSEMBLY THREE PIN 107l94A 1 THRUST WASHER 4 THRUST RING 7 ROLL PIN 2 NEEDLE BEARING 5 NEEDLE BEARING 8 PLANET GEAR CARRIER 3 PLANET GEAR 6 THRUST WASHER 9 BEARING SHAFT 1 3 4 6 8 9 2 5 7 ...

Страница 634: ...MBLY FOUR PIN RI06A014 1 RING GEAR 6 GEAR SHAFT 11 NEEDLE BEARING 2 GEARS CARRIER 7 HUB 12 NYLON SPACER 3 SHAFT 8 WASHER 13 PLANETARY GEAR 4 PIN 9 RETAINER RING 14 NYLON SPACER RIGHT HAND ONLY 5 RETAINER RING 10 WASHER 9 8 7 6 5 3 4 2 10 13 12 11 10 1 14 ...

Страница 635: ...y Models 215 and 245 will have two rows of 29 bearings in each gear Model 275 and 305 will have two rows of 33 bearings in each gear STEP 35 RDC195 Install the thrust washer on both sides of the planet gear STEP 36 T98003 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 STEP 37 T98...

Страница 636: ...et gear bearings until the roll pin hole can be seen in the planet gear carrier STEP 39 T97999 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 ...

Страница 637: ...1 10 13 14 15 16 17 18 2 3 4 5 1 RETAINING RING 7 AXLE HOUSING 13 AXLE BUSHING 2 THRUST RING 8 WASHER 14 AXLE WEAR INSERT 3 SHIMS 9 BOLT 15 AXLE SHAFT 4 BEARING CONE 10 BEARING CONE 16 OIL SEAL 5 BEARING CUP 11 BEARING CUP 17 WEAR SLEEVE IF NEEDED 6 DOLL PIN 12 O RING 18 RETAINING RING ...

Страница 638: ...on the shoulder STEP 43 T97988 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 STEP 44 4BSHG Press the axle bushing 1 onto the axle shaft with 222 500 N 50 000 lb force so that it is seated tightly on the shoulder Lubricate a new O ring 2 with transmission fluid or petroleum jelly and install in the ...

Страница 639: ...river to install the bearing cup in the axle housing until the cup is seated STEP 48 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 STEP 49 376L0 Install the axle shaft assembly as follows 1 Install the axle shaft assembly in the axle housing 2 Apply a light coat of oil to the bearing cone ID an...

Страница 640: ... 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 NOTE It may be necessary to make calculations to determine the force to use with your ram See How To Determine Ram Pressure on page 22 4 5 Inch Axle STEP 52 T98042 Press the inner bearin...

Страница 641: ...ll the shim pack thrust ring and retaining ring on the axle Be sure the thickest shim is next to the bearing 6 Be sure the retaining ring is fully seated in the groove STEP 54 375L0 T98043R Install the pushing bridge and a 30 ton ram onto the axle assembly Back press the 4 inch axle 75 650 N 17 000 lbs Back press the 4 5 inch axle 97 900 N 22 000 lbs Check to assure the snap ring is tight in the g...

Страница 642: ...axle assembly rolling torque The final specifications should be as follows 98 inch 4 Inch Dia Standard Axle New Bearings 16 0 to 24 0 Nm 140 to 210 lb in Used Bearings 8 0 to 12 0 Nm 70 to 105 lb in 98 120 Inch 4 Inch Dia Heavy Duty Axles New Bearings 16 0 to 26 0 Nm 140 to 230 lb in Used Bearings 8 0 to 13 5 Nm 70 to 119 lb in 120 Inch 4 1 2 Inch Dia Axle New Bearings 18 0 to 28 0Nm 160 to 250 lb...

Страница 643: ...58 T97974 Install the planetary assembly retaining ring in the groove on the axle shaft STEP 59 512L0 Install a new nylon wear insert in the axle STEP 60 T98015 280L7 4 Inch Axle 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 NYLON WEAR INSERT 1 AXLE END 1 2 1 1 ...

Страница 644: ...RTANT Use flat bar not shown between driver and seal to install seal flush with housing NOTE Do not apply Loctite 515 to seal OD on the 4 1 2 inch axle STEP 62 210L0 Remove any foreign material from the ring gear Put a bead of Loctite 515 gasket eliminator 1 on the axle side of the ring gear STEP 63 T97973 Install the ring gear on the axle housing assembly STEP 64 Repeat Steps 50 through 71 for th...

Страница 645: ... and into the rear frame NOTE If equipped make sure the locator button is installed on the RH sun gear shaft STEP 67 87S19 Remove the brake aligning tool from the brake discs STEP 68 92S5 If removed install the guide pins in the rear frame Apply Loctite 515 gasket eliminator on the mounting surface in the rear frame STEP 69 RD06A004 Use a lift strap and hoist to move the axle assembly into positio...

Страница 646: ...D06A002 Move the draft pin wiring tube bracket 1 and hitch cylinder hose bracket 2 into position Install the remaining axle bolts STEP 73 86S24CU Tighten the axle housing mounting bolts to a torque of 232 to 262 Nm 171 to 193 lb ft STEP 74 RD02F104 Install the cab mount bolt 1 While holding the plate 2 torque the bolt to 47 to 61 Nm 35 to 45 lb ft STEP 75 77S36X Install the cab jacking bolt 1 and ...

Страница 647: ... 190 to 244 Nm 140 to 180 lb ft STEP 77 86S1 Install the wheel and tire assemblies on the rear axles STEP 78 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 ...

Страница 648: ...T 7 BEARING CONE 13 LOCATOR BUTTON RIGHT HAND ONLY 19 RETAINING RING 2 BUSHING 8 PLANET GEAR CARRIER 14 SEAL 20 THRUST WASHER 3 SEAL 9 RING GEAR 15 THRUST WASHER 21 SHIMS 4 RING 10 WEAR INSERT 16 THRUST RING 22 RETAINING RING 5 AXLE HOUSING 11 SUN GEAR SHAFT 17 ROLL PIN 6 BEARING CUP 12 NEEDLE BEARINGS 18 PLANET GEAR SHAFT ...

Страница 649: ... old wear sleeve if equipped Check wear sleeve dimensions If a thick sleeve was installed a puller may be required to remove the sleeve STEP 82 94S6 Clean the axle bushing of any foreign material and remove any scratches Make sure that the axle bearing is not contaminated STEP 83 94S2 Clean the OD of the axle and the ID of the new wear sleeve with Loctite safety solvent ...

Страница 650: ...eve in a bearing oven to 191 to 204 C 375 to 400 F 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 51 mm 0 020 inch away from the axle bearing NOTE If the wear sleeve is driven onto the axle bushing make sure that the sleeve does not touch and preload the axle bearing WARNING Always wear heat protective gloves to pr...

Страница 651: ...P Lithium grease 1 STEP 88 94S34 Apply Loctite 515 gasket eliminator to the OD of the axle shaft STEP 89 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 1 ...

Страница 652: ...Section 31 Chapter 1 January 2006 POWER TAKE OFF CONTROL SYSTEM How it Works ...

Страница 653: ...er 1 31 1 2 TABLE OF CONTENTS POWER TAKE OFF 31 1 3 ELECTRONIC PTO CONTROL 31 1 4 PTO SYSTEM CONTROL 31 1 7 PTO CONTROL MODES 31 1 8 PTO VALVE OIL SUPPLY 31 1 10 PTO DIFFERENTIAL LOCK VALVE 31 1 11 TROUBLESHOOTING 31 1 12 ...

Страница 654: ...over at the back of the cab The PTO controller supplies current to the PTO valve solenoid to activate the PTO clutch based on commands from the operator PTO switch and signals supplied to it from the PTO shaft speed sensor during modulation and operation Diagnosing system faults is accomplished by reading appropriate faults codes through the tractor monitor display or with the service tool Refer t...

Страница 655: ...oller using a signal from the alternator W terminal PTO Shaft Speed Circuit PTO shaft speed is used in conjunction with engine RPM by the PTO controller to control clutch modulation clutch engagement rate and to monitor clutch slip percentage This allows smooth engagement and stops PTO operation if the clutch slips at an excessive rate The PTO shaft speed is calculated by the PTO controller from a...

Страница 656: ...Section 31 PTO Chapter 1 31 1 5 RD05J060 1 PTO CONTROL SWITCH 1 ...

Страница 657: ...s are displayed on the tractor instrumentation Refer to fault code section of this manual for complete listing of PTO fault codes Arm Rest Control Module MFD and differential lock operator commands are sent to the arm rest control module then relayed to the PTO controller via the Data Bus The arm rest controller provides control switch position information to the PTO controller for these functions...

Страница 658: ...FF LOCK CONTROL ENGINE ALTERNATOR W TRANSMISSION PTO CLUTCH VALVE PTO SHAFT SPEED SENSOR PTO SHAFT SIZE SENSOR AUX PTO HITCH CONTROL MODULE TMF PTO CLUTCH IMPLEMENT BRAKE LIGHTS TRACTOR BRAKE LIGHTS BRAKE LIGHT RELAY FWD VALVE FWD CLUTCH REAR FRAME HOUSING DIFF LOCK VALVE DIFF LOCK CLUTCH PTO SHAFT OFF ON OFF ON OFF ON D A T A B U S ENGINE SPEED ENGINE SPEED RANGE TRANSMISSION HOUSING DIFF L SWITC...

Страница 659: ...he slip rate of the PTO output shaft Current supplied to the PTO proportional current control solenoid is increased until the PTO clutch is filled Ramp Mode Ramp mode begins at the completion of the modulation mode The PTO controller increases the current supplied to the PTO proportional control solenoid at a constant rate until target coil current is reached Target coil current will be large enou...

Страница 660: ...current control solenoid output and flash the PTO output lamp An excessive slip fault code will be stored in the controller memory The operator may try to re initiate the sequence by turning the PTO switch from ON to OFF to ON again Missing PTO Signal Abort If the PTO frequency signal has not been detected by the PTO control module after 6 seconds from activation the control module will shut off c...

Страница 661: ...s hard wire to PTO controller to supply current to the PTO solenoid cartridge valve The valve supplies regulated pressure to the PTO clutch based on commands from the operator PTO switch and signals supplied to it from the engine RPM circuit PTO shaft speed sensor and dual shaft speed sensor The PTO clutch is applied with hydraulic pressure PTO Clutch Disengaged When the PTO switch is moved to the...

Страница 662: ...DENTIFICATION 1 4 2 3 2 2 13 12 6 7 8 9 10 11 12 13 5 1 VALVE INLET PORT 8 REMOTE VALVE PILOT SUPPLY 2 PLUGGED PORT 9 DIF LOCK SUPPLY 3 LUBE INLET PORT 10 TANK 4 PTO LUBE 11 MESH LUBE 5 TANK 12 PTO PROPORTIONAL CURRENT CONTROL SOLENOID 6 PTO CLUTCH SUPPLY 13 DIFF LOCK SOLENOID 7 BLOCKED PASSAGE ...

Страница 663: ... electrical circuit 1 Check wires 597A LU and 598A BK ground 2 Check all connections for excessive resistance Place the PTO switch in the ON position Check for voltage at the PTO valve coil C If voltage is found the electrical circuit is functioning properly D If voltage is not found troubleshoot the PTO electrical circuit 1 Check wires 597A LU and 598A BK ground 2 Check all connections for excess...

Страница 664: ...t clutch wear as the clutch is gradually engaged As the modulator spool shifts down it simultaneously blocks the PTO clutch return and begins increasing the clutch supply pressure The pressure available to the PTO clutch is also ported through a cross drilled and end drilled holes to the bottom of the modulator spool The balance between the increasing inner modulator spring force against the incre...

Страница 665: ...98A BK ground 5 Check all connections for excessive resistance 6 Check solenoid coil for improper installation loose etc 7 Place the PTO switch in the OFF position Check for voltage at PTO valve coil A If voltage is not found the electrical circuit is functioning properly B If voltage is found troubleshoot the PTO electrical circuit 8 Check wires 597A LU and 598A BK ground 9 Check all connections ...

Страница 666: ...Section 31 PTO Chapter 1 31 1 15 RH02A059 BEVEL PIN LUBE DIFF LOCK SOLENOID REGULATED SUPPLY PTO CLUTCH LUBE DIFFERENTIAL LOCK PISTON PTO CLUTCH PISTON PTO SOLENOID ...

Страница 667: ...roubleshooting 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 PTO clutch piston hanging or damaged 6 Repair PTO clutch ...

Страница 668: ...stance 5 Check for loose connections 6 Solenoid partial short Check solenoid coil resistance 7 Controller current supply is weak Internal controller failure B Clutch hydraulic circuit leaking Check regulated pressure circuit 8 Inspect PTO solenoid cartridge valve seals 9 Inspect PTO clutch for leaking seals 10 Internal tube supply leaking 11 Engine speed signal too high A Check wire 216D Y B Check...

Страница 669: ...Section 31 PTO Chapter 1 31 1 18 RH98H048 BEVEL PIN LUBE DIFF LOCK SOLENOID REGULATED SUPPLY PTO CLUTCH LUBE DIFFERENTIAL LOCK PISTON PTO CLUTCH PISTON PTO SOLENOID ...

Страница 670: ...Section 31 Chapter 2 January 2006 PTO CLUTCH ASSEMBLY Single Reversible and Dual Speed ...

Страница 671: ... 16 Cross Section of PTO Clutch and Output Shaft Assembly 31 2 31 SINGLE SPEED REVERSIBLE SHAFT PTO 31 2 32 Disassembly 31 2 32 Assembly 31 2 35 Exploded View of PTO Output Shaft and Driven Gear Assembly 31 2 35 SINGLE SPEED REVERSIBLE SHAFT PTO DRIVEN GEAR 31 2 39 Removal 31 2 39 Assembly 31 2 41 Reversible PTO Output Shaft Bearing Adjustment 31 2 43 SINGLE SPEED REVERSIBLE SHAFT PTO 31 2 45 Cros...

Страница 672: ...lling 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 90 to 100 Nm 66 to 74 lb ft PTO Driven Gear Bearing Cage Bolts 51 to 58 Nm 38 to 43 lb ft PTO Manifold Plate Mounting Bolts 51 to 58 Nm 38 to 43 lb ft PTO Clutch Assembly Mounting Bolts 51 to 58 Nm 38 to 43 lb ft PTO Speed Sensor 16 to 22 Nm 12 to 16 lb ft ...

Страница 673: ...ervicing the following components will have to be removed cab see Cab Removal Section hitch rock shaft see Hitch Removal Section and final drive top cover see Final Drive Section PTO CLUTCH SERVICE Removal STEP 1 If unit is equipped with a quick coupler properly support the coupler 1 remove the third link 2 at the rear frame remove the pins 3 and lift the coupler from the draft arms STEP 2 If equi...

Страница 674: ...harness 3 from the speed sensor and remove the sensor 2 Remove the PTO manifold plate 3 NOTE Hitch rock shaft removed for photographic purposes STEP 5 Remove the PTO jumper tubes 1 Remove the O rings 2 from both ends of each tube and discard Remove the manifold plate O ring seals 3 and discard STEP 6 Remove the two upper PTO assembly mounting bolts NOTE Hitch components and draw bar rear support a...

Страница 675: ...995 6 guide pins 1 then remove the two lower mounting bolts 2 STEP 8 Remove the PTO assembly 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 RD05A047 1 2 RD05A048 RD05A019 ...

Страница 676: ... 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 STEP 11 Remove the snap ring STEP 12 Remove the clutch backing disc STEP 13 Remove the eight friction plates and eight separator plates and discard RD05A020 2 1 RD05A022 RD05A024 RD05A025 ...

Страница 677: ...P 14 Turn the carrier over as shown and tap the carrier on a hard surface to dislodge the piston STEP 15 Remove the piston STEP 16 Remove the seal ring and discard STEP 17 Remove the O ring and discard RD05A027 RD05A028 RD05A029 RD05A030 ...

Страница 678: ...discard STEP 19 Remove the brake pusher disc STEP 20 Remove the Belleville washer retaining ring 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 RD05A031 RD05N141 RD05N144 RD05N143 ...

Страница 679: ... STEP 25 Place Special Tool 380002454 1 over the hub so that the feet of the tool are sitting on the three brake adjuster pins Compress the three brake adjuster pins until they are flush with the brake pusher plate 2 Reset the tool so that the gap in the snap ring 3 is centered in the opening of the tool 1 Compress the brake pusher plates 2 just enough to relieve the pressure on the snap ring RD05...

Страница 680: ... snap ring STEP 27 Remove the top brake holder plate 1 Note the tabs 2 on the holder plate are facing towards the friction plate STEP 28 Remove the brake friction plate STEP 29 Remove the three brake adjuster pins RD05N146 RD05N147 2 1 RD05N148 RD05N149 ...

Страница 681: ...der plate are facing towards the friction plate STEP 31 Remove the first brake apply disc spring STEP 32 Remove the second brake apply disc spring STEP 33 Remove the two needle bearings 1 and needle bearing support ring 2 from the PTO drive shaft assembly RD05N150 1 3 1 RD05N151 RD05N152 1 3 RD05B033 2 1 ...

Страница 682: ... and the needle bearing 2 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 STEP 36 Remove the snap ring STEP 37 Remove bearing spacer RD05B034 2 1 RD05B036 RD05B037 RD05B038 ...

Страница 683: ...g cage 1 between two support blocks 2 and press the drive shaft assembly 3 free of the bearing cage IMPORTANT Do not allow the shaft to fall to the floor STEP 40 Remove the three seal rings and discard STEP 41 Press the bearing from the shaft RD05B039 RD05B040 3 2 1 RD05D001 RD05D002 ...

Страница 684: ...Section 31 PTO Chapter 2 31 2 15 STEP 42 Remove bearing cones from each side of the bearing cage RD05D008 RD05D010 ...

Страница 685: ...TCH SEPARATOR DISC 3 RETAINING RING 17 SEAL RING 31 PTO CLUTCH FRICTION DISC 4 THRUST WASHER 18 BEARING CUP 32 PISTON 5 THRUST BEARING 19 BEARING CONE 33 O RING 6 NEEDLE BEARING 20 SPACER 34 SEAL RING 7 NEEDLE BRG SUPPORT RING 21 PTO DRIVE GEAR 35 SEALING RING 8 BELLEVILLE WASHERS 22 SPRING 36 O RING 9 JUMPER TUBE 23 PLATE 37 CARRIER 10 O RING 24 BRAKE DISC 38 RETAINING RING 11 RETAINING RING 25 B...

Страница 686: ...aft 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 STEP 46 Apply petroleum jelly or Lubriplate to the seal rings and install Make sure each seal is properly locked after placing in the groove RD05D011 RD05D012 RD05D006 RD05B042 ...

Страница 687: ...ng cage over the shaft and press the bearing until a slight drag is felt on the cage as it is turned STEP 48 Install the shim pack STEP 49 Install the bearing spacer 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 RD05B041 RD05B039 RD05B038 RD05D013 ...

Страница 688: ...e shaft 3 where the internal spline is NOTE DO NOT overpress or deflection of the spacer and retaining ring will occur This will affect the shimming STEP 53 Check end play End play should be between 0 001 to 0 005 inches If end play is not correct disassemble and adjust the shim pack assemble and check end play again STEP 54 Install the first brake apply disc spring Make sure spring fingers 1 are ...

Страница 689: ... STEP 56 Discs should be installed as shown STEP 57 Install the first brake holder plate Make sure the tabs 1 are pointed away from the disc spring 2 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 RD05N151 1 3 2 1 RD05N158 RD05N150 1 2 RD05N155 2 1 ...

Страница 690: ...tall the brake friction plate 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 RD05N149 RD05N148 1 3 RD05N147 1 3 1 ...

Страница 691: ...the holder plate 4 to allow the retaining ring to seat into the groove IMPORTANT Before removing the compression tool make sure the retaining ring is fully seated into the ring groove and is not touching the adjuster pins STEP 63 Turn the hub over and GENTLY tap the brake adjuster pin as shown If pin does not move the retaining ring will be set into the pin groove STEP 64 If needed turn the assemb...

Страница 692: ...ring 2 and thrust washer 1 STEP 66 Install needle bearing 1 bearing spacer 2 and needle bearing 3 STEP 67 Place the gear hub assembly over the shaft STEP 68 Install a thrust washer 1 bearing 2 and thrust washer 1 RD05B034 2 1 RD05B033 1 3 2 1 3 RD05B032 RD05N145 1 3 2 1 ...

Страница 693: ... ring grooves left after installing this retaining ring 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 STEP 71 Install the Belleville washer retaining ring RD05N142 RD05N143 RD05N157 RD05N144 ...

Страница 694: ... and install NOTE Make sure the O ring is not twisted when installed 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 STEP 75 Apply petroleum jelly to a new O ring and install on the piston NOTE Make sure the O ring is not twisted when installed RD05N141 RD05B028 RD05B029 RD05A032 ...

Страница 695: ...tall the piston into the clutch carrier STEP 78 Install the first separator plate 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 NOTE Friction and separator plates come as complete sets NOTE Dip all friction plates in CLEAN transmission fluid before assembly RD05A033 RD05A028 RD05A026 R...

Страница 696: ...e the three measurements Record this measurements to obtain A 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 Record this measurement to obtain B If A B is less than or equal to 11 235 MM use the 3 5 MM brake pusher plate 2 If A B is greater than 11 235 MM use the 3 0 MM brake pusher plate 2 RD05A024 RD05A02...

Страница 697: ...nd 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 STEP 85 Press down on the clutch carrier and install the snap ring STEP 86 Air test the piston pressure port for seal ring leakage NOTE Some air leakage will occur If leakage is excessive sealing ring may have been damaged during assembly and will ...

Страница 698: ...align the splines of the clutch drive shaft with the countershaft STEP 88 Remove the guide pins and install the two upper mounting bolts STEP 89 Install new O rings on both ends of the jumper tubes 1 and push into place Install new O ring seals 2 STEP 90 Install the PTO manifold plate 1 and speed sensor 2 Reconnect the speed sensor wire harness 3 RD05A047 1 3 1 2 RD05A046 1 3 RD05A012 1 3 1 1 2 RD...

Страница 699: ...k support PTO clutch cover plate with a new gasket STEP 92 If equipped install the quick coupler STEP 93 If equipped with a hydraulic cylinder assisted third link note the position of the hoses and install into the quick couplers RD05A014 1 3 RD05A013 1 3 RD05A017 ...

Страница 700: ...PER TUBE 13 BOLT M10 X 30 CL 10 9 23 BRAKE PUSHER DISC 4 PTO DRIVE SHAFT ASSEMBLY 14 NEEDLE BEARING 24 PTO BRAKE HOLDER PLATE 5 PTO INTERMEDIATE DRIVE SHAFT 15 NEEDLE BEARING SUPPORT RING 25 PTO BRAKE FRICTION PLATE 6 TAPPER ROLLER BEARING CONE 16 MFD CLUTCH SEPERATOR DISC 26 BRAKE APPLY DISC SPRING 7 COUNTERSHAFT RETAINER RING 17 MFD CLUTCH FRICTION DISC 27 PTO DRIVE GEAR 8 SHIM PACK 18 BELLEVILL...

Страница 701: ...asher 1 Remove pivot rod washers and spring 2 Remove the PTO top shield 3 STEP 95 Push quick disconnect coupler 1 to expose the locking ring 2 and remove the ring NOTE Hitch components and draw bar rear support are removed for photographic purposes STEP 96 Remove the coupler RD05A014 1 3 2 RD05B016 1 2 RD05B015 ...

Страница 702: ...33 STEP 97 Remove the four coupler retaining balls STEP 98 Remove the shaft seal and discard STEP 99 Remove the eight mounting bolts STEP 100 Remove the housing cover Clean both mounting surfaces RD05B014 RD05B018 RD05B011 RD05A060 ...

Страница 703: ...sleeve shaft NOTE If bearing and cup on the PTO driven gear 1 needs service see Single Speed Reversible Shaft Driven Gear Section STEP 102 Remove the bearing cone from the housing STEP 103 Press the bearing from the output sleeve shaft RD05A059 1 83LS9 RD05B020 ...

Страница 704: ...HIELD COVER 7 SHIMS 13 BEARING CONE 2 RETAINING CLIP 8 BEARING CAGE 14 COVER 3 PTO DRIVEN GEAR 9 BOLT M10 X 30 10 9 15 BOLT 4 BEARING 10 WASHER 11 X 20 X 2MM 16 OIL SEAL 5 BEARING CUP 11 TRANSMISSION SLEEVE 17 REVERSIBLE OUTPUT SHAFT 6 OIL SHIELD 12 BEARING 18 QUICK COUPLER 6 10 8 2 7 1 11 17 3 4 5 16 18 14 15 9 12 13 ...

Страница 705: ...e is fully seated IMPORTANT Before final reassembly the rolling torque needs to be checked See Reversible PTO Output Shaft Bearing Adjustment Section STEP 106 Apply grease to the splines and install the output shaft sleeve IMPORTANT USE ONLY Multi Purpose 2 Lithium Grease Grade 251H EP STEP 107 Place a bead of Loctite 515 around the sealing surface of the housing cover NOTE Make sure the Loctite i...

Страница 706: ...que of the output shaft See Reversible PTO Output Shaft Bearing Adjustment Section STEP 109 Apply Loctite 721 to the O D of the seal and seal bore STEP 110 Press the seal in until the face of the seal 1 is 41 MM from the outer face of the housing 2 STEP 111 Place petroleum jelly or grease in each coupler retainer ball hole RD05B011 RD05B017 RD05B018 1 2 RD05B013 ...

Страница 707: ...de the coupler over the shaft STEP 114 Push the coupler inward to expose the ring grove and install the locking ring 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 RD05B014 RD05B015 RD05B016 RD05A014 1 3 2 ...

Страница 708: ...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 NOTE Hitch components and draw bar rear support are removed for photographic purposes STEP 117 Lift the gear 1 and rear half of the shield 2 out as a unit through the top of the final drive housing STEP 118 Remove the six...

Страница 709: ...shield STEP 120 Remove bearing cage and shim pack from the housing STEP 121 Remove the shim pack from the bearing cage Measure the thickness of the shim pack and note for reinstallation STEP 122 Remove the bearing cone from the bearing cage RD05A054 RD05A053 RD05A052 RD05B030 ...

Страница 710: ...l 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 STEP 125 Press the bearing cone into the bearing gear cage making sure it is properly seated RD05A056 RD05A057 RD05B031 ...

Страница 711: ...cage NOTE If starting with all new parts start with a shim pack of 0 025 STEP 127 Install the bearing cage with shim pack STEP 128 Install the front portion of the PTO oil shield STEP 129 Install the six bearing carrier bolts and torque to 55 Nm 41 lb ft RD05A052 RD05A053 RD05A054 RD05A055 ...

Страница 712: ... the rear half of the PTO oil shield 1 over the gear 2 and lower them into place STEP 131 Install the four shield retaining clips Reversible PTO Output Shaft Bearing Adjustment STEP 132 Install the output shaft sleeve RD05A058 1 2 RD05B019 RD05A059 ...

Страница 713: ...heck the rolling torque using a inch pound torque wrench The required rolling torque range is 2 18 lb in If the torque is too low disassemble and add shim s to the bearing cage If torque is too high disassemble and remove shim s from the bearing cage After adding or removing shims recheck rolling torque When the rolling torque is to specification remove the PTO output shaft cover To continue the a...

Страница 714: ...3 BOLT M12 X 45 CL 10 9 2 BOLT M10 X 30 CL 10 9 8 SHIMS 14 PTO HOUSING COVER 3 WASHER 11 X 21 X 2 5 MM 9 PTO DRIVEN GEAR OIL SHIELD 15 QUICK DISCONNECT COUPLER 4 PTO DRIVEN GEAR BRG CAGE 10 PTO OIL SHIELD COVER 16 PTO OUTPUT SHAFT SLEEVE 5 PTO DRIVEN GEAR 11 OIL SHIELD RETAINING CLIP 6 BEARING 12 APPLY LOCTITE AS REQUIRED 6 2 7 5 13 12 14 4 1 8 6 9 10 16 15 11 3 7 ...

Страница 715: ...Section 31 PTO Chapter 2 31 2 46 This Page Left Blank ...

Страница 716: ...Section 33 Chapter 1 January 2006 BRAKE VALVE ...

Страница 717: ...1 33 1 2 TABLE OF CONTENTS SPECIAL TORQUES 33 2 2 BRAKE VALVE 33 2 3 Removal 33 2 3 Disassembly 33 2 4 Assembly 33 2 6 Installation 33 2 8 SPECIAL TORQUES Allen head plate to valve body retaining screw 35 to 40 Nm 26 to 30 lb ft ...

Страница 718: ...d hood See Hood Removal Section in this manual STEP 1 RD02K118 Tag and remove the four brake valve lines 1 Tag and remove the two brake switch connectors 2 STEP 2 102R 5 Remove steering column side cover STEP 3 102R 4 Remove top cover from steering column STEP 4 RD02K120 If equipped remove the foot throttle by removing the roll pin and sliding the throttle arm off the pivot shaft STEP 5 101R 35A R...

Страница 719: ...lve mounting bolts Remove the brake valve and gasket from the firewall Disassembly STEP 7 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 ...

Страница 720: ... 4 and return spring 5 from the spool Inspect all parts for damage or wear Repeat steps for the second spool assembly STEP 11 RD02K109 Remove and discard the spool seal and O ring Repeat for second spool STEP 12 RD02K110 Remove both brake switches Discard O rings Inspect for damage or wear STEP 13 RD02K111 Remove and discard the two poppet sleeve seals 00 5 4 3 1 2 1 ...

Страница 721: ...ew backing O ring then a new seal STEP 15 RD02K110 Install new O rings and install the brake switches 1 BODY 6 SPOOL 11 POPPET 2 SWITCH 7 O RING 12 GASKET 3 O RING 8 SEALRING 13 PLATE 4 SPRING 9 SLEEVE 14 SEAL 5 RETAINING RING 10 SPRING 15 SCREW 1 2 3 4 5 6 7 8 9 10 15 14 13 12 11 1 ...

Страница 722: ...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 STEP 17 RD02K112 Install a new brake valve gasket STEP 18 RD02K111 Install new poppet shaft seals STEP 19 RD02K107 Install the firewall brake plate onto the brake body STEP 20 RD02K113 Install the three retaining scews and torque to 35 40 Nm 26 to 30 lb ft 5 4 3 1...

Страница 723: ...on of this Service Manual for the brake pedal adjustment procedure STEP 22 RD0K118 Install new O rings on all hose and tube connectors Install the supply and return lines the right and left brake lines 1 and the brake switch connectors 2 Start vehicle and check for leaks and proper brake switch operation STEP 23 101RS35A Install the right side air duct STEP 24 RD02K120 If equipped install the foot...

Страница 724: ...Section 33 Brakes Chapter 1 33 1 9 STEP 26 102RS5 Install the right side cover ...

Страница 725: ...Section 33 Brakes Chapter 1 33 1 10 ...

Страница 726: ...Section 33 Chapter 2 January 2006 BRAKE CYLINDERS ...

Страница 727: ...Section 33 Brakes Chapter 2 33 2 2 TABLE OF CONTENTS SPECIAL TORQUES 33 2 3 SPECIFICATIONS 33 2 3 BRAKE CYLINDERS 33 2 3 Disassembly 33 2 3 Assembly 33 2 5 ...

Страница 728: ...nd planetarium from the rear frame See Rear Axle and Planetaries Section in this Service Manual for axle removal STEP 2 RD02D051 Remove the brake tube 1 and diff lock tube 2 from the rear frame housing STEP 3 87 35 Lift the supply tubes out of the brake cover If the supply tubes are to be removed from the rear frame remove the lower O rings from the tube first STEP 4 T97946 Remove two brake cover ...

Страница 729: ...adjuster return plate from the brake dics STEP 7 TBD Remove the friction and separator plates from the rear frame STEP 8 T97952 Remove the three brake adjusters from the differential retainer STEP 9 T97953 Remove the five locating pins from the differential retainer STEP 10 T97955 Remove the sun gear shaft seal from the differential retainer ...

Страница 730: ... 3 3 4 4 6 5 8 9 7 1 BEARING RETAINER 6 EXTERNAL RETAINING RING 11 PISTON 2 OIL SEAL 7 AXLE ASSEMBLY HOUSING 12 BRAKE COVER 3 SEPARATOR PLATE 4 8 BRAKE ADJUSTER ASSEMBLY 13 O RING 4 FRICTION PLATE 4 9 LOCATING PIN 14 SUPPLY TUBE 5 BELLEVILLE WASHER 10 ADJUSTER RETURN PLATE ...

Страница 731: ...pect 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 STEP 13 A21050 Use compressed air to push the brake piston out of the brake cover STEP 14 A21052 Carefully remove the piston from the cover Repeat procedures for the other piston ...

Страница 732: ...er to install a new seal in the differential retainer Lubricate the ID of the seal with Hy Tran Plus fluid STEP 17 T97954 Install aligning dowels in the differential carrier STEP 18 T97953 Install the five locating pins in the differential carrier STEP 19 RH97K064 If new brake plates are to be installed the brake adjusters must be reset Adjust the depth of the retaining rings to 25 477 mm 1 in If ...

Страница 733: ...fferential plate carrier 2 Install a friction plate against the separator plate 3 Install three more separator and friction plates A friction plate must be the last part installed STEP 22 T98031 Install the adjuster return plate on the locating pins The tabs on the plate must contact the adjuster dowel assemblies STEP 23 T97947 Install the brake cover onto the locating dowels STEP 24 T97945 Instal...

Страница 734: ...e supply tubes Install the tubes into the brake cover STEP 26 RD02D051 Install the brake supply tube 1 and connect the diff lock tube 2 Repeat installation procedures for the other brake cylinder STEP 27 RD02D050 See Rear Axle and Planetaries Section in this Service Manual for the installation of the rear axle housing 1 2 ...

Страница 735: ...Section 33 Brakes Chapter 2 33 2 10 ...

Страница 736: ...LY RELIEF A B TANK SIGNAL SUPPLY RELIEF A B TANK SIGNAL SUPPLY RELIEF LUBE SUPPLY LUBE CLUTCH PTO LOCK VALVE PTO DIFF MANIFOLD OPTIONAL POWER BEYOND RETURN SUPPLY SIGNAL DRAIN CASE Ø 1 07 Ø 1 0 DYN Ø 0 89 DAMPING BLEED Ø 0 45 Ø 1 0 CLUTCH MFD CLUTCH LOW CLUTCH MED CLUTCH HIGH CLUTCH REVERSE CLUTCH FIFTH CLUTCH THIRD CLUTCH FIRST CLUTCH EVEN CLUTCH ODD OR 50 KPH CLUTCH CREEP TRANSMISSION CONTROL VA...

Страница 737: ... B TANK SIGNAL SUPPLY RELIEF A B TANK SIGNAL SUPPLY RELIEF LOCK VALVE PTO DIFF VALVE PRIORITY REGULATOR MANIFOLD OPTIONAL POWER BEYOND RETURN SUPPLY SIGNAL DRAIN CASE Ø 1 07 Ø 1 0 DYN Ø 0 89 BLEED Ø 0 45 DAMPING Ø 1 0 REGULATED CIRCUIT PUMP FLOW CLUTCH MFD CLUTCH LOW CLUTCH MED CLUTCH HIGH CLUTCH REVERSE CLUTCH FIFTH CLUTCH THIRD CLUTCH FIRST CLUTCH EVEN CLUTCH ODD OR 50 KPH CLUTCH CREEP TRANSMISS...

Страница 738: ...Section 35 Chapter 1 January 2006 HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC ...

Страница 739: ...Section 35 Hydraulic Systems 3PT Chapter 1 35 1 2 TABLE OF CONTENTS HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC 35 1 3 SIMPLE SCHEMATIC 35 1 13 COMMON SYMBOLS 35 1 15 ...

Страница 740: ...e several systems of symbols used when making schematic diagrams They are as follows I S O International Standards Organization A N S I American National Standards Institute A S A American Standards Association J I C Joint Industry Conference A combination of these symbols are shown in this section There are differences between the symbols but there is enough similarity so that if you understand t...

Страница 741: ...s close to the components The reservoir is usually the only component symbol pictured more than once Lines Tubes and Hoses A hydraulic line tube hose or any conductor that carries the fluid between components is shown as a line A working line such as an inlet pressure or return is shown as a solid line Working lines with arrows show direction of flow Pilot or control lines are broken into long das...

Страница 742: ... triangles in it and they will be opposite each other A variable displacement pump is designated by drawing an arrow through the pump symbol at 45 degrees To indicate a variable displacement pressure compensated pump a small box with an arrow in it will be added to the side of the pump symbol If the pump is controlled by a lever or a pedal it will be shown on the side of the pump A drive shaft is ...

Страница 743: ...at is inserted into the rectangle The symbol can be drawn in any position If the cylinder is single acting there is only one port shown on the symbol The port is shown on the end of the cylinder that receives pressurized fluid and the opposite end of the cylinder is left open A double acting cylinder symbol has both ends closed and has two ports on the symbol A double rod end cylinder has a rod ex...

Страница 744: ...uch as a relief or sequence valve is shown with the arrow offset from the ports and toward the pilot pressure line side of the square The spring holds the valve closed until the pilot line oil pressure is greater than the spring pressure Mentally visualize a build up of pressure in the pilot line and the square moving over compressing the spring The oil can now flow through the valve Normally Open...

Страница 745: ...r line When the piston in the primary cylinder reaches the end of its stroke the pressure in the supply line increases The sequence valve is also connected to the supply line and also feels the increase in pressure As pressure increases the square and directional flow arrow moves over connecting the inlet and outlet ports allowing fluid to flow to the secondary cylinder Directional Control Symbols...

Страница 746: ... position it would be as shown below Here pressurized oil is being supplied to the piston end of the cylinder and oil from the rod end of the cylinder is allowed to flow to the reservoir Three Position Valves Three position valves will have a centered neutral position The centered position can be either open or closed to flow The open center is usually used with a fixed displacement pump and the c...

Страница 747: ... with a small hole in it or a small drilled passageway within a valve If it is an adjustable restriction it could be thought of as a water faucet that can be controlled by turning the handle to regulate the flow Restrictors can be applied to meter out meter in and bleed off circuits There are adjustable restrictors that are pressure compensated That means that the size of the opening in the restri...

Страница 748: ...is spring loaded gas charged or other features A dotted line perpendicular to the flow line indicates a filter or strainer FILTER OR STRAINER 716L8E A solid line perpendicular to the flow with black triangles pointing out indicates a cooler COOLER 716L8F The symbol for a heater is like the symbol for a cooler except the black triangles point in HEATER 731L8G Two sets of triangles pointing in and o...

Страница 749: ...Section 35 Hydraulic Systems 3PT Chapter 1 35 1 12 NOTES ...

Страница 750: ...ted 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 A A D C D C B B 715L8 DETENT FLOAT ...

Страница 751: ...r via the valve Both ends of the cylinder are also connected to the return line to the reservoir Valve C This valve is also similar to valve A but is designed to control a single acting cylinder When you visualize placing the upper envelope in the center position you will see that oil can drain back to the reservoir from cylinder C At the same time oil from the pump can flow through valve C to the...

Страница 752: ...S CROSSING LINES JOINING 710L8P 729L8N 729L8P LIQUID DIRECTION OF FLOW GASEOUS DIRECTION OF FLOW 711L8C FLEXIBLE LINE 730L8G MECHANICAL CONNECTIONS TWO PARALLEL LINES SHAFTS LEVERS ECT 730L8H VARIABLE COMPONENT RUN ARROW THROUGH SYMBOL AT 45 DEGREES 730L8J SPRING 729L8D HYDRAULIC PUMP FIXED DISPLACEMENT 729L8E HYDRAULIC PUMP VARIABLE DISPLACEMENT 729L8F PRESSURE COMPENSATED VARIABLE DISPLACEMENT P...

Страница 753: ...MOSPERER 710L8A PRESSURIZED RESERVOIR 710L8F LINE TO RESERVOIR BELOW FLUID LEVEL 710L8E LINE TO RESERVOIR ABOVE FLUID LEVEL 711L8P SINGLE ACTING 711L8P 730L8E 749L8EP 712L8A DOUBLE ACTING SINGLE ROD END DOUBLE ACTING DOUBLE ROD END SINGLE ROD END FIXED CUSHION BOTH ENDS SINGLE ROD END ADJUSTABLE CUSHION ROD END ONLY 730L8F DIFFERENTIAL CYLINDER 731L8A 731L8B 712L8J CHECK VALVE PILOT OPERATED CHECK...

Страница 754: ... 4 WAY OPEN CENTER CROSS OVER 749L8C VALVE CAPABLE OF INFINITE POSITIONING INDICATED BY HORIZONTAL LINES DRAWN PARALLEL TO THE ENVELOPE 712L8B PRESSURE RELIEF VALVE 731L8D 2 POSITION 3 WAY VALVE PRESSURE REDUCING VALVE 712L8H 716L8H NON ADJUSTABLE RESTRICTOR 716L8B ADJUSTABLE RESTRICTOR 716L8C ADJUSTABLE RESTRICTOR PRESSURE COMPENSATED 716L8D ADJUSTABLE RESTRICTOR TEMPERATURE AND PRESSURE COMPENSA...

Страница 755: ...730L8J 729L8B 729L8C SOLENOID DETENT SPRING MANUAL PUSH BUTTON PUSH PULL LEVER 713L8F PEDAL 729L8G MECHANICAL 729L8H PRESSURE COMPENSATED 731L8F PILOT PRESSURE REMOTE SUPPLY 731L8M LIQUID SUPPLY 716L8E FILTER 716L8F COOLER 731L8G HEATER 731L8H TEMPERATURE CONTROLLER 716L8G ACCUMULATOR HYDRO PNEUMATIC ...

Страница 756: ...ms 3PT Chapter 1 35 1 19 730L8K REVERSING MOTOR 730L8M PRESSURE INDICATOR 730L8N TEMPERATURE INDICATOR 730L8L STATION OR TEST POINT 730L8P PRESSURE SWITCH 731L8K 731L8J QUICK DISCONNECTS DISCONNECTED QUICK DISCONNECTS CONNECTED ...

Страница 757: ...Section 35 Hydraulic Systems 3PT Chapter 1 35 1 20 ...

Страница 758: ...Section 35 Chapter 2 January 2006 HYDRAULIC SYSTEM HOW IT WORKS WITH TROUBLESHOOTING ...

Страница 759: ... PUMP FLOW TEST 35 2 25 STEERING RELIEF PRESSURE TEST AND ADJUSTMENT PROCEDURE 35 2 27 STEERING SYSTEM PROBLEMS 35 2 29 PRIORITY AND REGULATOR VALVE 35 2 31 PFC AXIAL PISTON PUMP 35 2 34 PFC PUMP HIGH PRESSURE STANDBY CHECK AND ADJUSTMENT PROCEDURE 35 2 42 PFC PISTON PUMP FLOW TEST 35 2 43 PFC PISTON PUMP FLOW COMPENSATOR SETTING 35 2 44 STANDARD PUMP COMPENSATOR VALVE INSPECTION 35 2 46 PFC PUMP ...

Страница 760: ...e pump flow rate at rated speed 2667 RPM 2000 RPM engine speed is 177 L min 47 US GPM Regulated Circuit Pump 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 maintai...

Страница 761: ...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 RI06A091 1 CHARGE LUBRICATION PUMP OUTLET REAR SECTION 3 PFC PISTON PUMP 2 REGULATED CIRCUIT PUMP OUTLET FRONT SECTION 4 DUAL GEAR PUMP REGULATED SYSTEM FILTER HOUSING 1 2 4 3 ...

Страница 762: ...d is equipped with internal plugs to separate the MegaFlow supply flow signal line pressure and signal line pilot relief from the standard PFC piston pump circuit The MegaFlow pump supplies only the third fourth or fifth remote sections The two PFC pump hydraulic circuits operate independently The maximum pump flow rate through one remote section at rated speed 2667 RPM 2000 engine speed is 117 L ...

Страница 763: ... RI06A090 RI06A074 1 REMOTE MANIFOLD LOAD SENSE 6 PFC PISTON PUMP 2 PFC PUMP TO PRIORITY REGULATOR VALVE 7 REMOTE MANIFOLD RETURN TUBE 3 REMOTE MANIFOLD RETURN HOSE 8 REMOTE MANIFOLD SUPPLY 4 MAIN FILTER ASSEMBLY 9 PRIORITY REGULATOR VALVE 5 PUMP LOAD SENSE 1 2 3 4 5 6 4 3 2 7 9 8 ...

Страница 764: ...I06A077 RI06A074 1 REMOTE MANIFOLD LOAD SENSE 6 PFC PISTON PUMP 2 PFC PUMP TO PRIORITY REGULATOR VALVE 7 REMOTE MANIFOLD RETURN TUBE 3 REMOTE MANIFOLD RETURN HOSE 8 REMOTE MANIFOLD SUPPLY 4 MAIN FILTER ASSEMBLY 9 PRIORITY REGULATOR VALVE 5 PUMP LOAD SENSE 1 2 3 4 5 6 4 3 2 7 8 9 ...

Страница 765: ... 8 MegaFlow PFC Pump Layout RH02K092 RI06A099 1 REMOTE MANIFOLD RETURN HOSE 4 MEGAFLOW REMOTE MANIFOLD SUPPLY 2 MAIN FILTER ASSEMBLY 5 MEGAFLOW PFC PISTON PUMP 3 MEGAFLOW PFC PUMP LOAD SENSE LINE 6 REMOTE MANIFOLD RETURN TUBE 6 2 3 1 5 4 2 2 1 4 3 5 ...

Страница 766: ...5 2 9 Charge Pump Layout RI02D107 RI02D109 1 DUAL GEAR PUMP ASSEMBLY 5 LUBE RELIEF VALVE ASSEMBLY 2 PRIORITY REGULATOR VALVE 6 PUMP INLET SCREEN 3 REGULATOR SECTION INLET 7 SUCTION SCREEN SHROUD 4 REGULATED CIRCUIT FILTER 6 MICRON 2 3 4 5 1 5 6 7 ...

Страница 767: ...75 PSI by a lube relief valve The lubrication circuit provides a low pressure flow of oil to lubricate and cool the following transmission components master clutch bevel pinion gears brakes drop box odd even clutches FWD range creep drive and PTO differential lock lube RI06A079 1 LEFT BRAKE LUBE 6 DROP BOX LUBE 2 PTO LUBE SUPPLY 7 RIGHT BRAKE LUBE 3 RANGE LUBE 8 CHARGE PUMP TO FILTER INLET 4 MASTE...

Страница 768: ...Section 35 Hydraulic Systems 3PT Chapter 2 35 2 11 RI06A081 RI06A080 7 RIGHT BRAKE LUBE 10 LUBE RELIEF HOSE 11 DROP BOX OUTPUT LUBE WITHOUT CREEPER 12 DROP BOX REAR BEARING LUBE 10 7 12 11 ...

Страница 769: ...sion powershift valve includes FWD PTO differential lock valve master clutch inching valve brake valve hitch valve pilot pressure remote valve pilot pressure and FWD clutch supply RI06A086 NOTE Brake hitch and remote valves regulated supply tubes not shown See brake hitch and remote circuits in this section 1 RANGE REGULATED SUPPLY TUBE 6 MASTER CLUTCH DIAGNOSTIC COUPLER 2 SPEED TRANSMISSION CONTR...

Страница 770: ...apter 2 35 2 13 RI06A085 RI06A084 6 MASTER CLUTCH DIAGNOSTIC COUPLER 2 SPEED TRANSMISSION CONTROL VALVE REGULATED SUPPLY UPPER TUBE 9 REGULATED CIRCUIT ACCUMULATOR 10 SPEED TRANSMISSION CONTROL VALVE REGULATED SUPPLY LOWER TUBE 6 9 10 2 ...

Страница 771: ... 14 Steering And Brake Tube Layout RI06A083 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 DIAGNOSTIC COUPLER 3 5 1 2 4 6 7 8 ...

Страница 772: ... 2 35 2 15 Standard Brake Valve Plumbing Layout 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 BRAKE HOSE LEFT SIDE 3 1 2 5 6 4 7 ...

Страница 773: ...Chapter 2 35 2 16 Hitch System Plumbing Layout RI06A098 1 HITCH CYLINDER RIGHT HAND RETURN 4 HITCH CYLINDER LEFT HAND RETURN 2 HITCH CYLINDER RIGHT HAND SUPPLY 5 HITCH VALVE SECTION 3 HITCH CYLINDER LEFT HAND SUPPLY 1 2 3 4 5 1 2 3 4 5 ...

Страница 774: ...aintain high pressure standby condition 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 1 2 3 4 5 6 10 7 10 8 9 3 2 11 ...

Страница 775: ...Section 35 Hydraulic Systems 3PT Chapter 2 35 2 18 Motor Return Layout RI06A064 RI06A076 1 MOTOR CASE DRAIN COUPLER 3 MOTOR RETURN TUBE 2 MOTOR RETURN COUPLER 1 2 3 3 ...

Страница 776: ...xits the main filter base and supplies the PFC pump inlet and is distributed to supply system lube requirements RI06A097 NOTE Do not attempt to use the hitch during this pressure test Test Fitting and Tool Requirements 100 PSI 7 bar pressure gauge with extension hose long enough to reach into cab Diagnostic fitting P 322529A1 STEP 1 Preparation If necessary move the right rear tire out near end of...

Страница 777: ...sure was obtained the charge system is functioning correctly B If the charge pressure is less than 50 PSI 3 4 bar check for the following Low oil level in transmission Lube relief valve spring broke or poppet stuck open Inlet suction screen may be plugged You must drain transmission Air leaks on suction side of pump Is hydraulic oil aerated Low charge pump flow Low regulated pump flow See Regulate...

Страница 778: ...hrough the oil cooler and then to the filter base STEP 1 Regulated Pressure Check with the Tractor Monitor Start the engine Cover the front grill with a large piece of paper Press the INC or DECR key on the programmable instrumentation until the TRANS OIL TEMP screen is reached NOTE Screen order is set by the operator The TRANS OIL TEMP and TRANS SYS PRESSURE screens could or could not be together...

Страница 779: ...d so the pressure reading is taken with the FWD OFF If the pressure dipped when the circuit was actuated but does not return to the Regulated Circuit Baseline Reading the FWD clutch is leaking If the pressure does not dip when the circuit is actuated check the solenoid function and electrical system connections See FWD and Diff Lock System Section and double check for fault codes on the PTO contro...

Страница 780: ...nsmission control lever from PARK to NEUTRAL and back to PARK Pressure Reading with transmission control lever in NEUTRAL at 1000 RPM ____________ NOTE The Park Brake is spring engaged and hydraulically disengaged so the pressure reading is taken with the transmission control lever in NEUTRAL If the pressure dipped when the circuit was actuated but does not return to the Regulated Circuit Baseline...

Страница 781: ...107 Start and run the engine at 1500 RPM Heat the transmission oil to 120 F 49 C Loosen the lock nut and turn the adjustment screw 1 in or out until the correct pressure is read on the tractor monitor Tighten the lock nut to a torque of 30 to 40 lb ft 41 to 54 Nm After tightening the lock nut check the regulated pressure again A If the correct pressure cannot be obtained check the following 1 Tran...

Страница 782: ...Diff Lock Transmission Control Valves Service Brakes along with the Hitch and Remote valve pilot circuits When the demand for all these regulated circuits is met all the remaining front pump flow is directed through the oil coolers and then to the main filter base Test Fitting and Tool Requirements CAS 10280 Flowmeter with 3 4 inch hoses Test Fitting Kit 380040106 STEP 1 Preparation Connect test f...

Страница 783: ... 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 Front Regulated Pump flow specification 27 0 GPM 102 2 L min minimum at 2000 RPM A If the pump flow is 24 0 GPM 90 8 L min or greater the regulated pump is functioning correctly B If the pump flow is 21 6 to 24 0 GPM 81 8 to 90 8 L min the pump output is...

Страница 784: ...he tractor out of park RD98E102 Tee a 5000 PSI 344 bar pressure gauge at the steering cylinder port STEP 2 Steering Relief Pressure Measurement Heat the transmission oil to a minimum of 120 F 50 C Start and run the engine at 1000 RPM Cover the oil cooler to help heat the oil With the engine at 1000 RPM turn the steering wheel and hold against the stop Steering Pressure Specification 3000 PSI 207 b...

Страница 785: ...the lock nut and turn the adjustment screw in or out until the correct pressure is obtained Steering Pressure Specification 3000 PSI 207 bar A If the correct pressure is obtained torque the lock nut to 30 to 35 lb ft 41 to 50 Nm After the lock nut is torqued check the steering pressure B If the correct pressure is not obtained check for the following Contamination in steering relief valve Remove a...

Страница 786: ...sary C Poor hydraulic system performance C Perform General Hydraulic System Testing this section PROBLEM Excessive steering wheel rotation slippage at end of steering cylinder stroke POSSIBLE CAUSE PROCEDURE A Excessive steering hand pump internal 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...

Страница 787: ...URE 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 ...

Страница 788: ... builds on the top of the priority spool 11 and the spool shifts down to increase flow to the remote and hitch circuits When equipped with trailer brakes oil is also supplied from the priority valve to the trailer brakes Regulator Spool Supplied By Regulated Pump Section Regulated pump flow enters the Priority Regulator valve at the right side port 7 Oil flows across the regulator spool 12 and sup...

Страница 789: ... open at 2970 psi 205 bar 80 psi 5 5 bar RD99M135 1 PRIORITY REGULATOR VALVE 8 REGULATED PRESSURE ADJUSTMENT 2 SUPPLY FROM PFC PISTON PUMP 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 REMOTE 7 REGULATED SUPPLY 4 5 10 8 9 13 7 2 1 ...

Страница 790: ...PRIORITY REGULATOR VALVE 8 REGULATED PRESSURE ADJUSTMENT 2 SUPPLY FROM PFC PISTON PUMP 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 REGULATED SUPPLY 8 10 1 11 12 2 3 7 9 6 13 5 ...

Страница 791: ...onnection from the control valves to the compensator spool If several control valves are operated at the same time the signal line at the higher pressure will cause the check valve s to seat against the signal at the lower pressure This prevents signal bleed off through other control valves and ensures that the highest signal line pressure will act on the compensator spool Operating Modes The pump...

Страница 792: ...r 2 35 2 35 RH02B011 5 CONTROL PISTON 8 PUMP HOUSING 11 PISTON BLOCK LOADING SPRING 18 COMPENSATOR ASSEMBLY 6 CONTROL SPRING 9 SWASH PLATE 12 PISTON BLOCK 20 CONTROL PISTON ROD 7 DRIVE SET 10 PISTON 13 BACK PLATE 5 6 7 8 9 10 11 12 13 18 20 ...

Страница 793: ...the pump control piston The pressure acting on the pump control piston tilts the pump swash plate against the swash plate control spring to a near neutral position In this condition the pump will provide just enough flow to make up for internal leakage thus maintaining a minimum system pressure of 340 to 390 psi 23 5 to 27 bar The pump will remain in the low pressure standby position as long as th...

Страница 794: ...d 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 This occurs almost instantly and makes engine starting much easier RH02B011 5 CONTROL PISTON 8 PUMP HOUSING 11 PISTON BLOCK LOADING SPRING 18 COMPENSATOR ASSEMBLY 6 CONTROL SPRING 9 SWASH PLATE 12 PISTON BLOCK 20 CONTROL PIS...

Страница 795: ...ase and the pump flow will rise until the flow demand has been met The flow from the pump is determined by the size of the orifice in the control valve which is being operated This orifice is created by limiting the main valve spool travel within the control valve When a control valve is operated the oil pressure in the circuit being supplied will increase to its operating pressure This pressure w...

Страница 796: ...iston This will move the swash plate to a position where the increased flow is maintained and the pressure stabilized Decreased Flow Demand If there is a reduction in the demand for flow pump pressure will increase until the pump outlet pressure exceeds the signal line pressure by more than 340 to 390 psi 23 5 to 27 bar This will cause the flow compensator spool to move down to allow some oil to f...

Страница 797: ...r 2 35 2 40 RH02B012 5 CONTROL PISTON 8 PUMP HOUSING 11 PISTON BLOCK LOADING SPRING 18 COMPENSATOR ASSEMBLY 6 CONTROL SPRING 9 SWASH PLATE 12 PISTON BLOCK 20 CONTROL PISTON ROD 7 DRIVE SET 10 PISTON 13 BACK PLATE 5 6 7 8 9 10 11 12 13 18 20 ...

Страница 798: ... its spring The movement of the spool allows the full pump delivery pressure to be applied to the pump control piston to destroke the pump very rapidly from full stroke to almost zero Within 8 to 10 milliseconds The swash plate will stabilize in a position to provide just sufficient flow to make up internal leakage to maintain the maximum pressure limit of 3250 psi 224 bar in the hydraulic system ...

Страница 799: ...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 NOTE The high pressure limiting spool is adjustable and can be removed for inspection RH02B012 5 CONTROL PISTON 8 PUMP HOUSING 11 PISTON BLOCK LOADING SPRING 18 COMPENSATOR ASSEMBLY 6 CONTROL SPRING 9 SWASH PLATE 12 PIS...

Страница 800: ...TLET 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 HIGH PRESSURE SPRING 1 4 3 2 15 16 17 18 19 21 ...

Страница 801: ...ssion control lever out of park 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 Place the number one remote valve control lever into the extend position RI06A085 HIGH PRESSURE STANDBY ADJUSTMENT High Pressure Standby Specification 3250 PSI 224 bar Remove the cap from the high pressure adjustment Loosen the lock...

Страница 802: ...oad valve on the flowmeter to 1500 PSI 103 bar and heat the transmission oil to a minimum of 120 F 49 C RD98E117 Increase engine speed to 2000 RPM Individually flow rate each remote valve section Adjust the load valve on the flowmeter to 1000 PSI 69 bar Full Flow Specification for Standard Flow Pump 34 3 GPM 130 L min Full Flow Specification for Optional High Flow Pump 34 3 GPM 130 L min Full Flow...

Страница 803: ...etting may be checked too Use the gauge connection 3 on the right side of manifold for MegaFlow Use remote section No 3 for checking MegaFlow system RD02D162 RD02D152R NOTE Use 3 4 inch hose with a minimum working pressure of 3000 PSI 206 bar for this test Install the CAS 10280 Flowmeter into the No 1 remote section Set all the remote valve variable flow controls to the maximum flow position Set t...

Страница 804: ...lf the maximum flow rate Adjust flow to approximately 18 GPM for standard flow pump Adjust flow to approximately 26 GPM for high flow pump At one half flow rate and a 1000 PSI 69 bar pressure reading at the remote manifold the compensator pressure gauge should read 1365 PSI 94 bar Adjust the load sense spool as necessary to attain the 365 PSI 25 bar differential pressure The load sense spool is th...

Страница 805: ...nt screw ____________ Remove low pressure cap Measure and record the distance from the lock nut to the end of the low pressure adjustment screw ____________ Check for broken springs Remove high pressure spool Make sure it moves freely within the bore Remove low pressure spool Make sure it moves freely within the bore Clean cored passages in the compensator valve Assemble compensator valve Set high...

Страница 806: ...nual POOR HYDRAULIC PERFORMANCE LOW FLOW TO HITCH AND ALL BUT ONE REMOTE VALVE CIRCUIT A Bad signal check in the one working remote section POOR HYDRAULIC PERFORMANCE HITCH OPERATING OKAY BUT LOW FLOW FROM ALL REMOTE CIRCUITS A Check for remote system fault codes If there are fault codes continue with fault code troubleshooting If there no fault codes check hitch valve signal check for leakage POO...

Страница 807: ...Section 35 Hydraulic Systems 3PT Chapter 2 35 2 50 This Page Left Blank ...

Страница 808: ...Section 35 Chapter 3 January 2006 PTO AND DIFFERENTIAL LOCK VALVE ...

Страница 809: ...m 4 to 6 lb ft Plug 34 to 54 Nm 25 to 40 lb ft Solenoid Cartridge 12 to 18 Nm 9 to 13 lb ft Valve Mounting Bolts 41 to 46 Nm 30 to 34 lb ft SPECIFICATIONS Modulation Spring smaller Free Length 39 17 mm 1 542 inch Compress to 2 70 mm 1 063 inch 122 9 to 159 2 N 27 6 to 33 8 lb Preload Spring larger Free Length 39 17 mm 1 542 inch Compress to 47 52 mm 1 871 inch 96 07 to 117 43 N 21 6 to 26 4 lb ...

Страница 810: ...ck the PTO controller for fault codes See the PTO Sections in this Service Manual for procedure and corrective action if a fault exists Depending on which system is not functioning correctly see Power Take Off Control System How It Works or Differential Lock Control System How It Works STEP 2 If other regulated pressure functions such as braking or transmission control are not operating properly C...

Страница 811: ...ipped it may be necessary to remove hydraulic tubes that run across the top of the valve in order to remove the valve 1 Disconnect the tube from the valve inlet 1 2 Disconnect the tubes from the lube inlet 2 3 Disconnect the wire harness from the PTO PWM solenoid 3 4 Disconnect the wire harness from the diff lock solenoid 4 5 Remove the two mounting bolts 5 and remove the valve from the mounting p...

Страница 812: ...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 STEP 7 RD02E114 Remove the PTO solenoid coil and two O rings and the diff lock solenoid from the valve STEP 8 RD02E115 Remove the solenoid cartridges from the valve and disc...

Страница 813: ...ings 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 ...

Страница 814: ...artridges with clean hydraulic fluid during assembly RI98G167 1 2 3 3 3 5 6 7 10 9 8 11 12 3 1 DIFF LOCK SOLENOID 5 MODULATOR SPOOL 9 MODULATION SPRING 2 CARTRIDGE 6 STEEL BALL 10 PRELOAD SPRING 3 O RING 7 MODULATOR PISTON PIN 11 MODULATION PISTON 4 PTO SOLENOID 8 RETAINER SLEEVE 12 BODY ...

Страница 815: ... no O rings on the diff lock solenoid STEP 12 RI02E060 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 Push on the retaining sleeve 3 and compress the modulation spring 2 a small amount Install the end of the modulator piston pin into the modulator spool ...

Страница 816: ... 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 2 Connect the wire harness connectors to the diff lock solenoid 4 and PTO solenoid 3 3 Connect and tighten the tube to the lube inlet fitting 2 4 Connect and tighten the tube to the valve inlet fitting 1 5 4 3 2 1 1 INLET 4 DIFF LOCK SOLENOID 2 LUB INLET 5 MOUNTING BOLT 3 PTO PWM SOLEN...

Страница 817: ...10 PTO And Diff Lock Valve Cross Section RT98A024 1 2 3 9 4 7 10 2 8 6 5 1 DIFF LOCK SOLENOID 6 MODULATOR PISTON PIN 2 CARTRIDGE 7 RETAINER SLEEVE 3 PTO SOLENOID 8 MODULATION SPRING 4 MODULATOR SPOOL 9 PRELOAD SPRING 5 STEEL BALL 10 MODULATION PISTON ...

Страница 818: ...Section 35 Chapter 4 January 2006 REMOTE VALVE AND COUPLER SERVICE ...

Страница 819: ...IAL TORQUES Valve Section Mounting Bolts M12 x 100mm 40 to 45 Nm 30 to 33 lb ft M10 x 110mm 25 to 30 Nm 18 to 22 lb ft Solenoid Block Retaining Screws 10 to 13 Nm 7 to 10 lb ft Load Check Valve Cap 30 to 41 Nm 22 to 30 lb ft Main Valve Spool Plug 14 to 16 Nm 10 to 12 lb ft Pressure Compensating Spool Plug 5 8 50 to 58 Nm 37 to 43 lb ft Pressure Compensating Spool Plug 3 8 33 to 35 Nm 24 to 26 lb f...

Страница 820: ...ir or replacement is necessary follow the procedures in this section STEP 2 RI02D103 The remote valves are located at the rear of the tractor Remove the rear cover to access the valves Thoroughly clean the remote valves and surrounding area before performing any service work STEP 3 RI02D103 Use a 1 inch wrench to slowly loosen the load check cap to relieve any trapped pressure STEP 4 RD98E128 Remo...

Страница 821: ... 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 Assemble the load check STEP 7 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 2 5 3 1 5 4 ...

Страница 822: ... the valves Thoroughly clean the remote valves and surrounding area before performing any service work If remote valve sections 1 or 2 are to be serviced the hitch valve 6 must be removed first See the Hitch Valve Section in this Service Manual for hitch valve removal procedure NOTE For better valve access the rear wheels can be moved out on the axles STEP 10 RI02E042 NOTE This procedure will depi...

Страница 823: ...r 4 35 4 6 STEP 12 RI02E044 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 1 1 ...

Страница 824: ...blocks and springs from each end of the valve section Note which side of the valve that the springs are from Inspect for damage STEP 15 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 STEP 16 RD02D057 Remove the pressure compensati...

Страница 825: ...rom the bore Check for wear or damage The plunger must move freely within the bore STEP 18 RD98K201 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 1 3 5 2 5 4 ...

Страница 826: ...install the cap 4 STEP 20 RD02E057 Install the plunger in the load check Install the load check assembly into the valve body and tighten the cap to a torque of 30 to 41 Nm 22 to 30 lb ft STEP 21 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 STEP 22 RD02D056 Install a washer on each ...

Страница 827: ...24 RD02E093 Tighten the retaining screws to a torque of 10 to 13 Nm 7 to 10 lb in STEP 25 RD02D054 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 STEP 26 RD02E058 Apply petroleum jelly to new O rings 1 and install them onto the valve ports Apply petroleum jelly to the two sign...

Страница 828: ...0 Nm 18 to 22 lb ft Tighten the M12 bolts to a torque of 40 to 45 Nm 30 to 33 lb ft NOTE Be sure that the two signal check springs do not fall from the ports when assembling the valve sections STEP 28 RI02E043 Install the raise and lower hydraulic tubes for the 4th and 5th remote valve sections STEP 29 RI02E042 Connect the wiring harness to the solenoids 1 Install the seven pin connector mounting ...

Страница 829: ...e Cross Section RI02B027 5 4 8 7 6 10 3 1 9 2 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 SIGNAL CHECK SPRINGS BACK SIDE OF VALVE ...

Страница 830: ...he coupler body 7 4 Remove the slipper seals 8 and O rings seals 9 Install new O rings and slipper seals Be sure the slipper seal is in front of the O ring 5 Remove the O ring 10 from the end of the coupler cartridge Install a new O ring 6 Assemble the coupler in reverse order 1 COVER AND GASKET ON EXPLODED VIEW 6 CARTRIDGE 2 SPRING RETAINER 7 BODY 3 COIL SPRING 8 SLIPPER SEAL 4 SNAP RING 9 O RING...

Страница 831: ...5 Hydraulic Systems 3PT Chapter 4 35 4 14 Exploded View RI02E028 9 8 7 6 4 2 1 3 5 10 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 O RING ...

Страница 832: ...Section 35 Chapter 5 January 2006 REMOTE HYDRAULIC SYSTEM How It Works and Troubleshooting ...

Страница 833: ...5 5 23 REMOTE VALVE PROPORTIONAL CURRENT CONTROL PCC SOLENOID OPERATION 35 5 25 REMOTE VALVE SYSTEM TESTING 35 5 26 REMOTE VALVE HIGH PRESSURE TEST 35 5 27 PFC PUMP HIGH PRESSURE STANDBY CHECK AND ADJUSTMENT PROCEDURE 35 5 28 PFC PISTON PUMP FLOW TEST 35 5 29 STANDARD PUMP COMPENSATOR VALVE INSPECTION 35 5 30 REMOTE VALVE SIGNAL CHECK AND HITCH SIGNAL CHECK 35 5 31 REMOTE VALVE COUPLER TEST 35 5 3...

Страница 834: ...NTROLS REMOTE CONTROLS ARM REST CONTROLLER HYDRAULIC VALVE TIMER STANDARD INSTRUMENTATION R E M O 1 T E AUX PTO HITCH CONTROLLER TMF REG SUPPLY PFC TO HITCH DATA BUS DATA BUS R E M O 2 T E R E M O 3 T E R E M O 4 T E R E M O 5 T E PCS PCS PCS PCS PCS PCS PCS PCS PCS PCS PCS PROPORTIONAL CURRENT SOLENOID ...

Страница 835: ...ectly to the instrument controller The instrument controller will display any system faults or fault code information through the standard instrumentation display When a fault occurs a 3 second continuous audible alarm will sound The audible alarm will stop after 3 seconds Once the fault has been corrected the fault codes should be erased To erase the fault codes from a controller press and hold b...

Страница 836: ...STEM COMPONENTS RD02D042 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 1 REMOTE COUPLERS 1 1 ...

Страница 837: ...Chapter 5 35 5 6 RI06A062 RI02J006 1 2 3 4 6 8 1 PROPORTIONAL CURRENT CONTROL SOLENOIDS 5 REMOTE MANIFOLD ASSEMBLY 2 HIGH PRESSURE ACCUMULATOR 6 SIGNAL LINE 3 MANIFOLD SUPPLY INLET 7 HITCH VALVE 4 MANIFOLD RETURN TUBE 8 LOAD CHECKS 5 7 ...

Страница 838: ...EMOTE MANIFOLD BASE BOTTOM VIEW 3 REMOTE SECTION NO 3 12 MARKER DRAIN 4 REMOTE SECTION NO 4 13 REGULATED SUPPLY PRESSED IN SCREEN PLUG 5 REMOTE SECTION NO 5 14 PILOT DRAIN 6 HITCH VALVE 15 LOAD SENSE PORT 7 LOAD CHECKS 16 RETURN PORT 8 INLET 17 REMOTE MANIFOLD 9 INTERNAL CHECK VALVE 36 PSI 2 5 BAR 18 POWER BEYOND PORT 3 11 1 2 6 4 5 7 8 9 10 12 13 14 15 16 17 7 18 8 ...

Страница 839: ... condition 1 2 3 4 5 6 7 10 12 10 8 9 3 2 11 12 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 12 POWER BEYOND ASSEMBLY MANIFOLD ...

Страница 840: ...Section 35 Hydraulic Systems 3PT Chapter 5 35 5 9 RD05M054 REAR VIEW CONTROLLERS 1 AUX PTO HITCH TMF 2 TRANSMISSION FRONT AXLE 1 2 ...

Страница 841: ...he No 1 remote lever forward will direct remote flow to the retract port of the hydraulic coupler 1A Pulling the remote lever rearward will direct remote flow to the extend port of the hydraulic coupler 1B RD05J060 Item 5 is the optional 5th remote switch RD02D042 All the retract A ports are on the outside All the extend B ports are to the inside Remote Valve Control Lever Positions Remote Valve F...

Страница 842: ...ol levers can be locked in the neutral position This prevents a remote lever from being accidentally operated during transport This can be done by moving the remote control lever to the neutral position and rotating the remote function control to the right lock position NOTE This must be done for each remote control lever that you intend to be locked out No Float Position RH97J002 Remote Valve Fun...

Страница 843: ...low control to regulate the hydraulic motor speed To stop driving the hydraulic motor move the remote control lever back up to the float position This will allow the hydraulic motor to slowly come to a stop IMPORTANT Do not rotate the remote function control from the hydraulic motor position during motor applications as it can cause the hydraulic motor to stop immediately This will cause damage to...

Страница 844: ...timer bars around the timer control When the timer control is turned fully clockwise to the 10th bar the detents will not time out and will remain in detent RD05J093 Variable Flow Control Each circuit of the five remote hydraulic system has a variable flow control Use the variable flow control to increase or decrease the rate of flow of hydraulic fluid to the remote hydraulic couplers The flow can...

Страница 845: ... prevent the settling of a load in neutral because of control spool leakage It also serves as a check valve to prevent a drop in a partially raised cylinder when the remote valve is operated 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 The plunger then contacts the main poppet moving it to...

Страница 846: ...e of the flow control spool tries to close flow down Once the intermediate pressure is high enough to overcome the flow control spring force the flow control spool blocks the flow path to the main valve spool In neutral the intermediate pressure is blocked from the work ports by the main valve spool lands A load check valve is installed into the extend port which will prevent the settling of a loa...

Страница 847: ...MBLY 7 EXTEND 2 MAIN VALVE SPOOL 8 PROPORTIONAL SOLENOID VALVE ASSEMBLY 3 RETRACT PORT 9 FLOW CONTROL SPRING 4 LOAD CHECK PLUNGER 10 PFC PUMP SUPPLY 5 EXTEND PORT 11 PRESSURE COMPENSATED FLOW CONTROL SPOOL 6 LOAD CHECK 12 RETRACT 1 2 3 4 5 6 7 8 9 10 11 12 PFC PUMP SUPPLY PRESSURE INTERMEDIATE PRESSURE WORKING PRESSURE RETURN PRESSURE ...

Страница 848: ...e drop is maintained through a balance of intermediate pressure on the left hand side of the pressure compensated flow control spool and work pressure plus the spring force on the right hand side of the spool At the same time the main valve spool first shifts work pressure is also directed to the signal checks The work port pressure can open the signal check valve and signal the pump compensator t...

Страница 849: ...Y 7 EXTEND 2 MAIN VALVE SPOOL 8 PROPORTIONAL SOLENOID VALVE ASSEMBLY 3 RETRACT PORT 9 FLOW CONTROL SPRING 4 LOAD CHECK PLUNGER 10 PFC PUMP SUPPLY 5 EXTEND PORT 11 PRESSURE COMPENSATED FLOW CONTROL SPOOL 6 LOAD CHECK 12 RETRACT 1 2 3 4 5 6 7 8 9 10 11 12 PFC PUMP SUPPLY PRESSURE INTERMEDIATE PRESSURE WORK PRESSURE RETURN TO FILTER INLET PRESSURE ...

Страница 850: ...f the filter base Differential pressure between the raise port and the spring side of the main poppet also contribute to unseating the main poppet At the same time work pressure is communicated to the signal checks through the center drilled passage in the main valve spool The signal check is forced off the seat and the signal pressure is then directed to the pump compensator to increase PFC pump ...

Страница 851: ...LY 7 EXTEND 2 MAIN VALVE SPOOL 8 PROPORTIONAL SOLENOID VALVE ASSEMBLY 3 RETRACT PORT 9 FLOW CONTROL SPRING 4 LOAD CHECK PLUNGER 10 PFC PUMP SUPPLY 5 EXTEND PORT 11 PRESSURE COMPENSATED FLOW CONTROL SPOOL 6 LOAD CHECK 12 RETRACT 1 2 3 4 5 6 7 8 9 10 11 12 PFC PUMP SUPPLY PRESSURE INTERMEDIATE PRESSURE WORK PRESSURE RETURN TO FILTER INLET PRESSURE ...

Страница 852: ...The plunger moves to the right unseating the load check main poppet When the extend and retract work ports are connected to the return to filter inlet it allows the implement to float and follow the contour of the ground The valve will now float a double acting or single acting cylinder RI02F018 1 EXTEND PORT 9 REGULATED PRESSURE SUPPLY 2 RETRACT PORT 10 BACK TO TANK 3 LOAD CHECK PLUNGER 11 SIGNAL...

Страница 853: ...ND 2 MAIN VALVE SPOOL 8 PROPORTIONAL SOLENOID VALVE ASSEMBLY 3 RETRACT PORT 9 FLOW CONTROL SPRING 4 LOAD CHECK PLUNGER 10 PFC PUMP SUPPLY 5 EXTEND PORT 11 PRESSURE COMPENSATED FLOW CONTROL SPOOL 6 LOAD CHECK 12 RETRACT 1 2 3 4 5 6 7 8 9 10 11 12 PFC PUMP SUPPLY PRESSURE INTERMEDIATE PRESSURE WORK PRESSURE RETURN TO FILTER INLET PRESSURE ...

Страница 854: ...will be greatly reduced and erratic Set the flow control pot to the maximum setting at 2000 engine RPM and a 500 PSI load If approximately 33 GPM 125 L min is not reached the flow control spring could be broken Note this assumes that the maximum 33 GPM 125 L min can be achieved on another remote section 1 PROPORTIONAL SOLENOID VALVE ASSEMBLY 8 EXTEND 2 MAIN VALVE SPOOL 9 PROPORTIONAL SOLENOID VALV...

Страница 855: ... 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 ...

Страница 856: ...spool stops and maintains that position 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 The increased pressure moves the spool further to the left until the spring force once...

Страница 857: ...plers MECHANICAL CONNECTIONS Couplers male and female and control spools Talk to the owner operator about the problem Gather as much information about what should be happening versus what is happening Note as many symptoms as possible Next operate the system and attempt to duplicate the problem If the problem is not repeatable it could be user error or an intermittent problem If the problem cannot...

Страница 858: ...ler problem Test the other valve port to eliminate the coupler as a cause Perform Remote Valve Flow Test If the tractor PFC pump goes to high pressure standby based on engine sound when the tractor is started and the remote control levers are in neutral check the following Hitch is fully raised and not turning off see TMF Controller calibration and Fault codes Remote valve is partially engaged a m...

Страница 859: ...t the transmission control lever out of park Test Procedure 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 Place the number one remote valve control lever into the extend position High Pressure Standby Specification 3250 PSI 224 bar Remove the cap from the high pressure adjustment Loosen the lock nut and use t...

Страница 860: ...0 PSI 206 bar for this flow test Install the CAS 10280 Flowmeter into the No 1 remote section Place the remote valve control lever into the detent retract position Adjust the load valve on the flowmeter to 1500 PSI 103 bar and heat the transmission oil to a minimum of 120 degrees F 49 degrees C Increase engine speed to 2000 RPM Individually flow rate each remote valve section Adjust the load valve...

Страница 861: ...Remove low pressure cap Measure and record the distance from the lock nut to the end of the low pressure adjustment screw ____________ Check for broken springs Remove high pressure spool Make sure it moves freely within the bore Remove low pressure spool Make sure it moves freely within the bore Clean cored passages in the compensator valve Assemble compensator valve Set high and low pressure adju...

Страница 862: ...ther circuits REMOTE SIGNAL CHECK LEAKING All remaining remote circuits and hitch are operating at reduced flow The leaking remote section operates normally HITCH SIGNAL CHECK LEAKING All remotes operating at reduced flow Hitch operates normally RI02F021 REMOTE VALVE SIGNAL CHECKS RD06A065 HITCH VALVE SIGNAL CHECK INTERNAL 1 2 4 3 1 SIGNAL CHECK TO PUMP COMPENSATOR 3 SIGNAL CHECK POPPET AND SPRING...

Страница 863: ...ut the problem Find out what type of male coupler tip is being used 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 Check to make sure the implement supply and return hoses are properly supported to prevent unnecessary loading of the female coupler cartridge Clean the coupler Remove all dirt from i...

Страница 864: ...ck is used in applications where a remote hydraulic cylinder must be hydraulically locked in position with a minimal amount of leak down RI06A064 Lower suspended raised implements Clean the load check area Slowly loosen the load check and relieve any trapped pressure Use a needle nose pliers to retrieve the plunger Inspect seals and check for damage See Remote Valve Service Manual Section 1 1 LOAD...

Страница 865: ...improper usage C There is extreme pressure within the cylinder hose bleed hose to reduce pressure LOW REMOTE VALVE FLOW THROUGH THE COUPLER A Find out what type of male coupler tip is being used B Check the male tip 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 C Perform remote valve coupler test to check for internal ...

Страница 866: ...Section 35 Chapter 6 January 2006 PRIORITY AND REGULATOR VALVE ...

Страница 867: ...ems 3PT Chapter 6 35 6 2 TABLE OF CONTENTS SPECIAL TORQUES 35 6 3 PRIORITY VALVE AND REGULATOR 35 6 4 Removal 35 6 4 Disassembly 35 6 6 Assembly 35 6 9 Installation 35 6 12 CROSS SECTION OF PRIORITY AND REGULATOR VALVE 35 6 14 ...

Страница 868: ...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 Regulator Spool Lock Nut 41 to 48 Nm 30 to 35 lb ft Pilot Relief Valve Assembly 75 to 108 Nm 55 to 80 lb ft ...

Страница 869: ...n Section in this Repair Manual for the cab raising procedure NOTE The steering sensing line 7 runs toward the rear of the tractor if equipped with trailer brakes STEP 2 RD02D088 Remove the steering supply line 1 Remove the brake valve supply line 2 STEP 3 RD02D104 Remove the PFC pump supply hose to the priority valve 1 1 REMOTE HYDRAULIC MANIFOLD SUPPLY LINE 5 SIGNAL LINE TO REMOTE VALVE 2 PTO SU...

Страница 870: ...T Chapter 6 35 6 5 STEP 4 RD02D089 Remove the three priority valve mounting bolts 1 STEP 5 RD02D093 Remove the priority valve from the top of the transmission Remove the O ring 1 in the top of the transmission housing and discard 1 1 ...

Страница 871: ...scard the O rings STEP 7 RD02D108 Unscrew the PFC pump signal orifice and screen plug STEP 8 RD02D110 Remove the plug Inspect the screen and clean as needed STEP 9 RD02D112 Unscrew the logic check valve plug STEP 10 RD02D114 Remove the logic check valve plug and discard the O ring and backup ring Inspect the spring and valve for damage or wear ...

Страница 872: ... pilot relief valve assembly to the body of the valve before removing the lock nut Remove the pilot relief valve lock nut STEP 13 RD02D120 Remove the pilot relief valve assembly STEP 14 RD02D124 Remove and discard the O rings 1 and the backup ring 2 from the pilot relief valve orifice fitting STEP 15 RD02D126 Unscrew the pilot relief valve adjuster from the orifice fitting and discard the O ring 1...

Страница 873: ...gulator spool to the body of the valve before removing the lock nut Remove the lock nut from the regulator spool adjusting plug STEP 17 RD02D130 Unscrew the regulator spool adjusting plug STEP 18 RD02D134 Remove and discard the O ring from the adjusting plug Remove the spring and the regulator spool Inspect for damage or wear ...

Страница 874: ...ements made during the disassembly procedure to install the regulator spool adjusting plug Install the regulator spool adjusting plug 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 STEP 22 RD02D126 Lubricate and install a new O ring 1 on the pilot relief valve adjuster Lubricate the needle valve and the spring Install the needle valv...

Страница 875: ...seated in the priority valve Tighten the pilot relief valve assembly to a torque of 75 to 108 Nm 55 to 80 lb ft NOTE Use the measurements made during the disassembly procedure to install the pilot relief valve assembly STEP 25 RD02D119 Install the pilot relief valve lock nut STEP 26 RD02D117 Lubricate the priority valve spool and the spring Install the spool and the spring into the valve assembly ...

Страница 876: ...ore the O ring STEP 28 RD02D112 Install the logic check valve plug Tighten the plug to a torque of 16 to 19 Nm 12 to 14 lb ft STEP 29 RD02D110 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 RD02D108 Tighten the plug to a torque of 14 to 21 Nm 10 to 15 lb ft STEP 31 RD02D106 Lubricate and inst...

Страница 877: ...he transmission housing Place the priority valve on the top of the transmission STEP 33 RD02D089 Install the three priority valve mounting bolts 1 STEP 34 RD02D104 Install the PFC pump supply hose to the priority valve 1 STEP 35 RD02D088 Install the steering supply line 1 Install the brake valve supply line 2 1 1 1 1 2 ...

Страница 878: ...el and add fluid as necessary The steering priority valve and regulator must be adjusted after disassembly Refer to the Hydraulic System How It Works and Troubleshooting Section of this Repair Manual for the adjustment procedure 1 CHARGE PUMP TO PRIORITY VALVE HOSE 5 OIL COOLER SUPPLY LINE 2 STEERING SENSING LINE 6 REGULATED SUPPLY LINE 3 PFC COMPENSATOR SIGNAL LINE 7 PTO SUPPLY LINE 4 SIGNAL LINE...

Страница 879: ...02E009 2 3 4 8 1 5 9 7 6 10 11 12 9 1 PRIORITY AND REGULATOR VALVE 5 PRIORITY VALVE SPOOL 9 LOCKING NUT 2 LOGIC CHECK VALVE ASSEMBLY 6 PLUG 10 ADJUSTING PLUG 3 ORFICE AND SCREEN PLUG 7 REGULATOR SPOOL 11 PILOT RELIEF VALVE ASSEMBLY 4 REGULATOR SPRING 8 STEERING SPRING 12 ORFICE FITTING BODY ASSEMBLY ...

Страница 880: ...Section 35 Chapter 7 January 2006 CHARGE PUMP ...

Страница 881: ...Section 35 Hydraulic Systems 3PT Chapter 7 35 7 2 TABLE OF CONTENTS CHARGE PUMP 35 7 3 Removal 35 7 3 Installation 35 7 4 ...

Страница 882: ...sen the six rear wheel bushing bolts and move the wheel outward on the axle STEP 2 RD02D006 Remove the cover plate and two bolts from the charge pump flange Remove the O ring 1 from the flange Remove the two suction hose flange bolts 2 from the suction screen housing on the transmission STEP 3 RD02D009 Remove the charge pump outlet hose 1 to the filter head Remove the outlet line to the priority v...

Страница 883: ...will be necessary to loosen the hose clamps on the rubber charge pump suction hose and pry up on the hose to provide needed clearance for the suction flange O ring Install the two suction hose flange bolts 1 and tighten the hose clamps Install a new O ring 2 on the charge pump flange Install the cover plate and bolts STEP 6 Move the rear wheel inward on the axle Apply antiseize to the bushing bolt...

Страница 884: ...Section 35 Chapter 8 January 2006 PFC PISTON PUMP ...

Страница 885: ...Section 35 Hydraulic Systems 3PT Chapter 8 35 8 2 TABLE OF CONTENTS SPECIAL TORQUES 35 8 3 PFC PISTON PUMP 35 8 3 Removal 35 8 3 Installation 35 8 4 ...

Страница 886: ...ccess to the piston pump NOTE Right hand fuel tank removed for photographic purposes STEP 2 RD06A136 Disconnect the connector from the lube oil pressure sensor 1 Tag and remove ALL hydraulic lines from the filter head Remove the PFC pump compensator signal line 2 STEP 3 RD02D018 Remove the four bolts 1 that attach the filter head to the piston pump Remove and discard the filter head to piston pump...

Страница 887: ...ll hydraulic lines Install and tighten all filter head hydraulic lines Install the pressure sensor connector and nut 1 do not over tighten the nut Install the compensator signal line 2 STEP 8 RD02D002 Prior to start up ensure the piston pump is filled with oil by removing the plug from the side of the pump housing pump drain port and filling the pump with 2 Liters 2 1 U S Quarts of hydraulic fluid...

Страница 888: ...Section 35 Chapter 9 January 2006 HITCH SYSTEM How it Works ...

Страница 889: ...ulic Systems 3PT Chapter 9 35 9 2 TABLE OF CONTENTS THREE POINT HITCH 35 9 3 ELECTRONIC HITCH CONTROL 35 9 4 ELECTRONIC HITCH CONTROL SYSTEM FEATURES 35 9 7 HITCH CONTROL VALVE 35 9 14 SETUP ADJUSTMENT SEQUENCE 35 9 22 ...

Страница 890: ...ied from the hitch control valve The hitch control valve is mounted on the left hand side of remote valve stack rear top of the transmission The electro hydraulic control valve is supplied from the Pressure Flow Compensating PFC hydraulic system and the regulated system The regulated supply is used to operate the valve and the PFC supply provides the high pressure flow to extend the cylinders and ...

Страница 891: ... signals Wheel speed and optional True Ground speed signals are sent to the Instrument Cluster Unit ICU then relayed to the Hitch Controller Diagnostic and programming information are communicated between the EHC controller and the Instrument Cluster Unit ICU by way of the Data Bus OPERATING MODES The EHC system operates in three modes based on operator commands and measurement signals from the hi...

Страница 892: ... Select Switch Diff Lock Switch FWD Switch Brake Switches Remote Up Down Switches Wheel Speed True Ground Speed Instrumentation Cluster Controller Slip Value Diagnostics Data Bus Rockshaft Position Sensor Left Draft Sensor Right Draft Sensor PFC Signal PFC Pressure Hitch Cylinders Regulated Pressure Hitch Control Valve Aux PTO Hitch Controller TMF Arm Rest Controller PTO Controller RI06A039A ...

Страница 893: ...if this is below the position command LOAD CONTROL In the Load Control Mode the EHC maintains a constant draft load on the tractor s three point hitch in changing soil conditions When an increase in load is sensed by the lower link draft pins the EHC will raise the hitch until the load matches the load set by the operator with the Load Control With a decrease in load the EHC will lower the hitch t...

Страница 894: ... Control When the switch is put in the DOWN position the hitch will lower to the limit set by the Position Control Lever at the speed set by the Drop Speed Control When the switch is pushed into the MOMENTARY position and released pushed again and held within 2 seconds the hitch will lower to the lowest possible position at maximum speed bypassing the Drop Rate Speed setting and position control l...

Страница 895: ... ELECTRONIC HITCH CONTROL RD05J154 RD05J116 1 HITCH POSITION CONTROL KNOB 5 UPPER LIMIT CONTROL 2 LOWER LIMIT STOP RING 6 DROP SPEED TRANSPORT LOCK 3 UP DOWN SWITCH 7 TRAVEL CONTROL KNOB 4 HITCH LOAD CONTROL 8 SLIP LIMIT CONTROL SWITCH 3 2 4 6 1 8 5 7 ...

Страница 896: ... faster speed would be used for plows and rippers Turning the knob fully counterclockwise to the detent will prevent the hitch from lowering during roading REMOTE UP DOWN SWITCHES The REMOTE UP DOWN SWITCHES are located on the tractor rear fenders The switches are used to operate the hitch momentarily from outside the cab to make small slow movements to the hitch to aid in attaching implements to ...

Страница 897: ...NIC HITCH CONTROL SYSTEM FEATURES RD05J154 RD05J116 1 HITCH POSITION CONTROL KNOB 5 UPPER LIMIT CONTROL 2 LOWER LIMIT STOP RING 6 DROP SPEED TRANSPORT LOCK 3 UP DOWN SWITCH 7 TRAVEL CONTROL KNOB 4 HITCH LOAD CONTROL 8 SLIP LIMIT CONTROL SWITCH 3 2 4 6 1 8 5 7 ...

Страница 898: ...Control Mode If no limit has been set the system will default to 30 3 SET Momentary This position is used to set the slip limit To set the SLIP LIMIT the tractor must be properly ballasted for the load being pulled and moving over 2 MPH with the hitch set for the desired implement load or position Move the Slip Limit Control Switch to the ON middle position then press the SET momentary and release...

Страница 899: ...ATURES RD05J154 MT04M013 RD05J116 1 HITCH POSITION CONTROL KNOB 6 DROP SPEED TRANSPORT LOCK 2 LOWER LIMIT STOP RING 7 TRAVEL CONTROL KNOB 3 UP DOWN SWITCH 8 SLIP LIMIT CONTROL SWITCH 4 HITCH LOAD CONTROL 9 DIFFERENTIAL LOCK SWITCH 5 UPPER LIMIT CONTROL 10 FWD SWITCH 3 2 4 6 1 8 5 7 10 9 ...

Страница 900: ...itions 1 ON FWD symbol 2 AUTOMATIC A 3 OFF O ISO Symbol AUTOMATIC MODE FUNCTION When the FWD and Diff Lock are in the automatic mode and the hitch is raised to the upper third of travel they will disengage and reengage when the hitch is lowered below the upper third of travel The automatic mode of operation of the FWD also provides these additional features The FWD will disengage when A Travel spe...

Страница 901: ...FC pump Regulated pressure from the raise pilot spool 3 will move the spool against spring force which will open the PFC pump port and expose PFC pump pressure to the load check ball 10 and the signal port Lower Poppet The lower poppet 9 lower pilot poppet 8 and spring 15 trap oil in the hitch cylinder circuit The lower pilot poppet 8 is held on its seat by a spring 15 and cylinder circuit pressur...

Страница 902: ...SOLENOID 11 PFC PUMP SUPPLY 3 RAISE PILOT SPOOL 12 REGULATED PRESSURE SUPPLY 4 LOWER PILOT SPOOL 13 RETURN PORT 5 RAISE SPOOL 14 CONTROL PIN 6 OVERLOAD RELIEF 15 SPRING 7 LOWER CONTROL PISTON 16 ORIFICE 8 LOWER PILOT POPPET 17 TANK PORT 9 LOWER POPPET 18 RAISE LOWER PORT 2 3 4 5 6 7 8 9 10 11 12 12 13 13 14 15 16 14 1 17 18 ...

Страница 903: ... of the poppet TROUBLESHOOTING Problem Hitch will not hold position or leaks down 1 Check the function of other systems Transmission Remote Valves etc A If the other systems do not function properly refer to troubleshooting of the non functioning system B If other systems function properly go to Step 2 2 Check for HITCH fault codes A If fault codes are found follow procedures outlined in HITCH fau...

Страница 904: ...WER SOLENOID 11 PFC PUMP SUPPLY 3 RAISE PILOT SPOOL 12 REGULATED PRESSURE SUPPLY 4 LOWER PILOT SPOOL 13 RETURN PORT 5 RAISE SPOOL 14 CONTROL PIN 6 OVERLOAD RELIEF 15 SPRING 7 LOWER CONTROL PISTON 16 ORIFICE 8 LOWER PILOT POPPET 17 TANK PORT 9 LOWER POPPET 18 RAISE LOWER PORT 2 3 4 5 6 7 8 9 10 11 12 12 13 13 14 15 16 14 1 17 18 ...

Страница 905: ...e controller shuts off current to the raise solenoid 1 Regulated pressure acting on the right hand end of the raise pilot spool will shift the pilot spool outward shutting off regulated pressure supply 12 and opening the return port 13 to release the pressure on the raise spool The spring will shift the raise spool 5 shutting off the PFC inlet port The pressure in the hitch cylinders will seat the...

Страница 906: ...HECK BALL 2 LOWER SOLENOID 11 PFC PUMP SUPPLY 3 RAISE PILOT SPOOL 12 REGULATED PRESSURE SUPPLY 4 LOWER PILOT SPOOL 13 RETURN PORT 5 RAISE SPOOL 14 CONTROL PIN 6 OVERLOAD RELIEF 15 SPRING 7 LOWER CONTROL PISTON 16 ORIFICE 8 LOWER PILOT POPPET 17 TANK PORT 9 LOWER POPPET 18 RAISE LOWER PORT 2 3 4 5 6 7 8 9 10 11 12 12 13 13 14 15 16 14 1 17 18 ...

Страница 907: ...f the lower pilot spool 4 moves the spool outward closing the regulated pressure supply 12 to the lower control piston 7 As the pressure drops on the piston the pilot poppet 8 returns to its seat by spring force With the pilot poppet port closed pressure from the hitch cylinders builds behind the lower poppet 9 through the orifice 16 forcing the poppet onto its seat trapping oil in the hitch cylin...

Страница 908: ...HECK BALL 2 LOWER SOLENOID 11 PFC PUMP SUPPLY 3 RAISE PILOT SPOOL 12 REGULATED PRESSURE SUPPLY 4 LOWER PILOT SPOOL 13 RETURN PORT 5 RAISE SPOOL 14 CONTROL PIN 6 OVERLOAD RELIEF 15 SPRING 7 LOWER CONTROL PISTON 16 ORIFICE 8 LOWER PILOT POPPET 17 TANK PORT 9 LOWER POPPET 18 RAISE LOWER PORT 2 3 4 5 6 7 8 9 10 11 12 12 13 13 14 15 16 14 1 17 18 ...

Страница 909: ...N 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 POTENTIAL DEPTH OPTIMUM OPERATING DEPTH VARIANCE ...

Страница 910: ...Section 35 Chapter 10 January 2006 HITCH CONTROL VALVE ...

Страница 911: ...n 35 Hydraulic Systems 3PT Chapter 10 35 10 2 TABLE OF CONTENTS HITCH CONTROL VALVE 35 10 3 Removal 35 10 3 Disassembly 35 10 5 Assembly 35 10 7 Installation 35 10 9 HITCH CONTROL VALVE CROSS SECTION 35 10 11 ...

Страница 912: ...on what hydraulic accessories your tractor is equipped with i e how many remote sections power beyond motor return etc STEP 2 RD02D042 Remove the seven pin connector mounting bracket if equipped with four or more remote STEP 3 RD02D043 If equipped remove the power beyond supply line to help obtain access to the hitch valve to case return line STEP 4 RD02D044 Disconnect the hitch valve solenoids fr...

Страница 913: ...5 Disconnect the hitch valve load sensing signal lines STEP 7 RD02D046 If equipped remove the hydraulic trailer brake line mounting clamp STEP 8 RI02D067 Remove the case drain line STEP 9 RI02D045 Remove the three hitch valve mounting bolts and remove the hitch valve ...

Страница 914: ... both O rings Inspect for heavy wear or damage Replace the valve assembly if necessary Repeat for the lower solenoid core STEP 13 RD02D037 Remove the raise spool Discard the O ring Inspect for heavy wear or damage Replace the valve assembly if necessary STEP 14 RD02D038 Remove the load check spring and ball Discard the O ring STEP 15 RD02F147 If not removed remove the tee fitting from the load sen...

Страница 915: ...dy spring and poppet Discard the O rings Inspect for heavy wear or damage Replace the valve assembly if necessary NOTE There are shims on the poppet that must be kept for assembly STEP 18 RD02D040 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 ...

Страница 916: ...orque of 21 to 27 Nm 15 to 20 lb ft STEP 20 RD02D039 Lubricate the new O rings with petroleum jelly Install two new O rings on the overload relief body Install the spring and poppet with shims into the body Install the assembly into the valve Tighten the body to a torque of 14 to 28 Nm 10 to 21 lb ft STEP 21 RD02F148 Install the load sense check into the valve STEP 22 RD02F149 Use a 3 16 inch alle...

Страница 917: ...ue of 14 to 28 Nm 10 to 21 lb ft STEP 25 RD02C200 Lubricate the new O rings with petroleum jelly Install two new O rings onto the raise solenoid core Lubricate the pilot spool control pin and solenoid core with clean hydraulic fluid and install into the valve Tighten the core to a torque of 14 to 28 Nm 10 to 21 lb ft Repeat the procedure for the lower solenoid core STEP 26 RD02C199 Install the coi...

Страница 918: ...valve on the remote valve stack and install the three mounting bolts Tighten the two M12 bolts 1 to a torque of 40 to 45 Nm 30 to 33 lb ft and the one M10 bolt 2 from 25 to 30 Nm 18 to 22 lb ft STEP 29 RI02D067 Install and tighten the case drain line STEP 30 RD02D046 If equipped install the hydraulic trailer brake line mounting clamp STEP 31 RD02D045 Connect the hitch valve load sensing signal lin...

Страница 919: ...P 32 RD02D047 Connect the valve supply line STEP 33 RD02D044 Connect the hitch valve solenoids to the wire harness STEP 34 RD02D043 If equipped connect the power beyond supply line STEP 35 RD02D042 If removed install the seven pin connector mounting bracket ...

Страница 920: ... 15 16 14 1 17 18 1 RAISE SOLENOID 10 LOAD CHECK BALL 2 LOWER SOLENOID 11 PFC PUMP SUPPLY 3 RAISE PILOT SPOOL 12 REGULATED PRESSURE SUPPLY 4 LOWER PILOT SPOOL 13 RETURN PORT 5 RAISE SPOOL 14 CONTROL PIN 6 OVERLOAD RELIEF 15 SPRING 7 LOWER CONTROL PISTON 16 ORIFICE 8 LOWER PILOT POPPET 17 TANK PORT 9 LOWER POPPET 18 RAISE LOWER PORT ...

Страница 921: ...Section 35 Hydraulic Systems 3PT Chapter 10 35 10 12 ...

Страница 922: ...Section 35 Chapter 11 January 2006 TRACTOR HITCH ...

Страница 923: ... 35 11 2 TABLE OF CONTENTS SPECIAL TORQUES 35 11 3 TRACTOR HITCH 35 11 3 EDC PIN ASSEMBLY 35 11 20 POTENTIOMETER HITCH POSITION SENSOR 35 11 21 CAM SWAY LIMITER 35 11 23 CAM BUMPERS FOR DRAFT ARM 35 11 25 DRAWBAR HIGH VERTICAL CAPACITY 35 11 26 ...

Страница 924: ...r 62 to 80 Nm 46 to 59 lb ft Locking Bolt for Cam Bumper 385 to 495 Nm 285 to 365 lb ft Bolt for Drawbar Support bracket 610 to 730 Nm 450 to 540 lb ft TRACTOR HITCH Removal of 3 Point Hitch NOTE If the Quick Coupler is attached remove it IMPORTANT Move the tires out to gain access to the hitch orient the chain holes with the hitch tie rod before starting so the tie rod cam be removed later in Ste...

Страница 925: ... 7 6 3 9 5 8 7 13 1 IMPORTANT Position round area of pin toward the wire exit in cover 2 1 COVER 7 SILICONE SEALANT 3 PLACES 2 EDC PIN 8 ANTI SEIZE COMPOUND 3 TUBE 9 BOLT 4 GROMMET 10 CONDUIT RH SIDE ONLY 5 HEX HEAD BOLT 2 11 HITCH SUPPORT ARM 6 SHOULDER BOLT 12 REAR FRAME HOUSING 13 TUBE BRACKET ...

Страница 926: ...dden drop of the draft arm as the pin is removed NOTE Removal of the tube bracket 13 from the axle carrier is not required STEP 5 27 7 Remove the EDC pin from the other side of the rear frame housing also STEP 6 INF5299L Once the EDC pins have been removed pull and remove the draft arms STEP 7 RI03G003 Remove the hex head bolt washer spacer and nut 1 from the locking plate 2 where the vertical lif...

Страница 927: ... 12 Remove the hydraulic lines to the hitch lift cylinder as follows 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 STEP 10 35 24 Secure the rockshaft assembly as follows 1 Attach a chain hoist to the top of the rockshaft assembly 2 Place enou...

Страница 928: ...oving the hitch lift cylinders If the cylinders are removed first there may be excessive travel of the rockshaft which would damage the sensor STEP 12 36S17 Remove the nut from the link assembly STEP 13 36S15 If necessary remove the three nuts from the bolts that attach the hitch potentiometer bushing to the sensor bracket and sensor NOTE This is a subassembly and does not need to be disassembled ...

Страница 929: ...ENSOR 8 NUT 3 BUSHING 9 SHIELD 4 LINK ASSEMBLY 10 WASHER 5 SNAP RING 11 BOLT 6 NUT 8 2 1 6 9 5 11 5 A A A A 3 4 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 10 ...

Страница 930: ...embly 12 HITCH SUPPORT C BRACKET 21 ROCKER PIN 13 ROCKSHAFT 22 FLAG PLATE 14 BOLT 23 BOLT 15 PIN 24 BOLT 16 RETAINER 25 SEAL 17 WASHER 26 BOLT 18 TIE ROD 27 NUT 19 POSITION LOCATOR BRACKET 28 HITCH LIFT CYLINDER 20 NUT 4 11 16 2 13 1 9 7 8 6 14 7 10 3 12 17 12 A 15 A 5 ...

Страница 931: ...cylinder Repeat Steps 17 and 18 for opposite side IMPORTANT Note the position of the plate to the slot for correct assembly STEP 16 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 36 5 Remove the position sensor bracket NOTE This step only needs to be performed if the tires pr...

Страница 932: ...ry STEP 19 35 30 Remove the pin to rockshaft retainers from both ends of the rockshaft NOTE If necessary tap the rockshaft casting near the retainer to loosen the retainer STEP 20 35 21 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 IMPORTANT Use the hoist to hold the ...

Страница 933: ...he large pin bearing hole in one of the hitch support arms Take the slack out of the sling but do not lift up on the bracket If bushings and seals are not going to be replaced use care not to damage seal or bushing nor contaminate them with dirt grease or oil STEP 24 35 8 Remove the seven attaching bolts that pass through the hitch support C brackets into the rear frame housing STEP 25 35 5 Lift o...

Страница 934: ...ith a hoist and sling These components should be replaced with new components during installation 1 Bushing and seals 2 M24 bolts and nuts 3 Retainers STEP 28 35 8 Attach both hitch support C brackets to the rear frame housing Install new M24 bolts but do not tighten Keep a gap of 5mm between M24 bolt and bracket The C brackets must be free to move easily STEP 29 35 10 Remove the sling and hoist S...

Страница 935: ...2 hitch retaining bracket 3 and prevent torque nut 4 With a minimum of three threads 5 showing torque the nut to 490 to 550 Nm 362 to 410 lb ft STEP 34 79S9 Install the tie bolt Install the washer and M24 nut on the opposite left hand side STEP 35 36 9 While preventing the M24 nut on the right hand side from rotating shown above tighten the left hand M24 nut to 490 to 555 Nm 362 to 410 lb ft NOTE ...

Страница 936: ...4919 29 HITCH SUPPORT C BRACKET 30 REAR FRAME HOUSING 1 2 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 ...

Страница 937: ...hten bolt to a torque of 82 to 106 Nm 60 to 78 lb ft STEP 38 36 15 Install the three nuts that attach the hitch potentiometer bushing to the sensor bracket and sensor Tighten to a torque of 3 5 to 6 3 Nm 2 6 to 4 6 lb ft NOTE This step may not be required If required refer to potentiometer assembly drawing shown on page 21 STEP 39 36 18 Install the nut for the link assembly Tighten to a torque of ...

Страница 938: ...ng pin through the holes STEP 42 RD03F119 Install the bolt washer spacer and nut Tighten to a torque of 82 to 106 Nm 60 to 70 lb ft Be sure the locking plate and slot are positioned correctly to prevent damage to plate Repeat for opposite side STEP 43 27 12 Attach the hydraulic line to the top of the hitch Repeat for the other hitch lift cylinders STEP 44 26 27 Attach a vertical lift link as follo...

Страница 939: ... 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 NOTE Be sure there is alignment of parts Refer to Steps 6 and 10 STEP 47 76 5 Install the locking flag plate as follows 1 Insert the locking flag plate 2 Install the bolt and nut Ti...

Страница 940: ... three bolts to hold the cover in place 4 Install the shoulder bolt in the upper forward hole 5 Install the bolt to secure the tube Tighten to a torque of 17 to 31 Nm 13 to 23 lb ft 6 Tighten to a torque of 62 to 80 Nm 57 to 73 lb ft NOTE For details on assembly of the EDC pin refer to EDC Pin Assembly in this section STEP 49 26 16 Check hitch operation as follows 1 Turn on the ignition key 2 Oper...

Страница 941: ...t On the grommet the bead should be applied where wire exits at the top and between the grommet and tube Apply a 5 MM bead all around 2 Place anti seize compound on the EDC pin and install pin 3 Install the cover Check the finished installation All voids in sealant must be closed If necessary reapply RTV sealant to fill voids 4 Slide EDC conduit past EDC connector on wire harness Assemble the EDC ...

Страница 942: ...5 11 21 POTENTIOMETER HITCH POSITION SENSOR INF6913 31 BRACKET 35 RING 39 SHIELD 32 SENSOR 36 NUT 40 WASHER 33 BUSHING 37 BOLT 41 BOLT 34 LINK ASSEMBLY 38 NUT Section A A A A 8 11 7 3 1 2 9 5 6 10 4 RIGHT SIDE OF VEHICLE Unused hole in subassembly ...

Страница 943: ...the bushing Assembly STEP 55 Lubricate the link and slide it into the bushing as far as possible Install an E ring on the backside of the bushing STEP 56 Pull the link back until the E ring bottoms out Install the second E ring STEP 57 Hold the bushing and link subassembly Position the bend in the link over the corner that does not have a bolt Insert the three bolts into the bushing Slide the brac...

Страница 944: ...he 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 42 CAM 44 CLEVIS PIN 43 PIVOT BOLT 45 LOCKING PIN 4 4 2 1 3 1 3 ...

Страница 945: ...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 ...

Страница 946: ... from other parts in new order Installation STEP 62 Install a cam bumper as follows 1 Place a bolt through the draft arm from the back side 2 Stack shims over the bolt shank on front side 3 Place the cam bumper spacer over the bolt shaft with the high risers facing away from the draft arm 4 Start the draft arm bumper onto the locking bolt Turn locking bolt into bumper and tighten bolt to 385 to 49...

Страница 947: ...ting to the high vertical capacity drawbar Remove the support Remove the bolt and washer for the pin retainer 20 Remove the retainer 6 HEAVY DUTY DRAWBAR 17 M20X150 BOLT 7 SAFETY CHAIN SUPPORT 18 HAMMERSTRAP LATCH 8 DRAWBAR STRAP SPACER 19 HAMMERSTRAP LATCH SPACER 9 HAMMERSTAP SPACER 20 BOLT 10 HAMMERSTRAP 21 NUT 11 WASHER 22 HAMMERSTRAP PIN 12 DRAWBAR SUPPORT 23 COTTER PIN 13 M20X220 BOLT 24 PIVO...

Страница 948: ...wn STEP 66 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 Install two M20 x 220 bolts to and tighten to a torque of 485 to 620 Nm 358 to 458 lb ft Install the hammerstrap pin and cotter pin If hammerstrap latch was removed tighten the bolt t...

Страница 949: ...Section 35 Hydraulic Systems 3PT Chapter 11 35 11 28 This Page Left Blank ...

Страница 950: ...Section 41 Chapter 1 January 2006 STEERING COLUMN AND STEERING HAND PUMP REMOVAL AND INSTALLATION ...

Страница 951: ... 1 41 1 2 TABLE OF CONTENTS SPECIAL TOOLS 41 1 2 SPECIAL TORQUES 41 1 3 STEERING COLUMN REMOVAL 41 1 3 STEERING HAND PUMP SERVICE 41 1 6 STEERING COLUMN ASSEMBLY 41 1 8 SPECIAL TOOLS 380000795 Steering Line Quick Disconnect Tool ...

Страница 952: ...ower console panel Leave the circular heater duct outlets in the panel Disconnect the electrical plugs from the ignition and light switch and remove the panel STEP 3 RD02C083 Remove all circular heater duct outlets from the upper console panel Remove the two retaining screws 1 on each side of the panel Disconnect the electrical plugs from the switches and upper indicator lights Pull up on the cab ...

Страница 953: ...ard pull NOTE If the steering wheel cannot be removed by the method above use a steering wheel puller STEP 7 RD02C098 Remove the retaining screw from the steering column upper control housing STEP 8 RD02C096 Remove the two steering column electrical connectors 1 Remove the cable clip with pin 2 from the steering column tilt mechanism cable Loosen the cable lock nuts 3 from the anchor bracket and m...

Страница 954: ...d the steering sensing line 2 from the steering hand pump Cap the lines and open fittings If your tractor is equipped with quick disconnect fittings use special tool 380000795 to disconnect the lines STEP 12 RD02C111 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...

Страница 955: ...olator on the steering hand pump Loosen the bolts and remove as a unit STEP 14 114S15 Remove the four washers STEP 15 114S12 Remove the shaft noise seal STEP 16 114S9 Remove and replace the outer seal of the steering hand pump if necessary STEP 17 114S12 Install a new shaft noise seal STEP 18 114S15 Install the four washers ...

Страница 956: ...mp NOTE The pump bracket must be squarely aligned with the housing of the pump Otherwise the steering column may bind and not properly center If this happens the steering wheel will move constantly back and forth trying to center STEP 20 114S29 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 p...

Страница 957: ...Section 41 Steering Chapter 1 41 1 8 STEERING COLUMN ASSEMBLY RI02G035 1 BELLOW SET 5 STEERING COLUMN 2 COVER SET 6 SEGMENT SET 3 RELEASE DEVICE SET 7 SPRING SET 4 BEARING SET 3 4 5 2 6 7 2 1 ...

Страница 958: ...n the steering wheel to one stop then the other Re center the steering wheel Turn the engine off and unplug the ignition switch Mark the top of the steering column shaft to identify the centered position Tighten the steering column lock nuts to a torque of 29 to 32 Nm 22 to 24 lb ft Remove the steering wheel STEP 23 RD02C109 Place the boot 1 with wire stiffener and boot plate installed over the st...

Страница 959: ...all the upper control housing and tighten the retaining screw STEP 27 RD02C090 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 Tighten the nut to a torque of 45 to 54 Nm 33 to 40 lb ft Install the horn button STEP 28 RD02C095 RD02C093 Us...

Страница 960: ...ct the electrical plugs to the switches and upper indicator lights Install the circular heater duct outlets into the upper console panel STEP 31 RD02C075 Connect the electrical plugs to the ignition switch and the light switch Install the two screws 1 for the lower console panel STEP 32 Make sure the transmission shift lever is in PARK Start the engine and check the operation of the steering hand ...

Страница 961: ...Section 41 Steering Chapter 1 41 1 12 ...

Страница 962: ...Section 41 Chapter 2 January 2006 WHEEL TOE IN SETTING SuperSteer FWD Axle ...

Страница 963: ...Section 41 Steering Chapter 2 41 2 2 TABLE OF CONTENTS WHEEL TOE IN SETTING 41 2 3 WHEEL TOE IN SETTING DIAGRAM 41 2 9 SPECIAL TOOL LAYOUT DRAWINGS 41 2 10 ...

Страница 964: ... appropriate lift straps in the weight package if equipped Remove the weight package retaining bolts STEP 2 Carefully remove the weight package Adjust the air pressure in both front tires so that they are equal STEP 3 Remove the grease fitting from the upper linkage pin Place a circular ring or other suitable device over an M10 x 60 1 0 bolt If metric bolt is not available a 3 8 in 24 x 2 5 in bol...

Страница 965: ... If this step is not performed correctly all other measurements and adjustments will be incorrect STEP 5 Remove two nuts and washers from the rim mounting bolts from the location shown Use an appropriate solvent to clean the nuts and washers STEP 6 Measure the combined thickness of the nut and washer The stack height must be within 0 05 mm 0 002 in of each other If they are not within specificatio...

Страница 966: ...will affect the accuracy of future measurements Install and tighten the measured washers and nuts STEP 8 Install the two fabricated threaded spacer tubes onto the rim bolts Hand tighten firmly against the rim STEP 9 Install the fabricated straightedge onto the two spacer tubes using two M16 bolts RD05E083 RD05E084 RD05E085 ...

Страница 967: ...that the straightedge is parallel to the floor when mounted on the spacer tubes STEP 11 Locate two points about 500 mm 20 in apart on the machine frame milled surface Mark these points A and B STEP 12 Measure and record the distance from the straightedge to point A RD05E086 RD05E087 RD05E088 ...

Страница 968: ...oid repositioning of the axle Turn the tube when viewed from the wheel clockwise to shorten the tie rod Turn the tube counterclockwise to lengthen the tie rod NOTE Check to be sure that the axle is still Dead Centered after the tie rod had been adjusted If the axle has moved from the dead center position the steering cylinder lines will have to be connected and the axle must be steered back to dea...

Страница 969: ...nt where the plumb bob intersects the floor Repeat the procedure at the rear inside of the rim A total of four marks will be made two from each tire STEP 17 Accurately measure and record the distance across the two rear marks Repeat the measurement across the front two marks Compare the two measurements The distance across the front marks should be within 3 mm of the rear measurement The front dis...

Страница 970: ...eering Chapter 2 41 2 9 WHEEL TOE IN SETTING DIAGRAM Top View Of Front Axle RI05E015 1 MAINE CHASSIS FRAME 5 STRAIGHTEDGE 2 AXLE 6 500 MM 20 IN 3 AXLE DEAD CENTERED 7 MACHINED FRAME PADS 4 SPACER TUBES 7 1 2 3 4 5 6 ...

Страница 971: ...OOL LAYOUT DRAWINGS RI05F002 RI05F001 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 1 5 X 1 8 INCH X 72 INCH 2 62 INCHES 3 16 INCHES 4 11 16 INCHES 3 2 1 1 3 4 2 ...

Страница 972: ...Section 50 Chapter 1 January 2006 AIR CONDITIONING SYSTEM Troubleshooting and Fault Codes ...

Страница 973: ...TC Fault Code 128 50 1 23 ATC Fault Code 129 50 1 24 ATC Fault Code 130 50 1 24 ATC Fault Code 131 50 1 25 ATC Fault Code 132 50 1 25 ATC Fault Code 133 50 1 26 ATC Fault Code 134 50 1 26 Locating System Problems Without Fault Codes 50 1 27 Controller Based Resistance Tests 50 1 27 ATC Controller Test Connector J8 Test Points 50 1 29 ATC Field Reported Symptoms Causes 50 1 32 Compressor And Clutch...

Страница 974: ...t Test 50 1 57 Defog Defrost Switch and Circuit Test 50 1 57 Cab Pressurizer Blower 50 1 58 Background 50 1 58 Power and Ground 50 1 58 Cab Pressurizer Blower Relay Power Supply and Ground Test 50 1 58 ACCESSING THE HVAC BOX 50 1 59 STANDARD AIR CONDITIONING STD TROUBLESHOOTING 50 1 60 Standard A C Operation 50 1 61 Smart Pressure Switch Cycling System 50 1 61 Standard A C Controls and Their Funct...

Страница 975: ...lectrical Test Sensor 50 1 83 Power Circuit 50 1 84 Service Note Too Little Cooling Too Much Heating without Symptoms 50 1 84 Evaporator Temperature Sensor and Circuit Test 50 1 84 Controller Power Ground And A C Switch 50 1 86 Background 50 1 86 Power and Ground Circuit 50 1 86 Possible Failure Modes 50 1 86 Controller Power Supply and Ground Test 50 1 86 A C Switch and Circuit Test 50 1 87 Cab P...

Страница 976: ...d for frostbite or a physician must be seen if you get refrigerant on your skin M799 3 Keep refrigerant containers in correct upright position Always keep refrigerant containers away from heat and sunlight The pressure in a container will increase with heat M743 4 Always check refrigerant purity with the OEM4450 Refrigerant Identifier before recovering refrigerant and before testing the system M77...

Страница 977: ...M1440 Red 20 Foot Length Quick Disconnect Refrigerant Hoses OEM1442 Set includes Yellow Blue and Red hoses RD99K079 Compressor Tool Set CAS10747A The compressor dipstick can be found in the Compressor Tool Set or purchased separately CAS10747 19 299L7B 9 Inch Stem Type Thermometer 0 TO 250 F CAS10248 299L7B Combination Impact and Chemical Splash Safety Goggles RR99M070 Refrigerant Identifier OEM44...

Страница 978: ...tioner system in order to prevent corrosion of the internal components NOTE Not all refrigerant leaves the condenser as a liquid Some leaves as a gas without affecting system performance Liquid refrigerant pools at the bottom of the receiver drier while the lighter gas collects at the top Since the pick up tube draws refrigerant from the bottom of the receiver drier only liquid refrigerant flows t...

Страница 979: ...50 Climate Control Chapter 1 50 1 8 209L95 1 COMPRESSOR 3 RECEIVER DRIER 5 EVAPORATOR 2 CONDENSOR 4 THERMAL EXPANSION VALVE 1 2 3 4 5 LOW PRESSURE GAS LOW PRESSURE LIQUID HIGH PRESSURE GAS HIGH PRESSURE LIQUID ...

Страница 980: ...onents Automatic Temperature Control RI05H007 RI05H008 1 BLOWER SPEED DRIVER 4 HEATER CONTROL VALVE 7 EVAPORATOR TEMPERATURE SENSOR 2 ATC CONTROLLER 5 BLOWER MOTOR ASSEMBLY 8 CAB TEMPERATURE SENSOR 3 THERMAL EXPANSION VALVE 6 EVAPORATOR CORE 9 COMPRESSOR CLUTCH RELAY 6 7 5 1 2 4 3 9 8 ...

Страница 981: ...SION VALVE 2 ATC CONTROLLER 9 A C LIQUID LINE TUBE 16 DRAIN HOSE 3 BLOWER SPEED DRIVER 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 HEATER EVAPORATOR ASSEMBLY 14 EVAPORATOR BOX ASSEMBLY 1 4 12 3 5 7 6 15 2 11 9 10 8 13 14 16 17 ...

Страница 982: ...er 1 50 1 11 Chassis Components RRI06A027 RI06028 RI06029 1 RECEIVER DRYER 2 CONDENSER 3 COMPRESSOR 4 HIGH PRESSURE SWITCH 5 PRESSURE TUBE 6 SUCTION TUBE 7 HEATER SUPPLY 8 HEATER RETURN RIGHT HAND SIDE FRONT 1 2 4 3 2 1 5 6 8 7 3 TOP ...

Страница 983: ...emperature Setpoint Temperature selected by the operator with temperature control on desired cab temperature Evaporator Temperature Sensor inserted in the evaporator heater assembly on current cooling or heating temperatures Low Pressure Switch on the status of abnormal system pressures on the low side High Pressure Switch on the status of abnormal system pressures on the high side Blower Speed Co...

Страница 984: ...Speed Control Manual selection of blower speed which overrides controller selection A Blower OFF B Maximum Blower Speed 2 ATC Switch Selects operational mode C Automatic Mode D OFF E Manual Mode 3 Defog Defrost Switch F Defog Defrost Mode 1 A C 3 D 2 F E O N M 5 B ...

Страница 985: ...en temperature display and fault code number H Displays F or C for Fahrenheit or Celsius To change the display to F or C press and hold the key pad AUTO key for three seconds after the screen has been turned on I Icon displays when system is operating in Defog Defrost mode J Auto Manual Switch Status K Blower Control Status L Blower Control Level 5 Temperature Control Selects temperature setpoint ...

Страница 986: ...ulated air flow warms to 12 8 C 55 F OFF Mode OFF mode is selected by placing the three position mode switch in OFF mode center position In OFF mode the blower fan is disengaged and the HVAC system provides no means of cooling or heating the cab The pressurizer blower continues to operate to provide fresh air and to pressurize the cab Manual Override of the Blower Fan While in OFF Mode If the blow...

Страница 987: ...osed as needed to drive to or maintain the desired cab temperature setpoint Manual Override of Blower Control Blower speed remains in position selected by operator Instrument Cluster Display no longer displays Auto for automatic Temperature and mode door control remain automatic but controller cannot use any speed beyond that selected to achieve the desired setpoint Turning ATC switch OFF and then...

Страница 988: ...emperature sensor and then ON again when temperature sensed warms to 37 F 3 C Heater Control Valve Heater control valve is opened or closed as needed to drive to or maintain the desired cab temperature setpoint Manual Override of Blower Control Blower speed remains in position selected by operator Instrument Cluster Display continues to display defog icon Temperature and mode door control remain a...

Страница 989: ...ure does not display until four occurrences within a 60 second internal The interval starts with the first occurrence but may be as short as 10 seconds if the pressure problem is constant Only fault codes 129 and 134 latch the compressor clutch OFF The keyswitch must be toggled OFF and ON or the ATC switch must be toggled OFF and then to the A or snowflake position before the clutch is reenabled A...

Страница 990: ...n replace harness 3 If no fault found with cab temp sensor wire harnesses or connectors then replace ATC module ATC Fault Code 115 Evap temp sensor open or shorted to power 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 O...

Страница 991: ... temp sensor wire harness or connectors then replace ATC module ATC Fault Code 120 Blower speed selector open or shorted to power Cause Wire harness connector failure Blower speed selector failure ATC module failure Possible failure modes If in auto mode then the ATC module automatically adjusts the blower speed If in manual mode then the ATC module defaults the blower speed to 75 Solution 1 Disco...

Страница 992: ...then replace harness 3 If no fault found with temperature pot wire harness or connectors then replace ATC module ATC Fault Code 122 Mode select pot open or shorted to power Cause Wire harness connector failure Mode pot failure ATC module failure Possible failure modes ATC module Manual Mode defaults to Defrost mode ATC module Automatic Mode defaults to Automatic mode Solution 1 Disconnect mode pot...

Страница 993: ...r wires If a short exists then replace harness 2 If no fault found with wire harness or connectors then replace ATC module ATC Fault Code 126 High pressure switch shorted to ground 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 Compresso...

Страница 994: ...r wires If a short exists then replace harness 2 If no fault found with wire harness or connectors then replace ATC module ATC Fault Code 128 High pressure switch shorted to ground 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 Compresso...

Страница 995: ...ition If a short or open exists then replace harness 3 Disconnect high pressure switch from harness and check its resistance It should be closed measure around 0 Ohms if system charged correctly Replace if faulty 4 If no fault found with system charge wire harness connectors or high pressure switch then replace ATC module ATC Fault Code 130 Low pressure switch shorted to power Cause Wire harness c...

Страница 996: ...er wires If a short exists then replace harness 2 If no fault found with wire harness or connectors then replace ATC module ATC Fault Code 132 Low pressure switch shorted to power 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 ...

Страница 997: ...se Incorrect charge in system Wire harness connector failure NOTE If system is properly charged then the low pressure switch will be closed and the failure could be on either leg of the switch Low pressure switch failure ATC module failure Possible failure modes Compressor clutch locked out until unit is cycled off then back on Solution 1 Verify that system charge is within specification 2 Disconn...

Страница 998: ...Power OPEN 15 Clutch Relay Coil AC ATC 16 Condenser Fan Relay Coil DEFLT Or 17 Switch Batt B 252 Or 18 Ground 309 N Less than 10 ohms If open line see Controller Power and Ground 19 RCV From Keypad OPEN 20 TK To Keypad 262 Or 21 Cab Temp SEN Or If open line see Sensors Perform initial temperature versus resistance test to check if sensor is failing See same reference Retest at sensor location temp...

Страница 999: ...st the resistance between the pins indicated and the battery negative post NOTE Use an appropriately sized probe when testing to avoid damaging the pins 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 DEFSW Or 32 Cab Pressure Input OPEN 33 High Pressure Input 80 Or 34 High Pressure Input HP Bk 35 Low Pressure Input LP Or ...

Страница 1000: ...l troubleshooting 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 ATC controller and many components are grounded to HVAC ground HVAC ground is both a groundin...

Страница 1001: ... 11 5 to 1 5V while turning blower speed control from full CCW to full CW Actions If no voltage replace the controller If no voltage change test the pot circuit See Blower Speed Pot testing Confirm control signal to mode door motor Pin 7 to Battery GND Condition s Keyswitch ON and ATC Switch to AUTO Expected Result 0 0 to 5 0V while turning mode door control from full CCW to full CW Actions If no ...

Страница 1002: ...o Battery GND Condition s Keyswitch and A C switch ON Expected Result 0 0 to 3 0V while turning blower speed pot from full CCW to full CW Actions If no voltage replace the controller Test mode door control pot output Pin 30 to Battery GND Condition s Keyswitch and A C switch ON Expected Result 0 0 to 3 0V while turning mode door control from full CCW to full CW Actions If no voltage replace the co...

Страница 1003: ...tic mode when switching from maximum cool range to warmer setpoint if temperature sensed at cab temperature sensor is less than the setpoint selected controller opens heater valve and warm air blows out the vents Heat output continues until the cab temperature sensor reaches the setpoint System anomaly Instrument Cluster Display is blank No compressor heater valve operation Blower speed at 100 onl...

Страница 1004: ...harness The clutch should disengage smoothly with little noise from the pulley or the bearings Reconnect the harness to the clutch The clutch should engage rapidly and operation should be smooth and quiet RD02H026 3 If operation is noisy feel the compressor next to the clutch for vibration If the compressor is vibrating next to the clutch and the noise changes when the clutch disengages the clutch...

Страница 1005: ...ate is stamped with a D and S to indicate the discharge and suction ports RD02H031 5 Verify an internal problem when compressor failure is suspected Turn the A C system and tractor OFF Remove the three Torx screws to remove dust cover 1 from clutch Use a wrench to slowly rotate the compressor clockwise Compressor rotation should be smooth and not require much effort If severe rough spots or catche...

Страница 1006: ...mpressor 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 alignment Adjust the compressor on the mounting bracket if required The drive belt should be firmly seated in the clutch grooves Check for too much belt wear cracking cord wear piling chunking glazin...

Страница 1007: ...izes the relay by supplying power through pin 15 to pin 2 on the clutch relay 12V is fed from pin 5 on the relay through C139 C C333 26 and C60 P to energize the clutch coil at C72 1 Possible Failure Modes 1 Short circuit or open circuit in clutch coil 2 Open circuit in power or ground between controller and relay 3 Open circuit in power and ground between clutch and relay 4 Controller fault Compr...

Страница 1008: ...continuity from clutch relay pin 5 to connector 139 pin C OKAY Go to next Step NOT OKAY Locate and repair the open condition between the clutch relay pin 5 to connector 139 pin C 7 Check continuity from connector 139 pin C to connector 333 pin26 OKAY Go to next Step NOT OKAY Locate and repair the open condition between the connector 139 pin C to connector 333 pin 26 8 Check continuity from connect...

Страница 1009: ...1 to 0 79 mm The gap must be even all the way around the plate If necessary lightly lift or push down on the plate to make the gap even NOTE If the gap does not meet the above specifications remove the front plate and add or subtract clutch shims as required Reference See A C System Service in this manual for clutch disassembly and adjusting the air gap during clutch replacement RD99N145 12 Check ...

Страница 1010: ...sulting from a leak s Sometime low pressure switch activation however is caused by a restriction where because of the location either pressure switch may activate first For example a restriction at the output of the receiver drier could cause either high or low pressure switch activation Refer to the A C Troubleshooting Foldout and performance testing to locate the cause for your system When eithe...

Страница 1011: ... switch opens at system pressures above 400 psi 10 2758 kPa 69 The switch closes when system pressure drops below 250 psi 10 1724 kPa 69 2 Any intermittent open condition at a connector in the circuit appears the same to the controller 134 Controller has detected an open condition in low pressure switch circuit Compressor clutch is latched OFF Smart Pressure Switch Counting Code 134 is not activat...

Страница 1012: ... C high and low side pressure gauges High reading above 400 psi 10 psi 2758 kPa 69 kPa YES Perform corrective actions from A C Troubleshooting Foldout NO Go to next Step 2 Shut off the tractor Disconnect the switch from the harness and the unit Check that switch is closed across pins A and B OK Go to next Step NOT OK Replace switch 3 Reinstall the switch in the unit do not reconnect the harness Ke...

Страница 1013: ...s open across pins A and B OK Go to next Step NOT OK Replace switch 3 Reinstall the switch in the unit do not reconnect the harness Keyswitch ON and ATC switch to Auto Is 5V present at pin B at the harness to the switch YES Go to next Step NO Go to Step 5 4 Keyswitch OFF Measure resistance from pin A at the switch to HVAC ground Less than 1 ohm YES Go to next Step NO Locate open condition and repa...

Страница 1014: ... not mirror control movement or does not move perform the valve motor electrical test RD99N053 Valve Leak Through A common problem with the valve is hot coolant flow when cab cooling is desired This usually occurs by a when a valve does not close completely To test for leak through from the valve 1 Operate the A C system at maximum cooling and blower speed for 15 minutes See conditions for Perform...

Страница 1015: ...ally or actuator fault Go to Step 2 If no voltage or no voltage change go to Step 5 If voltage change and slot movement are continuous heater valve tests okay 2 Keyswitch OFF Disconnect harness connector to motor Measure resistance through the motor from pin 7 to pin 10 Open line reading YES Replace the heater control valve assembly NO Go to next Step 3 Measure resistance from pin 7 on valve harne...

Страница 1016: ...me resistance rating 0 10K ohms When a potentiometer fails or an open condition is detected in the control circuit a fault code is displayed on the Display Possible Failure Modes Fault Codes 120 121 Fault Code Description 120 Controller has detected an open or short to power condition in blower speed control pot circuit Blower speed defaults to maximum output which cannot be varied with the contro...

Страница 1017: ...the fault code displays 120 or 121 only in certain locations the pot is the likely suspect Go to next Step 2 Open the overhead panel Remove and resistance test the pot between pins B and C Resistance must change smoothly 0 10K ohms as the pot is turned from full CCW to full CW Drop outs still present in certain locations YES Replace the pot NO Go to next Step 3 Reconnect the pot to the harness Is ...

Страница 1018: ... although code 120 indicates a fault in the blower speed control circuit Power Signal and Ground Circuit 12V is fed to the blower motor and blower driver on pin A from fuse 26 30 amp whenever accessory power is present The voltage signal is fed from CJ8 5 to pin 3 on the blower speed driver The blower speed driver is grounded from SBC1 2 to chassis ground at ring terminal 173B The blower motor is ...

Страница 1019: ...p 6 NO Go to next Step 5 Is 12V present at fuse 49 30 amp YES Locate open condition and repair between pin A at blower driver and fuse 49 through C139 K NO Locate and correct problem from accessory relay to fuse 49 6 Keyswitch ON and ATC switch to Auto Measure voltage between pin B and pin A of the blower driver while turning the blower speed control Does voltage follow pattern below Blower pot fu...

Страница 1020: ...r also prevents the system from operating in low ambient temperatures where damage to the system might occur When temperature sensed at the evaporator falls to 32 F 0 C the controller cycles the compressor clutch OFF When temperature sensed at the evaporator rises to 37 F 3 C the controller cycles the clutch back ON In Defog mode or in Automatic mode at the maximum cooling setting where the compre...

Страница 1021: ... for view from inside the HVAC box Since the cab temperature sensor is located behind the recirculation air filter any obstruction in the return air path will reduce system performance The sensor will only detect air temperature in the HVAC box and not the true cab air temperature Check the area behind the operator s seat for obstructions at the recirculation filter and check the filter for cleann...

Страница 1022: ...thermometer used must be accurate and the temperature recorded must be the temperature at the sensor NOTE See Electrical Schematic section 60 Power Circuit Minimal voltage is fed to the sensors about 0 5V at 70 F 21 C and voltage drops as the temperature increases Current is fed to the evaporator sensor from CJ8 23 and the cab sensor from CJ8 21 Service Note Too Little Cooling Too Much Heating Wit...

Страница 1023: ...e sensor the fault code displays until the cab warms above this temperature If fault code does not clear when cab warms the sensor requires service 115 Controller has detected an open or shorted to power condition in the evaporator temperature sensor circuit Compressor clutch does not engage for cooling but heater valve opens and closes for cab heating A displays on Instrument Cluster Display but ...

Страница 1024: ...nsor 2 Keyswitch ON and ATC switch to Auto Measure voltage at female connector on sensor Is voltage present NOTE Voltage reading will be very low 0 5V at 70 F 21 C and voltage decreases as temperature increases YES Go to next Step 4 NO Go to next Step 3 Measure voltage at CJ8 21 at the controller Is voltage present YES Locate and repair open condition between CJ8 21 at the controller and the senso...

Страница 1025: ...o next Step 4 NO Go to next Step 3 Measure voltage at CJ8 23 Is voltage present YES Locate and repair open condition between CJ8 23 and the sensor NO Test the controller See ATC Controller Tests 4 Measure resistance from the sensor to HVAC box ground stud Less than 1 ohm YES YES Wrong reading taken Test again NO Locate and repair open condition between sensor and HVAC box ground stud NOTE Verify t...

Страница 1026: ...9 56 13 33 33 249 34 102 34 955 57 13 89 32 387 33 217 34 047 58 14 44 31 548 32 357 33 166 59 15 00 30 735 31 523 32 311 60 15 56 29 945 30 713 31 481 Range Ambient Temperature F C 2 5 Kohms 2 5 61 16 11 29 179 29 927 30 675 62 16 67 28 434 29 163 29 892 63 17 22 27 710 28 421 29 132 64 17 78 27 008 27 701 28 394 65 18 33 26 327 27 002 27 677 66 18 89 25 664 26 322 26 980 67 19 44 25 020 25 662 2...

Страница 1027: ...t pin 4 grounding CJ8 26 with the switch provides the automatic mode request to the controller The controller feeds 5V from CJ8 25 through CJ6R1 M to the switch at pin 6 grounding CJ8 26 with the switch provides the Defog Defrost mode request to the controller The switch is grounded from pin S to chassis at CJ6R1 S Possible Failure Modes 1 Fuse 47 or open condition in power or ground to controller...

Страница 1028: ...n pin 26 at controller through C139 L and pin 4 at the switch NO Test the controller See ATC Controller Tests in this Section Steps and Test Point Corrective Actions 1 Disconnect DEFOG DEFROST switch from harness DEFOG DEFROST switch to ON Measure resistance between pins 2 and 3 on switch Less than 1 ohm YES Go to next Step NO Replace switch 2 Measure resistance from pin 2 at the DEFOG DEFROST har...

Страница 1029: ...o the motor on pin B from the pressurizer relay pin 5 to start the motor at the proper engine rpm Ground to the relay is from ring terminal 173E the relay is energized on pin 2 wire 304 Bk Cab Pressurizer Blower Relay Power Supply and Ground Test Steps and Test Point Corrective Actions 1 Operate the engine at rpm greater than 500 to engage the cab pressurizer blower Check fuse 10 15 amp Is 12V pre...

Страница 1030: ...ght position Adjust seat to the full upright and back position STEP 3 RD99N152 Remove four bolts in the seat base corners STEP 4 RD99N153 Disconnect the seat harness STEP 5 Hinge seat forward and rest on steering wheel STEP 6 After completion of service reinstall the seat harness Realign ATC controller mounting plate if equipped with mounting holes and reinstall seat mounting hardware Reconnect ri...

Страница 1031: ... the rear of the HVAC box and chassis ground at ring terminal 172F on wire 85_CCU N within the box and wire 177F Bk outside the box The stability of this ground is essential for reliable troubleshooting WARNING All operating controls must be in neutral or park lock position when performing these tests NOTE Use a multimeter DVOM for these tests Do NOT use a self powered test light for any of these ...

Страница 1032: ...witch within a 60 second interval The compressor is also latched OFF after two activations of the high pressure switch within a 60 second interval The 60 second interval starts with the first activation of the switch in both cases IMPORTANT Actual interval may be as short as 10 seconds if the open condition is constant The controller flashes the pressure warning lamp mounted in the A C On Off swit...

Страница 1033: ...ure Warning Indicator the warning lamp blinks slowly approximately 7 times in a 10 second period for low pressure switch activation or quickly approximately 13 times in a 10 second period for the high pressure switch activation 3 Temperature Control Compressor is engaged or heater valve is opened in direct proportion to the movement of the control B Maximum Cooling Zone 32 F 0 C compressor runs co...

Страница 1034: ...period See High and Low Pressure Clutch Latching in this Section Evaporator temperature sensor freeze setting reached cycling the clutch OFF See Evaporator Temperature Sensor in this Section Open in switched ground to relay from controller Power and ground to clutch relay Clutch relay defective See Electrical Test for Clutch Relay in this Section Controller defective See Standard Controller Test i...

Страница 1035: ...n Too little cooling too little heating with system pressures and components normal Evaporator temperature sensor failing Open line to evaporator temperature sensor See Evaporator Temperature Sensor in this Section Cab pressurization blower does not run when switched B is present Power and ground to cab pressurizer blower Fuse 10 Cab pressurizer relay disconnected or defective Power and ground to ...

Страница 1036: ...ption Wire Color Test Points 6 Pin Conn 2 A Controller Power 252 Or Pin A to Battery GND 7 B Evaporator Temp Sensor PB S Pin B to Battery GND 5 C High Pressure Switch 80 Or Pin C to Battery GND 9 D Temperature Control Pot 103 Or Pin D to Battery GND 11 E A C On Off Switch 112 Or Pin E to Battery GND 1 F Controller Ground MOD Bk Pin F 6 pin to HVAC ground 5 Pin Conn Description Wire Color Test Poin...

Страница 1037: ...voltage replace the controller If voltage out of range for temperature test sensor See sensor test page 83 Test controller switched ground to clutch relay Pin A 5 pin to chassis ground Condition s Keyswitch ON Expected Result 0 0V or 12V see actions Actions A C switch ON with temperature control to max cool and normal pressures 0 0V indicates proper operation A C switch OFF and keyswitch ON 12V in...

Страница 1038: ...harness The clutch should disengage smoothly with little noise from the pulley or the bearings Reconnect the harness to the clutch The clutch should engage rapidly and operation should be smooth and quiet RD02H026 3 If operation is noisy feel the compressor next to the clutch for vibration If the compressor is vibrating next to the clutch and the noise changes when the clutch disengages the clutch...

Страница 1039: ...late is stamped with a D and S to indicate the discharge and suction ports RD02H031 5 Verify an internal problem when compressor failure is suspected Turn the A C system and tractor OFF Remove the three Torx screws to remove dust cover from clutch Use a wrench to slowly rotate the compressor clockwise Compressor rotation should be smooth and not require much effort If severe rough spots or catches...

Страница 1040: ...mpressor 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 alignment Adjust the compressor on the mounting bracket if required The drive belt should be firmly seated in the clutch grooves Check for too much belt wear cracking cord wear piling chunking glazin...

Страница 1041: ...ontroller grounds the compressor clutch relay to provide 12V from fuse 49 via the blower switch to energize the clutch coil and engage the compressor Power and Ground Circuit Switched 12V is fed to the compressor clutch relay on pins 3 and 2 through the blower switch from fuse 49 The controller energizes the relay by supplying switched ground from pin A on CCU2 to pin 1 on the relay 12V is fed fro...

Страница 1042: ... to next Step NO Repair open circuit or replace wire Retry the unit NOT OK Go to next Step RH02G158 2 Measure resistance from C72 A through clutch to ground screw on bracket Is resistance between 3 6 4 2K ohms YES Go to next Step NO If open line or resistance is severely out of range replace the clutch NOTE If clutch is shorted also check condition of fuse 49 30 amp The clutch draws enough amperag...

Страница 1043: ...placement RI03B040 5 Is 12V present at pin 3 of compressor clutch relay YES Go to next Step NO Locate and repair open condition between pin 3 on relay and pin F on blower speed switch through C139 A 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 NO Rep...

Страница 1044: ...first For example a restriction at the output of the receiver drier could cause either high or low pressure switch activation Refer to the A C Troubleshooting Foldout and performance testing to locate the cause for your system NOTE Your A C systems are designed to prevent A C compressor failure due to low pressure or low refrigerant charge Operation on days below 40 F 4 C may actuate the low press...

Страница 1045: ...essure switch has opened because of high side system pressures High pressure switch opens at system pressures above 400 psi 10 2758 kPa 69 The switch closes when system pressure drops below 250 psi 10 1724 kPa 69 2 Any intermittent open at a connector in the circuit appears the same to the controller Warning lamp flashes slowly about 7 times in a 10 second period Controller has detected an open co...

Страница 1046: ...m corrective actions from A C Troubleshooting Foldout NO Go to next Step 2 Shut off the tractor Disconnect the switch from the harness and the unit Check that switch is closed across pins A and B OK Go to next Step NOT OK Replace switch 3 Reinstall the switch in the unit do not reconnect the harness Keyswitch and A C ON blower control on any speed and temperature control on maximum cool setting Is...

Страница 1047: ... OK Go to next Step NOT OK Replace switch 3 Reinstall the switch in the unit do not reconnect the harness Keyswitch and A C ON blower control on any speed and temperature control on maximum cool setting Is 5V present at pin B at the harness to the switch YES Go to next Step NO Go to Step 5 4 Keyswitch OFF Measure resistance from pin A at the switch to the HVAC ground stud Less than 1 ohm YES Go to...

Страница 1048: ...ckwise If the valve does not mirror control movement or does not move perform the valve motor electrical test Valve Leak Through A common problem with the valve is hot coolant flow when cab cooling is desired This usually occurs by a when a valve does not close completely To test for leak through from the valve 1 Operate the A C system at maximum cooling and blower speed for 15 minutes See conditi...

Страница 1049: ...o to Step 5 If voltage change and slot movement are continuous heater valve tests okay 2 Disconnect harness connector to motor Measure resistance through the motor from pin 7 to pin 10 Open line YES Go to next Step NO Replace the heater control valve assembly 3 Measure resistance from pin 7 on valve harness to HVAC ground stud Less than 1 ohm YES Go to next Step NO Locate and repair open condition...

Страница 1050: ...ossible Failure Modes 1 Control potentiometer failure 2 Open condition in power or ground to control potentiometer 3 Controller failure Temperature Control Potentiometer and Circuit Test Steps and Test Point Corrective Actions 1 Keyswitch and A C switch OFF Open the right hand control panel Disconnect the potentiometer from the harness Check for variation in resistance 0 10K ohms across B and C on...

Страница 1051: ...ailure requires replacement of the motor Power and Ground Circuit 12V is fed to blower motor from fuse 49 30 amp whenever switched B is present and whenever the blower speed switch is set to any position other than OFF Based on the speed switch position 12V is routed through the in line connector to the step down resistors The blower motor is grounded from pin B to the HVAC ground stud and ring te...

Страница 1052: ...age at blower speed switch pin 4 Is 12V present YES Go to next Step NO Replace switch 6 Turn blower control to HIGH Measure voltage at blower speed switch pin 3 Is 12V present YES Go to next Step NO Replace switch 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 te...

Страница 1053: ...tep 12 Measure voltage at C139 E Is 12V present YES Locate and repair open circuit between C139 E and in line connector terminal 3 NO Go to next Step 13 Measure voltage at blower switch on pin 4 Is 12V present YES Locate and repair open circuit between C139 E and the switch pin 4 NO Test switch 14 Turn blower control to HIGH Does blower motor operate at high speed YES Wrong reading taken Retest NO...

Страница 1054: ...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 core up to the angled section being careful not to kink the sensor RH99D218 Evaporator Core Rear View Electrical Test Sensor NOTE See Electrical Schematic sections 58 60 and 61 The sensor has a well known resistance vs temperature...

Страница 1055: ...perature 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 85 Is the resistance reading within the minus or plus 2 5 range in the table YES Go to next Step NO Replace the sensor 2 Keyswitch and A C switch ON Measure voltage at pin 1 to sensor Is voltage present NOT...

Страница 1056: ...9 56 13 33 33 249 34 102 34 955 57 13 89 32 387 33 217 34 047 58 14 44 31 548 32 357 33 166 59 15 00 30 735 31 523 32 311 60 15 56 29 945 30 713 31 481 Range Ambient Temperature F C 2 5 Kohms 2 5 61 16 11 29 179 29 927 30 675 62 16 67 28 434 29 163 29 892 63 17 22 27 710 28 421 29 132 64 17 78 27 008 27 701 28 394 65 18 33 26 327 27 002 27 677 66 18 89 25 664 26 322 26 980 67 19 44 25 020 25 662 2...

Страница 1057: ...ding pin 6 with the switch provides the ON request to the controller The switch is grounded from pin 5 to chassis at Splice C14 Pressure Warning Lamp The controller provides switched ground from pin C on CCU2 through C139 M to the switch at pin 9 for the pressure warning lamp The lamp is powered at pin 10 with switched B from Splice C43 Possible Failure Modes 1 Fuse 47 or open condition in power o...

Страница 1058: ...p 6 NO Go to next Step 5 Is 5V present at pin E at the controller CCU1 YES Locate and repair open condition between pin E at controller and pin 6 at switch through C139 L and C322 A NO Test the controller See Standard Controller Test in this Section 6 Is 5V present at pin 10 at the harness connector to the switch YES Go to next Step NO Locate and repair open condition in switched B to pin 10 at sw...

Страница 1059: ... The motor blower assembly is located behind the fresh air filter The motor is energized by a relay activated by switched B Only the pressurizer blower relay and motor troubleshooting are covered here Power and Ground Unswitched B is continuously provided to the relay on pin A3 from fuse 10 15 amp The relay is grounded on pin A2 to the engine relay Whenever Switched B is present the relay is energ...

Страница 1060: ...p NO Locate and repair open condition between pin B at the motor and Splice F3 on wire 179 Bk 5 Reconnect motor to the harness Keyswitch ON Is 12V present at pin A3 of the blower relay and chassis ground YES Go to next Step NO Locate and repair open between fuse 10 and relay on wire 195 K 6 Is 12V present at pin A1 of the blower relay and chassis ground YES Go to next Step NO Locate and repair ope...

Страница 1061: ...Section 50 Climate Control Chapter 1 50 1 90 NOTES ...

Страница 1062: ...Section 50 Chapter 2 January 2006 AIR CONDITIONER SYSTEM SERVICE ...

Страница 1063: ... Detection 50 2 53 Fluorescent Dye Injection 50 2 53 Fluorescent Leak Testing 50 2 59 A C SYSTEM COMPONENTS 50 2 60 Cab HVAC Box Components Automatic Temperature Control 50 2 60 Cab HVAC Components Standard Systems 50 2 62 Chassis Components 50 2 64 A C COMPRESSOR CLUTCH 50 2 65 Clutch Removal 50 2 65 Exploded View of Clutch 50 2 71 Compressor Clutch Replacement 50 2 71 A C COMPRESSOR 50 2 79 Oil ...

Страница 1064: ... 50 2 107 ATC Controller 50 2 107 Standard A C Controller 50 2 107 Blower Speed Driver ATC Units Only 50 2 108 CAB AIR FILTER SERVICE 50 2 109 CAB RECIRCULATION AIR FILTER SERVICE 50 2 110 CAB PRESSURIZATION TEST 50 2 111 CAB PRESSURIZER MOTOR REPLACEMENT 50 2 113 VISCOUS FAN DRIVE 50 2 116 ...

Страница 1065: ... ft Dust Cover Screws 7 to 11 Nm 5 to 8 lb ft SPECIAL TOOLS Combination Impact and Chemical Splash Safety Goggles Compressor Tool Set CAS10747A The compressor dipstick 1 can be found in the Compressor Tool Set or purchased separately CAS10747 19 Refrigerant Recovery Station OEM1415 6 Foot Length Quick Disconnect Refrigerant Charging Hoses OEM1438 Yellow OEM1439 Blue OEM1440 Red 20 Foot Length Quic...

Страница 1066: ...apter 2 50 2 5 Refrigerant Identifier OEM4450 Air Powered Recovery Station with Tank OEM1691 Additional 50 lb Contaminated Refrigerant Tanks OEM1692 1 4 Inch FFLX to 1 2 Inch Acme Adapter OEM1693 RR99M070 RR00D078 RR00E140 RR00E139 ...

Страница 1067: ...r 2 50 2 6 Electronic Leak Detector OEM1437 UV Leak Detection Lamp and Goggles BSL750 Recovery Station UV Dye Injector for R 134a Refrigerant BSL734 UV Leak Detection Dye for R 134a Refrigerant B726012 A22090 RR00F098 RR00F101 RR00F102 ...

Страница 1068: ...34a Quick and Easy Dye Injector Tool BSL738 Quick and Easy R134a Charge Cans 6 Pack BSL634 UV Fluorescent Dye Cleaner B795016 Power Flush Model 17550 BS33801 A C Flushing Solution Case of Six 1 Gallon Containers RD01F248 RD01F249 RR00F100 RR00F093 ...

Страница 1069: ...se of Six 1 Gallon Containers Coalescing Air Filter Dryer 1 Similar to Ingersoll Rand Model IR5CHE or Grainger Model 4KR65 Pressure Regulator Capable of Providing 45 psi at 4 0 cfm 310 kPa at 0 11 cmm with Integrated Pressure Gauge 17582 Universal Flush Fitting Kit RP00G007 RI00F041 1 RI00F042 RR00F148 ...

Страница 1070: ... burns or a physician must be seen if you get refrigerant on your skin M799 3 Keep refrigerant containers in correct upright position Always keep refrigerant containers away from heat and sunlight The pressure in a container will increase with heat M743 4 Always check refrigerant purity with OEM4450 Refrigerant Identifier before recovering refrigerant and before testing the system M777 5 Use the a...

Страница 1071: ...gerant NOTE In the United States EPA regulations require that tanks of contaminated refrigerant be sent to a refrigerant reclaimer for the contents to be purified or destroyed Call 1 800 296 1996 to locate a reclaimer in your area WARNING 134a is the only refrigerant approved in 134a systems Alternative refrigerants which boast better cooling capabilities are in most cases highly flammable Do not ...

Страница 1072: ...reservoir This oil requires proper disposal and should never be returned to the vehicle When vacuum is depressed the vacuum pump on OEM1415 evacuates the atmosphere in the vehicle A C system to a vacuum of 28 to 29 1 2 inches of mercury Hg Air and moisture are removed in the process and only SP 20 PAG oil remains in the vehicle s A C system When recycle is depressed the entire contents of the reco...

Страница 1073: ...cooling and maximum blower speed ATC switch set to DEFOG DEFROST standard A C switch set to ON STEP 2 Clean the external surfaces of the compressor and hoses Remove the caps from the service ports on the suction and pressure lines RH02J044 Standard A C Controls RH05J039 ATC A C Controls 1 BLOWER CONTROL 3 TEMPERATURE CONTROL 2 ATC OR STANDARD A C SWITCH 4 DEFOG DEFROST SWITCH 1 3 2 1 3 2 4 RD02H03...

Страница 1074: ...ose from the low pressure gauge to the port on the suction hose Turn in valve depressor Connect the hose from the high pressure gauge to the port on the discharge hose Turn in valve depressor STEP 4 Open the drain valve to make sure that the oil separator is drained prior to recovery Oil may have mistakenly been left in the recovery unit itself from the previous service job An oily mist will disch...

Страница 1075: ...s and observe the manifold pressure gauges for a pressure rise If no pressure rise recovery is complete If pressure rises above 0 PSI depress the HOLD CONT switch and repeat until pressure holds for two minutes Then wait for the compressor to automatically shut OFF NOTE Refrigerant may pool inside the tractor s A C system When the recovery unit s compressor is turned off the refrigerant will vapor...

Страница 1076: ...Slowly open the oil drain valve and drain the oil into the reservoir When the oil stops draining close the oil drain valve completely STEP 10 Record the amount of oil in the reservoir This amount of new oil should be added back to the system Dispose of any oil in the bottle in an appropriate manner and return the bottle to the station STEP 11 All refrigerant has been removed from the A C system re...

Страница 1077: ...PORTANT Read all safety warning and maintenance sections of the operator s manual before operating the station Preparing the Tank STEP 12 The tank for the station may be filled with 10 to 15 psi of dry nitrogen which must be removed before it can be used Remove the cap from the red valve outlet Open the tank valve to release the nitrogen Close the tank valve STEP 13 Use the vacuum pump 1 on OEM141...

Страница 1078: ...e unit Connect the adapter to the red tank valve STEP 15 Connect the 96 inch 2 4 m blue hose with the R134a service coupler to the adapter STEP 16 Connect the R134a service coupler to the tee fitting on top of the vacuum pump on OEM1415 or OEM1418 Open the valve on the service coupler by turning it clockwise RR00E144 RR00E152 RR00E154 ...

Страница 1079: ...w side manifold on the control panel of OEM1415 or OEM1418 STEP 19 Press SHIFT RESET and ENTER at the same time Press 1 The vacuum pump starts and runs continuously until any other key is depressed Run the vacuum pump for a minimum of 5 minutes Then press 1 to stop the pump RR00E155 RR00E156 R00E141 ...

Страница 1080: ...t the blue hose from the vacuum pump STEP 21 Set the tank on the platform at the rear of the station Tighten the black strap securely around the tank STEP 22 Disconnect the R134a hose from the adapter Disconnect the adapter from the tank and store for future use Reinstall the cap on the red valve outlet port The tank is now prepared See the operator s manual to prepare the recovery station for use...

Страница 1081: ... switch set to DEFOG DEFROST or standard A C switch to ON Tests have shown that more refrigerant will be recovered if this action is performed NOTE Turn the system and tractor OFF before connecting the station STEP 24 Remove the cap on the low pressure port at the compressor Connect the blue R134a recovery hose from the station to the low side service port at the compressor STEP 25 Open the tank v...

Страница 1082: ...ze pressure on both sides of the compressor for easier starting 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 RR00E132 RR00E133 ...

Страница 1083: ... 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 NOTE Use a jumper cable to extend the negative lead if necessary to reach an engine ground STEP 29 Turn the control panel valve to RECOVERY The compressor sound should change Inlet pressure gauge should decrease an...

Страница 1084: ...ill 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 STEP 31 When the recovery process is complete close the valve on the recovery tank Close the low pressure hose valve and remove the hose from the port at the compressor STEP 32 Disconnect the compressed air line from the inlet on the r...

Страница 1085: ... in a proper manner NOTE If any significant amount of oil is drained measure and record that amount Add that equivalent of new SP 20 PAG oil back into the system at the end of the evacuation process IMPORTANT If the oil is suspected to be other than SP 20 PAG oil 1 See the flushing procedures in this Section for complete circuit flushing to remove the oil 2 Drain all oil from the compressor and ad...

Страница 1086: ...nd held for five minutes F Connect the tank valve hose and the float cable G Open the tank valve and the tank hose valve Recovery will continue as soon as both valves are open IMPORTANT Do not use recovered contaminated refrigerant in any A C system Send full tanks to a reclamation center for purifying or disposal of the contents STEP 36 All refrigerant has been removed from the A C system replace...

Страница 1087: ...ncapped longer than 5 minutes G Testing with refrigerant identifier OEM4450 showed contamination STEP 38 With the charging station manifold gauge valves in the closed position connect the hoses from the test gauges to the service ports as follows 1 Connect the hose from the low pressure gauge to the port on the suction hose blue 2 Connect the hose from the high pressure gauge to the port on the di...

Страница 1088: ... 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 STEP 40 Fully open the low and high pressure valves STEP 41 Open the red vapor and blue liquid valves on the tank A22113 A22114 A22107 ...

Страница 1089: ...leak test information in this section STEP 43 IMPORTANT Do not inject the PAG oil until the system will hold a proper vacuum OEM1415 has an injection system to return new SP 20 PAG oil equal to the amount recovered at the end of the evacuation process To add the new oil adjust the O ring around the oil return bottle to the required oil charge level NOTE If 2 4 oz 71 ml was recovered in the oil res...

Страница 1090: ...ear on the display The display shows the programmed amount and counts down to zero as charging proceeds When charging is completed the display shows CPL IMPORTANT Check the OEM equipment manual before performing Step 47 to avoid damaging recovery unit Pressure reading should be obtainable with valves closed Damage may occur if the tractor is started with the valves accidently open or if either or ...

Страница 1091: ...e the clutch is latched off by the controller Standard A C units blink the indicator light on the A C ON OFF switch indicating a system pressure problem To restart the compressor the switch must be turned to the OFF position and then ON On ATC units if the system pressure is to low or to high a fault code will toggle between the current cab temperature setpoint and the fault code on the Instrument...

Страница 1092: ...nt 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 STEP 50 Close any open valves on the couplers and carefully remove the gauge hoses from the ports on the suction and discharge lines A22117 RD02F045 RD02H029 ...

Страница 1093: ...Section 50 Climate Control Chapter 2 50 2 32 STEP 51 Install the caps on the service ports on the suction and discharge lines RD02H032 ...

Страница 1094: ...F 25 C 76 F 43 C 110 F 228 to 276 kPa 33 to 40 psig 255 to 319 kPa 37 to 45 psig 1813 to 2213 kPa 263 to 321 psig 1875 to 2289 kPa 272 to 332 psig 25 C 77 F 27 C 81 F 49 C 120 F 255 to 319 kPa 37 to 45 psig 283 to 345 kPa 41 50 psig 2034 to 2482 kPa 295 to 360 psig 2089 to 2551 303 to 370 psig 28 C 82 F 30 C 86 F Temperatures shown are highest normal temperatures expected actual louver temperature...

Страница 1095: ...essor failure For most New Holland condensers with a single flow path flushing effectively removes debris For condensers with parallel flow paths since flushing takes the path of least resistance around any blockage condenser replacement may be the only option The receiver drier has a fine mesh screen to capture contaminants but the contaminants may penetrated the screen Check the discharge port o...

Страница 1096: ...e gallon containers BS33801 Dry shop air source use filter below or equivalent Coalescing air filter dryer Ingersoll Rand IR5CHE or Grainger 4KR65 Desiccant type air driers should not be used Adapters to connect flush unit to the various A C system components These adapters can be purchased in kit form or built in the shop Clear Plastic Reinforced Hose to connect the tank to various components and...

Страница 1097: ...filtered and dried with coalescing filter or you will simply replace one source of contamination with another using dirty moisture saturated air The compressor receiver drier and thermal expansion valve must be bypassed removed when performing circuit flushing The compressor and receiver drier may never be flushed the thermal expansion valve can be back flushed Keep the lid on the flushing recover...

Страница 1098: ...ontaminants 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 STEP 54 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 STEP 55 Close the air and the flushing valves ...

Страница 1099: ...e flushing tank hose quick coupler from the evaporation plug STEP 57 Connect the flushing tank hose quick coupler to an extension or an adapter hose STEP 58 Connect CLEAN and DRY shop air supply to the quick coupler on the flushing valve RP00G018 RD00H203 RD00H202 ...

Страница 1100: ... forward flushing is performed to remove the contaminants STEP 60 Open the air valve 1 2 to 3 4 turn 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 on the components being flushed Turn the flushing valve to the FLUSH position and flush the component for 30 seconds STEP 61 Close the flushing and air...

Страница 1101: ...solvent must remain in the system when it is evacuated and recharged Turn the component so gravity can assist in solvent removal STEP 63 Turn the flushing valve to the CLOSED position Disconnect the flushing and drain hoses and adapters from the component STEP 64 Install the flushing tank hose quick coupler on the evaporation plug to prevent evaporation of the solvent remaining in the tank during ...

Страница 1102: ...ulsing 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 STEP 67 Remove the receiver drier and join the hoses together with an adapter hose Discard the receiver drier STEP 68 Remove the thermal expansion valve and use adapters to...

Страница 1103: ...harge lines from the compressor Attach flushing adapters to the lines STEP 70 Close the air and the flushing valves STEP 71 Remove the flushing tank hose quick coupler from the evaporation plug RH01F112 Universal A C Flush Fittings Shown RD00H200 1 AIR VALVE 2 FLUSH VALVE 1 2 RP00G018 ...

Страница 1104: ...e from the flush tank to the suction line connect the hose to the return bucket to the discharge line Reinforced clear hose is preferred to monitor the condition and removal of the used solvent NOTE Back flushing is done first to dislodge any contaminants and then forward flushing is performed to remove the contaminants NOTE The suction and discharge ports on the compressor are marked with the let...

Страница 1105: ...d air valves Reverse hose connections for forward flushing Connect the hose from the flush tank to the discharge line connect the hose to the return bucket to the suction line Open flushing and air valves and repeat flushing until the solvent is clear STEP 77 Turn the flushing valve to the AIR position Allow air to flow through the circuit until no noticeable mist is discharged NOTE Air pressure i...

Страница 1106: ... 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 RP00G018 ...

Страница 1107: ... to the canister and then the canister is pressurized with CLEAN and DRY shop air Pulse the trigger on the flush gun for greater flushing effectiveness STEP 80 To fill the canister remove the cap assembly Add no more than 20 oz 590 ml of New Holland flushing solvent to the canister Replace the cap assembly STEP 81 Pressurize the canister to a maximum of 90 psi 620 kPa with CLEAN and DRY shop air R...

Страница 1108: ...the refrigerant line or thermal expansion valve when flushing When back flushing the thermal expansion valve the suction and discharge ports must be flushed in different directions Collect used solvent in a container for proper disposal STEP 84 Use CLEAN and DRY shop air to purge the solvent and dry the valve RP00G010 RP00G011 Back flush the discharge port RP00G012 Back flush the suction port ...

Страница 1109: ...ngs using new HNBR green HFC 134a compatible O rings Lubricate the O rings with mineral oil prior to installation 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 STEP 88 Clean or replace the thermal expansion valve RP00G006 RD05E030 RP00G011 ...

Страница 1110: ...z 250 ml of new SP 20 PAG oil Some oil about 1 2 oz 35 ml will remain in the compressor even after it has been drained If the entire system was not flushed drain the oil from the compressor to be installed Add back new SP 20 PAG oil equal to 8 5 oz 250 ml minus oil amounts still in the components that were not flushed Use the table below NOTE Total system PAG oil should be 9 6 oz 285 ml and about ...

Страница 1111: ...ick 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 4 Evacuate and recharge the system Flushing Solvent Disposal Never reuse contaminated flushing solvent Good stewardship of our natural resources is everyone s business New Holland flushing solvent is a hazardous ma...

Страница 1112: ...r line connections all welded joints any visible damage C Receiver drier line connections D Thermal expansion valve line connections NOTE Remove the thermal insulation tape to check the expansion valve for leaks replace the tape when completed E Service ports valve core under the caps F Low and high pressure switches Check around the entire switch body where it is threaded into the line G Hoses li...

Страница 1113: ... the tractor and system off when leak testing 5 Clean oily spots with dry shop cloths solvents can leave a residue which may confuse OEM1437 6 Hold the leak detector probe under the point being checked since refrigerant is heavier than air 7 The probe on the leak detector should never come into contact with the component being checked 8 If OEM1437 indicates a leak move the probe away blow out the ...

Страница 1114: ...system is running because of change of temperature high system pressures vibration or contact between components This fluorescent dye will normally remain useful over the life of the system However due to a large refrigerant leak system flush or major component failure it may become necessary to reintroduce the dye into the refrigerant circuit Fluorescent Dye Injection Many methods are available t...

Страница 1115: ...injector 8 Recharge the A C system with the proper amount of refrigerant Start the recharging process and immediately open the valve on the station side of the dye injector to prevent drawing the dye into the charging station The dye will be injected into the system while recharging 9 Install the dye identification sticker on a clearly visible area on the compressor body close to the service ports...

Страница 1116: ...securely 9 Open the valve on tractor side of the reservoir on the dye injector 10 Recharge the A C system with the proper amount of refrigerant removed earlier 0 5 lb 0 23 kg Start the recharging process and immediately open the valve on the station side of the dye injector to prevent drawing the dye into the charging station The dye will be injected into the system while recharging 11 Install the...

Страница 1117: ...clockwise to tap the can 6 Hold the can upside down to allow the can contents to enter the A C system When complete turn the T handle counterclockwise to close the valve Disconnect the tool from the low pressure port NOTE You may have to operate the tractor and the A C system for a few minutes to completely empty the can 7 Install the dye identification sticker on a clearly visible area on the com...

Страница 1118: ...ompressor body close to the service ports This will alert service personnel in the future to the presence of the dye in the system 6 Operate the A C system for about 15 minutes to circulate the dye throughout the system Turn off the system and use the UV lamp and goggles to locate leaks The exact location of the leak will be shown by a bright yellow green glow of the dye NOTE The operating time ne...

Страница 1119: ... making sure the oil level in the oil return bottle does not drop below the dip tube 6 Recharge the A C system with the proper amount of refrigerant 7 Install the dye identification sticker on a clearly visible area on the compressor body close to the service ports This will alert service personnel in the future to the presence of the dye in the system 8 Operate the A C system for about 15 minutes...

Страница 1120: ...e than 5 minutes If the lamp heats up uncomfortably cease operation 8 Do not expose eyes or skin to ultraviolet light Do not stare into an ultraviolet light beam or operate the lamp without the ultraviolet lens filter in place 9 In direct sun sunlight or very bright ambient light use a cover of any type over the suspected area to reduce this light 10 If the lamp cannot be directed straight at a su...

Страница 1121: ...TROLLER 2 BLOWER MOTOR FAN ASSEMBLY 3 HEATER CONTROL VALVE NOT SCHOWN 4 BLOWER SPEED DRIVER 5 COMPRESSOR CLUTCH RELAY 6 CAB TEMPERATURE SENSOR 7 EVAPORATOR TEMPERATURE SENSOR 8 THERMAL EXPANSION VALVE 9 LOW PRESSURE SWITCH 10 EVAPORATOR HEATER ASSEMBLY RD06A191 RD02G075 RD02G102 Thermal Tape Removed for Clarity 1 2 7 4 6 5 8 9 10 ...

Страница 1122: ...LDMENT 12 ATC CONTROLLER 18 A C SUCTION LINE TUBE 24 EVAPORATOR BOX ASSEMBLY 13 BLOWER SPEED DRIVER 19 A C LIQUID LINE TUBE 25 THERMAL EXPANSION VALVE 14 BLOWER ASSEMBLY 20 HEATER SUPPLY HOSE 26 DRAIN HOSE 15 A C LOW PRESSURE SWITCH 21 HEATER RETURN HOSE 27 CHECK VALVE 16 HEATER CONTROL VALVE ASSY 22 EVAPORATOR TEMP SENSOR 1 2 15 3 5 4 10 14 8 9 16 11 13 12 6 7 17 ...

Страница 1123: ...90 1 STANDARD CONTROLLER 2 COMPRESSOR CLUTCH RELAY 3 EVAPORATOR HEATER ASSEMBLY 4 EVAPORATOR TEMPERATURE SENSOR 5 HVAC BOX GROUND 6 HEATER CONTROL VALVE 7 THERMAL EXPANSION VALVE 8 LOW PRESSURE SWITCH 9 BLOWER MOTOR ASSY WITH RESISTORS RD02G092 RD02G093 RD02G095 RD02G096 2 1 3 4 5 6 8 7 9 ...

Страница 1124: ...ORATOR COIL ASSY 14 BASE WELDMENT 3 BLOWER ASSEMBLY 8 HEATER CONTROL VALVE ASSY 15 EVAPORATOR BOX ASSEMBLY 4 RESISTOR ASSEMBLY 9 A C SUCTION LINE TUBE 16 THERMAL EXPANSION VALVE A RESISTOR 10 A C LIQUID LINE TUBE 17 CLUTCH RELAY B MOUNTING BRACKET 11 HEATER SUPPLY HOSE 18 DRAIN HOSE 5 WIRE HARNESS NOT SHOWN 12 HEATER RETURN HOSE 19 CHECK VALVE 14 1 17 2 15 13 7 6 4A 9 10 4B 3 12 11 8 16 18 19 ...

Страница 1125: ...er 2 50 2 64 Chassis Components RI06A027 RI06A028 RI06A029 1 RECEIVER DRYER 2 CONDENSER 3 COMPRESSOR 4 HIGH PRESSURE SWITCH 5 PRESSURE TUBE 6 SUCTION TUBE 7 HEATER SUPPLY 8 HEATER RETURN TOP RIGHT HAND SIDE FRONT 1 2 4 3 2 1 5 6 8 7 3 ...

Страница 1126: ...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 STEP 92 Remove the three Torx screws for the clutch dust cover STEP 93 Remove the clutch dust cover A21250 A21251 A21252 ...

Страница 1127: ... the front plate Use the special spanner wrench from the service tool set to keep the plate and shaft from turning STEP 95 Install the special puller from the service tool set on the clutch front plate STEP 96 Turn the center screw to pull the clutch front plate A21253 A21254 A21255 ...

Страница 1128: ...Section 50 Climate Control Chapter 2 50 2 67 STEP 97 Remove the shim s from the shaft STEP 98 Carefully remove the dust cover STEP 99 Remove the key from the rotor shaft A21256 A21257 A21258 ...

Страница 1129: ...snap ring for the bearing and pulley assembly 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 STEP 102 Turn the center screw on the puller A21260 A21261 A21262 ...

Страница 1130: ...0 Climate Control Chapter 2 50 2 69 STEP 103 Remove the pulley and bearing assembly STEP 104 Remove the snap ring for the clutch coil assembly STEP 105 Disconnect the clip for the lead wire A21263 A21265 A21264 ...

Страница 1131: ...Section 50 Climate Control Chapter 2 50 2 70 STEP 106 Remove the clutch coil assembly STEP 107 Remove the internal snap ring and remove the bearing from the pulley A21266 A21267 ...

Страница 1132: ...ading of more than 4 2 amperes indicates a short within the coil No amperage reading indicates an open circuit in the coil Replace the clutch coil if the amperage reading is not correct OR Method 2 Measure resistance Resistance must be 2 86 to 3 3 ohms Replace the clutch coil if the resistance reading is not correct 1 COIL ASSEMBLY 4 BEARING DUST COVER 7 DUST COVER 2 PULLEY 5 FRONT PLATE 8 COMPRES...

Страница 1133: ... 72 STEP 109 Install a new clutch coil assembly Align the coil so the lead wire is next to the clip mounting hole STEP 110 Install the clip for the coil lead wire STEP 111 Install the snap ring for the clutch coil assembly A21266 A21264 A21265 ...

Страница 1134: ...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 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 A21267 RR99D245 RR99D245 ...

Страница 1135: ... 2 74 STEP 115 Install the external snap ring on the front housing hub STEP 116 Install the key in the rotor shaft STEP 117 Place the bearing dust cover in the bore Place driver from special tool kit over the dust cover A21260 A21259 A21269 ...

Страница 1136: ...118 Install the dust cover STEP 119 Install the shim s on the rotor shaft 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 A21270 A21256 A21271 ...

Страница 1137: ... 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 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 A21272 A21253 ...

Страница 1138: ...measurement should be taken between each of the three rivets or on each outer rivet head to get an average measurement If necessary lightly lift or push down on plate to even the gap Spark Plug Gauge If a dial indicator is not available to check air gap clearance a spark plug gauge with 90 wire feelers may be used to check initial air gap in the field Slip the wire between the clutch plate and the...

Страница 1139: ...Section 50 Climate Control Chapter 2 50 2 78 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 A21251 ...

Страница 1140: ...harge 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 A Broken refrigerant hose B Large refrigerant leak C Compressor leak D Damage to or replaced system components E New compressor installed IMPORTANT If a new compressor is to be installed its oil level must ...

Страница 1141: ...osition Make sure the dipstick is inserted all the way to the stop The dipstick stop should be flush with the filler hole boss Take several readings for accuracy The oil level should cover five lines on the dipstick NOTE The illustration shows a front view of the compressor with the dust cover removed and the proper positions of the counterweight for insertion of the dipstick IMPORTANT When compre...

Страница 1142: ...t 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 RD02H046 ...

Страница 1143: ...r access to the fan drive belt Recover the refrigerant 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 STEP 134 Disconnect the compressor clutch wire above the test ports on the suction and discharge lines RD02H035 RD02H038 RD02H034 ...

Страница 1144: ...t the high pressure line from the discharge port Install protective caps on the open port and line STEP 137 Support the 90 fitting to the suction port 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 RD02H033 RD02H040 RD02H042 ...

Страница 1145: ...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 RD05N108 ...

Страница 1146: ...ANT Install the ring terminal ground to the upper front bolt when installing the compressor STEP 140 Slowly remove the protective cap and install the 90 elbow in the suction port on the compressor NOTE Use caution when removing the caps on a new compressor new compressors are pressurized when shipped STEP 141 Install a new O ring and connect the low pressure line to the 90 elbow Support the elbow ...

Страница 1147: ...NOTE Lubricate the O ring with mineral oil before installation STEP 143 Reconnect the high pressure switch at the connector STEP 144 Reconnect the clutch at the connector 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 RD02H041 RD02H033 RD02H034 ...

Страница 1148: ...diator Maximum air flow prevents engine overheating and offers the most efficient A C operation Remove the pin 1 and swing the condenser open to facilitate cleaning IMPORTANT Because condenser fins bend easily and have sharp edges be careful when cleaning the condenser STEP 147 Recover all refrigerant before replacing servicing the condenser fuel cooler Use the two hand two wrench method to discon...

Страница 1149: ... two or more years C Disassembly show small particles of moisture removing material gold or brown particles D If the system has been open for a long period of time because of a leak broken hoses loose connection that has permitted air and moisture to enter the system E If contaminated refrigerant was recovered from the system The receiver drier orientation is critical Make sure the outlet flange i...

Страница 1150: ...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 RD06A171 ...

Страница 1151: ...nut at the front of the right hand side of the seat B Remove the 18 mm bolt at the right hand rear of the seat and remove the console The console can be rested on the rear shelf or slid out the rear window and rested on the three point hitch for better access to the HVAC box STEP 154 Tilt the steering wheel to the full upright position Adjust seat to the full upright and back position STEP 155 Rem...

Страница 1152: ...d to prevent it from falling 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 hand control console if applicable D Reconnect right hand control harness E Ensure cab recirculation air filter is properly installed RD02F049 RD06A191 ATC HVAC Box Shown ...

Страница 1153: ...ATC switch to DEFOG DEFROST or Standard A C switch to ON and check the low pressure gauge reading Compare the gauge readings to the Temperature Pressure chart for your ambient temperature and humidity STEP 163 Remove thermal insulation tape from top of valve Use the palm of your hand to warm the expansion valve and watch the low pressure gauge The valve will open and pressure should rise STEP 164 ...

Страница 1154: ...ction lines from the thermal expansion valve Discard the O rings in the fittings STEP 168 Using the two hand two wrench method disconnect the thermal expansion valve from the evaporator tubes Discard the O rings on the tubes STEP 169 IMPORTANT Lubricate O rings with mineral oil NOT SP 20 PAG Lubricate new O rings with clean mineral oil and install between the evaporator core and thermal expansion ...

Страница 1155: ...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 STEP 172 Replace all thermal insulation tape and reconnect the low pressure cutout switch NOTE The thermal insulation tape is available in 30 ft 9150 mm bulk rolls 1954475C1 0 12 x 2 5 inches x 30 ft 3 x 63 ...

Страница 1156: ...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 STEP 174 The cab temperature sensor must be installed without contact with any box components in the return air stream at the rear of the HVAC box RH99D218 Rear View RI00A055 Side View 1 EVAPORATOR TEMPERATURE SENSOR 2 4 2 INCH 1...

Страница 1157: ... BOX page 90 2 Disconnect the blower motor assembly from the harness at the connector 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 RD06A191 RD02G114 ...

Страница 1158: ...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 4 Pinch the clamp 1 and disconnect the inlet hose to the core from the valve Pinch the clamp 2 and disconnect the supply hose at the bottom of the valve Remove the valve 5 Install a new heater control valve to the same connecting hoses Connect the valve ...

Страница 1159: ... heater supply hose on the right hand side of the engine Close the valve on the heater return hose at the engine See component locations in this Section for your engine STEP 178 Remove the thermal insulation tape from the expansion valve and the evaporator lines To test the valve see thermal expansion valve testing in this section Recover the A C system to remove the evaporator heater core STEP 17...

Страница 1160: ...eater valve and evaporator heater core Be prepared to collect a small amount of coolant that will drain into the HVAC box STEP 181 Remove the two screws securing the blower speed driver and its mounting plate at the rear of the box Remove the 6 pin connector from the driver and move the blower driver assembly out of the way STEP 182 Remove the evaporator temperature sensor from the evaporator heat...

Страница 1161: ... 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 STEP 185 Put the assembly on a clean bench Remove the expansion valve from the evaporator heater core Use the two wrench two hand method when removing the thermal expansion valve to ...

Страница 1162: ...Use the two wrench two hand method when installing the expansion valve to prevent damage to evaporator lines STEP 188 Install the evaporator heater assembly into the slide mounting brackets of the HVAC box STEP 189 Install the sensor harness with grommet in slot in the the evaporator Reinstall the top gasket on the evaporator NOTE The gasket seals the top of the evaporator and forces the air to mo...

Страница 1163: ...e 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 STEP 191 Install the 6 pin connector on the blower speed driver Install the two screws to secure the driver and its mounting plate at the rear of the box RD02G078 RD02G07...

Страница 1164: ... line 2 to the evaporator heater core and secure with the clamp 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 Lubricate the O rings with clean mineral oil prior to installation STEP 194 Using the two hand two wrench method reconnect the air conditioning suction and liquid lines to the valve RD...

Страница 1165: ...be insulated for maximum evaporator performance Apply thermal insulation tape around the expansion valve connectors and the inlet and outlet lines of the evaporator NOTE The thermal insulation tape is available in 30 ft 9150 mm bulk rolls 1954475C1 0 12 x 2 5 inches x 30 ft 3 x 63 5 x 9150 mm STEP 197 To remove air from the cooling system after installation of a replacement evaporator heater assem...

Страница 1166: ...front of the evaporator heater bottom Replace repair any seal which has deteriorated with age or which no longer seals properly Cleaning If the evaporator heater assembly is plugged with dirt and debris locate the source of the debris correct and then clean the assembly See CAB PRESSURIZATION TEST page 111 If the assembly is dry clean with low pressure compressed air If the assembly is wet flush w...

Страница 1167: ... 2 106 BLOWER AND EVAPORATOR REFERENCE ILLUSTRATION RI99D080 1 THERMAL EXPANSION VALVE 4 CHECK VALVE 7 EVAPORATOR TEMP SENSOR 2 BLOWER MOTOR 5 CONDENSATE DRAIN TUBE 8 EVAPORATOR CORE 3 BOX DRAINAGE 6 EVAPORATOR BOX ASSEMBLY 2 1 7 8 6 5 4 3 3 ...

Страница 1168: ...ect the harnesses Reinstall the seat with existing hardware Standard A C Controller STEP 199 The standard A C controller is located behind the evaporator and is mounted to the rear of the HVAC upper case With the ignition switch in the OFF position to replace the standard controller A See ACCESSING THE HVAC BOX page 90 B Disconnect the 6 pin and 5 pin wiring harnesses connected to the standard con...

Страница 1169: ...crews securing the blower speed driver assembly to the rear of the HVAC box C Disconnect the six pin connector to the blower speed driver D Remove the four screws securing the driver to the mounting plate E Install a new blower speed driver with the existing hardware Install the 6 pin connector on the driver and secure the assembly to the HVAC box rear with the two screws removed earlier Reinstall...

Страница 1170: ...cient 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 STEP 202 Open the two retaining clamps and remove the cover STEP 203 Pull the filter straight out Clean the inside of the filter housing Install a new filter by pushing straight in until i...

Страница 1171: ...um air pressure at the nozzle must not be more than 35 PSI 242 kPa Too much air pressure will cause damage to the filter IMPORTANT Do not use a washing method with filter washing compound to clean the filter CAB RECIRCULATION AIR FILTER SERVICE STEP 205 A Remove the vent and the recirculation air filter on both sides of the operators seat B Clean the filter as frequently as required by operating c...

Страница 1172: ...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 STEP 207 Start the engine Take a reading from the digital manometer Cab pressurization must be between 0 25 6 mm and 1 inch 25 4 mm of H2O STEP 208 If a digital...

Страница 1173: ...he seal will pinch off the sensing tube STEP 211 Hold the yard stick vertical Record the water level reading without the engine running Start the engine and measure the movement of water on one side of the yard stick Multiply that value by two Cab pressurization must be between 0 25 6 mm and 1 inch 25 4 mm of H2O STEP 212 If the reading is below 0 25 inch of H2O check the following seals and retes...

Страница 1174: ...b 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 STEP 214 Open the two clamps and remove the cover for the fresh air filter STEP 215 Remove the air intake line from the cab filter housing the post Remove the filter RD02E266 RD02E268 RD02E269 ...

Страница 1175: ... 2 50 2 114 STEP 216 Remove the four bolts and remove the filter housing STEP 217 Disconnect the motor assembly from the harness STEP 218 Remove the bolt nut and washer and remove the assembly from the tractor RD02E270 RD02E272 RD02E273 ...

Страница 1176: ...te Control Chapter 2 50 2 115 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 RI03B043 1 2 ...

Страница 1177: ...tioning 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 NOTE When performing the viscous fan drive test the air conditioning system should be OFF ...

Страница 1178: ... CHASSIS CLEAN GROUND T4 26 MAIN CHASSIS WHEEL SPEED T5 41 MAIN CHASSIS PARK BRAKE SOLENOID T6 38 MAIN CHASSIS RANGE PRESSURE T7 38 MAIN CHASSIS RANGE PRESSURE T8 MAIN CHASSIS NOT USED T9 MAIN CHASSIS NOT USED T10 MAIN CHASSIS NOT USED T11 MAIN CHASSIS NOT USED T12 MAIN CHASSIS NOT USED T13 MAIN CHASSIS NOT USED T14 51 MAIN CHASSIS REMOTE UP T15 51 MAIN CHASSIS REMOTE DOWN T16 51 MAIN CHASSIS REMO...

Страница 1179: ... LOWER 10A 26 FUSE 0 8 Bk 179CL 0 5 T 544A 0 8 R 531F 0 5 R 538A 0 5 LG 537A 0 5 LU 542A 0 8 Y 548A 1 0 R 531B 1 0 R 531A 0 8 DU 536A 0 8 DU 532A 0 8 R 531C SWITCH REGULATION AXLE MU8 SUSPENSION AXLE CONTROLLER 0 8 DU 532B 0 5 DU 536B 0 8 Y 537C 0 8 W 538C 0 8 N 179BK 0 8 DG 179BL CONN COLORED ORANGE SENSOR ON AXLE L H POSITION 1 2 3 7 8 LOCK UNLOCK 4 5 6 9 10 0 8 Bk 179BC 0 8 R 531G 0 8 N 544C LO...

Страница 1180: ...MOTE HITCH SWITCH SECTION 52 LOWER RAISE LOWER RAISE 0 8 R 599H 0 8 LU 513C 0 8 LU 526C 0 8 LU 526 2 0 8 LU 513 2 0 8 LU 513 1 0 8 LU 526 1 0 8 R 599 1 0 8 R 599 2 0 8 LU 526B 0 8 LU 513B 0 8 R 599J HITCH CONTROL SYSTEM EDC 1 2 3 7 8 ON OFF 4 5 6 9 10 0 8 DU 518C SWITCH CONTROL STD RIDE 0 8 DU 512C 1 2 3 7 8 RIDE CONTROL OFF 4 5 6 9 10 HITCH LATCH WITH PICKUP RIDE CONTROL PICKUP HITCH CONNECTOR ED...

Страница 1181: ... 135C 2 0 R 135D 2 0 R 135E 2 0 R 135F 0 8 R 135G 2 0 R 135B 3 0 Bk 134B 3 0 Bk 134C 2 0 Bk 134D 2 0 Bk 134E 2 0 Bk 134F 0 8 Bk 134G 2 0 R 136B 2 0 R 136C 2 0 Or 136D 2 0 Or 136E 2 0 Bk 134J 2 0 Bk 134H 2 0 R 135H 2 0 R 135J 2 0 R 103C 3 0 R 103B 3 0 R 101K 2 0 R 101L 20A FUSE 8 2 0 R 136A 2 0 R 135A 3 0 R 141A 3 0 R 141B 3 0 R 142A 3 0 R 141C 3 0 R 142B 3 0 R 142C 3 0 Bk 177AF 3 0 Bk 177G RECEPTA...

Страница 1182: ...Section 55 Chapter 1 January 2006 ELECTRICAL SYSTEM How It Works And Troubleshooting ...

Страница 1183: ... Diagnostic Tests 55 1 153 EXTERIOR LIGHTING SYSTEM 55 1 157 Exterior Lighting System Circuit Operation 55 1 157 Exterior Lighting System Circuit Troubleshooting 55 1 157 Exterior Lighting System Symptom Chart 55 1 158 Exterior Lighting System Diagnostic Tests 55 1 158 INSTRUMENTATION AND WARNING SYSTEM 55 1 163 Instrumentation and Warning System Circuit Troubleshooting 55 1 163 Instrumentation an...

Страница 1184: ...ircuit Troubleshooting 55 1 190 Starting System Symptom Chart 55 1 190 Starting System Diagnostic Tests 55 1 192 WIPER WASHER SYSTEM 55 1 197 Wiper Washer System Circuit Operation 55 1 197 Wiper Washer System Circuit Troubleshooting 55 1 197 Wiper Washer System Symptom Chart 55 1 198 Wiper Washer System Diagnostic Tests 55 1 199 ...

Страница 1185: ...em Chapter 1 55 1 4 SPECIAL TOOLS RD05C001 Electrical Connector and Terminal Repair Kit AJI1400004 See the Parts Merchandiser Catalog for ordering information and identification of components RD05C002 Digital Multimeter CAS 1559 ...

Страница 1186: ...uses 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 RD05J114 ...

Страница 1187: ...adlight Switch 10 19 Dome Light Map Light Radio 1 10 20 Amber Flashers 20 21 Tail Lights 10 22 Stop Lights 10 23 Beacon 15 24 Power Mirror Radio 10 25 Blank 26 Suspended Axle B 10 27 Side Roof HID Lamps 20 28 Blank 29 Seat Heater 10 30 Side Wiper 10 31 ISO 17783 10 32 Trans Controller B 20 33 RH Armrest Controller 2 10 34 True Ground Radar 5 35 Autoguidance 5 36 TMF Remote System Controller 15 37 ...

Страница 1188: ... LATCH 14 REAR WIPER 23 TRUC 6 NEUTRAL RELAY 15 SIDE WIPER 24 RADAR ARU 7 FRONT ROOF HID LAMPS 16 OPEN 25 SWITCH SOLENOID 100 AMP 8 BELTLINE WORK LAMPS 17 EGRESS LIGHTING 26 FLASHER MODULE INTERFACE 9 FRONT ROOF WORK LAMPS 18 OPEN 4 5 6 1 10 7 13 9 8 17 12 11 14 3 2 15 22 19 23 20 24 21 16 18 25 26 3 5 2 4 1 13 12 9 11 8 10 7 17 16 14 6 1 CENTER SIDE WORK LAMP FUSE 8 RH LOW BEAM RELAY FUSE 14 LOW ...

Страница 1189: ...Section 55 Electrical System Chapter 1 55 1 8 INSTRUMENTATION AND CONTROLS RD05J040 INSTRUMENTATION CLUSTER ...

Страница 1190: ... 1 9 RD05J066 INSTRUMENT PANEL CONTROLS RH02G113 STEERING COLUMN CONTROLS 1 ROAD LAMPS AMBER WARNING LAMPS SWITCH 3 WORK LAMP SWITCH 2 KEY SWITCH 1 DIRECTION TURN SIGNAL LEVER HORN BUTTON HIGH LOW BEAM SWITCH 2 TURN SIGNAL INDICATORS 1 2 3 1 2 ...

Страница 1191: ...NTROL 16 AUTO SHIFT CONTROL 9 HITCH LOAD CONTROL 17 REMOTE AUTO MODE CONTROL 10 HITCH POSITION CONTROL 18 PTO CONTROL 11 HITCH LOWER LIMIT POSITION RING 19 DISPLAY SELECTION KNOB FOR INTELLIVIEW II 12 PROGRAMMABLE SHIFT CONTROL OR ELECTRONIC END OF ROW STEP SWITCH IF EQUIPPED 20 HOME SWITCH FOR INTELLIVIEW II 13 FWD CONTROL 21 ESCAPE SWITCH FOR INTELLIVIEW II 14 DIFFERENTIAL LOCK CONTROL 22 INTELL...

Страница 1192: ...IDE CONTROL SWITCH IF EQUIPPED 2 SUSPENDED AXLE SWITCH IF EQUIPPED 3 AUTOGUIDANCE IF EQUIPPED 4 BEACON LIGHT SWITCH 5 ENGINE CONSTANT SPEED ON OFF SWITCH IF EQUIPPED 6 ENGINE CONSTANT SPEED ADJUST SWITCH IF EQUIPPED 7 CIGAR LIGHTER 8 BLOWER SPEED CONTROL KNOB 9 TEMPERATURE CONTROL KNOB 10 FRONT WINDSHIELD WIPER CONTROL 11 REAR WINDSHIELD WIPER CONTROL 12 POWER MIRROR SWITCH IF EQUIPPED 13 DEFOG CO...

Страница 1193: ...ontroller also known as the Tractor Multi Function TMF controller 1 AUX HITCH PTO CONTROLLER TMF CONTROLLER 8 CONNECTOR NO 57 2 TRANSMISSION AND FRONT AXLE CONTROLLER 9 CONNECTOR NO 355 3 CONNECTOR NO 54 10 CONNECTOR NO 353 4 CONNECTOR NO 55 11 CONNECTOR NO 350 5 CONNECTOR NO 56 12 CONNECTOR NO 351 6 CONNECTOR NO 58 13 CONNECTOR NO 335 7 CONNECTOR NO 53 1 2 4 13 3 5 6 7 8 9 10 11 12 ...

Страница 1194: ...rmation 1 CHASSIS TO CAB HARNESS CONNECTOR NO 10 2 BUSSMAN FUSE 100 AMP SECTION 19 OF SCHEMATIC 3 TRACTOR ECU ISO11783 CONNECTOR NO 282 1 ENGINE FUSE BOX 2 POWER DISTRIBUTION CONNECTOR NO 7M BLACK 3 ENGINE CONNECTOR NO 108 GRAY 4 SWITCHED POWER CONNECTOR NO 64 BLACK 5 UNSWITCHED POWER CONNECTOR NO 65 GRAY 6 OPERATOR SUPPLIED POWER CONNECTOR NO 121 BLUE 7 LIGHTING CONNECTOR NO 109 GREEN 2 3 1 6 2 4...

Страница 1195: ...OLENOID CONNECTOR NO 39 15 C1 CLUTCH SOLENOID CONNECTOR NO 31 5 PARK BRAKE SOLENOID CONNECTOR NO 49 16 C3 CLUTCH SOLENOID CONNECTOR NO 32 6 PTO DIFF LOCK VALVE 17 C5 CLUTCH SOLENOID CONNECTOR NO 33 7 POWERSHIFT VALVE RANGE 18 REVERSE SOLENOID CONNECTOR NO 34 8 FWD SOLENOID CONNECTOR NO 160 19 SYSTEM PRESSURE TRANSDUCER CONNECTOR NO 44 9 LOW CLUTCH SOLENOID CONNECTOR NO 36 20 DIFF LOCK SOLENOID CON...

Страница 1196: ...CTOR 140 LOWER CONNECTOR 340 2 REMOTE SECTION NO 2 TOP CONNECTOR 141 LOWER CONNECTOR 341 3 REMOTE SECTION NO 3 TOP CONNECTOR 142 LOWER CONNECTOR 342 4 REMOTE SECTION NO 4 TOP CONNECTOR 143 LOWER CONNECTOR 343 5 REMOTE SECTION NO 5 TOP CONNECTOR 144 LOWER CONNECTOR 344 6 HITCH LOWER CONNECTOR 152 7 HITCH RAISE CONNECTOR 151 1 2 3 4 5 6 7 ...

Страница 1197: ...Section 55 Electrical System Chapter 1 55 1 16 RT97K033 RT97K034 INCHING PEDAL 1 CONNECTOR NO 50 BOC SWITCH 3 INCHING PEDAL 2 CONNECTOR NO 52 CLUTCH POSITION POTENTIOMETER 1 1 2 3 3 ...

Страница 1198: ...Section 55 Electrical System Chapter 1 55 1 17 ARMRST RIGHT HAND CONSOLE 1 ARMREST CONTROLLER 1 ...

Страница 1199: ...55 1 18 RD98H143 LOWER FRONT CONSOLE RD02H179 BOTTOM RH FRONT CORNER OF CAB 1 TO TRANSMISSION CONTROL LEVER 1 CONNECTOR NO 60 IN LINE CONNECTOR FRONT TO REAR HARNESS 2 BRAIDED GROUND STRAP 3 CAB MOUNT GROUNDS NOT SHOWN SEE CAB MOUNT 1 3 2 1 ...

Страница 1200: ...ctrical System Chapter 1 55 1 19 RD06B002 INSTRUMENTATION CLUSTER RD05J085 TOP OF FUEL TANK 1 INSTRUMENTATION CLUSTER 3 CONNECTOR NO CN 2 2 CONNECTOR NO CN 1 4 CONNECTOR NO 380 1 CONNECTOR NO 66 FUEL SENDER 4 3 2 1 1 ...

Страница 1201: ...Chapter 1 55 1 20 RD02H177 BRAKE VALVE SWITCH CONNECTIONS RD02H216 LEFT HAND SIDE OF ENGINE 1 RIGHT BRAKE SWITCH 1 CONNECTOR 47 2 LEFT BRAKE SWITCH 2 CONNECTOR 48 1 AIR TO AIR TEMP SENSOR CONNECTOR NO 75 EMERGING MARKET ONLY 2 1 1 ...

Страница 1202: ...A176 ALTERNATOR 1 REMOTE HITCH SWITCHES LEFT CONNECTOR NO 313A RIGHT NO 313B 2 HYDRAULIC TOP LINK LEFT CONNECTOR NO 399 RIGHT NO 401 1 ALTERNATOR 4 CONNECTOR NO 85 ALTERNATOR EXCITE D 2 REGULATOR 3 CONNECTOR NO 77 ALTERNATOR B 5 CONNECTOR NO 86 ALTERNATOR W FREQUENCY ENGINE RPM 2 1 4 3 2 1 ...

Страница 1203: ...trical System Chapter 1 55 1 22 RD98E030 RIGHT HAND SIDE OF TRANSMISSION RD06A177 OPERATOR SEAT 1 CONNECTOR NO 88 TRANSMISSION FILTER RESTRICTION SENSOR 1 CONNECTOR NO 137 3 CONNECTOR NO 377 2 CONNECTOR NO 51 1 3 2 1 ...

Страница 1204: ...System Chapter 1 55 1 23 RD98G022A TOP REAR OF TRANSMISSION RD97K112 PTO SHAFT 1 CONNECTOR NO 145 TO PTO SHAFT SPEED SENSOR 2 PTO SHAFT SPEED SENSOR 1 CONNECTOR NO 146 TO PTO DUAL SPEED SENSOR 2 PTO DUAL SPEED SENSOR 2 1 2 1 ...

Страница 1205: ...Section 55 Electrical System Chapter 1 55 1 24 RD98E024 RIGHT HAND SIDE NEAR AXLE RD98E005 LEFT HAND SIDE NEAR AXLE 1 CONNECTOR NO 153 TO RH DRAFT PIN 1 CONNECTOR NO 154 TO LH DRAFT PIN 1 1 ...

Страница 1206: ...Section 55 Electrical System Chapter 1 55 1 25 RD98E025 RIGHT HAND SIDE AT ROCKSHAFT 1 CONNECTOR NO 155 ROCKSHAFT POTENTIOMETER BEHIND COVER 1 ...

Страница 1207: ...Section 55 Electrical System Chapter 1 55 1 26 RT97K036 BRAKE PEDALS 1 CONNECTOR NO 162 LEFT BRAKE SWITCH 2 CONNECTOR NO 163 RIGHT BRAKE SWITCH 1 2 ...

Страница 1208: ...Section 55 Electrical System Chapter 1 55 1 27 RD06A178 UNDER HOOD 1 INTERMEDIATE STARTING RELAY 1 ...

Страница 1209: ...Section 55 Electrical System Chapter 1 55 1 28 RD02H178 NON ELECTRONIC ENGINE RD02H220 ELECTRONIC ENGINE 1 ENGINE OIL PRESSURE SWITCH EMERGING MARKET 1 ENGINE OIL PRESSURE SWITCH 1 1 ...

Страница 1210: ...A C COMPRESSOR RD02H227 NON ELECTRONIC ENGINE 1 CONNECTOR NO 215 ENGINE COOLANT TEMPERATURE SENSOR ELECTRONIC ENGINE 2 BLOCK HEATER ALL ENGINES 1 INJECTION PUMP SOLENOID CONNECTOR NO 214 2 CONNECTOR NO 215 ENGINE COOLANT TEMPERATURE SENSOR EMERGING MARKET 1 2 1 2 ...

Страница 1211: ...1 30 RD02H217A LEFT SIDE OF ENGINE RD06A186 LEFT SIDE OF ENGINE 1 REAR OF TIMING GEAR COVER 2 CONNECTOR NO 246 ENGINE SPEED SENSOR 1 INTAKE MANIFOLD AIR TEMP BOOST PRESSURE CONNECTOR NO C4 2 AMBIANT AIR PRESSURE SENSOR CONNECTOR NO C29 2 1 1 2 ...

Страница 1212: ...r 1 55 1 31 RD06A179 LEFT SIDE ELECTRONIC ENGINE RD06A185 AIR INTAKE 1 ENGINE CONTROLLER CONNECTOR J1 2 ENGINE CONTROL MODULE CONNECTOR NO 256 3 ENGINE CONTROLLER POWER AND GROUND CONNECTOR NO 204 1 AIR FILTER RESTRICTION SWITCH 3 2 1 1 ...

Страница 1213: ...Section 55 Electrical System Chapter 1 55 1 32 RD06B001 RIGHT SIDE OF FRONT CONSOLE RD06A172 GRID RELAY 1 FOOT THROTTLE CONNECTOR NO 256 1 GRID RELAY 2 FUSE NO 370 200 AMP 1 2 1 ...

Страница 1214: ... This photo is from TG It is in same location on MX but unsure if it works for both RD06A182 REAR OF TRACTOR BELOW CONTROLLERS 1 PASSIVE TERMINATOR CONNECTOR NO 175 1 1 IMPLEMENT RELAY CONNECTOT NO 282 3 RELAY FUSE 327M 30 AMP 2 IMPLEMENT RELAY CONNECTOR NO 283 4 RELAY FUSE 328M 20 AMP 2 1 4 3 ...

Страница 1215: ...BER CIRCUIT REFERENCE 1 S5 SWITCHED B 1S 631801C1 SOCKET HOUSING 631801C1 2M 198714A1 SOCKET HOUSING 2S 230227A1 SOCKET HOUSING CAB HARNESS CONNECTOR 3M 294250A1 RH SIDE HID LIGHT CAV WIRE NUMBER CIRCUIT REFERENCE A 738G SIDE LAMP B B 170G GROUND CONNECTOR 3S 230227A1 SEAT COMPRESSOR CAV WIRE NUMBER CIRCUIT REFERENCE 1 S5 COMMON CONNECTOR 4M 198714A1 LH HEADLIGHT CAV WIRE NUMBER CIRCUIT REFERENCE ...

Страница 1216: ...TOR 5S 225316C1 OPERATOR PRESENCE CAV WIRE NUMBER CIRCUIT REFERENCE A S6 B B S8 GROUND 4S 631801C1 SOCKET HOUSING 631801C1 5M 294250A1 SOCKET HOUSING HEADLAMP HARNESS 5S 225316C1 SOCKET HOUSING CONNECTOR 6M 294250A1 HID CENTER LIGHT CAV WIRE NUMBER CIRCUIT REFERENCE A 738F CENTER HID LIGHT B B 170H GROUND CONNECTOR 6S 225316C1 OPERATOR PRESENCE CAV WIRE NUMBER CIRCUIT REFERENCE A S10 B B S11 GROUN...

Страница 1217: ...T RELAY E 172C START OUTPUT F 792E CENTER SIDE RELAY G 726C HIGH BEAM RELAY H 728D HIGH DIODE HIGH RELAY CONNECTOR 7S 198456A1 BACK HEATER CAV WIRE NUMBER CIRCUIT REFERENCE A S14 B B S28 GROUND 7M 409089A1 BLACK SOCKET HOUSING 7S 198456A1 SOCKET HOUSING CONNECTOR 8S 182077A1 SEAT HEATER CAV WIRE NUMBER CIRCUIT REFERENCE A S15 HEATER B B S20 HEATER GROUND C S26 HEATER B D S29 HEATER GROUND 8S 18207...

Страница 1218: ...GROUND CONNECTOR 9M 225319C1 TURN SIGNAL SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE 1 766B TURN SIGNAL COMMON B 2 768A LEFT TURN SWITCH 3 767A RIGHT TURN SWITCH 4 725A HEADLIGHT SWITCH B 5 726A HIGH BEAM 6 728A LOW BEAM 7 706D HEADLIGHT DIPPING B 8 178AA GROUND 9F 225320C1 PIN HOUSING 9M 225319C1 BLACK SOCKET HOUSING CONNECTOR 9S 182077A1 HEATER CONTROL MODULE CAV WIRE NUMBER CIRCUIT REFERENCE A S16...

Страница 1219: ...EN 28 565A PNEUMATIC BRAKE B 29 293A PTO ON ARMREST 30 566B PNEU BRAKE IND EURO 31 OPEN 32 OPEN CONNECTOR 10M 437552A1 CHASSIS TO CAB HARNESS CAV WIRE NUMBER CIRCUIT REFERENCE 33 547B CRUISE ON OFF 34 358B CRUISE INCREMENT 35 489B CRUISE DECREMENT 36 267B HYDRAULIC FILTER 37 267C TRANSMISSION FILTER 38 555A CLUTCH POT SIGNAL 39 556A 40 557C CLUTCH POT GND 41 754B RIGHT TURN LAMP 42 752H RIGHT HAZA...

Страница 1220: ...3 UNSWITCHED B 73 OPEN 74 518A PICKUP HITCH LATCH 75 512A RIDE CONTROL 76 900E AUX CONTROLLER B 77 223B GOV ING SW SIG 78 89B KEY BATTERY 79 172A FNRP START OUTPUT 80 722B HORN POWER B 81 836B FRONT WASHER 82 845B REAR WASHER 83 283B RADAR B 84 835B TO HVAC CLUTCH 85 195C CAB PRESSURE BLOWER 86 802B HVAC HIGH PRESS SW OUT 87 285B IMPLEMENT SWITCH 88 551A FNRP SHUTTLE F 89 553A FNRP NOT NEUTRAL CON...

Страница 1221: ... OF CLUTCH RLY NC 28 565C PNEUMATIC BRAKE B 29 293B PTO ON ARMREST 30 566A PNEU BRAKE IND EURO 31 OPEN 32 OPEN CONNECTOR 10F 437551A1 CAB BULKHEAD CAV WIRE NUMBER CIRCUIT REFERENCE 33 547A CRUISE ON OFF 34 358A CRUISE INCREMENT 35 489A CRUISE DECREMENT 36 267A HYD FILTER RESTRICT 37 267D TRANS FILTER RESTRICT 38 555D CLUTCH POT SIG 39 556D CLUTCH POT B 8V 40 557D CLUTCH POT GND 41 754A RIGHT TURN ...

Страница 1222: ...X CONTROLLER B 77 223A GOV ING SW ING 78 89A KEY BATTERY 79 172B FNRP START OUTPUT 80 722A HORN POWER B 81 836A FRONT WASHER 82 845A REAR WASHER 83 283A RADAR B 84 835A TO HVAC CLUTCH 85 195B CAB PRESSURE BLOWER 86 802A HVAC HIGH PRESS SW OUT 87 285A IMPLEMENT SWITCH 88 551D FNRP SHUTTLE F 89 553D FNRP NOT NEUTRAL 90 552B FNRP SHUTTLE R 91 561B FNRP SWITCH 5V 92 558A PARK RELAY COIL 93 OPEN CONNEC...

Страница 1223: ... 791A ROOF REAR WORKLIGHT R 790A FRONT ROOF WORKLIGHT T OPEN W 792A LOWER WORKLIGHT 11M BLACK SOCKET HOUSING CAB HARNESS 382391A1 12F 475083C1 SOCKET HOUSING CAB HARNESS CONNECTOR 11S 225316C1 SEAT SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE 1 S12 SWITCH B 2 S13 PRESENCE SIGNAL CONNECTOR 12S 225315C1 SEAT SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE 1 S7 SWITCH B 2 S9 PRESENCE SIGNAL CONNECTOR 13S 225316...

Страница 1224: ... CONSOLE LIGHT RADIO GND V 871B 871C DOME LIGHT RADIO UNSWITCHED B W 870C RADIO SWITCHED B X 135B ROOF AUX POWER UNSWITCHED B Y 136B ROOF AUX POWER SWITCHED B Z 134B AUXILIARY POWER GROUND CONNECTOR 13M 196155A1 CAB HARNESS CAV WIRE NUMBER CIRCUIT REFERENCE A 751C LEFT ROOF HAZARD TURN B OPEN C 752C RIGHT ROOF HAZARD TURN D 783A A POST WORKLIGHTS E 784A FRONT ROOF WORKLIGHTS F 178H CHASSIS GROUND ...

Страница 1225: ...HT CAV WIRE NUMBER CIRCUIT REFERENCE 1 LAMP B 2 LAMP GROUND 14F 15F PIN HOUSING LAMP 222136A1 14M 15M SOCKET HOUSING ROOF HARNESS 222135A1 CONNECTOR 16M 245482C1 LEFT REAR WORKLIGHT CAV WIRE NUMBER CIRCUIT REFERENCE A 793C B B 178AL GROUND CONNECTOR 16F 245483C1 LEFT REAR WORKLIGHT CAV WIRE NUMBER CIRCUIT REFERENCE A LAMP B B LAMP GROUND CONNECTOR 17M 245482C1 RIGHT REAR WORKLIGHT CAV WIRE NUMBER ...

Страница 1226: ... LEFT FENDER HARNESS CAV WIRE NUMBER CIRCUIT REFERENCE 1 787 LEFT WORKLIGHT B 2 753 LEFT WORKLIGHT GROUND 3 751 WIDE MARKER LIGHT 4 755 STOP LIGHT 5 750 LEFT TAIL CONNECTOR 20M 225351C1 RIGHT FENDER HARNESS CAV WIRE NUMBER CIRCUIT REFERENCE 1 787J RIGHT WORKLIGHT B 2 754B RIGHT TURN 3 752L WIDE MARKER LIGHT 4 755 C STOP LIGHT 5 750H RIGHT TAIL CONNECTOR 21M 225351C1 LEFT FENDER HARNESS CAV WIRE NU...

Страница 1227: ...F WORKLIGHTS 4 740B RIGHT LOW BEAM 5 741B RIGHT HIGH BEAM 6 180F CHASSIS GROUND 7 176C CHASSIS GROUND 8 744A PILOT 18M SOCKET HOUSING ROOF HARNESS 239449A1 22M 225320C1 SOCKET HOUSING CONNECTOR 22F 225320C1 FRONT HITCH LAMPS CAV WIRE NUMBER CIRCUIT REFERENCE 1 OPEN 2 OPEN 3 738F WORKLAMPS 4 OPEN 5 OPEN 6 180F CHASSIS GROUND 7 OPEN 8 OPEN CONNECTOR 25M 256342A1 FENDER HID BALLAST CAV WIRE NUMBER CI...

Страница 1228: ... 12162194 CONNECTOR 26F 86993701 FENDER HID BALLAST CAV WIRE NUMBER CIRCUIT REFERENCE 1 RED 2 WHITE 4 BLACK 26F 86993701 SOCKET HOUSING CONNECTOR 27F 225315C1 FENDER HID LIGHT CAV WIRE NUMBER CIRCUIT REFERENCE 1 RED B 2 BLACK GROUND 27F 225315C1 PIN HOUSING ...

Страница 1229: ...4A1 CREEP SOLENOID CAV WIRE NUMBER CIRCUIT REFERENCE 1 201N HIGH SIDE 2 590A LOW SIDE 29 30 31 32 33 34 36 37 38 39 371614A1 SOCKET HOUSING ROOF HARNESS CONNECTOR 30M 371614A1 EVEN SOLENOID CAV WIRE NUMBER CIRCUIT REFERENCE 1 201E HIGH SIDE 2 581A LOW SIDE CONNECTOR 32M 371614A1 3 4 SOLENOID CAV WIRE NUMBER CIRCUIT REFERENCE 1 201F HIGH SIDE 2 583A LOW SIDE CONNECTOR 34M 371614A1 REVERSE SOLENOID ...

Страница 1230: ...182064A1 LEFT FENDER GROUND CAV WIRE NUMBER CIRCUIT REFERENCE A 174F GROUND CONNECTOR 40M 182066A1 RIGHT FENDER GROUND CAV WIRE NUMBER CIRCUIT REFERENCE A 174 GROUND CONNECTOR 41M 182066A1 LEFT FENDER GROUND CAV WIRE NUMBER CIRCUIT REFERENCE A 174 GROUND CONNECTOR 44M 198456A1 SYSTEM PRESSURE CAV WIRE NUMBER CIRCUIT REFERENCE A 557B SYSTEM PRESSURE GROUND B 561C SYSTEM PRESSURE B C 563A SYSTEM PRE...

Страница 1231: ...BRAKE PARK SOLENOID SWITCH 2 CAV WIRE NUMBER CIRCUIT REFERENCE A 561G PARK B B 567B TO SOLENOID 47M 335461A1 SOCKET HOUSING 48M 335461A1 SOCKET HOUSING CONNECTOR 49F 225315C1 PARK SOLENOID CAV WIRE NUMBER CIRCUIT REFERENCE 1 567D PARK B 2 179BT GROUND CONNECTOR 49M 225316C1 PARK SOLENOID CAV WIRE NUMBER CIRCUIT REFERENCE 1 567C PARK B 2 179AE GROUND 49F SOCKET HOUSING FRONT TO REAR HARNESS 225315C...

Страница 1232: ...9MM 225316C1 PARK SOLENOID CAV WIRE NUMBER CIRCUIT REFERENCE 1 567G PARK B 2 179CA GROUND 49MM 225316C1 SOCKET HOUSING CONNECTOR 50M 227429A1 BOTTOM OF CLUTCH SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE A 553B BOTTOM OF CLUTCH B 568A NOT NEUTRAL SIGNAL 50M SOCKET HOUSING 227429A1 ...

Страница 1233: ...RP FORWARD 7 FNRP NOT NEUTRAL 8 FNRP GROUND 9 HORN 10 RT LT TURN COMMON GND 11 FNRP RIGHT TURN INDICATOR 12 FNRP LEFT TURN INDICATOR CONNECTOR 51M 223671A1 FNRP SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE 1 623A START INPUT 2 172B START OUTPUT 3 550J RUN INPUT 4 511A FNRP NOT PARK 5 552B FNRP REVERSE 6 551D FNRP FORWARD 7 553F FNRP NOT NEUTRAL 8 561B FNRP GROUND 9 723A HORN 10 178AB RT LT TURN COMMON...

Страница 1234: ... SWITCHED B 2 900B INTERLOCKED SWITCHED B 3 900C INTERLOCKED SWITCHED B 4 AUX1 TOP1 EHR 1 RAISE SOURCE 5 525B EDC RAISE SOL SOURCE 6 AUX3 BOT 1 EHR 3 LOWER SOURCE 7 AUX4 TOP 1 EHR 4 RAISE SOURCE 8 501E INTERLOCKED SWITCHED B 9 595C EHR ENABLE 10 AUX1 BOT 1 EHR 1 LOWER SOURCE 11 AUX2 BOT 1 EHR 2 LOWER SOURCE 12 528B EDC LOWER SOL SOURCE 13 597A PTO CLUTCH SOL SOURCE 14 114D BATTERY B 15 YELLOW CAN ...

Страница 1235: ...A FRONT WHEEL DRIVE CLUTCH SOL 9 530A REAR DIFF LOCK CLUTCH SOL 10 AUX2 TOP2 EHR 2 RAISE SOL SINK 13 AUX4 BOT1 EHR 4 LOWER SOL SOURCE 14 AUX6 TOP1 EHR 6 RAISE SOL SOURCE 15 AUX5 TOP1 EHR 5 RAISE SOL SOURCE 16 AUX6 BOT1 EHR 6 LOWER SOL SOURCE 17 702A BRAKE LIGHT RELAY 18 AUX4 BOT2 EHR 4 LOWER SOL SINK 21 294A PTO SHAFT SIZE FREQ 23 25 501D INTERLOCKED SWITCHED B 34 501C INTERLOCKED SWITCHED B 54M S...

Страница 1236: ...UX1 TOP2 EHR 1 RAISE SOL SINK 9 534A DB9 RS232 IN 10 533A DB9 RS232 OUT 13 AUX4 TOP2 EHR 4 RAISE SINK 20 295A PTO CLUTCH OUTPUT SPEED 21 179F POWER GROUND 25 179AL POWER GROUND 26 179AC POWER GROUND CONNECTOR 57M 87410946 TMF TRACTOR MULTI FUNCTION CONTROLLER CAV WIRE NUMBER CIRCUIT REFERENCE 2 507A EDC POSITION POT WIPER 4 918A EHR CYL 1 FEEDBACK 5 919A EHR CYL 2 FEEDBACK 9 515A EDC LEFT DRAFT PI...

Страница 1237: ...G OPEN 24 PLUG OPEN 25 199D RADAR SIGNAL FREQ 26 PLUG OPEN 27 YELLOW CDB HI TR 28 262B RADAR PRESENT 30 267B TRANS FILTER RESTRICTION SW 31 267C HYDRAULIC FILTER RESTRICTION SW CONNECTOR 60M HDP24 24 31SE CAB TO CHASSIS CAV WIRE NUMBER CIRCUIT REFERENCE 1 PLUG OPEN 2 183B ICU CLEAN GROUND 3 179S CLEAN GROUND 4 181A ICU SENSOR GND 5 PLUG OPEN 6 945A IDLE VALIDATION OFF 7 266A AIR FILTER 8 234A FUEL...

Страница 1238: ... NUMBER CIRCUIT REFERENCE A 234B FUEL SENDER 8V B 236B FUEL SENDER SIGNAL C 181M FUEL SENDER GROUND CONNECTOR 66F 245485C1 FUEL SENDER CAV WIRE NUMBER CIRCUIT REFERENCE A SENSOR FUEL SENDER B B SENSOR FUEL SENDER SIGNAL C SENSOR FUEL SENDER GROUND CONNECTOR 67F 225315C1 PNEUMATIC AIR SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE 1 566C SOLENOID B 2 179AB CHASSIS GROUND CONNECTOR 67M 225316C1 PNEUMATIC ...

Страница 1239: ... FRONT TO REAR CONNECTOR 69F 245483C1 WHEEL SPEED CAV WIRE NUMBER CIRCUIT REFERENCE A SENSOR WHEEL SPEED SIGNAL B SENSOR WHEEL SPEED GROUND CONNECTOR 69M 245482C1 WHEEL SPEED CAV WIRE NUMBER CIRCUIT REFERENCE A 215C WHEEL SPEED SIGNAL B 181N WHEEL SPEED GROUND CONNECTOR 70F 245483C1 PNEUMATIC PREFILL SOLENOID CAV WIRE NUMBER CIRCUIT REFERENCE A 565D B B 179B5 CHASSIS GROUND CONNECTOR 70M 245482C1 ...

Страница 1240: ...481C1 A C COMPRESSOR CLUTCH CAV WIRE NUMBER CIRCUIT REFERENCE A COMP A C COMPRESSOR CLUTCH B CONNECTOR 72M 245480C1 A C COMPRESSOR CLUTCH CAV WIRE NUMBER CIRCUIT REFERENCE A 835C A C COMPRESSOR CLUTCH B 71F SOCKET HOUSING 292549A1 71M PIN HOUSING 292548A1 72F 245481C1 PIN HOUSING 72M SOCKET HOUSING ENGINE HARNESS 245480C1 CONNECTOR 73F 475075C1 ETHER SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE A 600D...

Страница 1241: ...266C AIR FILTER REST 75M PIN HOUSING ENGINE HARNESS 182068A1 76F PIN HOUSING 291718A1 CONNECTOR 77F AMP_327175 ALTERNATOR OUTPUT B CAV WIRE NUMBER CIRCUIT REFERENCE 1 120A B CONNECTOR 78F 200338 INTERMEDIATE STARTING RELAY CAV WIRE NUMBER CIRCUIT REFERENCE 1 620A B CONNECTOR 79F 200312 STARTER START TERMINAL CAV WIRE NUMBER CIRCUIT REFERENCE 1 625A B CONNECTOR 81A 225068C1 ALTERNATOR OUTPUT B CAV ...

Страница 1242: ...REFERENCE 1 600A B CONNECTOR 84F 225065C1 STARTER START TERMINAL CAV WIRE NUMBER CIRCUIT REFERENCE 1 625A B CONNECTOR 85F 200329 ENGINE RPM CAV WIRE NUMBER CIRCUIT REFERENCE 1 126 W B 81F 83F 84F 87F RING TERMINAL CONNECTOR 86F 446658 ALTERNATOR EXCITE CAV WIRE NUMBER CIRCUIT REFERENCE 1 121 D B CONNECTOR 87F 225065C1 CHASSIS GROUND CAV WIRE NUMBER CIRCUIT REFERENCE 1 600E CHASSIS GROUND CONNECTOR...

Страница 1243: ...MBER CIRCUIT REFERENCE A BLOWER BLOWER B B BLOWER BLOWER GROUND 89F FRONT TO REAR HARNESS 222316A1 89M FRONT TO REAR HARNESS 222315A1 90M PIN HOUSING FRONT TO REAR HARNESS 872290R1 CONNECTOR 91F 227729A1 ROOF AUXILIARY POWER CAV WIRE NUMBER CIRCUIT REFERENCE A 134C GROUND B 136C SWITCHED B C 135C UNSWITCHED B CONNECTOR 91M 227728A1 ROOF AUXILIARY POWER CAV WIRE NUMBER CIRCUIT REFERENCE A 134B GROU...

Страница 1244: ...42C1 RIGHT HAND CONSOLE LIGHT CAV WIRE NUMBER CIRCUIT REFERENCE A 726D LIGHT B B 178N 178P GROUND 93M PIN HOUSING 93F SOCKET HOUSING 94F SOCKET HOUSING 291729A1 94M SOCKET HOUSING 255442C1 CONNECTOR 95A 292495A1 DELCO RADIO CAV WIRE NUMBER CIRCUIT REFERENCE 1 OPEN 2 OPEN 3 OPEN 4 870C SWITCHED B 5 OPEN 6 727E DIMMER 7 871B UNSWITCHED B 8 178M POWER GROUND CONNECTOR 95B 291494A1 DELCO RADIO CAV WIR...

Страница 1245: ...ENCE A SPEAKER SPEAKER B SPEAKER SPEAKER 96M PIN HOUSING 96F SOCKET HOUSING 97M PIN HOUSING 97F SOCKET HOUSING CONNECTOR 98F 245716C1 REAR WIPER MOTOR CAV WIRE NUMBER CIRCUIT REFERENCE A REAR WIPER HIGH B WIPER REAR WIPER LOW C WIPER REAR WIPER PARK D WIPER REAR WIPER BRAKE CONNECTOR 98M 245715C1 REAR WIPER MOTOR CAV WIRE NUMBER CIRCUIT REFERENCE A OPEN B 843 B REAR WIPER LOW C 841 B REAR WIPER PA...

Страница 1246: ...WIRE NUMBER CIRCUIT REFERENCE 1 178P GROUND 100M 101M 102M 103M SOCKET HOUSING 631801C1 CONNECTOR 104F FLAG_TERM RIGHT HAND REAR TURN SIGNAL CAV WIRE NUMBER CIRCUIT REFERENCE 1 752E RIGHT HAND REAR TURN SIG B CONNECTOR 105F FLAG_TERM RIGHT HAND REAR TURN SIGNAL CAV WIRE NUMBER CIRCUIT REFERENCE 1 178X GROUND CONNECTOR 106F FLAG_TERM LEFT HAND REAR TURN SIGNAL CAV WIRE NUMBER CIRCUIT REFERENCE A 75...

Страница 1247: ...CONNECTOR 110M 87426882 ETHER SWITCH EM ONLY CAV WIRE NUMBER CIRCUIT REFERENCE 2 720A ETHER FUSE 3 641A TO ETHER SOLENOID CONNECTOR 111F 225350C1 POWER MIRROR CONNECTOR CAV WIRE NUMBER CIRCUIT REFERENCE 1 949A LEFT MIRROR VERTICAL 2 950A LEFT MIRROR COMMON 3 951A LEFT MIRROR HORIZONTAL 4 952A RIGHT MIRROR VERTICAL 5 953A RIGHT MIRROR COMMON 6 954A RIGHT MIRROR HORIZONTAL CONNECTOR 111M 225351C1 PO...

Страница 1248: ...RROR HORIZONTAL 2 953A RIGHT MIRROR COMMON 3 952A RIGHT MIRROR VERTICAL CONNECTOR 113M 276424A1 RIGHT POWER MIRROR CAV WIRE NUMBER CIRCUIT REFERENCE 1 MIRROR H RIGHT MIRROR HORIZONTAL 2 MIRROR C RIGHT MIRROR COMMON 3 MIRROR V RIGHT MIRROR VERTICAL 112F 113F PIN HOUSING 276426A1 112M 113M SOCKET HOUSING 276424A1 CONNECTOR 114F 222136A1 STROBE BEACON CAV WIRE NUMBER CIRCUIT REFERENCE 1 PPP STROBE BE...

Страница 1249: ... CONNECTOR 116F 245481C1 FRONT WIPER CAV WIRE NUMBER CIRCUIT REFERENCE A WIPER GROUND CONNECTOR 116M 245480C1 FRONT WIPER CAV WIRE NUMBER CIRCUIT REFERENCE A 178S GROUND 115M SOCKET HOUSING ROOF HARNESS 245715C1 116F PIN HOUSING 245481C1 116M SOCKET HOUSING 245480C1 CONNECTOR 118F FLAG_TERM LEFT HAND FRONT TURN SIGNAL CAV WIRE NUMBER CIRCUIT REFERENCE 1 751D LEFT FRONT TURN SIGNAL B CONNECTOR 119M...

Страница 1250: ... SOCKET HOUSING ROOF HARNESS 121M BLUE SOCKET HOUSING 409107A1 CONNECTOR 122M 382391A1 REAR WIPER CAV WIRE NUMBER CIRCUIT REFERENCE 1 844A BRAKE INPUT 2 843A WIPER ON 3 841F 841G WIPER B 4 OPEN 5 845A WASHER ON 6 841G WASHER B 7 OPEN 8 OPEN 9 OPEN 10 OPEN CONNECTOR 123M 429029A1 CLIMATE CONTROL CAV WIRE NUMBER CIRCUIT REFERENCE 1 OPEN 2 OPEN 3 OPEN 4 826C CLIMATE CONTROL AUTO 5 801C 801E CHASSIS G...

Страница 1251: ...ENCE A OPEN B BLACK ATC BLOWER SIGNAL C BLACK TEMP CONTROL BLOWER GROUND 124F PIN HOUSING 245485C1 124M SOCKET HOUSING 245484C1 CONNECTOR 125F 245485C1 TEMP CONTROL POTENTIOMETER CAV WIRE NUMBER CIRCUIT REFERENCE A OPEN B BLACK SIGNAL C BLACK TEMPERATURE CONTROL GROUND CONNECTOR 125M 245484C1 TEMP CONTROL POTENTIOMETER CAV WIRE NUMBER CIRCUIT REFERENCE A OPEN B 807A SIGNAL C 803B TEMPERATURE CONTR...

Страница 1252: ...1 STD A C BLOWER SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE 1 SWITCH OPEN 2 SWITCH B 3 SWITCH HIGH SPEED 4 SWITCH MEDIUM SPEED 5 SWITCH LOW SPEED 6 SWITCH A C CLUTCH 126F SOCKET HOUSING CAB HARNESS 449797C1 126M SOCKET HOUSING CAB HARNESS 892136C1 CONNECTOR 127F 449797C1 FRONT WIPER SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE 1 OPEN 2 836A 836C BATTERY B 3 833A 833C HIGH H 4 832A 832C MEDIUM M 5 834A 8...

Страница 1253: ... SOCKET HOUSING CAB HARNESS 892136C1 128M BLUE SOCKET HOUSING CAB HARNESS 429029A1 CONNECTOR 129M 429026A1 STROBE BEACON CAV WIRE NUMBER CIRCUIT REFERENCE 1 OPEN 2 821E SWITCH POWER 3 776A SIGNAL BEACON STROBE 4 OPEN 5 OPEN 6 OPEN 7 177P LAMP GROUND 8 776C LAMP B 9 OPEN 10 OPEN CONNECTOR 130M 375601A1 POWER MIRRORS CAV WIRE NUMBER CIRCUIT REFERENCE 1 OPEN 2 OPEN 3 177AA GROUND 4 277A LEFT MIRROR H...

Страница 1254: ... WIRE NUMBER CIRCUIT REFERENCE 1 73B SEAT POWER B FEED 2 73C SEAT POWER B FEED 3 177AC SEAT GROUND 4 177AD SEAT GROUND 5 73D SEAT SWITCH OPS B 6 303A SEAT SWITCH OPS RETURN 7 259A SEAT HEATER B 8 177AE SEAT HEATER GROUND 9 PLUG OPEN 10 PLUG OPEN 11 PLUG OPEN 12 PLUG OPEN CONNECTOR 133MM 225388C1 SEAT POWER CAV WIRE NUMBER CIRCUIT REFERENCE 1 73E SEAT POWER B FEED 2 73F SEAT POWER B FEED 3 SEAT GRO...

Страница 1255: ...PEN 10 OPEN 11 OPEN 12 OPEN 133F SOCKET HOUSING CAB HARNESS 225388C1 CONNECTOR 133FF 225389C1 SEAT POWER CAV WIRE NUMBER CIRCUIT REFERENCE 1 73E SEAT POWER B FEED 2 73F SEAT POWER B FEED 3 SEAT GROUND 4 177AG SEAT GROUND 5 73G SEAT SWITCH OPS B 6 303C SEAT SWITCH OPS RETURN 7 259B SEAT HEATER B 8 117AH SEAT HEATER GROUND CONNECTOR 134F 42913 2 UNSWITCHED CAB B CAV WIRE NUMBER CIRCUIT REFERENCE 1 1...

Страница 1256: ...CUIT REFERENCE 1 OPEN 2 OPEN 3 OPEN 4 YELLOW CDB HIGH TRACTOR 5 GREEN CDB LOW TRACTOR 6 OPEN 7 293B PTO ON 8 OPEN 9 OPEN 10 OPEN 11 179Z CLEAN GROUND 12 65A ARCU SWITCHED B 135M 225402C1 SOCKET HOUSING CAB HARNESS 137M SOCKET HOUSING CAB HARNESS 225389C1 CONNECTOR 138A 225067C1 SWITCHED B CAV WIRE NUMBER CIRCUIT REFERENCE 1 102B 102M 102E 102A 102F 102N 102C SWITCHED B CONNECTOR 138B 225067C1 SWIT...

Страница 1257: ...TC L 826A TO AC CUTOUT SW AUTO M 827A AC IND LT GND DEHUMIDIFY N 179AV MODE DOOR GROUND ATC P 179AU MODE DOOR GROUND ATC R 825A HVAC CONTROLLER B S 803A 803B TEMP CONTROL T 807A TEMP CONTROL POT SIGNAL U 804A GROUND FOR DISPLAY V 805A 5V DISPLAY PWR W 806A DATA TO DISPLAY X 765A EURO CELCIUS Y OPEN Z OPEN CONNECTOR 139MM 196155A1 HVAC ATC UNIT CAV WIRE NUMBER CIRCUIT REFERENCE A 70 OPEN B 80 HI PR...

Страница 1258: ... CONNECTOR 144F 291718A1 AUX 5 MOTOR RAISE CAV WIRE NUMBER CIRCUIT REFERENCE 1 AUX5 TOP1 B AUX 5 B RAISE 2 AUX5 TOP2 RETURN AUX 5 B RAISE 140F 141F 142F 143F AND 144F SOCKET HOUSING AUX PTO HARNESS 291718A1 CONNECTOR 145F 245483C1 DUAL SPEED PTO CAV WIRE NUMBER CIRCUIT REFERENCE A SENSOR PTO SHAFT SPEED B SENSOR SENDER GROUND CONNECTOR 145M 245482C1 PTO SPEED SENSOR CAV WIRE NUMBER CIRCUIT REFEREN...

Страница 1259: ...E 750G TAIL LIGHTS F 222C AUXILIARY SWITCHED B CONNECTOR 147M 182087A1 TRAILER CONNECTOR CAV WIRE NUMBER CIRCUIT REFERENCE A 787S WORK LIGHTS B 751S LEFT TURN C 752M RIGHT TURN D 755G STOP LIGHTS E 750S TAIL LIGHTS F 222G AUXILIARY UNSWITCHED B CONNECTOR 147A 121645C1 7 PIN TRAILER CONNECTOR CAV WIRE NUMBER CIRCUIT REFERENCE 1 173A LEFT TURN 2 787S FIELD LIGHTS 3 751S CHASSIS GROUND 4 755G RIGHT T...

Страница 1260: ...GROUND 150F PIN HOUSING 280453A1 150M SOCKET HOUSING AUX PTO HARNESS 280451A1 CONNECTOR 151F 225315C1 HITCH UP CAV WIRE NUMBER CIRCUIT REFERENCE 1 SOLENOID HITCH SOLENOID B 2 SOLENOID HITCH SOLENOID UP CONNECTOR 151M 225316C1 HITCH UP CAV WIRE NUMBER CIRCUIT REFERENCE 1 828B HITCH SOLENOID B 2 527A HITCH SOLENOID UP CONNECTOR 152F 225315C1 HITCH DOWN CAV WIRE NUMBER CIRCUIT REFERENCE 1 SOLENOID HI...

Страница 1261: ...R 154M 225295C1 LEFT HAND EDC PIN CAV WIRE NUMBER CIRCUIT REFERENCE A 517B GROUND B 515A SIGNAL C 516C 8V 153F PIN HOUSING 225294C1 153M SOCKET HOUSING TRANSMISSION HITCH HARNESS 225295C1 154F PIN HOUSING 225294C1 154M SOCKET HOUSING TRANSMISSION HITCH HARNESS CONNECTOR 155M 198550A1 ROCKSHAFT POTENTIOMETER CAV WIRE NUMBER CIRCUIT REFERENCE A 506A HIGH B 507A SIGNAL C 508A LOW CONNECTOR 165A 36613...

Страница 1262: ... CAV WIRE NUMBER CIRCUIT REFERENCE A 597A HIGH B B 598A LOW GROUND 157F PIN HOUSING 225164C1 158M SOCKET HOUSING TRANSMISSION HITCH HARNESS 225316C1 159M SOCKET HOUSING TRANSMISSION HITCH HARNESS 199707A1 CONNECTOR 160M 225316C1 FWD SOLENOID CAV WIRE NUMBER CIRCUIT REFERENCE 1 540A FWD SOL HIGH B 2 175D FWD CHASSIS GROUND CONNECTOR 161F 225253C1 IGNITION SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE 1 ...

Страница 1263: ...FERENCE A SWITCH RIGHT BRAKE SWITCH B SWITCH RIGHT BRAKE B 162M SOCKET HOUSING CAB HARNESS 227429A1 162F SOCKET HOUSING CAB HARNESS 227430A1 CONNECTOR 163M 227429A1 RIGHT BRAKE CAV WIRE NUMBER CIRCUIT REFERENCE A 599D RIGHT BRAKE B B 510B RIGHT BRAKE SWITCH CONNECTOR 163F 227430A1 RIGHT BRAKE CAV WIRE NUMBER CIRCUIT REFERENCE A SWITCH RIGHT BRAKE B B SWITCH RIGHT BRAKE SWITCH 163M SOCKET HOUSING C...

Страница 1264: ...ITCHED B B 141C UNSWITCHED B C 177E GROUND 164M SOCKET HOUSING CAB HARNESS 225351C1 165M SOCKET HOUSING 227728A1 CONNECTOR 166F 42913 2 UNSWITCHED CAB B CAV WIRE NUMBER CIRCUIT REFERENCE 1 101CC UNSWITCHED B CONNECTOR 167F 227729A1 AUXILIARY POWER 1 CAV WIRE NUMBER CIRCUIT REFERENCE A 136H SWITCHED B B 135H UNSWITCHED B C 134H GROUND CONNECTOR 167M 227728A1 AUXILIARY POWER 1 CAV WIRE NUMBER CIRCUI...

Страница 1265: ... 169M 314908A1 AUXILIARY POWER 3 CAV WIRE NUMBER CIRCUIT REFERENCE A 134F GROUND B 135F UNSWITCHED B 168F PIN HOUSING EXTENSION HARNESS 227729A1 168M SOCKET HOUSING SHELF HARNESS 227728A1 169M SOCKET HOUSING SHELF HARNESS 314908A1 CONNECTOR 170M 225295C1 MAP LIGHT CAV WIRE NUMBER CIRCUIT REFERENCE A 135G UNSWITCHED B B OPEN C 134G GROUND CONNECTOR 170F 225294C1 MAP LIGHT CAV WIRE NUMBER CIRCUIT RE...

Страница 1266: ...HOUSING CAB HARNESS 877291R1 CONNECTOR 172F 200338 CHASSIS GROUND CAV WIRE NUMBER CIRCUIT REFERENCE 1 178B 178C 178D 178F 178J 178H GROUND CONNECTOR 173F 200338 CHASSIS GROUND CAV WIRE NUMBER CIRCUIT REFERENCE 1 177E 177F 177G GROUND CONNECTOR 174M 310057A1 CDB DIAGNOSTIC CONN CAV WIRE NUMBER CIRCUIT REFERENCE A 177AM CHASSIS GROUND B 152A DIAGNOSTIC B UNSWITCHED C YELLOW CDB HIGH TRACTOR D GREEN ...

Страница 1267: ... CDB LOW TRACTOR 175M SOCKET HOUSING 239451A1 CONNECTOR 178F 227393A1 INTERMITTANT WIPER SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE A 832C HIGH B 833C LOW C 836C WASHER D 177AU GROUND E 831E BATTERY F 834C PARK CONNECTOR 178M 227392A1 INTERMITTANT WIPER SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE A WHITE HIGH B YELLOW LOW C BROWN WASHER D BLACK GROUND E RED BATTERY F BLUE PARK 178F PIN HOUSING 227393A1...

Страница 1268: ...9M SOCKET HOUSING 222135A1 CONNECTOR 181M 429028A1 AXLE REGULATION SW CAV WIRE NUMBER CIRCUIT REFERENCE 1 OPEN 2 531C 531D SWITCH B 3 532A LOCK UNLOCK 4 OPEN 5 OPEN 6 OPEN 7 536A LAMP GROUND 8 531D LAMP B 9 OPEN 10 OPEN CONNECTOR 183M 371614A1 SUS RAISE 1 CAV WIRE NUMBER CIRCUIT REFERENCE 1 538C FSUS RAISE 2 179BK RETURN CONNECTOR 184M 371614A1 SUS LOWER 2 CAV WIRE NUMBER CIRCUIT REFERENCE 1 537C ...

Страница 1269: ...44C SENSOR SIGNAL CONNECTOR 186M 371614A1 UPPER LOCK 30 CAV WIRE NUMBER CIRCUIT REFERENCE 1 541B B 2 548B RETURN CONNECTOR 187M 371614A1 LOWER LOCK 31 CAV WIRE NUMBER CIRCUIT REFERENCE A 542B B B 546B RETURN 185M SOCKET HOUSING 225295C1 185F PIN HOUSING 225294C1 186M 187M SOCKET HOUSING 371614A1 CONNECTOR 188F 245481C1 POSITION LAMPS CAV WIRE NUMBER CIRCUIT REFERENCE A LAMP B CONNECTOR 188M 245480...

Страница 1270: ...GND R R SELF CNCL B CONNECTOR 192F 280458A1 FRONT AXLE SOL CAV WIRE NUMBER CIRCUIT REFERENCE 1 538C S1 SOL B RAISE 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 7 541B UPPER LOCK SOL 8 548B UPPER LOCK SOL CONNECTOR 192M 280456A1 FRONT AXLE SOL CAV WIRE NUMBER CIRCUIT REFERENCE 1 538A S1 SOL B RAISE 2 179BG S1 SOL GND RAISE 3 357...

Страница 1271: ... REFERENCE A 784E B B 178AF GROUND CONNECTOR 197F 222136A1 RIGHT A POST WORKLIGHT CAV WIRE NUMBER CIRCUIT REFERENCE 1 LAMP B 2 LAMP GROUND 193M SOCKET HOUSING 291719A1 197F RING TERMINAL 222136A1 CONNECTOR 197M 222135A1 LEFT A POST WORKLIGHT CAV WIRE NUMBER CIRCUIT REFERENCE 1 786E B 2 177AX GROUND CONNECTOR 198M 222135A1 RIGHT A POST WORKLIGHT CAV WIRE NUMBER CIRCUIT REFERENCE 1 786F B 2 177AY GR...

Страница 1272: ...RCUIT REFERENCE 1 179A 179J 179AA 179AF CHASSIS GROUND 198F 222136A1 199F RING TERMINAL AMP 327175 200F FRONT TO REAR HAR NESS CONNECTOR 201F 225072C1 SECONDARY TRANS FILTER CAV WIRE NUMBER CIRCUIT REFERENCE 1 267C GROUND CONNECTOR 203F 378852A1 ICU CLEAN GROUND CAV WIRE NUMBER CIRCUIT REFERENCE 1 216F ICU CLEAN GROUND CONNECTOR 204F 87448363 ENGINE CONTROLLER B CAV WIRE NUMBER CIRCUIT REFERENCE 1...

Страница 1273: ...MBER CIRCUIT REFERENCE A 732A EGRESS B B 791B EGRESS B C 792G EGRESS B D 790D EGRESS B 205M 207F PIN HOUSING 245489C1 207M SOCKET HOUSING 245488C1 CONNECTOR 211F 245483C1 IMPLEMENT ICU CAV WIRE NUMBER CIRCUIT REFERENCE A SWITCH B FROM ICU B SWITCH GROUND CONNECTOR 211M 245482C1 IMPLEMENT ICU CAV WIRE NUMBER CIRCUIT REFERENCE A 285B B FROM ICU B 179AT GROUND CONNECTOR 212M 877291R1 FRONT WASH MOTOR...

Страница 1274: ...KET HOUSING FRONT TO REAR HARNESS 877291R1 CONNECTOR 214M 411986A1 FUEL SHUT OFF SOL EM CAV WIRE NUMBER CIRCUIT REFERENCE A 456B SOL B 604A SOL C 600B SOL GROUND CONNECTOR 215M 225316C1 ENGINE COOLANT TEMP EM CAV WIRE NUMBER CIRCUIT REFERENCE A 235C SIGNAL B 181Y GROUND 214M SOCKET HOUSING ENGINE HARNESS 411986A1 215F PIN HOUSING ENGINE HARNESS 225315C1 215M SOCKET HOUSING SENSOR 225316C1 ...

Страница 1275: ...ND CAV WIRE NUMBER CIRCUIT REFERENCE 1 270C HOT AIR B CONNECTOR 218F 225065C1 CHASSIS GROUND CAV WIRE NUMBER CIRCUIT REFERENCE 1 173A GROUND 216M SOCKET HOUSING 198456A1 217F ENGINE HARNESS 225067C1 218F ENGINE HARNESS 225065C1 CONNECTOR 219F ELOBAU_815 100 FNRP MODULE CAV WIRE NUMBER CIRCUIT REFERENCE 1 1 FNRP R 2 2 RUN INPUT 3 3 FNRP N 4 4 START INPUT 5 5 START OUTPUT 6 6 FNRP F 7 7 FNRP P 8 8 F...

Страница 1276: ...OMMON CONNECTOR 220D 1 4_FLAG UNIVERSAL SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE 1 23A TURN SIGNAL COMMON CONNECTOR 220E 1 4_FLAG UNIVERSAL SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE 1 24A TURN SIGNAL COMMON CONNECTOR 220F 1 4_FLAG UNIVERSAL SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE 1 25A TURN SIGNAL COMMON CONNECTOR 220G 1 4_FLAG UNIVERSAL SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE 1 26A TURN SIGNAL C...

Страница 1277: ...TURN SIGNAL INDICATOR CAV WIRE NUMBER CIRCUIT REFERENCE 1 010A COMMON 2 011A RIGHT TURN 3 012A LEFT TURN 221F PIN HOUSING TURN INDICATORS 221M SOCKET HOUSING GHW 16182 CONNECTOR 222M 379421A1 CD PLAYER CAV WIRE NUMBER CIRCUIT REFERENCE 7 OPEN 8 OPEN 9 CLEAR SHIELD GROUND 10 WHITE RIGHT AUDIO 11 RED LEFT AUDIO 12 BLACK AUDIO COMMON 13 BLACK GROUND 14 LIGHT GREEN E C DATA 15 ORANGE BATTERY 222M SOCK...

Страница 1278: ...NECTOR 225F FLAG_TERM RIGHT HAND FRONT TURN SIGNAL CAV WIRE NUMBER CIRCUIT REFERENCE 1 178V GROUND 223M SOCKET HOUSING TO RADIO 380431A1 224F AND 225F SOCKET 1 4 FLAG TERM CONNECTOR 228M 426708A1 LEFT STOP TAIL LIGHT CAV WIRE NUMBER CIRCUIT REFERENCE 1 174Z GROUND 2 753D TURN HAZARD 3 750P TAIL 4 755L STOP CONNECTOR 229F 222136A1 LEFT FENDER REAR MARKER LIGHT CAV WIRE NUMBER CIRCUIT REFERENCE 1 75...

Страница 1279: ...ND CONNECTOR 233M 426708A1 RH TAIL LIGHT CAV WIRE NUMBER CIRCUIT REFERENCE 1 174M GROUND 2 754C TURN HAZARD 3 750L TAIL 4 755D STOP 230F PIN HOUSING 222315C1 230M SOCKET HOUSING 222316C1 233M SOCKET HOUSING FENDER HARNESS 426708A1 CONNECTOR 234F 222136A1 RIGHT FENDER WIDE MARKER LIGHT CAV WIRE NUMBER CIRCUIT REFERENCE 1 751 MARKER LIGHT B 2 174 GROUND CONNECTOR 234M 222135A1 RIGHT FENDER WIDE MARK...

Страница 1280: ...OUND 235M PIN HOUSING 222136A1 235F SOCKET HOUSING 222135A1 236F PIN HOUSING 222136A1 236M SOCKET HOUS ING 222135A1 CONNECTOR 237F 222136A1 RIGHT FENDER WIDE MARKER LIGHT CAV WIRE NUMBER CIRCUIT REFERENCE 1 754F MARKER LIGHT B 2 174U GROUND CONNECTOR 237M 222135A1 RIGHT FENDER WIDE MARKER LIGHT CAV WIRE NUMBER CIRCUIT REFERENCE 1 LAMP LEADS MARKER LIGHT B 2 LAMP LEADS GROUND CONNECTOR 238A RING_TE...

Страница 1281: ...163A RELAY B D4 OPEN D5 162A CONTROLLER SW B E1 177AB EGRESS RELAY GROUND E2 731B EGRESS SIGNAL E3 788A REAR WORKLIGHTS B E4 961A FRONT REAR WORKLIGHTS B RELAY E5 960B EGRESS UNSW B F1 177H CONTROLLER RELAY GROUND F2 160A RELAY IGNITION FEED F3 102A CONTROLLER POWER F4 OPEN F5 200B CONTROLLER POWER 255F 144417A1 CONNECTOR 256M 242580A1 FOOT THROTTLE CAV WIRE NUMBER CIRCUIT REFERENCE 1 STOP LAMP 4 ...

Страница 1282: ...79BR CLEAN GROUND 6 547A ON OFF SIGNAL 7 OPEN 8 OPEN 9 OPEN 10 OPEN 257F WHITE SOCKET HOUSING CAB HARNESS 87426881 CONNECTOR 258F 87426889 CRUISE INCREMENT DECREMENT CAV WIRE NUMBER CIRCUIT REFERENCE 1 489A DECREMENT SIGNAL 2 179BP 179BR CLEAN GROUND 3 358A INCREMENT SIGNAL 4 OPEN 5 OPEN 6 OPEN 7 OPEN 8 OPEN 9 OPEN 10 OPEN 258F GREEN SOCKET HOUSING CAB HARNESS 87426889 ...

Страница 1283: ...WER CAB PRESSURE A10 106B C10 101M A11 821C FUSE 23 BEACON STROBE C11 73A FUSE 9 SEAT OPS A12 JUMPER C12 102F A13 312A FUSE 22 STOP LIGHTS C13 135A FUSE 8 AUX SHELF POWER UNSWITCHED A14 103F C14 101L B1 750C FUSE 21 LH AND RH TAIL POSITION LIGHTS D1 107A FUSE 7 KEY BATTERY B2 707A D2 101C B3 766A FUSE 20 FLASHER D3 241A FUSE 6 WORKLIGHT INTERLOCK B4 101F D4 JUMPER B5 871 A FUSE 19 DOME LIGHT MAP A...

Страница 1284: ...IPER WASHER C9 599E FUSE 38 PTO A12 102K C10 200C B1 820A FUSE 49 HVAC BLOWER C11 203B FUSE 37 ICU PMU SWITCHED B2 103D C12 JUMPER B3 136A FUSE 48 SHELF AUX POWER SWITCHED C13 900D FUSE 36 AUXILIARY B4 103C C14 200B B5 102M FUSE 47 HVAC CONTROLLER D3 283A FUSE 34 RADAR B6 142A D4 JUMPER B7 142A FUSE 46 FRONT REAR AUXILIARY SWITCHED D5 65A FUSE 33 ARM REST CONT UNIT B8 103B D6 200F B11 550C FUSE 44...

Страница 1285: ...NRP NO NEUTRAL COIL C1 792B 792C FENDER WORKLIGHTS COIL C2 177X 177AW COIL GROUND C2 177W 177AL COIL GROUND C3 550G NEUTRAL RELAY COMMON C3 795A FENDER WORK LIGHTS C4 OPEN C4 OPEN C5 220M NEUTRAL RELAY NO C5 787A REAR FENDER WORK LIGHTS D1 791A ROOF WORKLIGHTS COIL D1 790B FRONT ROOF WORK LIGHTS COIL D2 177X 177AR COIL GROUND D2 177V 177W COIL GROUND D3 788A 788B ROOF WORKLIGHTS B D3 788B FRONT RO...

Страница 1286: ...GROUND E3 OPEN OPEN E4 OPEN OPEN E5 OPEN OPEN F1 164C INTERLOCK ON F2 171F COIL GROUND F3 164A SWITCHED B F4 OPEN OPEN F5 164B SWITCHED B 265F 144417A1 CONNECTOR 266MM 239451A1 ACTIVE TERMINATOR CAV WIRE NUMBER CIRCUIT REFERENCE 1 CAN R56 CAN B AUTO 2 CAN Y56 CAN HI AUTO 3 CAN BK56 CAN GROUND AUTO 4 CAN DG56 CAN LO AUTO CONNECTOR 266M 631801C1 RECTIFIER ASSEMBLY CAV WIRE NUMBER CIRCUIT REFERENCE A...

Страница 1287: ...W BEAM DIMMING CONNECTOR 268F 739070C1 RECTIFIER ASSEMBLY CAV WIRE NUMBER CIRCUIT REFERENCE A 727C LOW BEAM DIMMING CONNECTOR 269F 225164C1 TO AUXILIARY POWER CONNECTOR CAV WIRE NUMBER CIRCUIT REFERENCE 1 142B SWITCHED B 2 141B UNSWITCHED B 3 177AF GROUND CONNECTOR 270F 225164C1 IMPLEMENT AUXILIARY POWER CAV WIRE NUMBER CIRCUIT REFERENCE 1 136H SWITCHED B 2 135H UNSWITCHED B 3 134H GROUND CONNECTO...

Страница 1288: ...ITCHED B 2 RADAR SIGNAL 3 SWITCHED B 4 179AZ CLEAN GROUND 5 RED CDB BATT B IMP 6 YELLOW CDB HI IMP 7 BLACK CDB GND IMP 8 GREEN CDB LOW IMP 9 OPEN 10 OPEN 11 OPEN 12 OPEN 273F PIN HOUSING INTELLIVIEW II INSIDE CAB 223672A1 273M SOCKET HOUSING CAB HARNESS 223671A1 CONNECTOR 273FF 223672A1 CAV WIRE NUMBER CIRCUIT REFERENCE 5 CDB R59 CAN IMP B 6 CDB Y59 CAN IMP HIGH 7 CDB BK59 CAN IMP GROUND 8 CDB DG5...

Страница 1289: ...ERSE CONNECTOR 276M REVERSE CAV WIRE NUMBER CIRCUIT REFERENCE 1 522AA REVERSE 276F PIN HOUSING 182064A1 276M SOCKET HOUSING 182066A1 CONNECTOR 278MM 239451A1 TO ACTIVE TERMINATOR CAV WIRE NUMBER CIRCUIT REFERENCE 1 CAN R48 CAN AUTO B 2 CAN Y48 CAN AUTO HI 3 CAN BK48 CAN AUTO GROUND 4 CAN DG48 CAN AUTO LO 278MM SOCKET HOUSING 239451A1 ...

Страница 1290: ...CAB HARNESS CONNECTOR 282M 4 1437291 0 TRACTOR ECU CAV WIRE NUMBER CIRCUIT REFERENCE 1 YELLOW CAN H IMP 2 GREEN CAN L IMP 3 CAN SHEILD 4 YELLOW CAN H TR 5 GREEN CAN L TR 6 CAN SHIELD 7 RS232 RX 8 RS232 TX 9 RS232 GND 10 401D ECU PWR 11 179CH ECU GND 12 403A PWR CONTROL RELAY 13 404A PWR CONTROL RELAY RTN 14 406A ECU PWR RELAY 15 405A ECU PWR RELAY RTN 16 138A KEY SWITCH 17 787M IMPLEMENT FLOOD 18 ...

Страница 1291: ...R CIRCUIT REFERENCE 1 344H ECU PWR 2 YELLOW CAN LO IMP 3 OPEN 4 OPEN 5 OPEN 6 OPEN 7 GREEN CAN HI IMP 8 179CD ECU GND 283M SOCKET HOUSING 225316C1 286M SOCKET HOUSING 225319C1 CONNECTOR 287M 382391A1 MANUAL SWITCH 2 345B SW B 3 AUTO MAN CONNECTOR 288M 239451A1 BREAKAWAY CAV WIRE NUMBER CIRCUIT REFERENCE 1 RED CAN TBC PWR 2 YELLOW CAN LO IMP 3 BLACK CAN TBC RTN 4 GREEN CAN HI IMP 287M SOCKET HOUSIN...

Страница 1292: ...NK 10 416E PRESSURE SENSOR 10 416A PRESSURE SENSOR 11 417E STEER POT SIGNAL 1 11 417A STEER POT SIGNAL 1 12 412B RS232 TX 12 412A RS232 TX 13 413B RS232 RX 13 413A RS232 RX 14 414B RS232 GND 14 414A RS232 GND 15 418E 5VDC REF 15 418A 5VDC REF 16 422F STEER POT SIGNAL 2 16 422A STEER POT SIGNAL 2 18 CAN R55 CAN AUTO B 18 CAN R53 CAN AUTO B 20 CAN_Y55 CAN AUTO HI 20 CAN_Y53 CAN AUTO HI 21 145F SWITC...

Страница 1293: ...9 CAN LOW IMP CONNECTOR 292M 297910A1 INTELLIVIEW II POWER RELAY CAV WIRE NUMBER CIRCUIT REFERENCE 30 401A LOW IMP B SWITCH 85 405A COIL B 86 406A IMP POWER ACT 87 137E COM IMP B SWITCH 87A OPEN 291M SOCKET HOUSING 323597A1 292M SOCKET HOUSING 297910A1 CONNECTOR 293M 310220A1 INTELLIVIEW II POWER RELAY CAV WIRE NUMBER CIRCUIT REFERENCE 30 400A IMP B SWITCHED 85 403A IMP POWER ACT 86 404A SWITCHED ...

Страница 1294: ... 1 CAN R32 CAN IMP B 2 CAN Y32 CAN IMP HI 3 137A LOW ECU SW POWER 4 138B SWB 5 1798J CLEAN GND 6 787K WORKLIGHT B 7 751L LEFT TURN 8 752K RIGHT TURN 9 750R TAIL LIGHT 10 PLUG OPEN 11 CAN BK32 CAN IMP GND 12 CAN DG32 CAN IMP LO 294M SOCKET HOUSING 223682A1 CONNECTOR 295M 223671A1 GPS ANTENNA RECEIVER CAV WIRE NUMBER CIRCUIT REFERENCE 1 CAN Y60 IMP CAN HI A 2 413E RS232 RX 3 412E RS232TX 4 421E PPS ...

Страница 1295: ... 11 179CE GROUND 12 344F SWITCHED B 296F PIN HOUSING 223682A1 CONNECTOR 297F 200338 RING TERMINAL CAV WIRE NUMBER CIRCUIT REFERENCE 1 407A 407B 407C CLEAN GROUND CONNECTOR 298FF 223682A1 TO VT EXTENSION HARNESS CAV WIRE NUMBER CIRCUIT REFERENCE 1 CAN R52 CAN AUTO B 2 CAN Y52 CAN AUTO HI 3 CAN BK52 CAN AUTO GROUND 4 CAN DG52 CAN AUTO LOW 5 CAN R52 CAN AUTO B 6 CAN Y53 CAN AUTO HI 7 CAN BK53 CAN AUT...

Страница 1296: ...UMBER CIRCUIT REFERENCE 1 CDB 36R CAN BATT IMP 2 CDB 36Y CAN HI IMP 3 CDB 36BK CAN GND IMP 4 CDB 36DG CAN LOW IMP 5 137H SW B 6 179CC CLEAN GROUND 298F PIN HOUSING 280453A1 298M PIN HOUSING 280453A1 CONNECTOR 299F 277904A1 GPS RECEIVER CAV WIRE NUMBER CIRCUIT REFERENCE 1 414B RS232 GND 2 413B RS232 RX 3 412B RS232 TX 4 421B PPS IN CONNECTOR 299M 277905A1 GPS RECEIVER CAV WIRE NUMBER CIRCUIT REFERE...

Страница 1297: ...LAG TERM CONNECTOR 313MA 198550A1 CENTER REMOTE HITCH SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE A 513G LOWER DOWN B 500J CENTER B C 526G RAISE UP CONNECTOR 313MB 198550A1 CENTER REMOTE HITCH SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE A 526E LOWER DOWN B 500K CENTER B C 513E RAISE UP CONNECTOR 314F 225294C1 REMOTE HITCH SWITCH CAV WIRE NUMBER CIRCUIT REFERENCE A 513C RAISE REMOTE UP B 500G COMMON B C ...

Страница 1298: ...ER REMOTE DOWN CONNECTOR 317F 225316C1 PNEUMATIC PARK SOLENOID CAV WIRE NUMBER CIRCUIT REFERENCE A 567H AUTO HITCH B B 179BW INDICATOR GROUND 315F PIN HOUSING 225294C1 315M SOCKET HOUSING 225295C1 317F SOCKET HOUSING 225316C1 CONNECTOR 318F 245483C1 PNEUMATIC PARK SOLENOID CAV WIRE NUMBER CIRCUIT REFERENCE A 567F PARK BRAKE FEEDBACK B 179BV CLEAN GROUND CONNECTOR 318M 245482C1 PNEUMATIC PARK SOLEN...

Страница 1299: ...0338 CONNECTOR 327M 300518A1 INTELLIVIEW II FUSE CAV WIRE NUMBER CIRCUIT REFERENCE 1 400B UNSWITCHED B 2 400C UNSWITCHED B CONNECTOR 328M 300518A1 INTELLIVIEW II FUSE CAV WIRE NUMBER CIRCUIT REFERENCE 1 401B UNSWITCHED B 2 401C UNSWITCHED B CONNECTOR 331F 225326C1 RIGHT FRONT HITCH LAMPS CAV WIRE NUMBER CIRCUIT REFERENCE 1 740B LOW BEAM B 2 741B HIGH BEAM B 3 744C PILOT 4 176E GROUND CONNECTOR 331...

Страница 1300: ...CH LAMPS CAV WIRE NUMBER CIRCUIT REFERENCE 1 742B LOW BEAM B 2 743B HIGH BEAM B 3 744B PILOT 4 176D GROUND CONNECTOR 332M 239451C1 LEFT FRONT HITCH LAMPS CAV WIRE NUMBER CIRCUIT REFERENCE 1 LAMP LOW BEAM B 2 LAMP HIGH BEAM B 3 LAMP PILOT 4 LAMP GROUND 332M SOCKET HOUSING 332F PIN HOUSING 225326C1 ...

Страница 1301: ...31F SUS AXLE B 10 544D SUS AXLE SEN SIG 10 544A SUS AXLE SEN SIG 11 179CN SUS AXLE SEN GND 11 179CL SUS AXLE SEN GND 12 723B OPEN 12 723C OPEN 13 89B UNSW B 13 89C UNSW B 14 172A SW B 14 172C SW B 15 266B AIR FILTER REST 15 266C AIR FILTER REST 16 836B FR WASH PUMP B 16 836D FR WASH PUMP B 17 845B REAR WASH PUMP B 17 845C REAR WASH PUMP B 18 CAN Y22 CAN HI 18 CAN Y23 CAN HI 19 724C HIGH BEAM ON 19...

Страница 1302: ...IT REFERENCE 1 450B ENGINE OIL PRESS 5V 1 255C ENGINE OIL PRESS 5V 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 6 455B ENG OIL PRESS INPUT 6 256C ENG OIL PRESS INPUT 7 181R COOLANT TEMP GND 7 181Y COOLANT TEMP GND 8 181T ENG OIL PRESS GND ...

Страница 1303: ...526D EDC REMOTE LOWER SW 23 293C PTO ON SWITCH 24 114D VP B 25 174C SHAFT SIZE GROUND 26 512B EDC AUTO HITCH SW 27 CAN Y5 CAN HI 28 599S VH B 29 CAN DG5 CAN LOW CONNECTOR 335M 87426772 AUXILIARY CONTROLLER CAV WIRE NUMBER CIRCUIT REFERENCE 1 501F VD VT B 2 179CS POWER GROUND 3 900D VF B 4 179CT POWER GROUND 7 599H VH B 8 175E DIFF SOLENOID 9 174A PTO CLUTCH OUTPUT GND 10 174R CHASSIS GROUND 11 565...

Страница 1304: ...A 225058C1 BACKUP ALARM CAV WIRE NUMBER CIRCUIT REFERENCE 1 571B ALARM POWER CONNECTOR 337B 225058C1 BACKUP ALARM CAV WIRE NUMBER CIRCUIT REFERENCE 1 174H CHASSIS GROUND 336M SOCKET HOUSING 245482C1 336F PIN HOUSING 245483C1 337A 337B RING TERMINAL 225058C1 CONNECTOR 338F 225315C1 BACKUP ALARM CAV WIRE NUMBER CIRCUIT REFERENCE 1 571A ALARM POWER 2 174G ALARM GND CONNECTOR 338M 225316C1 BACKUP ALAR...

Страница 1305: ... 344F 291718A1 AUX 5 MOTOR LOWER CAV WIRE NUMBER CIRCUIT REFERENCE 1 AUX5 BOT1 B AUX 5 B LOWER 2 AUX5 BOT2 RETURN AUX 5 A LOWER 340F 341F 342F 343F AND 344F SOCKET HOUSING 291718A1 CONNECTOR 350M 3 1437290 7 TRANSMISSION CONTROLLER CAV WIRE NUMBER CIRCUIT REFERENCE 1 550B SWITCHED B 12V 2 550D SWITCHED B 12V 3 550H SWITCHED B 12V 4 558B PARK BRAKE CONTROL 5 586A MASTER CLUTCH HIGH SIDE 6 201C C1 2...

Страница 1306: ...US LOCK UNLOCK 28 567L PARK BRAKE FEEDBACK 33 216E ENGINE ALT SPEED 34 215D TRANS WHEEL SPEED 351M CNH 87410946 TYCO 4 1437290 0 SOCKET HOUSING CONNECTOR 353M 3 1437290 8 TRANSMISSION CONTROLLER CAV WIRE NUMBER CIRCUIT REFERENCE 1 581A EVEN CLUTCH LOW SIDE 2 544A AXLE SENSOR SIGNAL 3 590A CREEP CLUTCH LOW SIDE 4 220B MASTER CLUTCH LOW SIDE 6 582A C1 2 LOW SIDE 7 541A SUS AXLE UPPER LOCK 8 580A ODD...

Страница 1307: ...IGH SIDE 15 542A FSUS LOWER LOCK 16 220E HIGH CLUTCH HIGH SIDE 18 220D LOW CLUTCH LOW SIDE 25 220G B 12V FROM NEUTRAL RELAY 34 220H NEUTRAL RELAY 12 CONNECTOR 360F AMP_41274 0 STROBE BEACON CAV WIRE NUMBER CIRCUIT REFERENCE 1 XXX GROUND CONNECTOR 361F AMP_41274 0 STROBE BEACON CAV WIRE NUMBER CIRCUIT REFERENCE 1 XXX STROBE BEACON B 355M CNH 87410947 TYCO POLARITY 2 KEYING SOCKET HOUSING 4 1437290 ...

Страница 1308: ...ERENCE 1 270C HOT AIR B CONNECTOR 371F 225067C1 HOT AIR UNSWITCHED B CAV WIRE NUMBER CIRCUIT REFERENCE 1 270A HOT AIR B 367F 225326C1 369F 225067C1 371F 225067C1 CONNECTOR 372F 225067C1 HOT AIR UNSWITCHED B CAV WIRE NUMBER CIRCUIT REFERENCE 1 270A HOT AIR B CONNECTOR 373F 225067C1 HOT AIR UNSWITCHED B CAV WIRE NUMBER CIRCUIT REFERENCE 1 270B HOT AIR B CONNECTOR 374F 225067C1 HOT AIR UNSWITCHED B C...

Страница 1309: ...TEERING POT CONTROLLER D 303D SEAT SW OPS RTN E 303E SEAT SW OPS RTN TO CONTROL LER F OPEN CONNECTOR 375F 196153A1 ROOF HID WORKLIGHTS CAV WIRE NUMBER CIRCUIT REFERENCE A 786B ROOF HID B B 177M ROOF HID GND C D E F G H 374M 245489C1 PIN HOUSING 375F 196153A1 CONNECTOR 375M 197503A1 ROOF HID WORKLIGHTS CAV WIRE NUMBER CIRCUIT REFERENCE A 786A ROOF HID B B 177L ROOF HID GND C D E F G H 375M 197503A1...

Страница 1310: ...B Y13 CAN HI TR 6 CDB DG13 CAN LO TR 7 OPEN 8 OPEN 9 OPEN 10 976A SWITCHED B 11 79CR CLEAN GROUND 12 971E UNSWITCHED B 377F 223672A1 PIN HOUSING CONNECTOR 379M 245488C1 EGRESS DIODE PACK 2 CAV WIRE NUMBER CIRCUIT REFERENCE A 792A FENDER BELTLINE LTS B 792J FENDER BELTLINE LTS C 791A REAR WORKLIGHTS D 791C REAR WORKLIGHTS E 790A REAR WORKLIGHTS F 790E REAR WORKLIGHTS CONNECTOR 380M 877291R1 RADAR C...

Страница 1311: ...ENCE 1 273D HOT AIR COIL B 382F 225072C1 383F 225072C1 CONNECTOR 386F 87428138 GPS RECEIVER CAV WIRE NUMBER CIRCUIT REFERENCE 1 CAN R55 CAN BATT AUTO 2 145F SW B 3 420E CLEAN GND CONNECTOR 386M 87428139 TO GPS RECEIVER CAV WIRE NUMBER CIRCUIT REFERENCE 1 CDB R62 CAN B IMP 2 138G SWITCHED B 3 179CV CLEAN GROUND CONNECTOR 387F 87428139 CAN SPL61 CAV WIRE NUMBER CIRCUIT REFERENCE 1 CAN R56 CAN BATT I...

Страница 1312: ...PIN HOUSING CONNECTOR 389F 276426A1 CAN SPL56 CAV WIRE NUMBER CIRCUIT REFERENCE 1 CAN Y56 CAN HI IMP 2 CAN BK56 CAN GND IMP 3 CAN DG56 CAN LO IMP CONNECTOR 389M 276424A1 CAN SPL61 CAV WIRE NUMBER CIRCUIT REFERENCE 1 CAN Y61 CAN HI IMP 2 CAN BK61 CAN GND IMP 3 CAN DG61 CAN LO IMP CONNECTOR 390M 239451A1 TO STEERING SOLENOID CAV WIRE NUMBER CIRCUIT REFERENCE 1 411E LH STEER VALVE LOW 2 419F L COIL H...

Страница 1313: ...GND CONNECTOR 391M 225316C1 TO CDB SPL51 CAV WIRE NUMBER CIRCUIT REFERENCE 1 345R SW B 2 179CR CLEAN GND 391F 225315C1 391M 225316C1 CONNECTOR 395F 225350C1 ALT COMP HARNESS CAV WIRE NUMBER CIRCUIT REFERENCE 1 835B A C CLUTCH B 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 395F 225350C1 ...

Страница 1314: ...UT NC 3 PTO SW OUT NO 4 957A EHR EXTEND 5 958A EHR RETRACT 6 OPEN 395M 225351C1 CONNECTOR 397F 280453A1 TO RT REMOTE EHR SW CAV WIRE NUMBER CIRCUIT REFERENCE 1 599V B 2 OPEN 3 OPEN 4 OPEN 5 957B REMOTE EHR NO 6 958B REMOTE EHR NC CONNECTOR 397M 280451A1 TO AUX HARNESS CAV WIRE NUMBER CIRCUIT REFERENCE 1 599AC REMOTE EHR B 2 OPEN 3 OPEN 4 OPEN 5 397D REMOTE EHR NO EXTEND 6 958D REMOTE EHR NC RETRAC...

Страница 1315: ...MOTE EHR NC 399F 291719A1 401M 291719A1 CONNECTOR 403M 87410948 TO SWCD CAV WIRE NUMBER CIRCUIT REFERENCE 1 CDB Y51 CAN IMP HI 2 CDB DG51 CAN IMP LO 3 966A ROTARY SIGNAL 1 4 967A ROTARY SIGNAL 2 5 CDB Y52 CAN TR HI 6 CDB DG52 CAN TR LO 7 OPEN OPEN 8 OPEN OPEN 13 972B UNSWITCHED B 14 179DK GROUND 15 968A SWITCHED B 16 OPEN OPEN 17 968A HOME SWITCH 18 969A ESCAPE SWITCH 19 970C ENTER SWITCH 20 971E ...

Страница 1316: ...8459A1 AUTOGUIDANCE CONTROLLER CAV WIRE NUMBER CIRCUIT REFERENCE 1 179CP CLEAN GROUND 2 413A RS232 RX 3 CAN Y51 CAN HI AUTO 6 986A AUTO MAN 9 423B POWER GND 10 419A S V RT SOURCE 11 345D SWB 12 414A RS232 GND 13 CAN DG51 CAN LO AUTO 16 415A WHEEL SPEED 18 417B STEER POT SIG 19 416A PRESS SEN 20 982A S V LT SOURCE 21 421A PPS IN 26 522D REVERSE 28 423A STEER ANGLE GND 29 984A PRESS TRAN 5V 30 410A ...

Страница 1317: ...522D REVERSE 7 179CX CLEAN GROUND 8 OPEN CONNECTOR 408M 280456A1 TO INSIDE AUTOGUIDANCE HARNESS CAV WIRE NUMBER CIRCUIT REFERENCE 1 CDB Y CAN HI TR 2 CDB DG CAN LO TR 3 971D TRACTOR SW B 4 177BE CHASSIS GROUND 5 215F WHEEL SPEED 6 552H REVERSE 7 177BB CLEAN GROUND 8 OPEN 408F 280458A1 408M 280456A1 CONNECTOR 409F 182068A1 TO ENGINE HARNESS CAV WIRE NUMBER CIRCUIT REFERENCE A 722C HORN B B 723C HOR...

Страница 1318: ... CAV WIRE NUMBER CIRCUIT REFERENCE 1 722C HORN GROUND CONNECTOR 412B AMP_41274 0 HORN B CAV WIRE NUMBER CIRCUIT REFERENCE 1 723C HORN B 409M 182069A1 CONNECTOR 413M 244615A1 AUTOGUIDANCE CONTROLLER CAV WIRE NUMBER CIRCUIT REFERENCE 1 424B RDL GROUND 2 412F RS232TX 5 CDB Y58 CAN HI TR 7 754E RDL POWER 8 413F RS232 RX 11 CDB DG58 CAN LO TR 14 414F RS232 GROUND CONNECTOR 414A 225326C1 SIDE WIPER MOTO...

Страница 1319: ...TO USB HARNESS CAV WIRE NUMBER CIRCUIT REFERENCE 1 SIDE WIPER HIGH 2 WIPER SIDE WIPER LOW 3 WIPER SIDE WIPER PARK 4 WIPER SIDE WIPER BRAKE 414B 239451A1 415M 87431893 CONNECTOR 430M PACKARD 12059183 LEFT SIDE LIGHT CAV WIRE NUMBER CIRCUIT REFERENCE A 738B B B 170D GROUND CONNECTOR 431M PACKARD 12059183 CENTER LIGHT CAV WIRE NUMBER CIRCUIT REFERENCE A 738C B B 170F GROUND CONNECTOR 432M PACKARD 120...

Страница 1320: ...P 2 450M 182066A1 500M 225351C1 CONNECTOR CN1 87410948 INSTRUMENT CLUSTER CAV WIRE NUMBER CIRCUIT REFERENCE 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 FILTER REST 11 566A PNEUMATIC IND 12 215E TRANS SPEED 13 199A RADAR SPEED 14 CAN DG24 CAN LO TR 15 CAN Y24 CAN HI TR 19 216A ALTERNATOR SPEED 20 453A ENGINE C...

Страница 1321: ...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 24 285A TRAILED IMP UP SW 26 266A AIR FILTER CN2 87410949 ...

Страница 1322: ...tched ON the cab power relay is energized supplying battery power to the switched power bus which in turn supplies power to fuses 1 2 3 4 5 6 9 12 22 23 24 25 26 27 29 30 31 34 35 37 39 41 43 44 45 46 47 48 49 50 and 52 Additionally the controller relay is energized and power is distributed to fuses 33 36 38 40 43 and 44 The front wiper wash circuit is also supplied with switched power through cir...

Страница 1323: ...ore performing any of the electrical tests be sure all operating controls are in neutral or park lock position This will eliminate accidental movement of the machine or start up of power driven equipment Symptom Possible Cause Reference Test No power at one fuse Power supply to fuse Go to fuse circuit chart to determine power supply circuit No power at switched fuses 1 2 3 4 5 6 9 12 20 22 23 24 2...

Страница 1324: ... of Bad Reading 1 Check for 12 volts at cab power relay terminal 240 12 volts If good reading continue with next step Open circuit 101A R 2 Ignition ON Check for 12 volts at cab power relay terminal 239 12 volts If good reading continue with next step Open 105A R diode 266 or 104A R circuit between ignition switch connector 161 terminal 5 and cab power relay terminal 239 or 12 volts not available ...

Страница 1325: ...ntroller relay terminal A3 and switched power bus 2 Ignition switch in Run or Acc Check for 12 volts at controller relay base terminal A2 12 volts If good reading continue with next step Open 106C R circuit between ignition switch connector 161 terminal 6 and controller relay terminal A2 12 volts not available from terminal 6 of ignition switch connector 161 Refer to ignition switch test 3 Check f...

Страница 1326: ...ltimeter 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 WARNING Before performing any of the electrical tests be sure all operating controls are in neutral or park lock position This will eliminate a...

Страница 1327: ...s Audio unit If speaker s and circuit s are good audio unit is bad Poor quality distorted sound from all speakers Audio speakers H Speaker Resistance Test Substitute known good speaker s Circuit Perform relevant speaker circuit test s Audio unit If speaker s and circuit s are good audio unit is bad No sound from speakers Speakers H Speaker Resistance Test Substitute known good speaker s Circuit Pe...

Страница 1328: ... between connector 95A terminal 8 and connector 13M terminal U Less than 1 ohm If good reading repair open in 178C B circuit to ground Open 178M B circuit from connector 95A to connector 13M Repair open 3 Measure voltage at radio connector 95A terminal 7 12 volts If good reading go to test point 5 Blown fuse 19 or Open 871A R or 871B R circuit from connector 95A terminal 7 to unswitched B Check fu...

Страница 1329: ... Reading 1 Disconnect connector 95B from the radio and connector 96F from the right front speaker Measure resistance between radio connector 95B terminal 11 and right front speaker connector 96F terminal A Less than 1 ohm If good reading go to test point 2 Open short to ground in circuit 872B O between connectors 95B and 96F 3 Measure resistance between speaker connector 96F terminal B and radio c...

Страница 1330: ...e with next test point 2 Measure resistance between speaker connector 97F terminal B and radio connector 95B terminal 16 Less than 1 ohm If good reading left front speaker wiring is okay Open short to ground in circuit 875A B between connectors 95B and 93F B F Audio System Illumination Test Test point Good Reading Possible Cause of Bad Reading 1 Access connector 95A Attach test light to ground and...

Страница 1331: ...enna and frame ground H Speaker Resistance Test Test point Good Reading Possible Cause of Bad Reading 1 Disconnect suspect speaker electrical connector Measure resistance between the A and B terminals of the speaker Between 4 and 8 ohms If good reading speaker good electrically Bad circuit in speaker G Antenna Test Test point Good Reading Possible Cause of Bad Reading ...

Страница 1332: ... the alternator warms up If alternator output goes below or above specification the reconfigurable display will show an ISO symbol for the charging system and a message of High or Low Additionally a short audible alarm will sound Terminal 85 sends a pulsed rpm signal to connector CN1 terminal 19 of the instrument cluster ICU2 The ICU2 uses this signal to determine engine rpm Charging System Circui...

Страница 1333: ...ence Test System not charging or charging poorly Battery goes dead Alternator belt See engine repair section of Service Manual to replace or adjust belt B circuit A Charging System Output Test test points 2 4 D circuit B Excitation Circuit D Test Excitation control D Instrument Cluster ICU Excitation Control Test Alternator A Charging System Output Test test points 4 6 System overcharging D circui...

Страница 1334: ...f good reading circuit is good Go to next test point High resistance between battery and starter terminal 81A Repair replace wiring as needed 3 Attach negative lead of DVOM to starter terminal 81A and positive lead to starter terminal 81F Read voltage Less than 0 4 volts If good reading circuit is good Go to next test point High resistance in starter solenoid Clean connections repair replace as ne...

Страница 1335: ...ce between alternator connector 86 and in line connector 395M terminal 5 Less than 1 ohm If good reading go to next test point Open 121E Y circuit between connector 86 and connector 395 3 Measure resistance between in line connector 395 terminal 5 and in line connector 60M terminal 10 Less than 1 ohm If good reading go to next test point Open 121B Y circuit between connector 395 and connector 60 4...

Страница 1336: ...erminal 6 Less than 1 ohm If good reading go to next test point Open 126Y DG circuit between connector 85 and connector 395 3 Measure resistance between in line connector 395F terminal 6 and splice F6 Less than 1 ohm If good reading go to next test point Open 216C Y circuit between connector 395 and splice F6 4 Measure resistance between splice F6 and in line connector 60M terminal 12 Less than 1 ...

Страница 1337: ...ng 1 Place transmission in PARK Start engine and set at 1000 rpm Backprobing at Instrumentation Cluster ICU2 connector CN2 terminal 1 and measure voltage Turn on various loads lights heaters etc Voltage varies between 12 8 and 14 5 volts in response to load applied If good reading excitation control circuit is operating properly Instrument Cluster ICU2 ...

Страница 1338: ...t marker lights are On The work lamp Rotary switch controls the optional beltline work lamps center and optional fender work lamps center and side work lamps rear work lights and front roof work lamp and high beams The rotary switch controlled lamps are locked out when the headlight switch is On Exterior Lighting System Circuit Troubleshooting Before troubleshooting the Exterior Lighting system ma...

Страница 1339: ...nt WARNING Before performing any of the electrical tests be sure all operating controls are in neutral or park lock position This will eliminate accidental movement of the machine or start up of power driven equipment Work Lamp Switch Test Test point Good Reading Possible Cause of Bad Reading 1 Ignition in Run position Headlight switch Off Rotary switch Off Measure voltage at rotary switch termina...

Страница 1340: ...st Test point Good Reading Possible Cause of Bad Reading 1 Measure voltage at electronic flasher connector 135 terminal 8 12 volts If good reading go to test point 3 Open in unswitched B supply circuit Go to next test point 2 Measure voltage at fuse 20 12 volts If good reading repair open in 766 R circuit Fuse 20 or Open in 766 circuit from unswitched B 3 Measure resistance from electronic flasher...

Страница 1341: ...om in line connector 9 terminal 1 to electronic flasher connector 136 terminal 3 10 Headlight switch Off Universal switch in right turn position Measure voltage at electronic flasher connector 135 terminal 4 12 volts If good reading go to test point 15 Open circuit between electronic flasher and universal switch Go to next test point 11 Measure voltage at in line connector 9 terminal 3 12 volts If...

Страница 1342: ...s 11 12 with test light Test light flashes If light flashes electronic flasher operating properly Electronic flasher Universal Switch Test Test point Good Reading Possible Cause of Bad Reading 1 Disconnect electrical connector from universal switch Place universal switch in left turn position Measure resistance between terminals 220A and 220B Less than 1 ohm If good reading go to next test point O...

Страница 1343: ...h 5 Place universal switch in head lamp dipping position Measure resistance between terminals 220E and 220G Less than 1 ohm If good reading go to next test point Open circuit in universal switch 6 Press horn button Measure resistance between terminals 220H and 220J Less than 1 ohm If good reading universal switch is okay Open circuit in universal switch Universal Switch Test Test point Good Readin...

Страница 1344: ... 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 This will eliminate accidental movement of the machine or start up of power driven equipment Symptom Possible Cause Reference Test Coolant temperature gauge does not operate Sending unit B Engine Coolant Temperature Send...

Страница 1345: ...ircuit Go to next test point 2 Measure voltage at fuse 16 12 volts If good reading repair open in 202A R circuit Fuse 16 or Open in 101A R circuit from unswitched B 3 Ignition in Run position Measure voltage at instrument cluster connector CN2 terminal 2 12 volts If good reading go to test point 9 Open in unswitched B circuit Go to next test point 4 Measure voltage at fuse 37 12 volts If good read...

Страница 1346: ...eck continuity from J1 6 pin A to splice EC1 If good reading go to next test point Open in circuit 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 3 Check continuity from J1 6 pin B to Connector J1 pin 15 If good reading and Engine Coolant Temperature sensor does not work replace Engine Coolant Temper...

Страница 1347: ...t point 2 Measure voltage at in line connector 60 terminal 8 8 volts If good reading repair open in 234B R circuit Open in 234 R circuit from instrument cluster Go to next test point 3 Measure voltage at instrument cluster connector CN2 terminal 21 8 volts If good reading repair open in 234A R circuit 4 Measure resistance from fuel sender connector 66 terminal C to ground Less than 1 ohm If good r...

Страница 1348: ...witched so the dome light can be operated at any time The power supply for the horn is switched When the key is in the ON position the circuit is energized To operate the horn ground is provided by pressing the horn button on the universal switch Interior Lighting and Horn System Circuit Troubleshooting Before troubleshooting the Interior Lighting and Horn system make sure that the following opera...

Страница 1349: ... controls are in neutral or park lock position This will eliminate accidental movement of the machine or start up of power driven equipment A Horn System Circuit Test Test Point Good Reading Possible Cause of Bad Reading 1 Ignition in Run position Measure voltage at horn connector 412A 12 volts If good reading go to test point 7 Open in unswitched B circuit to horn Go to next test point 2 Measure ...

Страница 1350: ... next test point 10 While pressing horn switch measure resistance from in line connector 60 terminal 16 to ground Less than 1 ohm If good reading repair open in 723B B circuit Open in switched ground circuit from horn Go to next test point 11 While pressing horn switch measure resistance from in line connector 51 terminal 9 to ground Less than 1 ohm If good reading repair open in 723 A circuit Ope...

Страница 1351: ...witched B circuit Go to next test point 5 Measure voltage at fuse 18 12 volts If good reading repair open in J1 R circuit Open in 101H R circuit from unswitched B 6 Switch dome lamp to door operation Measure voltage at connector 101 of switch 12 volts If good reading go to next test point Bulb or Dome lamp and switch assembly 7 Remove electrical connector 100 from door switch Measure voltage at co...

Страница 1352: ...hed B Go to next test point 4 Measure voltage at in line connector 13 terminal X 12 volts If good reading repair open in 135B R circuit Open in circuit from unswitched B Go to next test point 5 Measure voltage at fuse 8 12 volts If good reading repair open in 135A R circuit Fuse 8 or Open in 101L R circuit from unswitched B 6 Measure resistance from map light connector 170 terminal C to ground Les...

Страница 1353: ...rror assembly Power and ground are supplied to the motors through three wires for each mirror assembly one wire for each motor and one wire in common therefore the motors can only be operated in one mode at a time up only down only in only or out only Change in mirror motor direction is accomplished by reversing current flow through the motors Power Mirror Circuit Troubleshooting Before troublesho...

Страница 1354: ... Ground Supply Test Mirror Switch B Power Mirror Switch Test Circuit to mirrors C First Circuit Test and D Second Circuit Test Left mirror inoperable Mirror Switch B Power Mirror Switch Test test points 1 2 7 8 9 10 15 16 17 and 18 Mirror Assembly F Left Mirror Assembly Test Circuit between switch and mirror C First Circuit Test test points 1 thru 3 and D Second Circuit Test test points 1 thru 3 R...

Страница 1355: ...B Power Mirror Switch Test test points 1 2 9 10 17 and 18 Mirror Assembly F Left Mirror Assembly Test test points 3 4 7 and 8 Open circuit between switch and mirror C First Circuit Test test points 2 3 and 4 and D Second Circuit Test test points 2 and 3 Left mirror in out inoperable Switch Faulty B Power Mirror Switch Test test points 1 2 7 8 15 and 16 Open circuit between switch and mirror C Firs...

Страница 1356: ...nd Ground Supply Test Test Point Good Reading Possible Cause of Bad Reading 1 Ignition in Run position Measure voltage at power mirror switch connector 130 terminal 9 12 volts If good reading go to test point 5 Open in circuit from switched B Go to next test point 2 Measure voltage at splice between power mirror switch connector 130 terminal 9 and in line connector 13 terminal W 12 volts If good r...

Страница 1357: ... Measure voltage at power mirror switch connector 130 terminal 10 12 volts If good reading go to next test point Open in power mirror switch 4 Hold mirror switch in OUT position Measure voltage at power mirror switch connector 130 terminal 7 12 volts If good reading go to next test point Open in power mirror switch 5 Hold mirror switch in UP position Measure voltage at power mirror switch connecto...

Страница 1358: ...ition Measure resistance from power mirror switch connector 130 terminal 7 to ground Less than 1 ohm If good reading go to next test point Open in power mirror switch 12 Hold mirror switch in OUT position Measure resistance from power mirror switch connector 130 terminal 10 to ground Less than 1 ohm If good reading go to next test point Open in power mirror switch 13 Hold mirror switch in UP posit...

Страница 1359: ...rminal 8 to ground Less than 1 ohm If good reading go to next test point Open in power mirror switch 17 Hold mirror switch in UP position Measure resistance from power mirror switch connector 130 terminal 7 to ground Less than 1 ohm If good reading go to next test point Open in power mirror switch 18 Hold mirror switch in DOWN position Measure resistance from power mirror switch connector 130 term...

Страница 1360: ...or 130 terminal 7 Go to next test point 3 Check for continuity between connector 111F terminal 2 and splice C6 Continuity If good reading repair open in 58B O circuit Open in 58B O circuit 4 Check for continuity between connector 111F terminal 3 and connector 130 terminal 4 Continuity If good reading go to next test point Open in 277A O circuit 5 Check for continuity between connector 111F termina...

Страница 1361: ...en connector 111M terminal 3 and connector 112 terminal 1 Continuity If good reading circuits between in line connector 111M and left mirror connector 112 okay Go to next test point Open in 951A Y circuit 4 Remove connector 113 from right mirror assembly Disconnect in line connector 111M from in line connector 111F Set DVOM to test continuity Check for continuity between connector 111M terminal 4 ...

Страница 1362: ...Circuit Test test points 2 3 and 6 and D Second Circuit Test test point 5 3 Hold mirror switch in UP position Measure voltage at terminal 1 of right mirror connector 113 12 volts If good reading go to next test point Open circuit between connector 113 and mirror switch Perform C First Circuit Test test point 5 and D Second Circuit Test test point 4 4 Hold Mirror switch in DOWN position Measure vol...

Страница 1363: ...ch in IN position Measure voltage at terminal 3 of right mirror connector 112 12 volts If good reading go to next test point Open circuit between connector 112 and mirror switch Perform C First Circuit Test test point 1 and D Second Circuit Test test point 1 2 Hold mirror switch in OUT position Measure voltage at terminal 2 of right mirror connector 112 12 volts If good reading go to next test poi...

Страница 1364: ...h in OUT position Check for continuity from left mirror connector 112 terminal 3 to ground Continuity If good reading go to next test point Open in power mirror switch 7 Hold mirror switch in UP position Check for continuity from left mirror connector 112 terminal 2 to ground Continuity If good reading go to next test point Open in power mirror switch 8 Hold mirror switch in DOWN position Check fo...

Страница 1365: ...0 position Turn the thumb wheel from the lowest position of 1 to the highest position of 6 to achieve heat control Seat adjustment and heating is available whenever the ignition switch is ON Power Seat System Circuit Troubleshooting Before troubleshooting the Seat system make sure that the following operating conditions are met A The batteries are fully charged and all connections are clean and ti...

Страница 1366: ...g controls are in neutral or park lock position This will eliminate accidental movement of the machine or start up of power driven equipment Symptom Possible Cause Reference Test Height adjustment not operating Height adjustment switch B Height Adjustment Circuit Test Power and ground supply A Seat System Power and Ground Supply Test Seat air pump compressor B Height Adjustment Circuit Test Air sy...

Страница 1367: ...re voltage at seat connector 133 terminal 2 12 volts If good reading go to next test point Open in circuit from switched B Go to test point 6 3 Measure voltage at seat connector 133 terminal 5 12 volts If good reading go to next test point Open in circuit from switched B Go to test point 7 4 Measure voltage at seat connector 133 terminal 7 12 volts If good reading go to test point 11 Open in circu...

Страница 1368: ... leakage Open in seat height adjustment circuits Go to next test point 2 Separate electrical connector 133F and 133M Engage seat height adjust switch and check for continuity from connector 133F terminal 1 to 2 Continuity Go to next test point Seat adjust switch Seat air pump compressor or Related circuits within seat assembly 3 Engage seat height adjust switch and check for continuity from connec...

Страница 1369: ... seat check for continuity between connector 133F terminals 5 and 6 Continuity If good reading go to next test point Open in operator presence switches and or circuits within seat assembly 2 Check for continuity between connector 133M terminals 5 and 6 with operator seat empty Open circuit If good reading go to next test point Short in operator presence switches and or circuits within seat assembl...

Страница 1370: ...o next test point 2 Measure voltage at fuse 29 12 volts If good reading repair open in 259A R circuit Open in circuit from switched B Go to next test point 3 Measure voltage at splice C21 12 volts If good reading replace fuse 29 or repair open in 102J R circuit Open in 102B R circuit from switched B 4 Measure resistance from seat connector 133 terminal 8 to ground Less than 1 ohm If good reading h...

Страница 1371: ...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 WARNING Before performing any of the electrical tests be sure all operating controls are in neutral or park lock position This will eliminate accidental movement of the machine or start up of power driven equi...

Страница 1372: ...st and confirm that switch turns off when key is released Starter relay D Starter Relay Test test point 6 and confirm that relay turns off when key is released Intermediate starter relay E Intermediate Starter Relay Test and confirm that relay turns off when the key is released Starter solenoid F Starter Motor Test test point 2 and confirm that 12 volts are not present at terminal 79 when key is r...

Страница 1373: ... at ignition switch connector 161 terminal 1 12 volts If good reading ignition switch power supply okay Open in circuit from unswitched B Go to next test point 2 Measure voltage at fuse 7 12 volts If good reading repair open in 107A R circuit Fuse 7 or Open in 101C R circuit from unswitched B B Ignition Switch Test Test point Good Reading Possible Cause of Bad Reading 1 Remove electrical connector...

Страница 1374: ...ng C FNRP Module Test Test point Good Reading Possible Cause of Bad Reading 1 Ignition switch in Run position Measure voltage at FNRP module connector 219 terminal 1 12 volts If good reading go to test point 4 Open in B circuit from ignition switch Go to next test point 2 Measure voltage at in line connector 51 terminal 1 12 volts If good reading repair open in 1 A circuit Open in B circuit from i...

Страница 1375: ... starter relay Measure voltage at starter relay terminal 1 12 volts If good reading go to next test point Open in B circuit from FNRP module Perform C FNRP Module Test 2 Measure voltage at starter relay terminal 3 12 volts If good reading go to test point 4 Open in unswitched B circuit Go to next test point 3 Measure voltage at ignition switch connector 161 terminal 1 12 volts If good reading repa...

Страница 1376: ...Starter Relay Test 3 Measure voltage at intermediate starter relay connector 78 12 volts If good reading go to test point 7 Open in B circuit from battery Go to next test point 4 Measure voltage at starter motor connector 81 12 volts If good reading repair open in 620A R circuit Open in B circuit from battery to starter motor connector 81 5 Measure resistance from intermediate starting relay conne...

Страница 1377: ...3 Ignition switch in Start position Measure voltage at intermediate starter relay terminal 84 12 volts If good reading repair open in 625A W circuit Open in B circuit Perform E Intermediate Starter Relay Test 4 Measure resistance from starter motor case to ground Less than 1 ohm If good reading go to next test point Check contact surface of starter motor with engine Ensure starter motor is mounted...

Страница 1378: ...parate 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 The batteries are fully charged and all connections are clean and tight B Transmission in neutral or park C Check all connectors for full installation loose corroded o...

Страница 1379: ...noperative Power Ground Supply Diagnostic test A Wiper Switch Diagnostic test C Wiper Motor Diagnostic test D Front wiper motor does not park stops when switch is turned off Wiper Motor Test point E 12 Wiper Switch Test point E 10 Front wiper motor low speed only Wiper Motor Test point E 6 Wiper switch Test point E 4 Front wiper motor high speed only Wiper Motor Test point E 9 Wiper switch Test po...

Страница 1380: ...ure all operating controls are in neutral or park lock position This will eliminate accidental movement of the machine or start up of power driven equipment A Front Wiper System Power and Ground Supply Test Test Point Good Reading Possible Cause of Bad Reading 1 Access connector 127 on front wiper switch Ignition ON Check for 12 volts at cavity 6 Wiper switch power supply good go to test point 4 G...

Страница 1381: ... fuse 52 3 Check for 12 volts at rear wiper motor connector 98 cavity C Rear wiper motor power supply good Go to next test point Open circuit 841B O 4 Check for continuity to chassis ground at rear wiper motor connector 99 cavity A Ground circuit OK Go to next test point C Front Wiper Washer Switch Test Test point Good Reading Possible Cause of Bad Reading 1 Key ON Select low speed on front wiper ...

Страница 1382: ...speed on front wiper switch Does front wiper motor operate at low speed Go to next test point Go to test point E 4 2 Select high speed on front wiper switch Does front wiper operate at high speed Go to next test point Go to test point E 7 3 Turn front wiper switch OFF Do wipers PARK Wiper motor good Go to test point E 10 4 Access front wiper switch connector 127 Check for 12 volts at cavity 3 Go t...

Страница 1383: ...t inline connector 13 cavity N Go to next test point Open circuit 830A O 12 Check for 12 volts at front wiper motor connector 115 cavity A Confirm front wiper motor ground test point A 4 If ground is good replace front wiper motor Open circuit 832B O F Front Washer Motor Test Test point Good Reading Possible Cause of Bad Reading 1 Operate front washer switch Check for 12 volts at front wiper washe...

Страница 1384: ...r supply is good replace switch 4 Check for 12 volts at inline connector 13 cavity L Go to next test point Open circuit 843C O 5 Check for 12 volts at rear wiper motor connector 98 cavity B Confirm rear wiper motor ground test point B 4 If ground is good replace rear wiper motor Open circuit 843B O 6 Check for 12 volts at rear wiper switch connector 122 cavity 3 Go to next test point Confirm switc...

Страница 1385: ...ower 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 Go to next test point Open circuit 845C O 4 Check for 12 volts at connector 333 cavity 17 Go to next test point Open circuit 845B O 5 Disconnect rear washer motor connector 213 Check for chassis ground at ...

Страница 1386: ...Section 55 Chapter 2 January 2006 INSTRUMENTATION CONTROLLER FAULT CODES ...

Страница 1387: ...34 55 2 10 FAULT CODE INST 10035 55 2 10 FAULT CODE INST 10036 55 2 10 FAULT CODE INST 10037 55 2 11 FAULT CODE INST 10038 55 2 11 FAULT CODE INST 11011 55 2 12 FAULT CODE INST 12011 55 2 13 FAULT CODE INST 12043 55 2 15 FAULT CODE INST 12051 55 2 17 FAULT CODE INST 12071 55 2 19 FAULT CODE INST 12091 55 2 21 FAULT CODE INST 12111 55 2 23 FAULT CODE INST 13010 55 2 25 FAULT CODE INST 13011 55 2 26...

Страница 1388: ...Section 55 Electrical System Controller Chapter 2 55 2 3 FAULT CODE INST 13052 55 2 32 FAULT CODE INST 53001 55 2 33 FAULT CODE INST 53005 55 2 33 FAULT CODE INST 65535 55 2 33 ...

Страница 1389: ...ESENT SW and add it to the VIEW LIST Now you can monitor the function of the seat switch Sit down and then stand up a few times The seat switch should close when the seat is sat in and open when the operator gets up If the status on the screen changes with the operators position the seat switch is functioning OK The fault code might be recorded for intermittent seat problems If the status on the s...

Страница 1390: ...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 ...

Страница 1391: ...round chassis ground Frequency range is from zero to 3 200 Hz worst case PTO SHAFT SIZE SPEED SIGNAL The PTO shaft size speed frequency is derived from a variable reluctance speed sensor in the transmission The sensor is connected directly to the AUX HITCH PTO controller and its output is proportional to PTO clutch output speed but is scaled differently from the PTO clutch speed signal depending u...

Страница 1392: ...engine RPM exceeded a preset limit Possible failure modes 1 The engine speed has exceeded a preset limit Solution The instrument cluster has received the engine speed signal from the engine controller through the data bus 1 Take precautions to avoid overspeed the engine Select a lower gear when traveling down inclines especially when pulling a heavy load FAULT CODE INST 5010 Engine Oil Pressure Se...

Страница 1393: ...controller pin when pin 18 wire is not connected NOTE Use the correct tool to remove pins from connectors 2 Check the sensor ground Measure the continuity between pin A of connector C216 to the chassis ground If there is good continuity less than 1 ohm go to the next step If there is not good continuity go to step 4 3 Check the function of the engine oil pressure sensor Validate that the sensor ou...

Страница 1394: ...st Possible failure modes Memory defect or intermittent controller Solution 1 Make sure the controller has a good connection CN 2 to the battery and is properly grounded 2 Calibrate the instrumentation controller Clear the fault code Shut down the tractor and restart 3 If the same fault code appears again change the controller NOTE See schematic sections 24 25 and 26 on the schematic poster FAULT ...

Страница 1395: ...re modes 1 Intermittent power supply or ground to controller 2 Controller memory defect Solution Verify power and ground to the controller Perform radar calibration per the operators manual 1 Make sure the controller has a good connection CN 2 to the battery and is properly grounded 2 Perform the radar calibration for the instrumentation controller per the operators manual 3 Clear the fault code T...

Страница 1396: ...schematic sections 24 through 26 of the poster schematic FAULT CODE INST 10038 Controller Memory Error Loss of Valid Remote Timer Information Cause Controller memory error Loss of remote hydraulic timer values Possible failure mode 1 Intermittent controller power supply or ground 2 Controller memory defect 3 Remote hydraulic timer value out of range Solution Verify power and ground to the controll...

Страница 1397: ...t step If there is not good continuity go to step 4 3 Check the function of the fuel level sensor Validate that the sensor output voltage is greater that 0 125 volts at pin B of connector C066 The power supply to the fuel sensor is 8VDC from connector CN 2 cavity 21 of the instrument controller When the fuel tank is empty the fuel level signal from pin B should be around 0 25 V When the fuel tank ...

Страница 1398: ...the power supply to the Tractor Data Bus A Check fuse 42 B Turn the tractor key switch to the ON position Verify approximately 12 volts power at fuse 42 If no power check the power supply to the key switch power stud 4 Check the Tractor Data Bus at the can bus resistor terminators The following checks are performed looking into one end of the data bus and checking the resistor terminator at the ot...

Страница 1399: ...ler 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 NOTE Alway...

Страница 1400: ...inator at the engine Raise the tractor hood The resistor terminator is located in harness that leads into Buss box Disconnect the terminator plug at connector C205 With the key switch in the ON position measure the voltage on each pin to ground on connector C205 At cavity A the yellow wire it should read from 2 5 to 2 8 volts At cavity B the green wire it should read from 2 2 to 2 5 volts If the a...

Страница 1401: ...ce 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 NOTE Always inspect connector ends for damaged bent or dislocated pins when troubleshooting the Data Bus One intermittent connection can cause the entire bus to stop communications NOTE When...

Страница 1402: ...ta bus and checking the resistor terminator at the other end A Check from the can bus resistor terminator at the engine Raise the tractor hood The resistor terminator is located in harness that leads into Buss box Disconnect the terminator plug at connector C205 With the key switch in the ON position measure the voltage on each pin to ground on connector C205 At cavity A the yellow wire it should ...

Страница 1403: ...ce 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 NOTE Always inspect connector ends for damaged bent or dislocated pins when troubleshooting the Data Bus One intermittent connection can cause the entire bus to stop communications NOTE When...

Страница 1404: ...a bus and checking the resistor terminator at the other end A Check from the can bus resistor terminator at the engine Raise the tractor hood The resistor terminator is located in harness that leads into Buss box Disconnect the terminator plug at connector C205 With the key switch in the ON position measure the voltage on each pin to ground on connector C205 At cavity A the yellow wire it should r...

Страница 1405: ...ce 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 NOTE Always inspect connector ends for damaged bent or dislocated pins when troubleshooting the Data Bus One intermittent connection can cause the entire bus to stop communications NOTE When...

Страница 1406: ... the Tractor Data Bus A Check fuse 42 B Turn the tractor key switch to the ON position Verify approximately 12 volts power at fuse 42 If no power check the power supply to the key switch power stud 4 Check the Tractor Data Bus at the can bus resistor terminators The following checks are performed looking into one end of the data bus and checking the resistor terminator at the other end A Check fro...

Страница 1407: ...ler 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 NOTE Alway...

Страница 1408: ...witch power stud 3 Check the Tractor Data Bus at the can bus resistor terminators The following checks are performed looking into one end of the data bus and checking the resistor terminator at the other end A Check from the can bus resistor terminator at the engine Raise the tractor hood The resistor terminator is located in harness that leads into Buss box Disconnect the terminator plug at conne...

Страница 1409: ...ler 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 NOTE Alway...

Страница 1410: ... when there is no engine controller 3 Software execution error in the engine controller Solution This fault code is for the tractors equipped with an engine controller The instrumentation controller received the coolant temperature signal from the engine controller though the Data Bus 1 Make sure the engine is running properly 2 Recalibrate the instrumentation cluster if there is no engine control...

Страница 1411: ...olant temperature sensor Inspect the connector and clean the connection Measure the sensor resistance between the connection and the chassis ground as shown in the table below If the resistance is not as specified replace the engine coolant temperature sensor If it is as specified go to the next Step 2 Check the wiring from the engine coolant temperature sensor to connector C061 at the instrumenta...

Страница 1412: ...gine coolant temperature sensor Inspect the connector Clean the connection Measure the sensor resistance between the connection and the chassis ground as shown in the table below If the resistance is not as specified replace the engine coolant temperature sensor If it is as specified go to the next Step 2 Check the wiring from the engine coolant temperature sensor to connector C061 at the instrume...

Страница 1413: ...spect the connector Clean the connection Measure the sensor resistance between the connection and the chassis ground as shown in the table below If the resistance is not as specified replace the transmission oil temperature sensor If it is as specified go to the next Step 2 Check the wiring from the transmission oil temperature sensor C89 pin 1 to connector C60 pin 22 to connector CN 1 pin 24 at t...

Страница 1414: ...nsor Inspect the connector Clean the connection Measure the sensor resistance between the connection and the chassis ground as shown in the table below If the resistance is not as specified replace the transmission oil temperature sensor If it is as specified go to the next Step 2 Check the wiring from the transmission oil temperature sensor C89 pin 1 to connector C60 pin 22 to connector CN 1 pin ...

Страница 1415: ...here is no engine controller 3 Software execution error in the engine controller Solution This fault code is for the tractors equipped with an engine controller The instrumentation controller received the air to air intake temperature signal from the engine controller through Data Bus 1 Make sure the engine is running properly 2 Recalibrate the instrumentation controller if there is no engine cont...

Страница 1416: ...spect pin A and B in the connector Clean the connection Clean the mating pin and the connector Use the table below and measure the sensor resistance between pin A and pin B If the resistance is not as specified replace the air to air intake temperature sensor If it is as specified go to the next Step 2 Check the wiring from the air intake temperature sensor to connector C061 at the instrumentation...

Страница 1417: ...r Inspect pin A and B in the connector Clean the connection Clean the mating pin and the connector Use the table below and measure the sensor resistance between pin A and pin B If the resistance is not as specified replace the air to air intake temperature sensor If it is as specified go to the next Step 2 Check the wiring from the air intake temperature sensor to connector C061 at the instrumenta...

Страница 1418: ... configuration for the instrument controller Validate that all the correct controllers are set to exist If desired use the AUTO menu selection It will automatically set the controller configuration in the instrument controller based on Data Bus information FAULT CODE INST 53005 Engine shutdown activated Cause This fault code is recorded if the engine shutdown is activated Possible failure mode 1 E...

Страница 1419: ...Section 55 Electrical System Controller Chapter 2 55 2 34 ...

Страница 1420: ...Section 55 Chapter 3 January 2006 AUX HITCH PTO FAULT CODES TRACTOR MULTI FUNCTION TMF CONTROLLER ...

Страница 1421: ... PTO FAULT CODE 19 55 3 18 AUX HITCH PTO FAULT CODE 21 55 3 18 AUX HITCH PTO FAULT CODE 22 55 3 19 AUX HITCH PTO FAULT CODE 23 55 3 20 AUX HITCH PTO FAULT CODE 24 55 3 21 AUX HITCH PTO FAULT CODE 25 55 3 22 AUX HITCH PTO FAULT CODE 26 55 3 23 AUX HITCH PTO FAULT CODE 28 55 3 24 AUX HITCH PTO FAULT CODE 29 55 3 24 AUX HITCH PTO FAULT CODE 30 55 3 25 AUX HITCH PTO FAULT CODE 31 55 3 26 AUX HITCH PTO...

Страница 1422: ... 37 AUX HITCH PTO FAULT CODE 56 55 3 38 AUX HITCH PTO FAULT CODE 57 55 3 39 AUX HITCH PTO FAULT CODE 58 55 3 40 AUX HITCH PTO FAULT CODE 59 55 3 41 AUX HITCH PTO FAULT CODE 60 55 3 41 AUX HITCH PTO FAULT CODE 61 55 3 42 AUX HITCH PTO FAULT CODE 62 55 3 42 AUX HITCH PTO FAULT CODE 63 55 3 42 AUX HITCH PTO FAULT CODE 64 55 3 43 AUX HITCH PTO FAULT CODE 65 55 3 43 AUX HITCH PTO FAULT CODE 66 55 3 44 ...

Страница 1423: ... HITCH PTO FAULT CODE 110 55 3 56 AUX HITCH PTO FAULT CODE 111 55 3 56 AUX HITCH PTO FAULT CODE 112 55 3 57 AUX HITCH PTO FAULT CODE 113 55 3 58 AUX HITCH PTO FAULT CODE 114 55 3 59 AUX HITCH PTO FAULT CODE 115 55 3 60 AUX HITCH PTO FAULT CODE 116 55 3 61 AUX HITCH PTO FAULT CODE 120 55 3 62 AUX HITCH PTO FAULT CODE 123 55 3 62 AUX HITCH PTO FAULT CODE 124 55 3 63 AUX HITCH PTO FAULT CODE 125 55 3...

Страница 1424: ...AUX HITCH PTO FAULT CODE 148 55 3 82 AUX HITCH PTO FAULT CODE 149 55 3 83 AUX HITCH PTO FAULT CODE 150 55 3 83 AUX HITCH PTO FAULT CODE 151 55 3 84 AUX HITCH PTO FAULT CODE 152 55 3 86 AUX HITCH PTO FAULT CODE 153 55 3 86 AUX HITCH PTO FAULT CODE 154 55 3 87 AUX HITCH PTO FAULT CODE 155 55 3 87 AUX HITCH PTO FAULT CODE 156 55 3 88 AUX HITCH PTO FAULT CODE 157 55 3 88 AUX HITCH PTO FAULT CODE 158 5...

Страница 1425: ...HITCH PTO FAULT CODE 169 55 3 99 AUX HITCH PTO FAULT CODE 170 55 3 100 AUX HITCH PTO FAULT CODE 171 55 3 101 AUX HITCH PTO FAULT CODE 172 55 3 101 AUX HITCH PTO FAULT CODE 173 55 3 102 AUX HITCH PTO FAULT CODE 174 55 3 103 AUX HITCH PTO FAULT CODE 175 55 3 104 AUX HITCH PTO FAULT CODE 178 55 3 106 AUX HITCH PTO FAULT CODE 179 55 3 107 AUX HITCH PTO FAULT CODE 180 55 3 108 ...

Страница 1426: ...The resistance should be Approximately 5 1 ohms at 40 C 40 F Approximately 6 9 ohms at 25 C 77 F Approximately 9 5 ohm at 100 C 212 F If the hitch raise solenoid resistance is not in the range go to step 2 If it is as specified start the engine and test the hitch again If fault code is recorded again check the function of the hitch controller If not problem fixed 2 Test the hitch raise solenoid re...

Страница 1427: ... pin 4 and pin 5 The resistance should be Approximately 5 1 ohms at 40 C 40 F Approximately 6 9 ohms at 25 C 77 F Approximately 9 5 ohm at 100 C 212 F If the hitch raise solenoid resistance is not in the range go to step 2 If it is as specified start the engine and test the hitch again If fault code is recorded again check the function of the hitch controller If not problem fixed 2 Test the hitch ...

Страница 1428: ... The resistance should be Approximately 5 1 ohms at 40 C 40 F Approximately 6 9 ohms at 25 C 77 F Approximately 9 5 ohm at 100 C 212 F If the hitch lower solenoid resistance is not in the range go to step 2 If it is as specified start the engine and test the hitch again If fault code is recorded again check the function of the hitch controller If not problem fixed 2 Test the hitch lower solenoid r...

Страница 1429: ...tance and its wiring harness If no other code exists check the hitch valve wiring 1 Check for fault code 4 If it exists follow its corresponding diagnosing procedures 2 If fault code 4 does not show up Check the wiring harness from connector C058 and C053 to C151 for an open circuit or short to ground NOTE Always inspect connector ends for damaged bent or dislocated pins when troubleshooting NOTE ...

Страница 1430: ...to the Tractor Data Bus A Check fuse 42 B Turn the tractor key switch to the ON position Verify approximately 12 volts power at fuse 42 If no power check the power supply to the key switch power stud 3 Check the Tractor Data Bus at the can bus resistor terminators The following checks are performed looking into one end of the data bus and checking the resistor terminator at the other end A Check f...

Страница 1431: ...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 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 t...

Страница 1432: ... end A Check from the can bus resistor terminator at the engine Raise the tractor hood The resistor terminator is located in harness that leads into Buss box Disconnect the terminator plug at connector C205 With the key switch in the ON position measure the voltage on each pin to ground on connector C205 At cavity A the yellow wire it should read from 2 5 to 2 8 volts At cavity B the green wire it...

Страница 1433: ...uts 12 through 18 on the schematic poster AUX HITCH PTO FAULT CODE 14 5 Volt Reference is Above the Upper Voltage Limit Cause The 5 volt reference voltage is monitored and is consistently greater than 5 8 volts Possible failure mode 1 Short circuit to 8 or 12 volt power source Solution 1 Turn the key switch ON Disconnect connector C055 center left on the AUX Hitch PTO controller Use a multimeter t...

Страница 1434: ...t should read approximately 5 volts If the reading is good go to step 2 B If the reading is below 4 2 volts replace the controller 3 Locate connector C150 6 pin at the rear of the tractor near the AUX Hitch PTO connector Remove the plug if the connector is not in use Use a multimeter to check for continuity between the harness connector C055 pin 23 to connector C150 pin 2 A If there is continuity ...

Страница 1435: ...otentiometer failed in the armrest controller in most cases 2 Software execution error in the armrest controller small chance Solution The hitch position command potentiometer is hard wired to the armrest controller If the hitch position command potentiometer fails in the armrest controller the fault code ARM 69 should exist 1 Check for fault code ARM 69 at the armrest controller If ARM 69 exists ...

Страница 1436: ...et screw on rockshaft potentiometer 3 Test the function of the rockshaft potentiometer Signal output from 0 to 5 VDC 1 24 volts per degree at pin B when pin A is connected to power supply and pin C is grounded Disconnect the rockshaft potentiometer at C155 The resistance is about 4 kohm measured across pins A and C The resistance increase with clockwise rotation from 0 to about 4 kohm measured acr...

Страница 1437: ... corresponding corrective action 2 Check the function the armrest controller NOTE See schematic sections 47 and 48 on the schematic poster AUX HITCH PTO FAULT CODE 21 Load Command Potentiometer Failure Cause The Data Bus signaled that the load command potentiometer has failed The hitch controller received the signal from the armrest controller Possible failure modes 1 Load command potentiometer in...

Страница 1438: ...r screen by click the Monitor Icon Click the CHANGE PARAMETER SELECTIONS Icon Click the HITCH DRAFT PIN RIGHT VOLTAGE and then ADD You will be able to monitor the draft pin signal status on the screen The voltage should be 2 95 to 3 05 when there is no load The voltage should change with the load change in the range of 2 3 to 5 3 VDC at 60 KN to 160 KN 3 Check the function of the draft pin a If a ...

Страница 1439: ...ts corresponding diagnosing procedures 2 If none of hitch 30 or hitch 31 exists check the power supply or the ground to the two pins a Check the power supply at either left pin connector or right pin connector There should be 8 volts at cavity C of C153 or cavity C of C154 If not check the continuity from connector C057 pin 25 to the cavity C of the right draft pin connector and from connector C05...

Страница 1440: ... into one end of the data bus and checking the resistor terminator at the other end A Check from the can bus resistor terminator at the engine Raise the tractor hood The resistor terminator is located in harness that leads into Buss box Disconnect the terminator plug at connector C205 With the key switch in the ON position measure the voltage on each pin to ground on connector C205 At cavity A the...

Страница 1441: ...spect connector ends for damaged bent or dislocated pins when troubleshooting the Data Bus One intermittent connection can cause the entire bus to stop communications NOTE Also see the Data Bus schematic foldouts 13 through 18 on the schematic poster AUX HITCH PTO FAULT CODE 25 Hitch Up Down Switch Failure Cause The Data Bus signaled that the hitch up down switch has failed The AUX Hitch PTO contr...

Страница 1442: ...nd start it again Check the fault code in the hitch controller If the fault code is gone the problem is fixed If the fault code appears again go to the next step 2 Test the function of the fender switch Disconnect the fender switch connector Check the continuities between the cavities There should be no continuity between any two cavities when the switch is not pressed There should be continuity b...

Страница 1443: ...tive action 2 Check the function the armrest controller NOTE See schematic sections 47 and 48 on the schematic poster AUX HITCH PTO FAULT CODE 29 Drop Rate Command Potentiometer Failure Cause The Data Bus signaled that the drop rate command potentiometer has failed The AUX Hitch PTO controller received the signal from the armrest controller Possible failure modes 1 The drop rate command potentiome...

Страница 1444: ...not change with the load change 2 Use the service tool Go to the Monitor screen by click the Monitor Icon Click the CHANGE PARAMETER SELECTIONS Icon Click the HITCH DRAFT PIN RIGHT VOLTAGE and then ADD You will be able to monitor the right draft pin signal status on the screen The voltage should be 2 95 to 3 05 when there is no load The voltage should change with the load change in the range of 2 ...

Страница 1445: ... present check the wiring from C154 to Pin 1 of C059 b Check the function of the left draft pin Replace the pin in any of the following cases No signal output Signal not within 2 95 to 3 05 when there is no load The output does not change with the load change 2 Use the service tool Go to the Monitor screen click the Monitor Icon Click the CHANGE PARAMETER SELECTIONS Icon Click the HITCH DRAFT PIN ...

Страница 1446: ...0 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 ...

Страница 1447: ...speed signal looks fine on service tool but not on the instrumentation cluster it is more likely a problem with the instrumentation cluster If both signals seem fine check the function of the AUX Hitch PTO controller 2 Test the resistance of the transmission speed sensor Locate the transmission speed sensor on top of the transmission Disconnect connector C069 from the sensor Inspect the connector ...

Страница 1448: ...onding corrective action 2 Check the function the armrest controller NOTE See schematic section 44 on the schematic poster AUX HITCH PTO FAULT CODE 34 Slip Select Switch Failure Cause The Data Bus signaled that the slip select switch has failed The AUX Hitch PTO controller received the signal from the armrest controller Possible failure modes 1 The slip select switch failed in the armrest controll...

Страница 1449: ...ly at pin C of connector C068 should be 12 Volts when the tractor key is in the RUN position There should be good continuity from pin A of connector C068 to the clean ground Check for open circuit and wiring shortage NOTE Always inspect connector ends for damage bent or dislocated pins when troubleshooting 2 Check the function of the radar The signal is from Pin B of the Radar and connected to the...

Страница 1450: ...he hitch drop rate control potentiometer is mounted on the second panel and wired to the armrest controller The potentiometer position information is broadcast over the Data Bus and can be monitored in the monitor screen of the service tool Most likely AUX Hitch PTO fault code 29 and ARM 159 have also been recorded See ARM 159 troubleshooting AUX HITCH PTO FAULT CODE 41 The ARU Specified Tractor W...

Страница 1451: ...ation aborted due to tractor moving Possible failure modes 1 Tractor moved during the calibration in most cases 2 Tractor speed sensor failure small chance Solution Make sure the tractor does not move during the calibration If the tractor did not move check the wheel speed sensor Refer to fault code hitch 32 for details of wheel speed sensor troubleshooting NOTE In rare cases external electromagne...

Страница 1452: ...ic pressure to the hitch valve Check for valve failure solenoid spool or the valve main spool stuck closed Repair or replace the spools or the valve according to the problem NOTE See schematic sections 51 and 52 on the schematic poster AUX HITCH PTO FAULT CODE 48 PWM Raise Threshold Is Too Low During Calibration Cause During calibration PWM threshold to start hitch raising is below the limit 6 Pos...

Страница 1453: ...shold to start hitch lower is above the limit 55 Possible failure modes 1 Lower solenoid coil resistance is too high 2 Wire harness or connector problem between hitch lower solenoid and hitch controller 3 Battery voltage is very low 4 Hitch valve lower portion is stuck closed Solution Make sure the calibration procedure is correct Then do the following for troubleshooting 1 Make sure the battery v...

Страница 1454: ... 14 7 volts DC 2 Test lower solenoid coil C152 and its wiring for low resistance Refer to fault code AUX Hitch PTO 5 troubleshooting procedures for details 3 Make sure there is proper hydraulic pressure to the hitch valve Check for valve failure center spring broken spool too loose Repair or replace the spools or the valve according to the problem NOTE See schematic sections 51 and 52 on the schem...

Страница 1455: ...screw on rockshaft potentiometer 3 Test the function of the rockshaft potentiometer Signal output from 0 to 5 VDC 1 24 volts per degree at pin B when pin A is connected to power supply and pin C is grounded Disconnect the rockshaft potentiometer at C155 The resistance is about 4 kohm measured across pins A and C The resistance increase with clockwise rotation from 0 to about 4 kohm measured across...

Страница 1456: ...hten set screw on rockshaft potentiometer 3 Test the function of the rockshaft potentiometer Signal output from 0 to 5 VDC 1 24 volts per degree at pin B when pin A is connected to power supply and pin C is grounded Disconnect the rockshaft potentiometer at C155 The resistance is about 4 kohm measured across pins A and C The resistance increase with clockwise rotation from 0 to about 4 kohm measur...

Страница 1457: ...ew on rockshaft potentiometer 3 Test the function of the rockshaft potentiometer Signal output from 0 to 5 VDC 1 24 volts per degree at pin B when pin A is connected to power supply and pin C is grounded Disconnect the rockshaft potentiometer at C155 The resistance is about 4 kohm measured across pins A and C The resistance increase with clockwise rotation from 0 to about 4 kohm measured across pi...

Страница 1458: ...s not change with the load change 2 Use the service tool Go to the Monitor screen by click the Monitor Icon Click the CHANGE PARAMETER SELECTIONS Icon Click the HITCH DRAFT PIN RIGHT VOLTAGE and then ADD You will be able to monitor the right draft pin signal status on the screen The voltage should be 2 95 to 3 05 when there is no load The voltage should change with the load change in the range of ...

Страница 1459: ...ut does not change with the load change 2 Use the service tool Go to the Monitor screen click the Monitor Icon Click the CHANGE PARAMETER SELECTIONS Icon Click the HITCH DRAFT PIN LEFT VOLTAGE and then ADD You will be able to monitor the left draft pin signal status on the screen The voltage should be 2 95 to 3 05 when there is no load The voltage should change with the load change in the range of...

Страница 1460: ...pin connector b Check the ground to the two pins There should be continuity between cavity A on both the left pin connector and right pin connector and cavity 23 of C053 If not check the wiring in between 3 If none of above check the function of the AUX Hitch PTO controller NOTE Always inspect connector ends for damaged bent or dislocated pins when troubleshooting NOTE See schematic sections 51 an...

Страница 1461: ... 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 If the reading is good go to step 2 B If the reading is above 8 8 volts replace the controller 2 Connect C057 back onto the AUX Hitch PTO controller Locate connector C153 at the right ha...

Страница 1462: ...o ground A The reading should be approximately 8 volts If the reading is good the problem may be intermittent B If the reading is below 7 2 volts there is an open or short to ground somewhere between connector C154 and connector C057 at the AUX Hitch PTO controller Locate and repair the open or short to ground AUX HITCH PTO FAULT CODE 65 12VH Voltage Supply is Below 8 Volts Possible failure mode 1...

Страница 1463: ...K check system voltage at cavity 1 2 and 3 of connector C053 at AUX Hitch PTO controller Check for bad connection and improper ground at cavity 19 of connector C053 at AUX Hitch PTO controller Check for shortage to the ground along the power supply to the controller 4 Test alternator output if the battery voltage would not hold even when the tractor has been running The voltage should be above 14 ...

Страница 1464: ... no continuity repair ground connection If no damage and continuity to ground is good measure across pin 1 and pin 2 at the MFD valve side The resistance should be in the range of 6 to 13 ohms If the resistance is higher than 13 ohms there is an open circuit in the solenoid coil If the resistance is less than 6 ohms there is a shortage in the solenoid coil In either case replace the solenoid on MF...

Страница 1465: ...ntinuity repair ground connection If no damage and continuity to ground is good measure across pin 1 and pin 2 at the Diff Lock valve side The resistance should be in the range of 6 to 13 ohms If the resistance is higher than 13 ohms there is an open circuit in the solenoid coil If the resistance is less than 6 ohms there is a shortage in the solenoid coil In either case replace the solenoid on Di...

Страница 1466: ...light relay base pin 1 F1 A If no continuity locate and repair open in wire Check for continuity between C335 pin 16 and C054 pin 17 and from C054 pin 17 to connector C010 pin 14 to isolate the open circuit B Good reading continue with step 3 3 Check the ground connection at brake light relay base There should be continuity from relay base pin 2 to chassis ground A No continuity repair open circui...

Страница 1467: ...n controller If the problem is with the wheel speed sender then fault code AUX Hitch PTO 32 and AUX Hitch PTO 87 should be recorded If there is no AUX Hitch PTO 32 and AUX Hitch PTO 87 the problem is most likely with the radar gun There is also a small chance of instrumentation controller malfunction 1 Check the wiring of radar gun Disconnect connector C068 at the radar The power supply at pin C o...

Страница 1468: ...he signal change when the tractor speed changes If there is no wheel speed signal go to step 2 If there is wheel speed signal compare it to the speed display on the instrumentation cluster If the speed signal looks fine on service tool but not on the instrumentation cluster it is more likely a problem with the instrumentation cluster If both signals seem fine check the function of the AUX Hitch PT...

Страница 1469: ...s inspect connector ends for damaged bent or dislocated pins when troubleshooting NOTE See schematic section 44 on the schematic poster AUX HITCH PTO FAULT CODE 89 Difflock Switch Failure 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 con...

Страница 1470: ...troller NOTE Always inspect connector ends for damaged bent or dislocated pins when troubleshooting NOTE See schematic section 44 on the schematic poster AUX HITCH PTO FAULT CODE 92 MFD Switch Failure Cause The Data Bus signaled that the MFD switch has failed The AUX Hitch PTO controller received the signal from the armrest controller Possible failure mode 1 The MFD switch failed in the armrest co...

Страница 1471: ...ails in the armrest controller the fault code ARM 1069 should exist 1 Check for fault code ARM 1069 at the armrest controller If ARM 1069 exists follow the corresponding corrective action 2 Check the function the armrest controller NOTE Always inspect connector ends for damaged bent or dislocated pins when troubleshooting NOTE See schematic section 44 on the schematic poster AUX HITCH PTO FAULT CO...

Страница 1472: ...one of above check the function of the AUX Hitch PTO controller NOTE See schematic sections 49 and 50 on the schematic poster AUX HITCH PTO FAULT CODE 99 12VT 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 alter...

Страница 1473: ...T You will now be able to monitor the 5 REMOTE SWITCH status on the screen NOTE See schematic sections 44 on the schematic poster AUX HITCH PTO FAULT CODE 107 The AUX Hitch PTO Controller Has Received The Electro Hydraulic 5 Control Retract 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 A...

Страница 1474: ...ill now be able to monitor the 1 REMOTE CONTROL LEVER status on the screen NOTE See schematic sections 45 on the schematic poster AUX HITCH PTO FAULT CODE 109 Electro Hydraulic Remote 2 Lever Position Control Pot Data Is Set To The Error State Cause The Data Bus signaled that AUX 2 lever potentiometer the 2nd remote hydraulic valve control is set to the error state The AUX Hitch PTO controller rec...

Страница 1475: ...ill now be able to monitor the 3 REMOTE CONTROL LEVER status on the screen NOTE See schematic sections 45 on the schematic poster AUX HITCH PTO FAULT CODE 111 Electro Hydraulic Remote 4 Lever Position Control Pot Data Is Set To The Error State Cause The Data Bus signaled that AUX 4 lever potentiometer the 4th remote hydraulic valve control is set to the error state The AUX Hitch PTO controller rec...

Страница 1476: ...t the function of the 1st variable flow control Connect the service tool to the tractor Data Bus do the following Go to the Monitor screen by click the Monitor Icon Click the CHANGE PARAMETER SELECTIONS Icon Click the ARMREST AUX REMOTE 1 FLOW CONTROL and then ADD Next click EXIT You will now be able to monitor the 1st variable flow control status on the screen Turn the flow control up and down an...

Страница 1477: ...t the function of the 2nd variable flow control Connect the service tool to the tractor Data Bus do the following Go to the Monitor screen by click the Monitor Icon Click the CHANGE PARAMETER SELECTIONS Icon Click the ARMREST AUX REMOTE 2 FLOW CONTROL and then ADD Next click EXIT You will now be able to monitor the 2nd variable flow control status on the screen Turn the flow control up and down an...

Страница 1478: ...st the function of the 3rd variable flow control Connect the service tool to the tractor Data Bus do the following Go to the Monitor screen by click the Monitor Icon Click the CHANGE PARAMETER SELECTIONS Icon Click the ARMREST AUX REMOTE 3 FLOW CONTROL and then ADD Next click EXIT You will now be able to monitor the 3rd variable flow control status on the screen Turn the flow control up and down a...

Страница 1479: ...st the function of the 4th variable flow control Connect the service tool to the tractor Data Bus do the following Go to the Monitor screen by click the Monitor Icon Click the CHANGE PARAMETER SELECTIONS Icon Click the ARMREST AUX REMOTE 4 FLOW CONTROL and then ADD Next click EXIT You will now be able to monitor the 4th variable flow control status on the screen Turn the flow control up and down a...

Страница 1480: ...st the function of the 5th variable flow control Connect the service tool to the tractor Data Bus do the following Go to the Monitor screen by click the Monitor Icon Click the CHANGE PARAMETER SELECTIONS Icon Click the ARMREST AUX REMOTE 5 FLOW CONTROL and then ADD Next click EXIT You will now be able to monitor the 5th variable flow control status on the screen Turn the flow control up and down a...

Страница 1481: ...chematic poster AUX HITCH PTO FAULT CODE 123 Current Sensed When The Aux 1 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 in...

Страница 1482: ...mage measure across pin 1 and pin 2 at the remote valve side The resistance should be in the range of 4 to 8 ohms If the resistance is higher than 10 ohms there is an open circuit in the solenoid coil If the resistance is less than 3 ohms there is a shortage in the solenoid coil In either case replace the solenoid in the 1st remote valve If the resistance is within the specified range replace or r...

Страница 1483: ...c controller to the remote valve Check the function of the remote hydraulic controller 1 Check the wiring harness from the AUX Hitch PTO controller connectors C053 pin 4 and C058 pin 1 to the remote valve connector C140 pins 1 and 2 There should be no shortage to12 volt power at any pin location NOTE Always inspect connector ends for damage bent or dislocated pins when troubleshooting 2 In any of ...

Страница 1484: ...mage measure across pin 1 and pin 2 at the remote valve side The resistance should be in the range of 4 to 8 ohms If the resistance is higher than 10 ohms there is an open circuit in the solenoid coil If the resistance is less than 3 ohms there is a shortage in the solenoid coil In either case replace the solenoid in the 1st remote valve If the resistance is within the specified range replace or r...

Страница 1485: ...c controller to the remote valve Check the function of the remote hydraulic controller 1 Check the wiring harness from the AUX Hitch PTO controller connectors C053 pin 11 and C058 pin 3 to the remote valve connector C341 pins 1 and 2 There should be no shortage to12 volt power at any pin location NOTE Always inspect connector ends for damage bent or dislocated pins when troubleshooting 2 In any of...

Страница 1486: ...mage measure across pin 1 and pin 2 at the remote valve side The resistance should be in the range of 4 to 8 ohms If the resistance is higher than 10 ohms there is an open circuit in the solenoid coil If the resistance is less than 3 ohms there is a shortage in the solenoid coil In either case replace the solenoid in the 1st remote valve If the resistance is within the specified range replace or r...

Страница 1487: ...c controller to the remote valve Check the function of the remote hydraulic controller 1 Check the wiring harness from the AUX Hitch PTO controller connectors C054 pin 6 and C058 pin 3 to the remote valve connector C141 pins 1 and 2 There should be no shortage to12 volt power at any pin location NOTE Always inspect connector ends for damage bent or dislocated pins when troubleshooting 2 In any of ...

Страница 1488: ...mage measure across pin 1 and pin 2 at the remote valve side The resistance should be in the range of 4 to 8 ohms If the resistance is higher than 10 ohms there is an open circuit in the solenoid coil If the resistance is less than 3 ohms there is a shortage in the solenoid coil In either case replace the solenoid in the 1st remote valve If the resistance is within the specified range replace or r...

Страница 1489: ...ic controller to the remote valve Check the function of the remote hydraulic controller 1 Check the wiring harness from the AUX Hitch PTO controller connectors C053 pin 6 and C058 pin 6 to the remote valve connector C342 pins 1 and 2 There should be no shortage to12 volt power at any pin location NOTE Always inspect connector ends for damage bent or dislocated pins when troubleshooting 2 In any of...

Страница 1490: ...mage measure across pin 1 and pin 2 at the remote valve side The resistance should be in the range of 4 to 8 ohms If the resistance is higher than 10 ohms there is an open circuit in the solenoid coil If the resistance is less than 3 ohms there is a shortage in the solenoid coil In either case replace the solenoid in the 1st remote valve If the resistance is within the specified range replace or r...

Страница 1491: ...c controller to the remote valve Check the function of the remote hydraulic controller 1 Check the wiring harness from the AUX Hitch PTO controller connectors C054 pin 5 and C058 pin 6 to the remote valve connector C142 pins 1 and 2 There should be no shortage to12 volt power at any pin location NOTE Always inspect connector ends for damage bent or dislocated pins when troubleshooting 2 In any of ...

Страница 1492: ...mage measure across pin 1 and pin 2 at the remote valve side The resistance should be in the range of 4 to 8 ohms If the resistance is higher than 10 ohms there is an open circuit in the solenoid coil If the resistance is less than 3 ohms there is a shortage in the solenoid coil In either case replace the solenoid in the 1st remote valve If the resistance is within the specified range replace or r...

Страница 1493: ...ydraulic controller to the remote valve Check the function of the remote hydraulic controller 1 Check the wiring harness from the AUX Hitch PTO controller connector C054 pin 13 and 18 to the remote valve connector C343 pins 1 and 2 There should be no shortage to12 volt power at any pin location NOTE Always inspect connector ends for damage bent or dislocated pins when troubleshooting 2 In any of t...

Страница 1494: ...age measure across pin 1 and pin 2 at the remote valve side The resistance should be in the range of 4 to 8 ohms If the resistance is higher than 10 ohms there is an open circuit in the solenoid coil If the resistance is less than 3 ohms there is a shortage in the solenoid coil In either case replace the solenoid in the 1st remote valve If the resistance is within the specified range replace or re...

Страница 1495: ... controller to the remote valve Check the function of the remote hydraulic controller 1 Check the wiring harness from the AUX Hitch PTO controller connectors C053 pin 7 and C054 pin 18 to the remote valve connector C143 pins 1 and 2 There should be no shortage to12 volt power at any pin location NOTE Always inspect connector ends for damage bent or dislocated pins when troubleshooting 2 In any of ...

Страница 1496: ...age measure across pin 1 and pin 2 at the remote valve side The resistance should be in the range of 4 to 8 ohms If the resistance is higher than 10 ohms there is an open circuit in the solenoid coil If the resistance is less than 3 ohms there is a shortage in the solenoid coil In either case replace the solenoid in the 1st remote valve If the resistance is within the specified range replace or re...

Страница 1497: ...ydraulic controller to the remote valve Check the function of the remote hydraulic controller 1 Check the wiring harness from the AUX Hitch PTO controller connector C054 pin 4 and pin 7 to the remote valve connector C344 pins 1 and 2 There should be no shortage to12 volt power at any pin location NOTE Always inspect connector ends for damage bent or dislocated pins when troubleshooting 2 In any of...

Страница 1498: ...mage measure across pin 1 and pin 2 at the remote valve side The resistance should be in the range of 4 to 8 ohms If the resistance is higher than 10 ohms there is an open circuit in the solenoid coil If the resistance is less than 3 ohms there is a shortage in the solenoid coil In either case replace the solenoid in the 1st remote valve If the resistance is within the specified range replace or r...

Страница 1499: ...lic controller to the remote valve Check the function of the remote hydraulic controller 1 Check the wiring harness from the AUX Hitch PTO controller connector C054 pin 4 and pin 15 to the remote valve connector C144 pins 1 and 2 There should be no shortage to12 volt power at any pin location NOTE Always inspect connector ends for damage bent or dislocated pins when troubleshooting 2 In any of the...

Страница 1500: ...age measure across pin 1 and pin 2 at the remote valve side The resistance should be in the range of 4 to 8 ohms If the resistance is higher than 10 ohms there is an open circuit in the solenoid coil If the resistance is less than 3 ohms there is a shortage in the solenoid coil In either case replace the solenoid in the 1st remote valve If the resistance is within the specified range replace or re...

Страница 1501: ...eference voltage at C057 pin 16 The voltage should read from 4 75 to 5 25 volts AUX HITCH PTO FAULT CODE 148 Out Of Range Error Low On The 1 Feedback Cause The 1 section feedback voltage is less than 5 volts Possible failure modes 1 Damaged wiring resulting short to ground or open circuit 2 Controller internal failure Solution 1 Check the wiring from the AUX Hitch PTO controller back to scraper co...

Страница 1502: ...n 16 The voltage should read from 4 75 to 5 25 volts AUX HITCH PTO FAULT CODE 150 Out Of Range Error Low On The 2 Feedback Cause The 2 section feedback voltage is less than 5 volts Possible failure modes 1 Damaged wiring resulting short to ground or open circuit 2 Controller internal failure Solution 1 Check the wiring from the AUX Hitch PTO controller back to scraper controls or implement Check f...

Страница 1503: ...actor Data Bus A Check fuse 42 B Turn the tractor key switch to the ON position Verify approximately 12 volts power at fuse 42 If no power check the power supply to the key switch power stud 3 Check the Tractor Data Bus at the can bus resistor terminators The following checks are performed looking into one end of the data bus and checking the resistor terminator at the other end A Check from the c...

Страница 1504: ... 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 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 pr...

Страница 1505: ...nector ends for damaged bent or dislocated pins when troubleshooting NOTE See schematic section 53 in schematic poster AUX HITCH PTO FAULT CODE 153 EHR Top Link Switch Conflict Cause The Data Bus signaled that the top link switches conflict The top link switch is hard wired to the AUX Hitch PTO controller Possible failure mode 1 Operator depressed top link switch in cab second person depressed opp...

Страница 1506: ...normally open AUX HITCH PTO FAULT CODE 155 Auto PTO Switch Data Is Set To The Error State Cause The Data Bus signaled that Auto 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 Auto PTO switch 2 Software execution error in the armrest controller small chance Solution 1 Erase fault code Reprogram Auto PTO...

Страница 1507: ...r Switch Short Cause The Data Bus signaled that PTO remote fender switch short The PTO remote switches are hard wired to the AUX Hitch PTO controller Possible failure modes 1 Bad remote PTO switch 2 Software execution error in the armrest controller small chance Solution 1 Check the wiring from the AUX Hitch PTO controller connector C057 back to remote fender switches Check for damage chaffed wire...

Страница 1508: ... If 12 volts is not present check both remote PTO fender switches Both switches are normally closed Replace the switch that is open AUX HITCH PTO FAULT CODE 159 PTO Remote Fender Switch Stuck On Cause The Data Bus signaled that a PTO remote fender switch is stuck on The PTO remote switches are hard wired to the AUX Hitch PTO controller NOTE AUX Hitch PTO fault code 158 may also be recorded Possibl...

Страница 1509: ...Check the alternator and the engine RPM signal from the alternator The PTO clutch input speed is the engine RPM signal from the alternator a Make sure the alternator is the correct model Incorrect alternator will give wrong signal frequency which may trigger this fault code b Check for worn alternator belt c Check the engine RPM signal wiring There should be good continuity between cavity 33 of AU...

Страница 1510: ...M The signal is a quasi sinusoidal waveform the amplitude of which is non linearly proportional to speed The amplitude range of the signal is from 3 volts peak to peak to 80 volts peak to peak centered around chassis ground Frequency range is from zero to 760 Hz worst case Solution Make sure the PTO shaft is not driven by the load such as in the down hill situation Test the PTO speed sensor and it...

Страница 1511: ...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 ...

Страница 1512: ...PTO clutch output speed but scaled differently from the PTO clutch speed signal depending upon which PTO shaft is in use i e 1 3 4 1000 RPM 1 3 8 1000 RPM or 1 3 8 540 RPM The signal is a quasi sinusoidal waveform the amplitude of which is non linearly proportional to speed The amplitude range of the signal is from 3 volts peak to peak to 80 volts peak to peak centered around chassis ground Freque...

Страница 1513: ... is proportional to PTO clutch output speed but scaled differently from the PTO clutch speed signal depending upon which PTO shaft is in use i e 1 3 4 1000 RPM 1 3 8 1000 RPM or 1 3 8 540 RPM The signal is a quasi sinusoidal waveform the amplitude of which is non linearly proportional to speed The amplitude range of the signal is from 3 volts peak to peak to 80 volts peak to peak centered around c...

Страница 1514: ...1000 RPM or 1 3 8 540 RPM The signal is a quasi sinusoidal waveform the amplitude of which is non linearly proportional to speed The amplitude range of the signal is from 3 volts peak to peak to 80 volts peak to peak centered around chassis ground Frequency range is from zero to 760 Hz worst case Solution Make sure the implement attached to tractor is not causing the PTO to turn Test the PTO speed...

Страница 1515: ...13 and connector C159 pin 1 Next use a multimeter to check the continuity between connector C058 pin 7 and connector C159 pin 2 If no damage and continuity checks are good measure across pin 1 and pin 2 at the PTO solenoid The resistance should be in the range of 6 to 13 ohms If the resistance is higher than 13 ohms there is an open circuit in the solenoid coil If the resistance is less than 6 ohm...

Страница 1516: ...ou will now be able to monitor the PTO SWITCH status on the screen If the switch checks out okay continue with the next step 2 Check remote PTO switch function Both switches are normally closed 3 Check the wiring harness from the AUX Hitch PTO controller connector C053 pin 13 to ground There should be no shortage to 12 volt power at this location with the PTO switch in OFF position NOTE Always ins...

Страница 1517: ...n 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 Connect the service tool to the tractor Data Bus do the following Go to the Monitor screen by click the Monitor Icon Click the CHANGE PARAMETER SELECTIONS Icon Click the PTO SWITCH and then ADD Next click EXIT You will now be able to monitor th...

Страница 1518: ...actor Data Bus do the following Go to the Monitor screen by click the Monitor Icon Click the CHANGE PARAMETER SELECTIONS Icon Click the PTO SWITCH and then ADD Next click EXIT You will now be able to monitor the PTO SWITCH status on the screen Turn the switch on and off and watch the status change If the status display matches the switch changes the switch is working OK If not continue the test pr...

Страница 1519: ...UX Hitch PTO controller 1 Connect the service tool to the tractor Data Bus do the following Go to the Monitor screen by click the Monitor Icon Click the CHANGE PARAMETER SELECTIONS Icon Click the PTO SWITCH and then ADD Next click EXIT You will now be able to monitor the PTO SWITCH status on the screen Turn the switch on and off and watch the status change If the status display matches the switch ...

Страница 1520: ...he wiring harness end pin 2 to ground There should be no voltage at this location with the PTO switch in OFF position 3 If B power is recorded at either pin inspect the harness back to AUX Hitch PTO controller for source of short to power If no short is located continue with next step NOTE Always inspect connector ends for damage bent or dislocated pins when troubleshooting Disconnect the connecto...

Страница 1521: ...arness back to AUX Hitch PTO controller for source of short to ground If no short is located continue with next step NOTE Always inspect connector ends for damage bent or dislocated pins when troubleshooting Disconnect the connector C053 and C058 at the AUX Hitch PTO controller 4 Check the AUX Hitch PTO controller connector C053 pin 13 to ground There should be no continuity to ground at this loca...

Страница 1522: ...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 ...

Страница 1523: ...a quasi sinusoidal waveform the amplitude of which is non linearly proportional to speed The amplitude range of the signal is from 3 volts peak to peak to 80 volts peak to peak centered around chassis ground Frequency range is from zero to 760 Hz worst case PTO CLUTCH SLIPPAGE The PTO clutch slippage limit is set as the follow PTO clutch slip 15 for 5 seconds Solution Make sure there is no PTO clu...

Страница 1524: ...onnector 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 NOTE See schematic sections 49 and 50 on the schematic poster ...

Страница 1525: ... 55 3 106 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 ...

Страница 1526: ...ensor in the transmission The sensor is connected directly to the AUX Hitch PTO control module and its output is proportional to PTO clutch output speed but scaled differently from the PTO clutch speed signal depending upon which PTO shaft is in use i e 1 3 4 1000 RPM 1 3 8 1000 RPM or 1 3 8 540 RPM The signal is a quasi sinusoidal waveform the amplitude of which is non linearly proportional to sp...

Страница 1527: ...e amplitude of which is non linearly proportional to speed The amplitude range of the signal is from 3 volts peak to peak to 80 volts peak to peak centered around chassis ground Frequency range is from zero to 3 200 Hz worst case PTO SHAFT SIZE SPEED SIGNAL The PTO shaft size speed frequency is derived from a variable reluctance speed sensor in the transmission The sensor is connected directly to ...

Страница 1528: ...Section 55 Chapter 4 January 2006 TRANSMISSION CONTROLLER FAULT CODES INCLUDES SUSPENDED AXLE ...

Страница 1529: ...CODE TRANS 51 55 4 15 FAULT CODE TRANS 52 55 4 16 FAULT CODE TRANS 53 55 4 17 FAULT CODE TRANS 54 55 4 19 FAULT CODE TRANS 59 55 4 21 FAULT CODE TRANS 60 55 4 22 FAULT CODE TRANS 66 55 4 23 FAULT CODE TRANS 67 55 4 24 FAULT CODE TRANS 68 55 4 25 FAULT CODE TRANS 69 55 4 26 FAULT CODE TRANS 70 55 4 27 FAULT CODE TRANS 72 55 4 27 FAULT CODE TRANS 73 55 4 28 FAULT CODE TRANS 74 55 4 28 FAULT CODE TRA...

Страница 1530: ...ULT CODE TRANS 111 55 4 45 FAULT CODE TRANS 112 55 4 46 FAULT CODE TRANS 113 55 4 47 FAULT CODE TRANS 114 55 4 48 FAULT CODE TRANS 115 55 4 49 FAULT CODE TRANS 116 55 4 50 FAULT CODE TRANS 117 55 4 51 FAULT CODE TRANS 118 55 4 52 FAULT CODE TRANS 119 55 4 53 FAULT CODE TRANS 120 55 4 54 FAULT CODE TRANS 121 55 4 55 FAULT CODE TRANS 122 55 4 56 FAULT CODE TRANS 123 55 4 57 FAULT CODE TRANS 124 55 4...

Страница 1531: ...S 134 55 4 62 FAULT CODE TRANS 135 55 4 63 FAULT CODE TRANS 136 55 4 65 FAULT CODE TRANS 137 55 4 67 FAULT CODE TRANS 138 55 4 68 FAULT CODE TRANS 139 55 4 69 FAULT CODE TRANS 140 55 4 70 FAULT CODE TRANS 141 55 4 71 FAULT CODE TRANS 142 55 4 72 FAULT CODE TRANS 143 55 4 72 FAULT CODE TRANS 144 55 4 73 FAULT CODE TRANS 145 55 4 74 FAULT CODE TRANS 147 55 4 75 FAULT CODE TRANS 148 55 4 77 ...

Страница 1532: ...essed Watch the display while slowly cycling the inching pedal If the number change follows the pedal movement smoothly the potentiometer and its wiring are working OK If the numbers are hard to control or do not fall in sequential order replace the pedal position potentiometer If numbers on display are locked up and will not change when clutch pedal is cycled check the pedal position potentiomete...

Страница 1533: ...tial order replace the pedal position potentiometer If numbers on display are locked up and will not change when clutch pedal is cycled check the pedal position potentiometer and its wiring NOTE There could be an intermittent problem and the tractor may still run so check for loose connections 2 Test the pedal position potentiometer and wiring Remove the rear controller cover Disconnect connector ...

Страница 1534: ...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 ...

Страница 1535: ...and ground to the Neutral relay There should be constant 12 V to cavity 3 If the 12 V is not present check from the cavity back to fuse 43 There should be constant 12 V to cavity 1 when the clutch pedal position is above 30 and the shuttle lever is in Forward OR Reverse The 12 V should disappear when the clutch pedal position is fully depressed or the shuttle lever is in Neutral OR Park If the 12 ...

Страница 1536: ...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 Reverse will be available 10 seconds after the last time that the shuttle lever was in forward without the clutch pedal do...

Страница 1537: ...fully depressed The number should smoothly drop as the clutch pedal is depressed The bottom of clutch switch will only be displayed as on if the transmission control relay and neutral relay have pulled in and the inching clutch is in the bottom of clutch position Enter TRANS VIEW or the monitor screen Watch the display while slowly cycle the inching pedal If the position display of the inching ped...

Страница 1538: ...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 ...

Страница 1539: ... is above 30 and the shuttle lever is in Forward OR Reverse The 12 V should disappear when the clutch pedal position is fully depressed or the shuttle lever is in Neutral OR Park If the 12 V is constant go to step 3 Otherwise check shortage to power in the wiring between cavity 5 and pin 25 or pin 34 of connector 355 3 Check the BOC switch and its wiring The BOC switch is located under the steerin...

Страница 1540: ...is 5 to 10 ohms If the reading is out of range replace the coil If the coil reading is okay continue with step 2 2 Check the wiring harness for an open circuit Check from pin 2 on harness end of connector C074 to chassis ground for continuity If no continuity locate and repair open ground wire Continuity okay continue with step 3 3 Disconnect transmission controller connector C0355 at rear of cab ...

Страница 1541: ... of the relay seat when Tractor is not in Park The 12 V should disappear when the Tractor is in Park If the 12 V presents when in Park check shortage to power in the wiring between cavity 1 of park relay seat and cavity 4 of connector 350 If the 12 V comes and goes as expected go to step 3 3 Check cavity 5 of Park relay seat Turn tractor off but Key on There should be no 12 V at the cavity If ther...

Страница 1542: ...e Forward or Reverse is selected either the Park switch failed open or its wiring shorted to ground 2 Troubleshooting by checking FNRP switch function Disconnect the cover panel under the steering column Locate connector C051 Measure continuities on the transmission control FNRP pot side Measure between Pin 6 Forward and Pin 8 5 Vref there should be about 500 600 Ohms when in Forward position and ...

Страница 1543: ...Key on There should be constant 12 V to cavity 3 of the relay seat If the 12 V is not present check from the cavity back to fuse 43 There should be 12 V to cavity 1 of the relay seat when Tractor is not in Park The 12 V should disappear when the Tractor is in Park If the 12 V is not present when tractor is not in Park check open circuit in the wiring between cavity 1 of park relay seat and cavity ...

Страница 1544: ...al position display If the Master clutch pedal position stays high on display when Master clutch pedal is depressed there is a good chance the wiring from the transmission controller to Master clutch pedal pot is shorted to power 3 Troubleshooting by checking pin connection Take pin 17 out of connector C351 and clear all Trans fault codes See the procedure for pin removal and erasing fault codes i...

Страница 1545: ...t 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 NOTE Pay attention to bent pin loose pin wire damage and any possible shortage between pins and wires ...

Страница 1546: ...y when Master clutch pedal is not depressed there is a good chance the wiring from the transmission controller to Master clutch pedal pot has shortage to ground 3 Troubleshooting by checking pin connection See the procedure for pin removal and erasing fault codes in front of this section Take pin 16 out of connector C351 and clear all Trans fault codes Turn the Key Off for a few seconds Then turn ...

Страница 1547: ...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 NOTE Pay attention to bent pin loose pin wire damage and any possible shortage between pins and wires ...

Страница 1548: ... Neutral switch failed open or its wiring shorted to ground 2 Troubleshooting by checking FNRP switch function Disconnect the cover panel under the steering column Locate connector C051 Measure continuities on the transmission control FNRP pot side Measure between Pin 6 Forward and Pin 8 5 Vref there should be about 500 600 Ohms when in Forward position and about 2500 3000 Ohms when in other posit...

Страница 1549: ... does not lit up on display when in Reverse either the Reverse switch failed open or its wiring shorted to ground If Neutral icon does not lit up steady when in Neutral or Park either the Neutral switch failed closed or its wiring shorted to power 3 Troubleshooting by checking FNRP switch function Disconnect the cover panel under the steering column Locate connector C051 Measure continuities on th...

Страница 1550: ...y ON and watch the shuttle position display If Forward icon does not lit up on display when in Forward either the Forward switch failed open or its wiring shorted to ground 2 Troubleshooting by checking FNRP switch function Disconnect the cover panel under the steering column Locate connector C051 Measure continuities on the transmission control FNRP pot side Measure between Pin 6 Forward and Pin ...

Страница 1551: ...d internally or its wiring shorted to power 2 Troubleshooting by checking FNRP switch function Disconnect the cover panel under the steering column Locate connector C051 Measure continuities on the transmission control FNRP pot side Measure between Pin 6 Forward and Pin 8 5 Vref there should be about 500 600 Ohms when in Forward position and about 2500 3000 Ohms when in other positions If not the ...

Страница 1552: ...e switch failed open or its wiring shorted to ground 2 Troubleshooting by checking FNRP switch function Disconnect the cover panel under the steering column Locate connector C051 Measure continuities on the transmission control FNRP pot side Measure between Pin 5 Reverse and Pin 8 5 Vref there should be about 500 600 Ohms when in Reverse position and about 2500 3000 Ohms when in other positions If...

Страница 1553: ...internally or its wiring shorted to power 2 Troubleshooting by checking FNRP switch function Disconnect the cover panel under the steering column Locate connector C051 Measure continuities on the transmission control FNRP pot side Measure between Pin 5 Reverse and Pin 8 5 Vref there should be about 500 600 Ohms when in Reverse position and about 2500 3000 Ohms when in other positions If not the Re...

Страница 1554: ...es for battery voltage low If most exist it is more likely that the battery voltage low 2 Test battery voltage It should be around 12 14 volts 3 If the battery voltage is Ok check system voltage at pin 14 of connector C350 Check for bad connection and improper ground at cavity 19 23 25 and 26 of the same connector Check for shortage to the ground along the power supply to the controller 4 Test alt...

Страница 1555: ...re 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 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...

Страница 1556: ...tween pin A and pin B The resistance should be around 3 k ohms If the resistance is much higher than 3K the sensor coil may be damaged internally If the resistance is close to 0 there must be a shortage inside the sensor In either case replace the transmission speed sensor If the resistance is close to 3k ohms go to next step 3 Check the wiring from the wheel speed sensor to the transmission contr...

Страница 1557: ...d Possible failure modes 1 Transmission regulated pressure accumulator is discharged most likely 2 Extensive internal clutch leaks Rare case Solution The transmission regulated pressure accumulator plays a big role in Powershift If the shift quality for all shifts is noticeably deteriorated it is a good indication that the transmission regulated pressure accumulator is discharged If the accumulato...

Страница 1558: ... fine The problem is more likely in the wiring connection from the alternator to the transmission controller Go to step 4 If the engine speed display is higher than it should be go to next steps 3 Disconnect the wire connection at the W terminal of the alternator Clear all trans faults Run the tractor and check trans faults again If fault code 79 appears again There is good chance the higher than ...

Страница 1559: ...e tractor at different gears and watch the wheel speed If the speed display is normal the wheel speed sensor is fine The problem is more likely in the wiring connection from the sensor to the transmission controller If the wheel speed display is higher than it should be go to next steps 2 Test the resistance of the transmission speed sensor Locate the transmission speed sensor on top of the transm...

Страница 1560: ...ransmission 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 With tractor moving the DC voltage will remain the same and the AC voltage will jump to several volts depending on loads in the harness The AC voltage will increase as tractor speed goes up If the wheel speed sensor functions normal check connections from the ...

Страница 1561: ...ake is released 4 If none of above fault code are recorded check and verify that the transmission clutches are slipping A Clear the fault code Engage different gears until the fault code shows up B Check whether the tractor speed is normal in the gears which create the fault code Pay attention to abnormal noise and sluggish gear engagement If It is suspected that the transmission slips in certain ...

Страница 1562: ...e but its signal may not be right To verify the validity of the speed signal is a complicated process If it is suspected that the signal may be wrong replace the transmission speed sensor 7 Test engine speed sensing refer to the troubleshooting procedure for fault 79 If the tractor has engine controller refer to engine diagnosing procedures for troubleshooting If the tractor does not have engine c...

Страница 1563: ... 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 Check the harness wiring for any visible damage ...

Страница 1564: ...first for the open If the harness is okay check the odd clutch solenoid for the open If the resistance is around 10 ohms go to next step 3 Measure the resistance between cavity 9 of connector C350 and the chassis ground If the resistance is less than a few ohms there is a short from the wire to ground Check the wire for damage between the odd clutch solenoid and the transmission controller Measure...

Страница 1565: ...rst for the open If the harness is okay check the even clutch solenoid for the open If the resistance is around 10 ohms go to next step 3 Measure the resistance between cavity 10 of connector C350 and the chassis ground If the resistance is less than a few ohms there is a short from the wire to ground Check the wire for damage between the even clutch solenoid and the transmission controller Measur...

Страница 1566: ...irst for the open If the harness is okay check the C1 2 clutch solenoid for the open If the resistance is around 10 ohms go to next step 3 Measure the resistance between cavity 6 of connector C350 and the chassis ground If the resistance is less than a few ohms there is a short from the wire to ground Check the wire for damage between the C1 2 clutch solenoid and the transmission controller Measur...

Страница 1567: ...rst for the open If the harness is okay check the C3 4 clutch solenoid for the open If the resistance is around 10 ohms go to next step 3 Measure the resistance between cavity 7 of connector C350 and the chassis ground If the resistance is less than a few ohms there is a short from the wire to ground Check the wire for damage between the C3 4 clutch solenoid and the transmission controller Measure...

Страница 1568: ...for the open If the harness is okay check the C5 6 clutch solenoid for the open If the resistance is around 10 ohms go to next step 3 Measure the resistance between cavity 13 of connector C355 and the chassis ground If the resistance is less than a few ohms there is a short from the wire to ground Check the wire for damage between the C5 6 clutch solenoid and the transmission controller Measure th...

Страница 1569: ...or the open If the harness is okay check the master clutch solenoid for the open If the resistance is around 10 ohms go to next step 3 Measure the resistance between cavity 5 of connector C350 and the chassis ground If the resistance is less than a few ohms there is a short from the wire to ground Check the wire for damage between the master clutch solenoid and the transmission controller Measure ...

Страница 1570: ... for the open If the harness is okay check the low clutch solenoid for the open If the resistance is around 10 ohms go to next step 3 Measure the resistance between cavity 14 of connector C355 and the chassis ground If the resistance is less than a few ohms there is a short from the wire to ground Check the wire for damage between the low clutch solenoid and the transmission controller Measure the...

Страница 1571: ... for the open If the harness is okay check the mid clutch solenoid for the open If the resistance is around 10 ohms go to next step 3 Measure the resistance between cavity 6 of connector C355 and the chassis ground If the resistance is less than a few ohms there is a short from the wire to ground Check the wire for damage between the mid clutch solenoid and the transmission controller Measure the ...

Страница 1572: ...for the open If the harness is okay check the high clutch solenoid for the open If the resistance is around 10 ohms go to next step 3 Measure the resistance between cavity 16 of connector C355 and the chassis ground If the resistance is less than a few ohms there is a short from the wire to ground Check the wire for damage between the high clutch solenoid and the transmission controller Measure th...

Страница 1573: ... open If the harness is okay check the reverse clutch solenoid for the open If the resistance is around 10 ohms go to next step 3 Measure the resistance between cavity 5 of connector C355 and the chassis ground If the resistance is less than a few ohms there is a short from the wire to ground Check the wire for damage between the reverse clutch solenoid and the transmission controller Measure the ...

Страница 1574: ... the open If the harness is okay check the creeper clutch solenoid for the open If the resistance is around 10 ohms go to next step 3 Measure the resistance between cavity 11 of connector C350 and the chassis ground If the resistance is less than a few ohms there is a short from the wire to ground Check the wire for damage between the creeper clutch solenoid and the transmission controller Measure...

Страница 1575: ... damage between even clutch solenoid wiring and fuse 44 5 Measure the resistance between cavity 10 and cavity 20 of connector C350 There should be no continuity If the resistance is less than a few ohms there is a shortage from the wire to the power Check for wire damage between even clutch solenoid and cavity 5 of Neutral Relay 6 Next measure the resistance between cavity 1 of connector C353 and ...

Страница 1576: ...damage between odd clutch solenoid wiring and fuse 44 5 Measure the resistance between cavity 9 and cavity 20 of connector C350 There should be no continuity If the resistance is less than a few ohms there is a shortage from the wire to the power Check for wire damage between odd clutch solenoid and cavity 5 of Neutral Relay 6 Next measure the resistance between cavity 8 of connector C353 and cavi...

Страница 1577: ... damage between C1 2 clutch solenoid wiring and fuse 44 5 Measure the resistance between cavity 6 and cavity 20 of connector C350 There should be no continuity If the resistance is less than a few ohms there is a shortage from the wire to the power Check for wire damage between C1 2 clutch solenoid and cavity 5 of Neutral Relay 6 Next measure the resistance between cavity 6 of connector C353 and c...

Страница 1578: ... damage between C3 4 clutch solenoid wiring and fuse 44 5 Measure the resistance between cavity 7 and cavity 20 of connector C350 There should be no continuity If the resistance is less than a few ohms there is a shortage from the wire to the power Check for wire damage between C3 4 clutch solenoid and cavity 5 of Neutral Relay 6 Next measure the resistance between cavity 13 of connector C353 and ...

Страница 1579: ...heck for wire damage between C5 6 clutch solenoid wiring and fuse 44 5 Measure the resistance between cavity 13 of connector C353 and cavity 20 of connector C350 There should be no continuity If the resistance is less than a few ohms there is a shortage from the wire to the power Check for wire damage between C5 6 clutch solenoid and cavity 5 of Neutral Relay 6 Next measure the resistance between ...

Страница 1580: ...ire damage between master clutch solenoid wiring and fuse 44 5 Measure the resistance between cavity 5 and cavity 20 of connector C350 There should be no continuity If the resistance is less than a few ohms there is a shortage from the wire to the power Check for wire damage between master clutch solenoid and cavity 5 of Neutral Relay 6 Next measure the resistance between cavity 4 of connector C35...

Страница 1581: ...ck for wire damage between low clutch solenoid wiring and fuse 44 5 Measure the resistance between cavity 14 of connector C355 and cavity 20 of connector C350 There should be no continuity If the resistance is less than a few ohms there is a shortage from the wire to the power Check for wire damage between low clutch solenoid and cavity 5 of Neutral Relay 6 Next measure the resistance between cavi...

Страница 1582: ...ck for wire damage between mid clutch solenoid wiring and fuse 44 5 Measure the resistance between cavity 6 of connector C355 and cavity 20 of connector C350 There should be no continuity If the resistance is less than a few ohms there is a shortage from the wire to the power Check for wire damage between mid clutch solenoid and cavity 5 of Neutral Relay 6 Next measure the resistance between cavit...

Страница 1583: ...heck for wire damage between high clutch solenoid wiring and fuse 44 5 Measure the resistance between cavity 16 of connector C355 and cavity 20 of connector C350 There should be no continuity If the resistance is less than a few ohms there is a shortage from the wire to the power Check for wire damage between high clutch solenoid and cavity 5 of Neutral Relay 6 Next measure the resistance between ...

Страница 1584: ...wer Check for wire damage between reverse clutch solenoid wiring and fuse 44 5 Measure the resistance between cavity 5 of connector C355 and cavity 20 of connector C350 There should be no continuity If the resistance is less than a few ohms there is a shortage from the wire to the power Check for wire damage between reverse clutch solenoid and cavity 5 of Neutral Relay 6 Next measure the resistanc...

Страница 1585: ...wire damage between creeper clutch solenoid wiring and fuse 44 5 Measure the resistance between cavity 11 and cavity 20 of connector C350 There should be no continuity If the resistance is less than a few ohms there is a shortage from the wire to the power Check for wire damage between creeper clutch solenoid and cavity 5 of Neutral Relay 6 Next measure the resistance between cavity 3 of connector...

Страница 1586: ...t 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 If the fault code still appears after the Even clutch is properly calibrated please contact TSG FAULT CODE TRANS 127 C1 2 Clutch is not calibrated Cause C1 2 Clutch is not calibrated Solution Clear the fault codes and calibrate the C1 2 Clutch If...

Страница 1587: ...ct 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 If the fault code still appears after the C5 6 clutch is properly calibrated please contact TSG FAULT CODE TRANS 130 Low Range Clutch is not calibrated Cause Low Clutch is not calibrated Solution Clear the fault codes and calibrate the Low Clutc...

Страница 1588: ...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 If the fault code still appears after the High clutch is properly calibrated please contact TSG FAULT CODE TRANS 133 Reverse Clutch is not calibrated Cause Reverse Clutch is not calibrated Solution Clear the fault codes and calibrate the Reverse ...

Страница 1589: ... 62 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 ...

Страница 1590: ...key switch to the ON position Verify approximately 12 volts power at fuse 42 If no power check the power supply to the key switch power stud 4 Check the Tractor Data Bus at the can bus resistor terminators The following checks are performed looking into one end of the data bus and checking the resistor terminator at the other end A Check from the can bus resistor terminator at the engine Raise the...

Страница 1591: ...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...

Страница 1592: ...the Tractor Data Bus A Check fuse 42 B Turn the tractor key switch to the ON position Verify approximately 12 volts power at fuse 42 If no power check the power supply to the key switch power stud 4 Check the Tractor Data Bus at the can bus resistor terminators The following checks are performed looking into one end of the data bus and checking the resistor terminator at the other end A Check from...

Страница 1593: ...k 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 Check the Data bus wiring o...

Страница 1594: ...ance between cavity 13 of connector C350 and cavity 7 of connector C353 at the wiring harness side The resistance should be around 5 6 ohms If the resistance is dramatically higher than specified there is an open in the circuit If the resistance is close to 0 there is a shortage in the circuit If the resistance is as specified go to the next step 3 Measure the resistance from cavity 13 of connecto...

Страница 1595: ...sion controller towards the solenoid Check for proper routing and wire damage 2 Disconnect connector C355 from the transmission controller Measure the resistance between cavity 8 of connector C355 and the chassis ground at the wiring harness side The resistance should be around 10 ohms If the resistance is dramatically higher than specified there is an open in the circuit If the resistance is clos...

Страница 1596: ...ion controller towards the solenoid Check for proper routing and wire damage 2 Disconnect connector C355 from the transmission controller Measure the resistance between cavity 15 of connector C355 and the chassis ground at the wiring harness side The resistance should be around 10 ohms If the resistance is dramatically higher than specified there is an open in the circuit If the resistance is clos...

Страница 1597: ... really been above the range go to next steps to check for electrical problems 3 Check the front axle position sensor The front axle position sensor voltage can be monitored on the Instrument controller Enter program mode on ICU Go to Fsus under Trans The front axle position sensor voltage will be displayed in both CAL and Manual mode The voltage should change smoothly from less than 1 volts to cl...

Страница 1598: ...next steps to check for electrical problems 3 Check the front axle position sensor The front axle position sensor voltage can be monitored on the Instrument controller Enter program mode on ICU Go to Fsus under Trans The front axle position sensor voltage will be displayed in both CAL and Manual mode The voltage should change smoothly from less than 1 volts to close to 5 volts when the front axle ...

Страница 1599: ... range for too long When the front axle suspension is turned on the system should bring the axle within the range quickly Make sure the tractor is properly ballasted and the implement is not too heavy for the tractor Check the installation of the front axle position sensor Make sure the front axle position sensor is properly installed There is no mechanical damage or blockage preventing the suspen...

Страница 1600: ...n the range quickly Make sure the tractor is properly ballasted and the front weight is proper for the tractor Check the installation of the front axle position sensor Make sure the front axle position sensor is properly installed There is no mechanical damage or blockage preventing the suspension back to the mid point If the above checks are all OK go to next steps 2 Check for electrical problems...

Страница 1601: ...oller Measure the resistance between cavity 3 and cavity 15 of connector C355 at the wiring harness side The resistance should be around 5 6 ohms If the resistance is dramatically higher than specified there is an open in the circuit If the resistance is close to 0 there is a shortage in the circuit If the resistance is as specified go to the next step 3 Measure the resistance from cavity 3 or cav...

Страница 1602: ...essure should have a sudden drop to fill the clutch Once the tractor is engaged the pressure should come back to normal If the pressure shows the sudden drop it is more likely a hydraulic problem If the pressure does not show the sudden drop it is more likely the sensor or its wiring problem NOTE The engaging of the transmission may cause sudden movement of the tractor Execute extreme caution when...

Страница 1603: ...Shorting pin C to pin A at the harness side and run the tractor This fault code should not reappear Shorting pin C to pin B at the harness side and run the tractor This fault code should reappear If above situations are true replace the pressure sensor Otherwise check the wiring Make sure the 5 V power supply is available from the controller at Pin A of C044 Make sure there is good continuity betw...

Страница 1604: ...r Measure the resistance between cavity 9 of connector C355 and the ground at the wiring harness side The resistance should be around 2 to 5 ohms If the resistance is dramatically higher than specified there is an open in the circuit If the resistance is close to 0 there is a shortage to the ground Check the harness If the harness is OK check the backup alarm 3 Check the backup alarm Disconnect th...

Страница 1605: ...Section 55 Electrical System Controller Chapter 4 55 4 78 ...

Страница 1606: ...Section 55 Chapter 5 January 2006 ARMREST CONTROLLER FAULT CODES ...

Страница 1607: ... ARM 109 55 5 13 FAULT CODE ARM 119 55 5 14 FAULT CODE ARM 129 55 5 15 FAULT CODE ARM 139 55 5 16 FAULT CODE ARM 149 55 5 17 FAULT CODE ARM 159 55 5 18 FAULT CODE ARM 169 55 5 19 FAULT CODE ARM 1029 55 5 20 FAULT CODE ARM 1039 55 5 21 FAULT CODE ARM 1049 55 5 22 FAULT CODE ARM 1059 55 5 23 FAULT CODE ARM 1069 55 5 24 FAULT CODE ARM 1079 55 5 25 FAULT CODE ARM 1089 55 5 26 FAULT CODE ARM 1099 55 5 ...

Страница 1608: ...RM 9012 55 5 31 FAULT CODE ARM 9013 55 5 32 FAULT CODE ARM 9014 55 5 32 FAULT CODE ARM 9015 55 5 33 FAULT CODE ARM 9021 55 5 33 FAULT CODE ARM 9031 55 5 34 FAULT CODE ARM 9041 55 5 34 FAULT CODE ARM 10091 55 5 35 FAULT CODE ARM 12013 55 5 36 FAULT CODE ARM 12081 55 5 38 FAULT CODE ARM 65535 55 5 39 ...

Страница 1609: ...for wiring damage loose connector or bent pin 3 Disconnect the throttle potentiometer at J208 and test its parameters a Measure the continuity between pin 1 or pin C and pin 3 or pin D The resistance should be 2 5 k ohms b Measure between pin 2 pin E and pin 1 pin C when moving the throttle from high to low idle The resistance should change continuously from below 500 ohms to about 2 k ohms 4 Chec...

Страница 1610: ...n 2 red wire It should be approximately 12 volts c Test the potentiometer power supply from the armrest controller at pin 3 orange wire It should be approximately 8 volts If no problem is found in above tests go to the next step 4 Connect the potentiometer from the 2nd or 3rd remote control lever J202 or J203 to the J201 in the controller Move the 2nd or 3rd lever forward and backward and monitor ...

Страница 1611: ...r at pin 2 red wire It should be approximately 12 volts c Test the potentiometer power supply from the armrest controller at pin 3 orange wire It should be approximately 8 volts If no problem is found in above tests go to the next step 4 Connect the potentiometer from the 1st or 3rd remote control lever J201 or J203 to the J202 in the controller Move the 1st or 3rd lever forward and backward and m...

Страница 1612: ...t pin 2 red wire It should be approximately 12 volts c Test the potentiometer power supply from the armrest controller at pin 3 orange wire It should be approximately 8 volts If no problem is found in above tests go to the next step 4 Connect the potentiometer from the 2nd or 4th remote control lever J202 or J204 to the J203 in the controller Move the 2nd or 4th lever forward and backward and moni...

Страница 1613: ...er at pin 2 red wire It should be approximately 12 volts c Test the potentiometer power supply from the armrest controller at pin 3 orange wire It should be approximately 8 volts If no problem is found in above tests go to the next step 4 Connect the potentiometer from the 2nd or 3rd remote control lever J202 or J203 to the J204 in the controller Move the 2nd or 3rd lever forward and backward and ...

Страница 1614: ...e approximately 8 volts If no problem is found in above tests go to the next step 4 Connect the potentiometer from the hitch load control or 5th remote flow control J205 or J207 to the J206 in the controller Turn control knob back and forth and monitor the hitch position control in the monitor screen of the service tool If the potentiometer functions OK now replace the hitch position control If th...

Страница 1615: ...t the potentiometer from the hitch position control or 5th remote flow control J206 or J207 to the J205 in the controller Turn control lever or knob back and forth and monitor the hitch load control in the monitor screen of the service tool If the potentiometer functions OK now replace the hitch load control If the lever or potentiometer does not function well and the fault code can be recorded ag...

Страница 1616: ...t codes always check the connection between the second panel and the armrest controller first Make sure there is no damaged wires loose connections or bent pins It is difficult but possible to test the flow control potentiometer and the wiring circuit 1 Open the armrest controller housing and disconnect connector J2 of the second panel from the armrest controller 2 Check the potentiometer a Measur...

Страница 1617: ... more possible that the potentiometer or its wiring to the armrest controller has failed Whether it is a single or multiple fault codes always check the connection between the second panel and the armrest controller first Make sure there is no damaged wires loose connections or bent pins It is hard but possible to test the flow control potentiometer and the wiring circuit 1 Open the armrest contro...

Страница 1618: ...s more possible that the potentiometer or its wiring to the armrest controller has failed Whether it is a single or multiple fault codes always check the connection between the second panel and the armrest controller first Make sure there is no damaged wires loose connections or bent pins It is hard but possible to test the flow control potentiometer and the wiring circuit 1 Open the armrest contr...

Страница 1619: ...s more possible that the potentiometer or its wiring to the armrest controller has failed Whether it is a single or multiple fault codes always check the connection between the second panel and the armrest controller first Make sure there is no damaged wires loose connections or bent pins It is hard but possible to test the flow control potentiometer and the wiring circuit 1 Open the armrest contr...

Страница 1620: ...the next step 4 Connect the potentiometer from the hitch position control or hitch load control J206 or J205 to the J207 in the controller Turn control lever or knob back and forth and monitor the 5th remote flow control in the monitor screen of the service tool If the lever or potentiometer functions OK now replace the 5th remote flow control If the lever or potentiometer does not function well a...

Страница 1621: ...possible that the potentiometer or its wiring to the armrest controller has failed Whether it is a single or multiple fault codes always check the connection between the second panel and the armrest controller first Make sure there is no damaged wires loose connections or bent pins It is hard but possible to test the timer control potentiometer and the wiring circuit 1 Open the armrest controller ...

Страница 1622: ...ore possible that the potentiometer or its wiring to the armrest controller has failed Whether it is a single or multiple fault codes always check the connection between the second panel and the armrest controller first Make sure there is no damaged wires loose connections or bent pins It is hard but possible to test the hitch upper limit control potentiometer and the wiring circuit 1 Open the arm...

Страница 1623: ...ore possible that the potentiometer or its wiring to the armrest controller has failed Whether it is a single or multiple fault codes always check the connection between the second panel and the armrest controller first Make sure there is no damaged wires loose connections or bent pins It is hard but possible to test the hitch drop rate control potentiometer and the wiring circuit 1 Open the armre...

Страница 1624: ...ible that the potentiometer or its wiring to the armrest controller has failed Whether it is a single or multiple fault codes always check the connection between the second panel and the armrest controller first Make sure there is no damaged wires loose connections or bent pins It is hard but possible to test the hitch travel control potentiometer and the wiring circuit 1 Open the armrest controll...

Страница 1625: ...ttention for wiring damage loose connectors or bent pins a When the switch is in EXTEND position there should be continuity between pin 1 and pin 2 and no continuity between pin 1 and pin 3 b When the switch is in RETRACT position there should be continuity between pin 2 and pin 3 and no continuity between pin 1 and pin 3 c When the switch is in OFF position there should be no continuity between a...

Страница 1626: ... its wiring Pay attention for wiring damage loose connectors or bent pins a When the switch is in ON position there should be continuity between pin 1 and pin 3 No continuity between pin 1 and pin 2 b When the switch is in OFF position there should be continuity between pin 1 and pin 2 No continuity between pin 1 and pin 3 If the switch is not functioning as specified above replace the switch 3 Ch...

Страница 1627: ...the hitch to make the system function again If this is not the case do the following 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 Open the armrest controller housing and disconnect connector J210 for HITCH UP DOWN control 2 Test the HITCH UP DOWN switch and its wiring Pay attention for wiring da...

Страница 1628: ...he switch is in SLIP SELECT position there should be continuity between pin 4 and pin 5 and no continuity between pin 4 and pin 6 b When the switch is in SLIP SET position there should be continuity between pin 4 and pin 6 and no continuity between pin 4 and pin 5 c When the switch is in OFF position there should be no continuity between any two of pin 4 pin 5 and pin 6 If the switch is not functi...

Страница 1629: ...switch is in AUTO position there should be continuity between pin 1 and pin 2 and no continuity between pin 1 and pin 3 b When the switch is in ON position there should be continuity between pin 2 and pin 3 and no continuity between pin 1 and pin 2 c When the switch is in OFF position there should be no continuity between any two of pin 1 pin 2 and pin 3 If the switch is not functioning as specifi...

Страница 1630: ...s in DIFF LOCK AUTO position there should be continuity between pin 1 and pin 2 and no continuity between pin 1 and pin 3 b When the switch is in DIFF LOCK ON position there should be continuity between pin 2 and pin 3 and no continuity between pin 1 and pin 2 c When the switch is in OFF position there should be no continuity between any two of pin 1 pin 2 and pin 3 If the switch is not functionin...

Страница 1631: ... When the momentary switch is in the UPSHIFT position there should be continuity between switch pin 2 and pin 3 and no continuity between pin 1 and pin 2 b When the momentary switch is in the DOWNSHIFT position there should be continuity between pin 1 and pin 2 and no continuity between pin 2 and pin 3 c When the switch is in OFF position there should be no continuity between any two of pin 1 pin ...

Страница 1632: ... 11 and pin 14 and no continuity between pin 12 and pin 14 b When the switch is in RETRACT LIMIT SET position there should be continuity between pin 12 and pin 14 and no continuity between pin 11 and pin 14 c When the switch is in OFF position there should be no continuity between any two of pin 11 pin 12 and pin 14 If the switch is not functioning as specified above replace the second panel panel...

Страница 1633: ... an integrated part of the throttle control potentiometer a Push the hand throttle to LOW IDLE position There should be continuity between pin 5 and pin 6 and no continuity between pin 5 and pin 4 b Push the hand throttle to HIGH IDLE position There should be continuity between pin 5 and pin 4 and no continuity between pin 5 and pin 6 c When the throttle is in the position between LOW IDLE and HIG...

Страница 1634: ...e there is no damaged wires loose connections or bent pins To test the HTS Record Play switch and the wiring circuit 1 Open the armrest controller housing and disconnect connector J2 of the second panel from the armrest controller 2 Check the HTS Record Play switch function a When the switch is in HTS RECORD position there should be continuity between pin 11 and pin 14 and no continuity between pi...

Страница 1635: ...t and lower limit set When each side of the switch is depressed the contacts should close 3 If the switch is bad replace the secondary panel FAULT CODE ARM 8011 Battery Voltage Low Cause Battery voltage low Possible failure modes 1 Battery voltage lower than 9 8 volts 2 The controller has a bad connection to power or is not grounded properly 3 Alternator regulator malfunction Solution Check for ba...

Страница 1636: ...mrest controller If the same fault code appears again replace the controller NOTE See schematic sections 47 and 48 on schematic poster FAULT CODE ARM 9012 Controller Memory Error Cause Controller memory error Loss of AUX remote lever 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...

Страница 1637: ...t controller If the same fault code appears again replace the controller NOTE See schematic sections 47 and 48 on schematic poster FAULT CODE ARM 9014 Controller Memory Error Cause Controller failure Loss of MFD switch 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 Shu...

Страница 1638: ...nd potentiometer calibration results not acceptable Possible failure mode 1 Calibration was done incorrectly 2 Hitch position command potentiometer or the lever are 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 Calibrate the hitch menu in th...

Страница 1639: ...3 Calibrate the throttle menu again in the armrest controller If the same fault code appears again replace the controller NOTE See schematic sections 47 and 48 on schematic poster FAULT CODE ARM 9041 EDC Drop Rate Potentiometer Calibration Error Cause EDC drop rate potentiometer calibration results not acceptable Possible failure mode 1 Calibration was done incorrectly 2 EDC drop rate potentiomete...

Страница 1640: ...l 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 ...

Страница 1641: ... 2 to 2 5 volts If the above checks are ok and all controllers came online it means that the opposite end resistor terminator and the data bus wiring are functioning correctly The engine end resistor terminator has most likely failed Test the engine end resistor terminator and replace if it has failed See step 4 B Check from the can bus resistor terminator in the TMF controller Reconnect the engin...

Страница 1642: ...ta bus wiring has the problem If the problem cannot be found in the wiring disconnect the engine controller to determine if it has failed NOTE Always inspect connector ends for damaged bent or dislocated pins when troubleshooting the Data Bus One intermittent connection can cause the entire bus to stop communications IMPORTANT When there is a bad connection along the Data Bus wiring the fault code...

Страница 1643: ...or C205 At cavity A the yellow wire it should read from 2 5 to 2 8 volts At cavity B 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 opposite end resistor terminator and the data bus wiring are functioning correctly The engine end resistor terminator has most likely failed Test the engine end resistor terminator and r...

Страница 1644: ...troller to determine if it has failed NOTE Always inspect connector ends for damaged bent or dislocated pins when troubleshooting the Data Bus One intermittent connection can cause the entire bus to stop communications IMPORTANT When there is a bad connection along the Data Bus wiring the fault code will be accompanied by multiple fault codes such as Aux Hitch PTO 11 INST 12011 INST 12031 and TRAN...

Страница 1645: ...Section 55 Electrical System Controller Chapter 5 55 5 40 ...

Страница 1646: ...Section 55 Chapter 6 January 2006 ELECTRONIC CONTROLLER CONFIGURATION CALIBRATION AND FAULT CODE RETRIEVAL ...

Страница 1647: ...Y SYMPTOM BASED FAULTS 55 6 17 ARMREST CONTROLLER CONFIGURATION AND CALIBRATION 55 6 19 TRANSMISSION CONTROLLER CONFIGURATION AND CALIBRATION 55 6 28 When Calibration is Required 55 6 28 Clutch Calibration Procedure 55 6 39 Calibration Error Messages 55 6 43 Front Suspension Calibration 55 6 48 REMOTE AUX SYSTEM CALIBRATION 55 6 55 Aux Cal Menu 55 6 61 HITCH SYSTEM CALIBRATION 55 6 64 PTO SYSTEM C...

Страница 1648: ...NT instrument cluster ENGINE TRANSMISSION ARMREST ATC automatic temperature control and AUX HITCH PTO auxiliary remote hydraulics three point hitch power take off NOTE The Aux Hitch PTO controller is also referred to as the Tractor Multi Function TMF controller STEP 3 MD05F040 When the required controller is displayed press the PROG key If a controller is selected that is not on the Data Bus does ...

Страница 1649: ...ll be erased STEP 6 RD06A068 When the fault codes are erased the display will return to the DIAG MENU screen for that controller STEP 7 MD05F003 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 STEP 8 RD06A072 To exit the select controller screen scroll until EXIT is displayed and press the PROG key This will return ...

Страница 1650: ...TE When replacing the standard instrumentation controller the fuel tank size selection must be selected using the service tool configuration window MD05F002 Configure the instrumentation with the key in the ON position and the engine not running Be sure the batteries are fully charged Turn off all accessories during configuration Operation Setup NOTE Configuration can only be entered within the fi...

Страница 1651: ...e Radius Radar Cal Old Hours and Exit The default will highlight Unit Press the PROG key STEP 5 MD05F007 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 Press the PROG key to save your choice The display will return to ...

Страница 1652: ...or determining tire radius the following preparations must be made 1 Mark a straight line course of 60 meters 196 86 feet with a start line and finish line that can be clearly seen from the cab 2 Position the tractor at an adequate distance from the start line to allow the tractor to achieve and maintain a steady speed faster than 2 MPH 3 22 KPH 3 Turn the key switch OFF Press and hold the PROG ke...

Страница 1653: ...he clutch and press the INCR key when the front wheels touch the start line The display will read WORKING and PRESS DECR TO STOP STEP 12 MD05F015 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 If unsuccessful due to unsteady tractor spe...

Страница 1654: ... is not equipped with radar the display will read RADAR NOT PRESENT STEP 14 MD05F017 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 If MANUAL is selected proceed to Step 15 If AUTO automatic is selected procee...

Страница 1655: ... distance from the start line to allow the tractor to achieve and maintain a steady speed faster than 2 MPH 3 22 KPH 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...

Страница 1656: ...s were not pressed at the proper time the display will read FAILED Repeat Steps 16 through 19 or press PROG to exit the RADAR CAL STEP 20 MD05F005 Press the DECR key to highlight EXIT Press the PROG key STEP 21 RD05G056 The CONFIG MENU is displayed STEP 22 RD06A060 Press the INCR key to highlight EXIT Press the PROG key to exit tractor setup and return to normal operation STEP 23 If the programmab...

Страница 1657: ...ECR key will toggle through the list of controllers The controllers will appear in this order if equipped INSTRUMENT Instrument Cluster TRANSMISSION ARMREST AUX HITCH PTO NOTE The Aux Hitch PTO controller is also referred to as the Tractor Multi Function TMF controller STEP 25 MD05F025 3 Press the PROG key with INSTRUMENT on the display The display will read CONFIG ICU 1 Operator Setup 2 Controlle...

Страница 1658: ...orrect the model number The display will read MANUAL and AUTO Use the INCR or DECR keys to select highlight either MANUAL or AUTO The default format is MANUAL If the MANUAL format is selected the controller menus must be toggled through and configured into the system manually If the AUTO is selected the instrumentation controller will check to see which other controllers are present on the tractor...

Страница 1659: ...ANS transmission controller Press the INCR or DECR key to toggle between YES and NO Select your choice press the PROG key The system will go to the next step STEP 31 MD05F176 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 STEP 32 RD06A074 The bottom of the display will read ATC automatic...

Страница 1660: ... 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 STEP 35 RD06A075 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 STEP 36 MD05F025 Press the DECR key The display will re...

Страница 1661: ...NFIG MENU Press the INCR key The display will read Exit Press the PROG key to return to normal operation STEP 38 Cycle the key switch OFF then ON Check 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 ...

Страница 1662: ...55 138 cab power relay 240 unswitched power Corrective action STEP 1 Cycle key switch 20 times Turn the front wiper on Turn the key switch on and off while monitoring the display and the front wiper the display and front wiper must turn on and off everytime when the key is cycled OK The display and front wiper turned on every time when key switch was turned on NOT OK The wiper turned on but the di...

Страница 1663: ...wire 160 to ignition switch or wire 102 to ring terminal 138 STEP 7 Check power and ground supply to the instrumentation controller Instrument Cluster Install fuse 37 Remove the instrumentation controller Turn the key on Check connector CN2 pin 2 for 12 volts NOT OK Replace the wire between fuse 37 and the instrumentation controller connector CN2 pin 2 OK Go to Step 8 STEP 8 Check the ground suppl...

Страница 1664: ... is configured for will appear on the display The possible menus are 1 HITCH This menu is for the calibration of the hitch position command potentiometer 2 THROTTLE This menu calibrates the hand throttle lever potentiometer voltage for high and low idle 3 AUX FLOW This menu calibrates the flow potentiometers for high and low flow 4 AUX LEVER Remote hydraulic valve This menu is used to tell the con...

Страница 1665: ... the program mode has been accessed and the display will read CONFIG MENU STEP 2 RD06A058 Press the DECR key until ARMREST is highlighted Press the PROG key to enter the programing menus NOTE If not equipped with a hitch go to Step 7 Hitch Menu STEP 3 MD05F097 Select the calibration option for the hitch control lever if equipped When the display reads ARM HITCH press the PROG key STEP 4 MD05F098 M...

Страница 1666: ...isplay the display will read cal failed and this calibration option will abort A problem will have to be corrected before calibration will be possible STEP 6 RD05F189 MD05F102 The display will now read Draft or No Draft There must be a hitch load command potentiometer in the armrest controller to select Draft Select No Draft and the hitch will be configured as a position only hitch The hitch calib...

Страница 1667: ... 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 read ARM THROTTLE To exit the armrest calibration go to Step 23 Press the DECR key and go to the next step to continue with the armrest calibration NOTE If either the high or l...

Страница 1668: ...5F107 Turn the 1 flow potentiometer completely counterclockwise until the 1 appears in the first X position of the display Press the PROG key STEP 12 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 STEP 13 The screen reads ARM AUX FLOW Press the DECR key to select AUX ARM LEVE...

Страница 1669: ... extend voltage recorded STEP 17 MD05F113 The display will read AUX RET retract Move all the remote hydraulic levers to the full retract position First forward detent NOTE Do not move the lever to the float position STEP 18 MD05F114 The display will indicate which levers are in the retract position with the number of the remote If the 5th remote was actuated for the extend position it need not be ...

Страница 1670: ...splay 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 ARM TRANS STEP 20 RD05F151 RD05F153 Select the software view option from the main menu The display will read ARM TRANS Press the PROG key The display will read YES Creeper Press the INCR key to change to NO Creeper if not equipped Press the PROG key to exit the ARM TRANS menu ...

Страница 1671: ...re is displayed in two parts The display will read Ver 1 on the top of and the first part of the software code on the bottom of the display Press the PROG key STEP 22 MD05F117 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...

Страница 1672: ... 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 ...

Страница 1673: ...ration mode 1 TRANS VIEW This menu displays clutch calibration values milliamp and temperature System oil temperature inching pedal calibration values software revision numbers transmission system pressure and engine load in percent Normal tractor operation is allowed while this menu is being displayed 2 TRANS SETUP This menu is used to enter the clutch calibration and to set default gear values f...

Страница 1674: ...onds after starting the tractor A short beep will indicate that the program mode has been accessed and the display will read CONFIG MENU STEP 2 RD06A057 Push the DECR key until the display reads TRANSMISSION and press the PROG key again STEP 3 RD05F104 The display will read TRANS VIEW Press DECR key STEP 4 RD05F125 The display will read TRANS SETUP Press DECR key ...

Страница 1675: ...read TRANS ADJUST Press the DECR key STEP 6 RD05G006 IMPORTANT The TRANS DIAG 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 DIAG Press DECR key STEP 7 RD06A079 The next display will be TRANS FSUS but only if equipped with the Suspended Axle Option Press DECR key STEP 8 RD05F134 The display will read TRANS ...

Страница 1676: ...wo 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 10 RD06A057 Push the DECR key until the display reads TRANSMISSION and press the PROG key again STEP 11 RD05F104 The display will read TRANS VIEW Press the PROG key to enter the Transmission View Menus STEP 12 RD05F105 The ...

Страница 1677: ...you to the upper level menu VIEW CLTCH STEP 15 RD05F107 The Master Clutch milliamp 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 mA reading STEP 16 RD05F105 The display will return to VIEW CLTCH To display the next Transmission View Menu push the DECR key STEP 17 RD05F108 The displ...

Страница 1678: ...formed Continue pushing the DECR key to display the calibrated clutch temperature values for C O C1 C3 C5 LOW MID HIGH REV and MSTR clutch NOTE Pushing the PROG key at any point will return you to the upper level menu CAL CLTCHTMP STEP 20 RD05F110 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 th...

Страница 1679: ...ns to OIL TEMP display To display the next Transmission View Menu push the DECR key STEP 25 RD05F113 The display will read VIEW PEDAL The Clutch Pedal View Menu displays the position of the clutch Push the PROG key STEP 26 RD05F114 The current pedal position is displayed 100 for inching pedal up top of clutch Depress the inching pedal to the floor STEP 27 RD05F115 The display will read 0 for inchi...

Страница 1680: ...play will read VER 1 Version 1 is the major software version number the lower number 1 11 is the minor software version number Push the DECR key STEP 31 RD05F118 The display will read VER 2 Version 2 is the engineering software version numbers Push the PROG key STEP 32 RD05F116 The display will again read SW REVISION To display the next Transmission View Menu push the DECR key STEP 33 RD05F119 The...

Страница 1681: ...CR key STEP 36 RD05G009 The display will read LOAD This is the engine load display Push the PROG key STEP 37 RD05F122 The display will read LOAD The engine load is displayed in percentage related to the engine torque Push the PROG key STEP 38 RD05G009 The display will again read ENG LOAD To display the next Transmission View Menu push the DECR key STEP 39 RD05F124 The display will read EXIT VIEW P...

Страница 1682: ...d clear any fault codes See Fault Code Retrieval in this section STEP 40 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 41 RD06A057 Push the DECR key until the display reads TRANS and press the PROG key again STEP 42 RD05F104 The...

Страница 1683: ...se Do Not enter this menu Press the DECR key STEP 46 The display will read SETUP BKUP ALM To see the next setup menu press the DECR key IMPORTANT The SETUP BKUP ALM menu will only appear when the Electronic Service Tool EST is in use Do Not enter this menu Press the DECR key STEP 47 The display will read SETUP FSUS To see the next setup menu press the DECR key IMPORTANT The SETUP FSUS menu will on...

Страница 1684: ...hin 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 RD06A057 Push the DECR key until the display reads TRANS and press the PROG key again STEP 51 RD05F104 When the TRANS VIEW menu is displayed push the DECR key STEP 52 RD05F125 The display will read TRANS SETUP Press the PROG key to enter the ...

Страница 1685: ...ration procedure may be continued Calibration at a lower temperature should only be performed when the recommended temperature range cannot be achieved NOTE If the oil temp is above 105 degrees C the display will read HOT OIL TEMP if the oil temp is below 10 degrees C the display will read COLD OIL TEMP The display will return to oil temperature display after 4 seconds STEP 56 MD05F072 The display...

Страница 1686: ... The display will read Odd mA The tractor transmission controller will automatically run through the Odd clutch calibration procedure STEP 62 RD05F175 The display will read ODD mA when the Odd clutch calibration is completed Push the PROG key WARNING Since the valve calibration process involves engaging transmission clutches this procedure should only be performed in open areas free of obstruction...

Страница 1687: ...ibrate the C1 C3 C5 LOW MID HIGH REV and MSTR clutch STEP 64 RD05F186 After performing the calibration procedure on all clutches the display will now read MSTR mA Push the PROG key once STEP 65 RD05G017 The display will now read EXIT CAL Push the prog key once STEP 66 RD05G018 The display will now read SHIFT TO PARK Shift the transmission control lever into PARK position STEP 67 RD05G017 The displ...

Страница 1688: ... When a tractor is started up and shifted into Forward the default gear is 7th If shifted into Reverse the default gear is 2nd Follow this procedure to change the Forward or Reverse default gear settings Forward gear default can be set for 1st through 13th gear Reverse gear default can be set for 1st throough 4th gear Calibration can only be entered by pressing and holding the PROG key within the ...

Страница 1689: ...31 The display will read GEAR DEFAULT Push the PROG key STEP 73 RD05F166 The display will read SETUP FWD GEAR Push the PROG key STEP 74 RD05F167 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 If no change is desired leave gear number as it is Press the PROG key when desired gear number is set STEP 75 RD05F168 The di...

Страница 1690: ...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 STEP 77 RD05F171 The display will read EXIT SET GEAR Press the PROG key to exit this menu ...

Страница 1691: ...nd 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 RD06A057 Push the DECR key until the display reads TRANS and press the PROG key again STEP 79 RD05F104 When the TRANS VIEW menu is displayed push the DECR key STEP 80 RD05F125 The display will read TRAN...

Страница 1692: ... exits this menu Front Suspension Menus The following menus are available for the Front Suspension 1 FSUS CAL This menu allows the user to Calibrate the Front Suspended axle 2 FSUS DEMO This menu can only be accessed when the Electronic Service Tool EST is in use on the tractor It allows the user to switch the Front Suspended Axle ON or OFF especially at speeds greater than 12 KMH 3 FSUS MANUAL Th...

Страница 1693: ... 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 RD06A057 Push the DECR key until the display reads TRANS and press the PROG key again STEP 85 RD05F104 When the TRANS VIEW menu is displayed push the DECR key STEP 86 RD05F125 The display will read TRANS SETUP Press the DECR key STEP 87 RD06A079 The...

Страница 1694: ...ibration is in progress This display is the front axle position sensor output voltage STEP 90 RD05G026 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 91 RD05G043 RD05G044 If the calibration process fails the display will read CAL FAILED The Suspended Axle Switch lamp will turn off I...

Страница 1695: ...r Chapter 6 55 6 50 STEP 92 RD05G047 Error Message Display Example Possible Error Messages tttt bbbbbbbb POT OPEN CKT POT HIGH VAL POT SHRT CKT POT LOW VAL POT LOW RNG SLOW UP MVMNT SLOW TO MAX SLOW DN MVMNT SLOW TO MIN NOT CAL WHEEL MOVED ...

Страница 1696: ...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 RD06A057 Push the DECR key until the display reads TRANS and press the PROG key again STEP 94 RD05F104 When the TRANS VIEW menu is displayed push the DECR key STEP 95 RD05F125 The display will read TRANS SETUP Press the DECR ke...

Страница 1697: ...s the user to switch the Front Suspended Axle ON or OFF especially at speeds greater than 12 KMH Front Suspension Manual Menu NOTE This menu will only work when the Electronic Service Tool is in use STEP 99 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 a...

Страница 1698: ...e display will read TRANS SETUP Press the DECR key STEP 102 RD05G019 The display will read TRANS FSUS Press the PROG key STEP 103 RD05G028 Push the DECR key until the display reads FSUS Manual and then press the PROG key STEP 104 RD05G030 The display will read POS nnnn mV This display is the front axle position sensor output voltage Press the DECR key ...

Страница 1699: ...ECR key again NOTE The manual lower feature can be useful for troubleshooting the lower function Power the lower solenoid ON and OFF and check for 12 volts at lower solenoid STEP 107 RD05G034 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 NOTE The manual lock feature can be...

Страница 1700: ...lace or repair any damaged par t as necessary Before calibrating the remote hydraulic controller be sure the Standard Instrumentation INST and Armrest ARM controllers are calibrated The hydraulic oil must be warmed to 49 C 120 F or higher Engine speed must be set to 1500 RPM or higher Disconnect any implements before calibration Aux Set Main Menu Remote hydraulic calibration is performed through t...

Страница 1701: ...n seconds A short beep will indicate that the program mode has been accessed and the display will read CONFIG MENU STEP 2 RD06A059 Push the DECR key three times The display should read AUX HITCH PTO Push the PROG key STEP 3 MD05F122 The display will read EDC MENU Press the DECR key twice STEP 4 RD06A059 The display should read EHR MENU Electro Hydraulic Remotes Press the PROG key to enter the main...

Страница 1702: ...nt controls There is the option of none one and two Default is none 4 AUX CAL The calibration menu allows the control to find the flow thresholds of the valves Only the valves that are configured in the armrest controller at power up are calibrated 5 AUX EXIT Used to exit the AUX MD05F003 Use the INCR or DECR key to move through these menus To enter the menu of your choice press the PROG key Aux V...

Страница 1703: ... key The display will now show how many scrapers are configured in the system Press the DECR key NOTE Scraper configuration is performed in the AUX SETUP menu STEP 5 RD06A103 The display will now read EXIT VIEW Press the PROG key STEP 6 RD06A099 The AUX VIEW screen will now be displayed Press the DECR key to display AUX ADJUST ...

Страница 1704: ...er between 40 to 40 will be displayed If the value displayed is increased the flow curve associated with that valve will be shifted to the left This results in a higher flow for a given flow potentiometer setting for that flow direction If the value is decreased the flow curve associated with that valve will be shifted to the right This results in a lower flow for a given flow potentiometer settin...

Страница 1705: ... return to the EXIT screen Press the PROG key NOTE The AUX controller must leave through the EXIT screen or the adjustments will not be saved Aux Setup Menu STEP 13 RD06A128 With AUX SETUP on the display push the PROG key STEP 14 RD06A170 The display will show the current setup value either AUX NONE 1SCRAPER 2SCRAPER or IMP ctl IMP ctl will display if installed Use the INCR or DECR key to select y...

Страница 1706: ...n raise The valve and section that is in process of calibration will be displayed If Equipped with MegaFlow For tractors equipped with the MegaFlow option a pause is provided to allow field technicians to calibrate both remote systems with one pressure transducer Once the calibration procedure is in progress for the 1st remote section move the 3rd remote lever out of neutral The calibration will p...

Страница 1707: ...L procedure make sure valve spools are moving freely With the engine running cycle each remote hydraulic section to the extend and retract detente position STEP 16 RD02E096 Connect Remote Hydraulic Calibration Tool CAS 2806 to the implement potentiometer connector C150M below cab and the load sensing diagnostic port on the remote valve STEP 17 RD06A129 With AUX CAL on the display Press the PROG ke...

Страница 1708: ... current calibrated out of range high Fault Detected AUX solenoid valve short or open during calibration CAN Fault ICU not present Time Out AUX feedback pressure drop was not detected during the calibration period Fault AUX k Detected AUX solenoid valve short or open prior to calibration STEP 21 MD05F177A The system will go automatically into the calibration process when the pre calibration is com...

Страница 1709: ...inimum and maximum limits Make sure that no interference exists during hitch movement such as a quick coupler contacting a draw bar Be sure there are no persons in the back of the tractor during hitch calibration Do not calibrate the hitch with the tractor moving The transmission oil must be warmed to more than 38 C 100 F The engine speed must be 1600 RPM or higher during calibration Hitch Setup M...

Страница 1710: ...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 val...

Страница 1711: ...ders 2 When the correct cylinder size is found press the PROG key to enter the selection STEP 4 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 If the armrest controller is calibrated for p...

Страница 1712: ...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 NOTE Once the controller has found the raise threshold of the valve the hitch will raise MD05F047A 2 When the controller has found the raise threshold of the valve the hitch will move to the maximu...

Страница 1713: ...Then the hitch will move down to the lower limit NOTE Calibration may take a few minutes To abort calibration press either the INCR or DECR key The system will go to Step 11 NOTE Be sure the engine is at 1600 RPM minimum NOTE If a failure is detected the system will go to Step 10 STEP 9 The display will now read Lower Limit ON The system wants you to acknowledge that the hitch has reached the lowe...

Страница 1714: ...play 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 If the display reads Cal Fail it means that a failure has occurred during the calibration process The ...

Страница 1715: ...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 If No is selected the hitch will raise to the rate specified in Step 12 The default setting for this step is No MD05F056 1 Press the INCR or DECR key to toggle between Yes and No 2 ...

Страница 1716: ...o Dif Lock functions There are four choices 60 70 80 and 90 The default is 70 MD05F058 1 Press the INCR or DECR key to change the selection 2 To select a percentage press the PROG key The system will go to step 14 STEP 17 The display will now read Done Settings This indicates that the user settings have been successfully programed RD06A088 1 Press the PROG key to return to HITCH SETTINGS the main ...

Страница 1717: ...menu Hitch view menu 1 RAISE mA 2 LOWER mA 3 PWMR Pulse width modulation count raise 4 PWML Pulse width modulation count lower 5 R DRAFT Software count right load pin 6 L DRAFT Software count left load pin 7 POS Hitch feedback position measured in millivolts STEP 19 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 MD05F063A...

Страница 1718: ...e reading when hitch is at minimum 4 r offset Count of no load voltage reading on right load pin 5 l offset Count of no load voltage reading on left load pin 6 aaa1 Count used to map position command range and the hitch position range 7 posrange Count indicating the full hitch position travel 8 Type Indicates tractor family series and model STEP 23 RD06A091 Press the PROG key The display will now ...

Страница 1719: ...formed through the programmable display on the standard instrumentation MD05F002 PTO Main Menu NOTE Controller programming can only be entered within the first 10 seconds of turning the key switch to the on or run position STEP 1 RD05G056 Turn the key switch to the ON position Push the PROG key and hold for two seconds within the first ten seconds of turning on the key switch A short beep will ind...

Страница 1720: ...s the operator to view PTO software version and the ratio between the engine speed and the PTO shaft speed 3 PTO RESET Reset PTO Cal current 4 PTO EXIT Returns to the main menu The INCR and DECR keys are used to toggle between these menus PTO Speed Menu STEP 5 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 ...

Страница 1721: ...y 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 This is the second part of the software version number STEP 9 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 ...

Страница 1722: ...Section 90 Chapter 1 January 2006 PEDAL AND PEDAL SWITCH ADJUSTMENTS ...

Страница 1723: ...Section 90 Cab Hood Seat Chapter 1 90 1 2 TABLE OF CONTENTS INCHING PEDAL SWITCH ADJUSTMENT 90 1 3 BRAKE PEDAL ADJUSTMENTS 90 1 4 ...

Страница 1724: ...rn the key switch to the ON position Enter the TRANS VIEW menu in the display Go to the inching pedal potentiometer position menu to observe the pedal position F Shift the tractor out of park Slowly cycle the inching pedal while watching the display The display should read 100 when fully up and smoothly go down to 0 when fully depressed G The switch should turn OFF and ON make a click noise betwee...

Страница 1725: ...he pedal springs 1a after adjustment is complete If there is turn the adjustment screw enough to remove any looseness in the spring Brake Link Rod Adjustment C Adjust the length of the left brake link rod 4 so that it just touches the bottom of the brake valve poppet sleeve 5 when the brake pedal is fully extended Tighten the clevis 6 lock nuts 7 when done Repeat for the right brake Brake Light Sw...

Страница 1726: ...Section 90 Chapter 2 January 2006 CAB RAISE REMOVAL AND INSTALLATION ...

Страница 1727: ...ction 90 Cab Hood Seat Chapter 2 90 2 2 TABLE OF CONTENTS SPECIAL TORQUES 90 2 3 SPECIAL TOOLS 90 2 3 CAB RAISE PROCEDURE 90 2 4 CAB LOWERING PROCEDURE 90 2 7 CAB REMOVAL 90 2 10 CAB INSTALLATION 90 2 17 ...

Страница 1728: ... lb ft Cab Mounting Bolt Nut 190 to 244 Nm 140 to 180 lb ft SPECIAL TOOLS 38 8R2 Cab Lift Tool CAS2531 RD02E108 Front Cab Lifting Bracket CAS2529 1 Part Of CAS2529 Kit RD03C059 Steering Line Quick Disconnect Tool 380000795 RD02E109 Cab Raising Bracket Kit CAS2577 Q4 Rear Cab Lifting Bracket CAS2529 2 Part Of CAS2529 Kit ...

Страница 1729: ...P 2 RD05K002 Loosen the two left thumbscrews 1 remove the two right thumbscrews 2 and remove the toolbox and battery cover STEP 3 RD02E069 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 Remove the two screws securing the left front cab panel Remove both panels from the tractor STEP 4 76 33 Open th...

Страница 1730: ...shers from the front cab mounts Remove the rear cab mount nuts and washers STEP 7 RD02F103 Install the right rear cab raising bracket CAS2577 1 from CAS2577 Cab Raising Bracket Kit into the right rear cab support tube STEP 8 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 Install a washer and a nut o...

Страница 1731: ...hrough 9 on the left rear side of the cab STEP 12 76 0A Install the upper cab raising bracket 1 from CAS2577 Cab Raising Bracket Kit into the left front cab support tube Install CAS2577 3 lower raising plate 2 on the front cab mounting bracket using two of the bolts from the kit Place a load bearing on top of the lower raising plate and insert one of the shorter threaded rods through the upper rai...

Страница 1732: ...d The cab bolt mounting sleeves can bind in the cab support tube holes so the cab cannot be lowered STEP 15 77 36X Remove the locking pin from the bottom of the threaded rod on the rear cab raising tool STEP 16 77 23 Remove the threaded rod from the raising bracket Remove the load bearing STEP 17 RD02F104 Remove the bolt 1 nut and the two washers from the cab side panel and the slot in the right r...

Страница 1733: ...1 76 0A 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 Detach CAS2577 3 lower raising plate 2 by removing the two bolts Repeat this procedure on the opposite side of the cab STEP 22 RD02C143 Set the preload on the front cab isomounts to a torque of...

Страница 1734: ... 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 STEP 25 RD05K002 Install the battery cover and tool box Tighten the thumbscrews STEP 26 RD02C070 Make sure the transmission shift lever is in PARK Start the engine and lower the rear hitch Turn the engine off and remove the key Remove the wheel block...

Страница 1735: ...ooling system capacity Properly support the tractor and remove the rear wheels if necessary NOTE It is not necessary to remove the rear wheels but may be required to gain enough clearance at the tractor chassis and the top of the lift STEP 28 RD05K002 STEP 29 RD02E069 Disconnect the negative battery cable 1 first Disconnect the positive battery cable 2 Remove the three screws 3 securing the right ...

Страница 1736: ... line 2 from the steering hand pump Cap the lines and open fittings If your tractor is equipped with quick disconnect fittings use Special Tool 380000795 3 to disconnect the lines STEP 32 RD02C162 Identify tag and remove the brake valve supply 1 and return line to sump 2 Cap the lines and open fittings STEP 33 RD05M060 Remove the cab connector 1 at the right hand front side of the cab STEP 34 RD05...

Страница 1737: ... pressurization blower NOTE Fuel tank removed for photographic purposes STEP 37 76 33 Open the rear window Remove the two bolts securing the rear cab panel to the cab Remove the panel STEP 38 RD05M054 Tag and remove all connectors 1 from the controllers 2 STEP 39 RD05M055 Remove the cab power supply cable 1 and ISO 11783 2 if equipped at the right rear of the cab 1 1 2 2 1 2 1 ...

Страница 1738: ...42 RD05M058 Remove the fuel tank vent filter clamp STEP 43 RD02E068 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 44 RD02C132 Once the A C system has been evacuated disconnect the A C lines at the cab firewall Discard the O...

Страница 1739: ...and swing the tractor rear warning marker lights down Finger tighten the upper bolt STEP 48 RD05M051 Remove the right and left side mount light if equipped STEP 49 RD05M052 Disconnect the right and left side light harness if equipped STEP 50 RD02E094 Remove the plastic plug if required from the cab rear window post and insert the J hook from CAS2529 2 rear cab lifting bracket in the hole The hooke...

Страница 1740: ...e wire harness when installing the J hook and lifting bracket NOTE Do not lift the cab until all electrical cables hydraulic lines and mechanical parts needed for cab removal have been tagged and disconnected STEP 52 RD02C143 Remove the cab floor plug Remove the nut and washer from the front cab mount bolt Have an assistant hold the head of the bolt under the cab Repeat this operation on the oppos...

Страница 1741: ... cab place supports between the cab rails and the cab mounting supports Lower the cab onto the supports STEP 56 RD02C155 If equipped remove the hydraulic trailer brake supply lines These lines are located below the cab at the right rear STEP 57 RD02E067 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 supp...

Страница 1742: ...king under the suspended cab place supports between the cab rails and the cab mounting supports Lower the cab onto the supports STEP 60 RD02E067 Install the heater hoses at the cab HVAC box located under the right hand side of the cab STEP 61 RD02C155 Lower the cab until the hydraulic trailer brake supply lines if equipped can be installed at the right rear side of the tractor Tighten the trailer ...

Страница 1743: ...g the bolt Install the rear 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 Have an assistant hold the bolt if necessary STEP 65 RD02C143 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 s...

Страница 1744: ... front lifting bracket STEP 71 RD02C133 Install the mirrors and the three mirror retaining bolts Connect the electrical plug if equipped STEP 72 RD02C132 Lubricate new O rings with refrigerant oil install on the A C fittings at the firewall and tighten STEP 73 RD02E068 Refer to Air Conditioning Component Service in this manual Recharge the air conditioning system with freon at the capped line fitt...

Страница 1745: ...d STEP 76 RD05M056 Install the cab power cables 1 and the wire connector 2 at the right rear of the cab STEP 77 RD05M055 Connect the cab power supply cable 1 and the ISO 11783 power cables 2 if equipped STEP 78 RD05M054 Connect the wire harnesses 1 to the controllers 2 STEP 79 76 33 Install the two bolts securing the rear cab panel to the cab 2 1 1 2 1 1 2 2 1 ...

Страница 1746: ... tags to install the return and supply line on the brake valve STEP 83 RD02E064 Use the identification tags to install the wiring harnesses on the two brake light switches 1 STEP 84 RD05M053 Use the identification tags to install the four hydraulic hoses 1 and the steering sensing line 2 to the steering hand pump NOTE After each is installed firmly pull back on the hose to make sure it is fully se...

Страница 1747: ... the negative battery cable 4 STEP 86 RD02C070 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 Remove the rear axle supports if the rear wheels were removed Fill the cooling system Refer to the Operators Manual for cooling system capacity Check the hydraulic fluid level Add fluid as needed Rem...

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